HI2151-20 bk

HI2151-20 bk
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
HI 2151/20WC
Weight Controller
OPERATION AND INSTALLATION
MANUAL
Corporate Headquarters
3860 Calle Fortunada
San Diego, CA 92123-1825
Phone (858) 278-2900
Fax (858) 278-6700
Gulf Coast Office
Sales, Service, and
Application Engineering
P.O. Box 1608
607 S. Friendswood Drive
Friendswood, TX 77546
Phone (713) 482-9653
Fax (713) 482-2104
Hardy Instruments Document Number:0596-0178-C
Copyright January 1995 Hardy Instruments, Inc. All Rights Reserved. Printed in U.S.A. (941028)
TABLE OF CONTENTS
Section
Title
Page
SECTION 1 - INTRODUCTION
1.1 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 EQUIPMENT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 STANDARD FEATURES AND OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SECTION 2 - INSTALLATION
2.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 MECHANICAL INSTALLATION (STANDARD UNIT ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 CABLING AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 INITIAL SYSTEM POWER-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
SECTION 3 - SCALE CALIBRATION
3.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 PRE-CALIBRATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 DETAILED CALIBRATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 CALIBRATION SETUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5 C2TM SECOND GENERATIN CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6 SOFTWARE - CALIBRATION (SOF-CAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.7a HARD CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7b QUICK HARD CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.8 ENHANCED SECURE MEMORY MODULE (SMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.9 WAVERSAVER® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.10 AUTO ZERO TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
SECTION 4 - OPERATION AND CONFIGURATION
4.1 INSTRUMENT CONFIGURATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPTION BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 OUTPUT OPTION BOARD ISTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 SETPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.4 SERIAL COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.4.1 BIDIRECTIONAL COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
HARDWARE OPTION BOARDS - RS-422/485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
SERIAL COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.5 PARALLEL BCD COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.6 ANALOG OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.7 BAR-GRAPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4.8 RATE OF CHANGE (ROC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.9 PEAK HOLD MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4.10 TOTALIZER MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4.11 ALLEN-BRADLEY REMOTE I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 SYSTEM INTEGRITY CHECK AND FAULT DETERMINATION . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 INTERPRETING DIAGNOSTIC/ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 OPERATION - USING SOLID STATE RELAYS WITH LIGHT LOADS (Optional Set Relays) . . 5-16
5.5 CUSTOMER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
i
TABLE OF CONTENTS - Continued
SECTION 6 - APPENDICES
A - KEYPAD, DIPSWITCH AND REMOTE FUNCTION DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 - KEYPAD DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 - DESCRIPTION OF REAR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 - INSTRUMENT CONFIGURATIO DIPSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4 - REMOTE FUNCTIONS CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5 - INTERNAL DIPSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
B - SYSTEM DATA SURVEY SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
C - DISPLAY MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
D - ERROR MESSAGES AND DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
E - NTEP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
F - GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
G - ASCII TO HEX TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
LIST OF FIGURES
Figure
Title
Page
1-1. Hardy Instruments' HI 2151/20 Weight Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2. HI 2151/20WC Standard and Optional Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3. HI 2151/20WC Range and Excitation Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1. HI 2151/20WC Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2. HI 2151/20WC Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3a. 4 Conductior Load Cell/Point Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-3b. 6 Conductior Load Cell/Point Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-3c. C2TM Load Cell Connections (J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3-1. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. HI 2151/20WC Calibration Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
4-1. Optional Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2. Option Label Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-3. Output Option Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-4. HI 2151/20WC Housing for Main Board, Power and Relay Board Alignment . . . . . . . . . . . . . . . . . . . . . 4-7
4-5. Setpoint Relay Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-6. Setpoint Relay Option Board Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-7. Low and High Trip Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-8. RS-232C Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-9. RS-422/485 Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-11. Parallel BCD Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4-12. BCD Quad Termination Board Option (P/N 0535-0384-1 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4-13. BCD Termination Board Installation Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-14. BCD Termination Board Installation Drill Template Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4-15. Analog Output Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
5-1. Typical Load Cell System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-2. SCR Switching Load Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
6-1. "Config" Dipswitch S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2. Remote Function (J2) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
ii
LIST OF TABLES
Table
Title
Page
1-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
3-1. Calibration Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-1a. C2TM Second Generation Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-1b. Soft Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-1c. Hard Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-2. Quick Hard Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-3. Restoring Data from the Secure Memory Module (SMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-4. WAVERSAVER Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
4-1. RS-422/485 Option Board Mode Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-2. BCD Timing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4-3. Cable Pinouts - Parallel BCD Board Connector to DB Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
5-1. Self-Test Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2. Troubleshooting Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
6-1. ASCII to HEX Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
iii
PREFACE
Read all safety, installation and operating instructions before the unit is operated. Warnings
and cautions indicate possible hazards that may result in injury. Follow all instructions and
retain the manual for future reference.
NOTE
All specifications herein are for the unit only. Our instrument is UL recognized. Please be
advised the NEMA 4 waterproof front panel has not yet been tested by UL, but should be
completed in the near future.
CAUTION
This unit contains components sensitive to damage by Electrostatic Discharge (static
electricity). Electrostatic Discharge (ESD) precautions are recommended when removing
the instrument chassis from the enclosure (i.e., wear an ESD wrist strap connected to
ground, ESD protective apparel, and/or have grounded work stations).
Dangerous voltage is present within the enclosure of the unit and presents the risk of
electrical shock. ALWAYS unplug the unit before opening it for servicing. Installation and
servicing of this unit should be performed by authorized and qualified service personnel
only.
PROPRIETARY NOTICE
The information and design disclosed herein was originated by and is the property of Hardy
Instruments, Inc. and constitutes confidential and proprietary design, whether or not
copyrighted or copyrightable and/or patented or patentable, all manufacturing, reproduction
use, and sales rights thereto, and to any article disclosed therein, except to the extent rights
are expressly granted to others. The foregoing does not apply to vendor proprietary parts.
PATENT PENDING
WAVERSAVER® is a registered trade mark symbol of Hardy Instruments, Inc.
iv
SECTION 1 - INTRODUCTION
SECTION 1
INTRODUCTION
1.1 HOW TO USE THIS MANUAL
This manual provides operational and installation instructions for the HI 2151/20 Weight Controller
with WAVERSAVER® (see Figure 1-1 HI 2151/20 Weight Controller). The manual is divided into
six sections as follows:
Section 1 provides an introduction to the instrument, as well as an overview of the equipment
and its capabilities.
Section 2 contains information needed to install your new unit and bring it to a power on
condition.
Section 3 covers calibration procedures. Quick Calibration instructions are also provided for
fast setup and periodic re-calibration.
Section 4 explains the configuration, serial communication, hardware configuration and options.
Section 5 guides you through troubleshooting and maintenance for the unit.
Section 6 contains Appendices A through F. The appendices include quick references such as
keypad, dipswitch and remote function definitions, as well as system data survey sheets, display
messages, error messages, NTEP operation specifications, and glossary of terms.
Figure 1-1. Hardy Instruments' HI 2151/20 Weight Controller
1-1
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
1.2 EQUIPMENT OVERVIEW
The Hardy Instruments HI 2151/20WC with WAVERSAVER® is a multipurpose, microprocessor
based weight converter/controller. Able to perform precise weight measurement even in environments
with vibration, the HI 2151/20WC's exclusive WAVERSAVER® quickly rejects noise with
frequencies above 0.25 Hz. Response time for stable readings is less than one second. For frequencies
above 7.5 Hz, the response time is even faster.
In addition, the HI 2151/20WC provides 985,000 displayed counts of resolution and accepts millivolt
signals of up to 30 millivolts from up to eight strain gage load cells/points for display and process
control by weight. The unit can also convert the millivolt-level load cell/point signal to an optional
4 to 20 mA, 0 to 20 mA, 0 to 10 or 0 to 5 Vdc analog signal providing noise immune transmission of
weight, or to an optional Binary Coded Decimal (BCD) format for parallel communication.
The HI 2151/20WC digitizes the the load cell/point signals for indication on its front panel, six-digit,
light emitting diode (LED) display and 30 segment bar graph. The bar graph can be set to display
either instrument status or an optional bar graph representation of one of five weight parameters.
Common language prompts lead you through the entire operation and calibration of the instrument.
Data is entered using the front panel keypad, which features a definite tactile feel for positive operator
control. In addition, parts of the keyboard can be locked to limit operator access and protect data.
Data is also protected with the HI 2151/20WC's unique Secure Memory Module (SMM). The SMM
stores and protects critical information from corruption such as calibration data, configuration of the
setpoints, the standard RS-232C serial port, and various options. All data except for Peak Hold is
stored automatically. In addition, data stored in one HI 2151/20WC may be restored in another by
simply transferring the Secure Memory Module.
C2TM Second Generation Calibration allows a scale system to be quickly calibrated on site without the
use of test weights, material substitution, or force calibration.
The HI 2151/20WC can be used in a multitude of industrial and commercial applications requiring
weight, level, or mass flow data. It can be used as a stand-alone unit or may be integrated into a
process control system by utilizing an extensive serial command set. The instrument provides bidirectional communication over its standard RS-232C port or, optionally, over RS-232C
or RS-422/485 serial ports (with the purchase of option boards). Multiple instruments (in RS-422
"multidrop" configuration) may be accessed from a host computer, Programmable Logic Controller
(PLC), or any other controlling computer.
Under license from Allen-Bradley, Hardy Instruments Inc. has developed a remote I/O Interface for
the HI 2151/20 weight controller. Each weight controller represents a quarter (1/4) rack of the PLC
and supports both discrete I/O and block transfers.
1-2
SECTION 1 - INTRODUCTION
GENERAL SPECIFICATIONS
Table 1-1. Specifications
Analog Section
Conversion Rate:
100 updates per second
Resolution (displayed):
1:985,000 (for 3 mv/v)
1:656,000 (for 2 mv/v)
1:1,048,576
(internal):
Averages:
1 to 200 selectable in increments of 1
Display Increments:
(graduations)
1, 2, 5, 10, 20, 50, 100, 200, 500 counts
selectable by keyboard.
Corresponding weight is
dependent on decimal point location.
Non-Linearity:
0.0015% of Full Scale
Common Mode Voltage Range:
+/- 2.5 Vdc
Temperature Coefficient:
less than 0.0005% per degree C for zero and span
Temperature Range:
-10E to 50EC (14E to 122EF)
Storage Temperature Range:
-20E to 85EC (-4E to 185EF)
Power:
120 or 240 VAC +/- 10% 10 watts maximum with options
installed from 47-63 Hz. 240 VAC operation requires
factory installed jumpers on the Power board.
Load Cells/points:
Up to eight 350 ohm load cells/points at 10 volt excitation.
(Maximum input = 31 mvdc.)
Inputs
Physical Characteristics
Panel Mount
Enclosure Rating:
Depth:
Panel Cutout:
Weight:
Wall Mount
Enclosure Rating:
Dimensions:
Weight:
None: Front Panel Bezel Nema 4
10" (254 mm)
3.09" x 5.75" (78.4 x 146 mm)
4.5 lbs (2.1 kg)
NEMA 4X (stainless steel)
14.25"H x 12.25"W x 6.00"D
361.95H x 311.15W x 152.4D (mm)
19.8 lbs (9 kg)
1-3
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
SYSTEM BLOCK DIAGRAM
Refer to Figure 1-2 for standard setup.
+))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
))))))))))),
*
*
*
*
*
+)))))))))))))))))))))))))))))))))))),
+)))))))))))))))))))), *
*
*
* Serial
*
Printer,
* *
*
*
*
* host
computer or
* *
* +)))))))))))))),
*
J3 - Serial Port - RRS-232C *=))))))))<* HI 120SO
serial to * *
* * Standard
*
*
*
* BCD
converter.
* *
* * 4 or 6 wire *
*
*
.))))))))))))))))))))- *
* * load cell
*=)))))))<* J1 - Load Cell
*
+)))))))))))))))))))), *
*
*
* Remote
* * (8 load cell *
Access
* *
*
*
*
* to common
* * maximum)
* *
* .))))))))))))))*
J2 - Remote Functions *=)))))))))1 functions
via
* *
*
*
* hardware
*
* *
*
+))))))))))))))))Q<* J4 - Opt Relays
*
* logic level
inputs.* *
*
*
*
*
.))))))))))))))))))))- *
*
*
*
*
+)))))))))))))))))))), *
*
*
*
*
* Two N/O or
* *
*
*
J5 - Setpoint Relays 1 & 2 /)))))))))<* N/C relays
*
for
* *
*
*
*
*
* setpoints.
3A
* *
*
*
*
*
.))))))))))))))))))))- *
*
+))))))))))))<* Option 1 slot
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
/))))))))))))<* Option 2 slot
*
*
*
*
*
.))))))))))))))))))))))))))))))))))))*
.))))))))3))))3))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
)))))))))))+))))))))3))))3))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
))))))))))),
*
*
*
*
*
*
*
Figure 1-2. HI 2151/20WC Standard and Optional Configurations
1-4
SECTION 1 - INTRODUCTION
1.3 STANDARD FEATURES AND OPTIONS
The basic HI 2151/20WC incorporates many quality features as standard, plus it offers a wide
assortment of hardware and software options to accommodate various types of process weighing
applications.
The configuration of your unit and options furnished with it (if ordered) are depicted by the model
number on the label on the top of the enclosure. The features, options, and model numbers are
explained below:
Standard Features
The basic weight controller, Model HI 2151/20WC, is provided with the following as standard
features:
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
Six digit display, 1:985,000 display resolution
Display type: 0.6" seven segment red LED
WAVERSAVER®
Secure Memory Module (SMM)
C2J Second Generation Calibration
3 modes of Calibration, C2®, Soft, Hard
Update rate: 20 readings per second
Gross or net modes of operation
Menu driven digital calibration
Front panel diagnostics
Averages of up to 200 readings in 1 unit increments
Powers up to eight 350 ohm strain gage load cells/points
Auto zero tracking
Motion detection
NTEP Certified Class III/IIIL (purchase of optional kit required)
UL/CSA Registered
Waterproof keyboard and weight display (NEMA 4)
Bi-directional RS-232C port
Two relay contact set points (SPDT, 3A, 115 VAC)
Panel mount enclosure with waterproof, gasketed bezel (mounting hardware included)
Remote functions connector
Tactile keypad
The HI 2151/20WC's resolution and range are as follows:
Resolution
Load Cell/Point Sensitivity
and Excitation
Load Cell/Point Signal Output
Utilizes 985,000 counts
3 mV/V with 10 Vdc excitation
0 to 30 mvdc maximum L/C output
Utilizes 656,667 counts
2 mV/V with 10 Vdc excitation
0 to 20 mvdc maximum L/C output
Figure 1-3. HI 2151/20WC Range and Excitation Voltages
1-5
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Models Available
HI 2151/20WC
HI 2151/20WC-WS
HI 2151/20WC-RM
HI 2151/20WC-BR
Panel Mount Unit
Wall Mount Unit (NEMA 4X Stainless Steel, 12.25"W x 14.25"H x
6"D)
Remote Mount Unit (This display mounts separately from instrument
body via a 5 foot flat ribbon cable.)*
Blind Remote Unit (Display is not included. An output option or
portable display must be purchased with this unit.)
CAUTION
* The flat ribbon cable for the remote mount version should not be run along side any AC
power wiring from the keyboard/display to the instrument!
Optional Features
The options available with your HI 2151/20WC are:
OUTPUTS
B1.
Analog Output (voltage and current)
B2.
BCD Data Output Tri-Stated (includes 37 pin D-subminiature connector and 6-inch
cable)
B3.
RS-232C/Current Loop
B4.
RS-422/485
B5.
BCD Data Output Tri-Stated (60" cable to B6 and B7 termination board options)
B6.
BCD Single Termination Board (used with B5)
B7.
BCD Quad Termination Board (used with B5)
B8.
Remote I/O interface for the Allen Bradley Network
B9.
BCD 24" inch cable (wall mount version only)
B10. RS-232C/Modbus (RTU)
B11. RS-422/485/Modbus (RTU)
B12. PROFIBUS Interface Option
CONTROL OPTIONS
C1.
Peak Hold
C2.
Rate-of-Change
C3.
Hardy Link Communications
C6.
Weight Totalization
C7.
Bar Graph
SETPOINT OPTIONS
D1.
Six TTL level outputs with mating connector and 60-inch unterminated cable
D2.
D1 +a solid state relay card with a 60" inch cable.
D3.
D1 +a solid state relay card with a 6" inch termination cable.
HARDWARE OPTIONS
E2.
240 VAC 50/60 Hz operation
E3.
NTEP Certification Kit
E4.
Portable Display (For Blind Remote unit only)
F1.
Intrinsic Barriers (internally mounted in wall mount version only)
1-6
SECTION 1 - INTRODUCTION
NOTE
Two slots are available for output option boards (B1 through B5, B8 and B9).
Only one option board, B3, B4 or B8 can be used in the instrument at any one time.
The B2, B5 or B9 option boards can only be mounted in option slot two.
Two B1 options can be mounted in the Instrument.
The B8 option can only be mounted in option slot one.
INTERPRETING YOUR MODEL NUMBER
Optional outputs and control hardware options are depicted by the model number on your unit, as
shipped from the factory. For example, an HI 2151/20WC with RS-232C/current loop output, rate-ofchange, six TTL level outputs, NTEP Certification Kit:
HI 2151/20WC-B3-C2-D1-E3
NOTE
If your unit has a model number "-E2", it is configured for 240 VAC input power;
however, if your model number does not show "-E2", then it is configured for 120 VAC.
1-7
SECTION 2 - INSTALLATION
SECTION 2
INSTALLATION
2.1 UNPACKING
The unit is enclosed in a protective foam insert inside a carton. Carefully open and remove the
package contents.
Inspection for Damage
Inspect the unit and accessories for any damage. If any damage is noted, immediately file a claim with
the carrier and notify Hardy Instruments' Customer Support (refer to Section 5).
Taking Inventory
Packed inside the carton are the following items:
a. Instrument (with mating connectors installed)
b. Mounting Hardware
c. HI 2151/20WC Operation and Installation Manual
Ensure all parts and accessories are unpacked. Save the protective foam insert for possible reshipment
at some future date. Ensure that any options ordered have been received and/or installed by referring
to your model number label. Record the data on the System Data Survey Sheet in Section 6,
Appendix B.
2-1
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
2.2 MECHANICAL INSTALLATION (PANEL MOUNT ONLY)
The unit fits a 3.09 inches by 5.75 inches panel cutout. Refer to Figure 2-1, HI 2151/20WC
Installation Details for cutout dimensions. Mounting is through the cutout and the unit is held in place
by four mounting bars and retaining screws, which are installed from the rear of the mounting panel.
Enclosure Mounting Instructions
When locating the panel cutout, allow a minimum of 1 inch on all sides of the bezel and any adjacent
units. This will provide approximately 2.34 inches between the left and right sides, and 1.65 inches
between the top and bottom of the unit's enclosure and adjacent equipment on the interior of the
mounting panel.
WARNING
Allow a minimum separation of 18 inches between weight controller and any 480 VAC power devices
or magnetic sources.
Allow a minimum of 2 inches between the unit's rear panel and the back of the mounting panel
enclosure for connector and cable clearance. That is, overall depth of the panel mounting enclosure
must be a minimum of 11-3/4 inches.
Perform the following steps to install the unit:
a. Carefully locate, mark, and make the cutout in the mounting panel, then deburr the cutout.
NOTE
A NEMA 4 waterproof gasket is applied to the back of the unit's bezel at the factory.
Ensure that this gasket is in place and flush against the bezel before installation.
b. Slide the unit into the mounting panel until the NEMA 4 gasket contacts the panel.
c. From inside the mounting panel enclosure, slide a mounting bar along each slotted corner of
the unit's case until it contacts the back of the mounting panel. See Figure 2-1 HI 2151/20WC
Installation Details. Insert the four furnished #6 Phillips screws into the threaded ends of the
four slotted corners.
d. While supporting the back of the unit with one hand and aligning it flush against the mounting
panel, partially tighten each of the four screws while going from corner-to-corner around the
case.
e. Gradually tighten each screw so the unit is firmly held against the mounting panel. The NEMA
4 waterproof gasket should be completely compressed between the unit's bezel and the front
of the mounting panel when the unit is fully tightened down.
f. Inspect the installation to ensure that the gasket is flush and evenly compressed behind the
bezel.
NOTE
If instrument is removed from the panel, a new NEMA 4 waterproof gasket (P/N 0524-0011)
must be installed prior to re-installation.
2-2
SECTION 2 - INSTALLATION
Figure 2-1. HI 2151/20WC Installation Details.
2-3
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
2.3 CABLING AND CONNECTIONS
Carefully plan your cable runs and wiring connections prior to routing, cutting, and trimming
cables and wires. Cables carrying 120/240 VAC primary and relay switched power (J2, J5
and J6) should be routed away from all other signal cables and load cell/point cables to avoid
electrical interference. All cabling to the rear panel should be neatly bundled, tied, and dressed
with a 6-inch service bend in order to relieve stress from the connectors and to facilitate servicing
the unit.
All cabling and electrical connections are made to the jacks on the rear panel of the unit (see Figure
2-2 HI 2151/20WC Rear Panel Connections). Mating plugs are furnished for all standard rear
panel jacks and are installed at the factory. Plugs are terminal block type with captive screws for
fastening cable wiring. Plugs are keyed so they fit only one way into the jacks on the rear panel.
NOTE
All plugs are held by a firm friction fit except J6, Power, which is held with two captive
clips. However, proper cable dress and a 6-inch service bend are especially important in a
high vibration environment to avoid connectors from working loose. All low level cables
should use shielded cable.
CAUTION
Once the unit is installed properly, label the mating connector or cable with the connector
number to preclude plugging the connector in the wrong jack and possible damage to the
instrument. J3, and J5 are interchangeable.
Figure 2-2. HI 2151/20WC Rear Panel Connections.
2-4
SECTION 2 - INSTALLATION
Load Cell/Point Connections (J1)
The unit is capable of powering a maximum of eight 350-ohm load cells/points. If more than eight
load cells/points are used, an external power supply is required. Figure 2-3 Load Cell/Point
Connections (J1) shows how to connect a full six-wire hookup, a four-wire hookup, and an external
excitation supply. Load cell/point cables are connected to J1 through a furnished mating plug, P1.
In order to ensure a "clean" signal from the load cells/points, the following precautions should be
taken:
a. Load cell/point cables MUST be run separate from all other cables and in their own
conduit. Load cell/point cable shield should be attached to ground screw on rear panel
only.
NOTE
Do not ground the other end of the shielded load cell/point cable.
b. Six-wire, shielded load cell/point cable should be used for lengths of 50 feet or more, or if
intrinsic safety barriers are used.
c. Avoid load cell/point cable splices. If cables are longer than needed, coil up and tape
excess cable. If cables are short, use an appropriate junction box. When terminal lugs are
installed on load cell/point cables, Hardy Instruments recommends the lug be crimped and
soldered.
d. When connecting the HI 2151/20WC weight controller to the HI 215JB junction box using
C2 load cell/point cable (6020-0001), use the following color code:
Load Point
Model
HI LPH
HI LPS
HI LPD
HI LPT
J-BOX
+EXC
GRN
RED
RED
RED
GRN
+SEN
ORN
+SIG
WHT
GRN
GRN
GRN
YEL
-EXC
BLK
BLK
BLK
BLK
BLK
-SEN
BLU
-SIG
RED
WHT
WHT
WHT
RED
Input Power Connections (J6)
This instrument requires at least 14 AWG power wiring.
AC POWER
WIRING
DIAGRAM
2-5
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
WARNING
DO NOT operate at incorrect line voltage; the unit will be damaged. Changing the input voltage
rating between 120 VAC and 240 VAC requires modifications at the factory. For further help
contact Customer Support (refer to Section 5).
A system ground wire has been installed between pin number 10 of the Remote Functions
connector and the shield screw. This wire ties the instruments analog/digital ground to the
instrument chassis ground. If grounding is required elsewhere in your system, this wire can be
disconnected.
The power and relay circuit card filters and conditions ac power. However, for noisy power lines,
external conditioning may be additionally required; consult Customer Support (refer to Section 5)
for more information. The ac power should be taken from a "clean" primary line directly from the
power panel. This line should not supply any other equipment and should be supplied with a
minimum 10 amp breaker.
Additional Cabling and Connections
It may be convenient at this point to install the remainder of the cabling for serial port(s), setpoint
relays, remote functions, or other options that are installed on the 2151/20WC. Please refer to the
appropriate sections for pin-out descriptions.
2-6
SECTION 2 - INSTALLATION
Figure 2-3a. 4 Conductor Load Cell/Point Connections (J1).
2-7
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Figure 2-3b. 6 Conductor Load Cell/Point Connections (J1).
2-8
SECTION 2 - INSTALLATION
Figure 2-3c. C2 Load Cell/Point Connections (J1).
2-9
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
2.4 INITIAL SYSTEM POWER-UP
When the unit has been satisfactorily cabled into the load cells/points, the next step is to plug the
unit in and proceed to Section 3 Scale Calibration.
2-10
SECTION 3 - SCALE CALIBRATION
SECTION 3
SCALE CALIBRATION
3.1 INTRODUCTION
This section contains a detailed calibration description, full calibration procedures and quick calibration
instructions. Quick calibration instructions are not meant to replace a full calibration of the instrument,
but instead provide a limited calibration of the zero and span parameters. This is useful in situations
where only re-calibration is necessary. This section also explains the Secure Memory Module.
3.2 PRE-CALIBRATION PROCEDURES
When the installation has been completed and the unit is successfully powered up, allow a minimum
of a 15 minute "warm-up" period prior to calibrating the instrument. Proceed with the following
paragraphs prior to calibrating the instrument.
Vessel/Scale System Inspection
"System" performance and overall accuracy are a combined function of the unit, load cells/points,
mechanical interface, and environmental conditions. To optimize accuracy and repeatability, the
system must have minimal binding and maximum flexibility. Inspect the system for any binding that
may cause the vessel to fail to return to the original zero reference point. In addition, all cables, tubes,
lines, etc., attached to the vessel must be inspected for ample flexibility. This will ensure accurate and
linear weight readings throughout the calibrated span. Consult our Customer Support or our
Applications Engineering Department for additional applications information or recommendations.
Load Cell/Point Installation Inspection
Load cells/points must be mounted properly to avoid costly damage. Refer to load cell/point
documentation for installation instructions. (Some load cells/points, i.e. some single and double ended
shear beam, have an arrow (9) indicating that the load cell/point should be mounted with the arrow
pointing in the direction of the applied load.)
Typical Load Cell/Point Input/Output Measurements (EXC & SIG Outputs)
The HI 2151/20WC is designed to supply 10 vdc excitation to as many as eight load cells/points. The
expected output from each load cell/point depends on the mV/V rating of the load cell/point. For
example, a 2 mV/V load cell/point will respond with a maximum of 20 mVdc at full capacity. If the
load cell/point capacity is rated at 500 pounds, the load cell/point output will be 20 mvdc at 500
pounds. The zero reference varies from system to system depending on the "Dead Load" of the vessel.
NOTE
Load cell/point measurements are checked with a digital volt meter at the summing junction box
or the J1 connector on the rear panel of the HI 2151/20WC.
3-1
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Description of Front Panel
The front panel contains 16 tactile membrane keys for operator control and calibration, and a large, six
digit, seven-segment LED display. There are also 30 dedicated status indicator LEDs that function
as a bar-graph display (optional).
Keys are arranged into two functional areas. The four large, circular keys across the top are dedicated
to those repetitive functions typical of process weighing. These are ZERO, MODE, TARE, and
PRINT. The remaining keys are utilized for setup of various option boards, instrument parameters and
calibration. The Enter key is similar to ENTER on a computer keyboard, and is dedicated to parameter
selections. The remaining keys perform combination numerical 0 - 9 and secondary functions, such
as options, setpoints, etc.
Figure 3-1 Front Panel depicts the HI 2151/20WC and gives a brief description of the front panel.
Following Figure 3-1 are sections which describe each function in detail. Please refer to Appendix A
for a detailed explanation of each key function.
Figure 3-1. Front Panel
3-2
SECTION 3 - SCALE CALIBRATION
PROCESS WEIGHING FUNCTION KEYS
ITEM LABEL
BRIEF DESCRIPTION (refer to Section 6, Appendix A for details)
1.
ZERO
2.
MODE
3.
TARE
4.
PRINT
Sets current count as new zero reference. The ZERO key will only zero up
to the zero tolerance value entered in the calibration menu. Also exits a
numeric entry in a menu.
Toggles between net/gross/rate-of-change*/peak hold* and total display
modes*
Captures current gross weight; places value in tare register. Sets display to
zero in net mode.
Outputs to designated printer port (NOT used with multidrop).
OPERATOR DISPLAY
5.
N/A
6.
N/A
Dual function display. Displays either weight controller status or bar-graph
representation of selected weight display mode.
Seven-segment LED display for displaying menus, operator inputs and
selected weight displays.
SET-UP AND CALIBRATION KEYS (see Section 6, Appendix A,
Keypad Descriptions for details)
7.
-/Test/Clr
8.
1/Tare Val
9.
10.
11.
12.
13.
14.
15.
2/Bar/Status
3/lb kg
4/8
5/7
6/Set Pt
7/Option
8/Cal
16.
17.
18.
9/9
0/Exit
Enter
Initiates self test, clears display of digits in any menu, and also enters
negative values. In CAL mode, reverts back to unit sub-menu from any
other sub-menu heading.
Enters digit 1; also displays current value in tare register, allowing it to be
changed.
Enters digit 2; also selects bar-graph display mode* or status indicators.
Enters digit 3; also toggles display units between pounds and kilograms.
Enters digit 4; also advances menu to next parameter.
Enters digit 5; also moves selectable decimal point one position left.
Enters digit 6; also selects setpoint menu.
Enters digit 7; also selects option menu.
Enters digit 8; also selects calibration setup menu to set calibration
parameters.
Enters digit 9; also resets menu to previous parameter.
Enters digit 0; also exits from current menu or sub-menu.
Enters data and advances menu item.
* Operational only if this option is installed.
3-3
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Seven Segment Display
The LED display is a six-digit, seven segment display with selectable decimal placement. The display
can show positive values up to 999999 and negative values down to -99999. The LED display shows
operational status messages as well as actual numeric values.
Combination Status Indicator/Bar-Graph LEDs (optional)
There are 30 discrete LEDs above the seven segment display that function as status indicators and bargraph display. To switch between status and bar graph display, press the Status/Bar key. In the status
mode, LEDs will light to indicate the following weight controller conditions:
DISPLAY
MEANING
CTR ZERO
Indicates when the sensed weight is within 1/4 of a display grad of calibrated
zero.
MOTION
Indicates when the variation in consecutive weight readings exceeds the
calibrated motion tolerance.
ZERO TRACK
Indicates when the zero track function is activated. Zero track is toggled on or
off by the 0 Trk dipswitch (S3) on the rear panel.
ALARM 1
The status alarm LED flashes when the respective setpoint value has been
reached. Indication is only for the standard, internal setpoints.
ALARM 2
The status alarm LED flashes when the respective setpoint value has been
reached. Indication is only for the standard, internal setpoints.
GROSS/NET/
TOTAL/ROC/
PEAK
Indicates the mode of the measured value on the display.
lb/Kg
Indicates U.S. or metric unit-of-measure of the weight parameter on the
display.
The bar-graph menu is used to select which parameter the bar-graph displays. This is explained in
Section 4, Bar-Graph Menu Setup Procedure.
3-4
SECTION 3 - SCALE CALIBRATION
3.3 DETAILED CALIBRATION DESCRIPTION (This is a description only, refer to section 3.4
Full Calibration Procedures for step by step instructions).
To enter the Calibration (CAL) Menu, the instrument must be in the gross mode. On the Panel Mount
and Remote Mount versions Config Dipswitch S3-CAL, found on the rear of the instrument, must be
toggled (changed from previous position). On the Wall Mount version Remote Cal Access Switch S1
must be pressed. When the front panel Cal key is pressed, the display will read CAL for a moment
and then read UNIT. Menu items are displayed sequentially each time the Enter key is pressed.
Editing a menu item is accomplished two ways: 1) press the Enter key and enter the new value or,
2) press Enter and then use the up/down arrow keys to select a displayed value. Calibration values can
be entered using the numeric keys. Pressing the Enter key will set the new value. The Enter key must
be pressed to seal the calibration when the display reads ENDCAL.
The calibration data for the instrument consists of the following parameters (refer to Section 3-4 Full
Calibration Procedure for step by step instructions):
a.
b.
c.
d.
e.
f.
g.
h.
i.
Units (1b/kg)
Decimal point position
Total Decimal Point (optional)
Motion tolerance
Graduation size
Zero Tolerance
Number of readings averaged
Scale capacity
Cal type
(1) C2TM Second Generation Calibration
(a) Load point detection
(b) Reference point
(c) Return
(2) Software calibration
(a) Sensitivity
(b) Range
(c) Sticker
(d) Reference point
(e) Return
(3) Hardware calibration
(a) Zero
(b) Span
(c) Linear Correction
(d) Return
j. End Calibration
NOTE
When the desired calibration menu item is being displayed, press the Enter key to
view the current numeric value. To clear the current value, press the -/Test/Clr key,
and use the numeric keys to enter new values. If an error is encountered when
entering the new value, refer to Appendix C for error message definitions.
3-5
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
The number of readings averaged automatically changes to 200 every time the CAL Menu is entered.
(This will not be noticed by the user because the previously entered averages will be displayed.) This
changes the response delay (averaging time) to approximately 12 seconds. If the scale weight is
changed for any reason, wait at least 12 seconds before performing zero, span, or linear correction.
After exiting the CAL Menu, the previously set number of averages will be automatically restored.
a. Units. With the display indicating "unit", press the Enter key so that the display indicates a
unit of measure ("lb" or "kg"). Press the up arrow to select pounds or kilograms, then press
the Enter key to accept the units. Note that the unit of measure can be changed during normal
operation. Selection of the unit is needed prior to calibration so that the values entered can be
interpreted in the proper unit-of-measure. The calibration units will be the units upon which
all setpoints are based.
b. Decimal Point Position. Change the decimal point position by pressing Enter when the
display indicates "DECPNT". The display will then show six eights. Pressing the left arrow
key moves the decimal point to the left one digit. When the desired position is reached, press
the Enter key to set the position.
c. Total Decimal Point (Option). The Total Decimal Point feature is operational only when
used in conjunction with the optional weight totalizer. The Total Decimal Point must be less
than or equal to the standard decimal point position. Change the total decimal point position
by pressing Enter when the display indicates "tot dp". The display will then show six eights.
Pressing the left arrow key moves the decimal point to the left one digit. When the desired
position is reached, press the Enter key to set the position.
d. Motion Tolerance. This is the tolerance value used to determine if the scale is in motion. The
default motion tolerance is three graduations. The instrument indicates motion whenever a
change in the displayed (averaged) reading is outside the value entered. The -/Test/Clr key
may be used to clear previous tolerance values. To enter new values, use the numeric keys.
NOTE
When the motion value is exceeded, the unit will not transmit data to printer.
e. Graduation Size. Press Enter. This is the minimum increment computed and displayed by
the instrument. It may be increased or decreased by pressing the up or down arrow keys when
"GRAD" is displayed. Acceptable graduation sizes are:
1
50
2
100
5
200
10
500
20
The graduation size is recalculated each time the instrument is calibrated for span. The
graduation size can then be changed if desired.
f. Zero Tolerance. This value is the zero tracking window. When the auto zero tracking
function is enabled, any weight within tolerance of zero and not in motion will cause the
display to indicate zero. The default zero tolerance is 10 graduations. Weight can accumulate
up to the value entered for the zero tolerance, and the instrument will still display 0. Zero
3-6
SECTION 3 - SCALE CALIBRATION
tolerance can also be used with the round ZERO key to zero the display. (See Figure 1-1
Hardy Instruments' HI 2151/20WC Weight Controller). Set a new zero tolerance value when
"0TOL" is displayed, press the Enter key and use numeric keys to enter the new value. Press
the Enter key to set the value. The maximum Zero Tolerance number that can be entered is
32766.
g. Number of Readings Averaged. This sets the number of weight readings which will be used
to compute the displayed weight. The average will be a running (or sliding) average so that
a new average is available for display at every reading. The default number of readings per
average is 100. Any number from 1 to 200 can be entered. Enter a new value when
"AVRAGE" is displayed. Press the Enter key, the -/Test/Clr key, and use the numeric keys
to enter the new value. Press the Enter key to set the new value.
h. Scale Capacity. This value represents the nominal operating capacity of the scale. If the
weight should exceed 105% of this value, the display will indicate an over capacity condition
"HI". The value entered, in most cases, should be the lesser of the scale capacity or the
combined value of the load cells/points. To enter a new scale capacity value, press the Enter
key with SC CAP displayed. Press -/Test/Clr and use the numeric keys to enter the new value.
Press the Enter key to set the value.
i. Cal. This menu allows access to C2TM Second Generation Calibration, Software Calibration
and Hardware Calibration sub-menus. Pressing the enter key with CAL displayed prepares the
instrument for the C2TM, Soft-Cal or Hard-Cal routine. Pressing the up or down arrow key
will display all of these menus for selection.
(
C2TM Second Generation Calibration. C2TM will only work with Hardy Instruments
Load Points. It does not require any test weights. To enter this routine, press the Enter key.
(a) Load Point Detection. It will automatically read how many Hardy Load Points that
are installed.
(b) Reference Point. This is usually zero, but can be a known "live" weight on the scale.
Press the Enter key. A previously set reference point will be displayed. Erase this
value by pressing -/Test/Clr key. Next, use the numeric keys to enter the data. Press
the enter key to set the value.
(c) Return. Pressing the Enter key takes the instrument to End Calibration. The up arrow
key will take the instrument back to L/C Count. The down arrow key will return the
instrument to Reference Point.
(2) Software Calibration. Soft-Cal uses parameters found on the manufacturer's load
cell/point calibration certificate for each load cell/point and one reference point (usually
zero). It does not require any test weights (refer to section 3.6). To enter this routine, press
the Enter key.
(a) Sensitivity. This is the full scale output in mV/V, as found on the load cell/point
calibration certificate. Press the enter key and then the -/Test/Clr key to clear the
display. Next, use the numeric keys to enter the data. Press the enter key to set the
value.
3-7
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
(b) Range. This is the total capacity of the load cells/points as specified on their
calibration certificates. Press the Enter key to clear the display. Next, use the numeric
keys to enter the data. Press the Enter key to set the value.
(c) Sticker. This is the factory normalized value of the instrument. This value should
only be changed during a Secure Memory Module change. Press the up arrow to move
to the next parameter.
(d) Reference Point. This is usually zero, but can be a known "live" weight on the scale.
Press the Enter key. A previously set reference point will be displayed. Erase this
value by pressing -/Test/Clr key. Next, use the numeric keys to enter the data. Press
the enter key to set the value.
(e) Return. Pressing the Enter key takes the instrument to End Calibration. The up arrow
key will take the instrument back to Zero. The down arrow key will return the
instrument to Reference Point.
(3) Hardware Calibration. Hard-Cal is the traditional way of calibrating a scale requiring a
reference point and the physical placement of test weights on the scale. To enter this
routine, press the Enter key.
(a) Zero. With the display indicating "ZERO," remove all weight from the scale. When
all weight has been removed, press the Enter key. Press -/Test/Clr, then wait 12
seconds and press Enter. The current deadload load cell/point signal reading will be
accepted as the zero calibration value.
(b) Span. Place a test weight (such as a certified test weight) on the scale and with
"SPAN" displayed, press the Enter key. Press -/Test/Clr and use the numeric keys to
enter the value of the test weight. Ideally the test weight added to the dead load should
be the typical weight to be measured in the application. After waiting 12 seconds,
press the Enter key to set the span.
(c) Linear Correction. This parameter corrects for non-linearity in the load cells' output;
however, in most applications, this is not necessary. The midpoint linearity value
default is set to zero. To set a value other than zero, first test for accuracy by placing
a test weight on the scale. Keep adding weight until the discrepancy between actual
weight and test weight is greatest. Use the numeric keys to enter the test weight value
and press Enter.
(d) Return. Pressing the enter key takes the instrument to End Calibration. The up arrow
key will take the instrument back to Zero. The down arrow key will return the
instrument to Linear correction.
j.
3-8
End Calibration. This item seals all calibration changes. Press the Enter key when "ENDCAL"
is displayed to set the calibration values and exit the calibration menu.
SECTION 3 - SCALE CALIBRATION
3.4 CALIBRATION SETUP PROCEDURE
This procedure is an example of how to calibrate all features of the unit from the Calibration Menu.
To enter the calibration menu, configuration dipswitch S3-CAL on the rear panel must be toggled prior
to pressing the Cal Key (panel and remote mount). For the wall mount, the calibration button inside
the enclosure should be pressed. The unit must also be operating in the Gross Mode (press Mode key
to change modes). For the sake of examples using this full calibration procedure, the parameters will
be set per the following list (use the appropriate parameters for your particular application):
1.
2.
3.
4.
5.
6.
7.
8.
UNIT = lbs.
DECIMAL POINT POSITION = 2 places
TOTAL DECIMAL POINT = 2 places
MOTION = 2.00
GRADUATION = 2
ZERO TOLERANCE = 1.00
AVERAGE = 10
SCALE CAPACITY = 500.00
NOTE
To correct a mistake during calibration, or to return to a previous calibration parameter,
press the down arrow. To bypass parameters, press the up arrow.
Table 3-1. Calibration Setup Procedure
(To be done for all calibration types)
PROCEDURE
KEY
DISPLAY
Cal
SEtUP *
1. Enter Calibration Menu.
NOTE: If "error 8" is displayed re-toggle config
dipswitch S3-CAL. If "error 5" is displayed select
gross mode.
a. Press Cal key.
Unit
2. Select units (lbs. or kgs.).
a. Press Enter key.
Enter
Lb
* Display Momentarily Flashes
3-9
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 3-1. Calibration Setup Procedure - Continued
PROCEDURE
KEY
DISPLAY
b. Press Up or Down arrow key to toggle display
units between pounds (LB), or kilograms, (Gr).
8 9
Lb
c. When desired unit value is displayed, press the
Enter key.
Enter
Good
DecPnt
3. Enter decimal point.
a. Press Enter key.
Enter
888888
b. Press LEFT arrow (select/digit) key until the
decimal point is at the desired position.
7
8888.88
c. Press Enter key.
Enter
Good
tot
4. Enter Total Decimal Point.
(only used with the optional totalizer feature)
*
dP**
a. Press Enter key.
Enter
888888
b. Press LEFT arrow (select/digit) key until the
decimal point is at the desired position.
7
8888.88
c. Press Enter key.
Enter
Good
NOTE: Previously set motion tolerance value will be
displayed. A motion tolerance of 2.00 will be set in
the following example.
a. Press Enter key.
Enter
0.03
b. Press -/Test/Clr key.
-/Test/Clr
0.00
c. Press the corresponding number keys
200
2.00
** Displayed only if TOTALIZER option is enabled.
* Display momentarily flashes good if value is a valid entry.
*
motion
5. Enter Motion Tolerance.
3-10
*
SECTION 3 - SCALE CALIBRATION
Table 3-1. Calibration Setup Procedure - Continued
PROCEDURE
KEY
DISPLAY
d. Press Enter.
Enter
Good
grAd
6. Enter Graduation size.
Enter
1
b. Press Up or Down arrow key until desired
graduation size is displayed.
8
2
c. Press Enter Key.
Enter
a. Press Enter key.
*
NOTE: Previously set graduation size value will be
displayed. For this example, a graduation size value
of 2 will be set.
9
Good
0 toL
7. Enter Zero Tolerance.
Enter
0.10
b. Press -/Test/Clr key.
-/Test/Clr
c. Enter desired zero tolerance value.
100
0.00
1.00
d. Press Enter key.
Enter
a. Press Enter key.
*
NOTE: Previously set zero tolerance value will be
displayed. For this example, a zero
of 1.00 will be set.
Enter
Good *
AVrAgE
100
-/Test/Clr
000
8. Enter Number of Readings Per Average.
a. Press Enter key. (Example)
NOTE: Previously set number of readings per average
value will be displayed. For this example, an average
of 10 will be set.
b. Press the -/Test/Clr key.
* Display momentarily flashes good if value is a valid entry.
3-11
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 3-1. Calibration Setup Procedure - Continued
PROCEDURE
KEY
DISPLAY
c. Enter desired number of readings per average
value.
10
10
d. Press Enter key.
Enter
Good
Sc CAP
9. Enter Scale Capacity.
a. Press Enter key.
*
Enter
NOTE: Previously set scale capacity value will be
displayed. For this example, a scale capacity value
of 500 will be set.
b. Press -/Test/Clr key.
-/Test/Clr
0.00
c. Enter new scale capacity.
50000
500.00
Enter
Good
Note: Three or more digits must be used. For low
capacities use decimal points.
d. Press Enter key.
10. Continue with one of the following calibration steps:
Section 3.5, Table 3-1a: C2TM Second Generation Calibration procedures.
Section 3.6, Table 3-1b: Soft Calibration Procedures.
Section 3.7, Table 3-1c: Hard Calibration Procedures.
3-12
*
CAL
SECTION 3 - SCALE CALIBRATION
3.5
C2TM SECOND GENERATION CALIBRATION
C2 TM Second Generation Calibration (C2) automatically calibrates a scale system without the use of
test weights, material substitution, or force calibration. Unlike Hard-Cal, the vessel does not have to be
empty to calibrate as long as the weight of material inside the vessel is known. Later, when the vessel
is empty, you can set zero as the new reference point for calibration to provide a better reference. Unlike
Soft-Cal, C2 calibration eliminates the potential human errors that may occur from manually entering
the load cell data, to obtaining and maintaining files for this data for future use. The C2 Menu can't be
entered while in the NBS mode.
A C2 certified weighing system consists of up to eight load points, a junction box, interconnect cable
and an instrument with C2 capabilities, like the HI2151/20WC.
Hardy Instruments C2 certified Load Points contain digital information detailing the unique performance
characteristics of each individual load point. These load points are available as single-ended or doubleended shear beams, or "S" beam types with capacities ranging from 40 LBS to 250,000 LBS. Each load
point has C2 certified cable that should never be cut or spliced. C2 cannot be performed unless All load
points in the system are C2 certified.
Hardy Instruments C2 certified Junction Box contains circuitry in a waterproof NEMA 4X painted steel,
stainless steel, or fiberglass enclosure. The circuitry transfers excitation voltage to each load point, sums
up to four load point signals, and transfers the weight signals and digital C2 information back to the
weight controller. Two junction boxes can be cabled together to handle up to eight load points. Its
unique multiple connector design allows for easy voltage and resistance measurement during
troubleshooting. Each box comes with five pre-drilled holes, up to five cable grip fittings, and three
packaged hole plugs to accommodate cables with 3/8" (0.375) to 1/2" (0.5) O.D.
Hardy Instruments C2 certified Load Point Interconnect Cable is a 22 AWG, 8-conductor, shielded
cable designed to easily handle the low voltages found in weighing systems as well as the load point
performance characteristics. The braided shield protects the load point signals from EMI/RFI
interference. The Gray and Violet, twisted pair wires are assigned to the C2 connector terminals.
Hardy Instruments 2151/20 Weight Controller is a C2 certified instrument that detects the quantity of
C2 certified load points in the system and reads the unique performance characteristics of each individual
load point. It then can be calibrated by simply entering a reference point reflecting the current weight
on the scale, from zero to scale capacity. Hard-Cal and Soft-Cal are also included as alternate calibration
methods that can be used as well.
Theory of Operation: When power is applied to the unit, the C2 certified HI2151/20WC polls the load
points searching for C2 information. When a C2 certified load point is detected, the performance
characteristics of that load point are read and stored in the instrument. The HI2151/20WC then searches
for additional C2 certified load points in the system and stores their unique performance characteristics
in memory. This is all completed during the power up sequence.
Calibration: To calibrate a system for the first time, physically inspect the scale system looking for and
correcting any mechanical binding problems, potential motion constraints as weight is added, and verify
that the weight is applied vertically on the load points. Next, check all load point cables for proper colorcode wiring and secure connections. (Refer to figure 2-2 REAR PANEL CONNECTIONS for connector
pin assignments)
3-13
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Make sure that you have followed the Calibration setup steps in Table 3-1. Calibration Setup Procedure,
then follow the procedure outlined below on Table 3-1a. C2TM Second Generation Calibration Procedure.
After the initial setup, calibration can be repeated at any time as long as the approximate weight on the scale
is known.
Table 3-1a. C2TM Second Generation Calibration Procedures
PROCEDURE
KEY
DISPLAY
1. Enter Calibration mode.
2.
CAL
a. Press Enter key.
Enter
Hd CAL
b. Press Down Arrow key.
9
C2 CAL
c. Press Enter key.
Enter
LC Cnt
a. Press Enter key.
* Up to 8 load points can be detected.
Enter
1*
b. Press Enter key.
Enter
rEF Pt
a. Press Enter key.
Enter
-
b. Press -/Test/Clr key.
-/Test/Clr
0.00
c. Enter the Reference weight on
the scale, or press Enter if
zero reference weight is used.
5000
50.00
Verify the number of load points detected by
C2 calibration matches the actual number of
load points installed in the system.
3.
Enter Reference Point.
NOTE: This example uses 50.00 LBS as a reference
point with 2 decimal places, but any known weight
within the scale range can be used. The recommended
and default value is zero.
3-14
SECTION 3 - SCALE CALIBRATION
Table 3-1a. C2TM Second Generation Calibration Procedures - Continued
PROCEDURE
KEY
d. Press Enter key.
4.
Enter
Good*
rEturn
Enter
EndCAL
Enter
__**__
Go to EndCal.
a. Press Enter key.
5.
DISPLAY
Exit Calibration Menu.
a. Press Enter key.
** Display shows actual weight on scale.
*
3.6
Display momentarily flashes good if value is a valid entry.
SOFTWARE-CALIBRATION (SOFT-CAL)
Soft-Cal allows a scale system to be quickly calibrated on-site without the use of test weights, material
substitution, or force calibration. This process uses the certified, full scale mV/V output (sensitivity,
input resistance and range) of each load cell/point which is mathematically combined with a measured
reference point (which is usually, but not restricted to, zero) to calibrate the scale. The certified, full
scale mV/V data is found on the calibration certificate which is shipped with each load cell/point. This
process assumes a consistent center of gravity on the scale with even distribution. The load cells/points
must be installed correctly and there must not be any binding in the mechanics of the scale. The load
cell/point cable must be the same length as supplied by the load cell/point manufacturer. The cables
must not be cut. For multiple cell/point systems where a junction box is used, balance potentiometer and
resistors must be zero. The Soft-Cal menu cannot be entered while in the NBS mode.
For multiple load cell/point systems, an additional software program is available through our service
department. This allows users to enter data for up to eight load cells/points from their respective
calibration certificates. The program returns one equivalent sensitivity value and one range value. The
data entered for the load cells/points is the maximum weight (range) from the data sheet of one of the
load cells/points (they should all be the same), the serial number for each load cell/point, the full scale
value for each load cell/point, and the input impedance for each load cell/point.
3-15
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Make sure that you have followed the Calibration setup procedures in Table 3-1. Calibration Setup
Procedure, then follow the procedure outline on below on Table 3-1b. Software Calibration
Procedure. After the initial setup, calibration can be repeated at any time as long as the approximate
weight on the scale is known.
Table 3-1b. Software Calibration Procedure
PROCEDURE
KEY
DISPLAY
CAL
1. Enter Calibration mode.
a. Press Enter key.
Enter
HdCAL
b. Press Up Arrow key.
8
S CAL
c. Press Enter key.
Enter
SnStUy
a. Press Enter key.
Enter
-
b. Press -/Test/Clr key.
-/Test/Clr key
0
2. Enter the load cell/point full scale output in mV/V
as found on the load cell/point calibration certificate.
c. Use numeric keys to enter full scale output. Use
29998
DOS utility program to compute total full scale
output sensitivity for more than one load cell/point.
29998
NOTE: You must enter five digits. If load cell
is listed at less than five digits make data the
unlisted least significant digits zero.
Enter
good*
a. Press Enter key.
Enter
rAnGE
b. Press Enter key.
Enter
10000
c. Press -/Test/Clr key.
-/Test/Clr key
0
d. Press Enter key.
3. Enter the scale RANGE (capacity).
*
Display flashes "good" when accepted
3-16
SECTION 3 - SCALE CALIBRATION
Table 3-1b. Software Calibration Procedures - Continued
PROCEDURE
KEY
DISPLAY
d. Use the numeric key pad to enter the sum of the
rated capacities of all the load cells/points being
used on this scale.
Enter
SticKr
8
rEFPt
a. Press the Enter key.
*The previously set reference point will be
displayed.
Enter
-
b. Press the -/Test/Clr key.
-/Test/Clr key
c. Press the Enter key.
Enter
0.00
good*
rEtUrn
Enter
EndCAL
Enter
__**__
e. Press the Enter key.
4.
Sticker. This is the value which normalizes each
instrument and should only be changed when
replacing the Secure Memory Module (SMM).
Refer to Section 3.7.
a. Press Up arrow key once.
5.
500.00
50000
Enter Reference Point.
NOTE: This example uses zero as a reference point
but any known weight within the scale range can be
used. The Zero point is recommended.
6.
Go to EndCal.
a. Press the Enter key.
7.
Exit Calibration Menu.
a. Press Enter key to seal calibration.
NOTE: All calibration parameters are updated in
the cal menu and are saved to the Secure Memory
Module when EndCal is entered.
*
Display flashes "good" when accepted.
3-17
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
3.7a
HARD CALIBRATION
Make sure that you have followed the Calibration setup procedures in Table 3-1. Calibration Setup
Procedure, then follow the procedure outlined below on Table 3-1c. Hard Calibration Procedure.
Table 3-1c. Hard Calibration
PROCEDURE
KEY
DISPLAY
CAL
1. Enter Calibration Mode.
a. Press Enter key.
Enter
Hd CAL
b. Press Enter key.
Enter
ZEr0
a. Press Enter key.
Enter
-
b. Press -/Test/Clr key.
-/Test/Clr
0.00
Enter
Good
2. Enter Zero.
NOTE: Remove weight from scale to bring load
cell/point output to the lowest reading.
c. Wait 12 seconds.
d. Press Enter key.
SPAn
3. Enter Span.
NOTE: Any calibrated weight can be used to set span. It
is recommended that a weight greater than 80% of the
scale capacity be used. For this example, a 250 pound
weight will be used.
a. Place 250 lb. weight on scale.
b. Wait 12 seconds.
c. Press Enter key.
Enter
-
d. Press -/Test/Clr key.
-/Test/Clr
0.00
NOTE: Previously set span value will displayed.
3-18
*
SECTION 3 - SCALE CALIBRATION
Table 3-1c. Hard Calibration Procedure - Continued
PROCEDURE
KEY
DISPLAY
e.
Press -/Test/Clr key.
-/Test/Clr
0.00
f.
Enter new span value.
25000
250.00
Enter
Good
g. Wait 12 seconds.
h. Press Enter key.
*
LinCor
4. Enter Midpoint Linearity.
NOTE: Only non-linear load cell/point applications require
midpoint linearity calibration. Follow this calibration
procedure if you have a non-linear load cell/point application.
a. Test accuracy by placing a test weight on the scale.
An inaccurate weight will be displayed.
b. Wait 12 seconds.
c. Keep adding weight until you notice the greatest
discrepancy between actual and displayed weight
(about1/2 of the load cells' capacity, or midpoint).
d. Press the Enter key.
Enter
0.00
e. Use the numeric keys to enter the test weight.
(50 pounds will be used for this example)
.
5000
50.00
f.
Enter
Press Enter key.
(example)
Good *
rEturn
3-19
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 3-1. Hard Calibration Procedure - Continued
PROCEDURE
KEY
rEtUrn
5. Go to EndCAL.
a. Press Enter key.
Enter
EndCAL
EndCAL
6. Exit Calibration Menu.
a. Press Enter key to seal calibration.
DISPLAY
Enter
*
* Display shows actual weight on scale.
NOTE
All calibration parameters are updated only in the cal menu and are saved to the Secure Memory
Module when EndCAL is entered.
3-20
SECTION 3 - SCALE CALIBRATION
3.7b QUICK SETUP PROCEDURES FOR HARD CALIBRATION
This procedure will allow calibration of zero and span only. All other menu items are eliminated. To
enter the calibration menu, dipswitch S3-CAL on the rear panel must be toggled prior to pressing the Cal
button, and the unit must be operating in the Gross Mode. If the Cal switch is not toggled the display
will read ERR8. You may simply review these calibration values without changing them. Press the Test
key and the calibration values will be displayed. To change the calibration values, toggle the CAL
switch and press the Cal button.
Table 3-2. Quick Setup Procedures for Hard Calibration
PROCEDURE
1. Press Cal key.
KEY
DISPLAY
Unit*
CAL
2. Press the UP arrow key until CAL
prompt is displayed.
8
CAL
3. Press Enter key.
Enter
HdCAL
4. Press Enter key.
Enter
ZEr0
5. Press Enter key.
Enter
-
6. Press -/Test/Clr key. Remove weight from scale
to bring load cell/point input to lowest reading.
-/Test/Clr
0
8. Press Enter key. Zero is set and menu proceeds
to span. Place test weight on scale to bring the
load cell/point input to full range.
Enter
SPAn
9. Press Enter key.
Enter
-
10. Press -/Test/Clr key.
-/Test/Clr
100.00
11. Press -/Test/Clr key again. Enter the desired weight
value for span using the number keys.
-/Test/Clr
0.00
7. Wait 12 seconds.
* SETUP flashes momentarily.
3-21
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 3-2. Quick Calibration Procedure for HI 2151/20WC - Continued
PROCEDURE
KEY
DISPLAY
13. Press Enter key, span is now set.
Enter
LinCor
14. Remove test weight from scale. Use the up arrow
to advance to RETURN.
8
rEtUrn
15. Press Enter.
Enter
EndCAL
16. Press Enter to seal calibration.
Enter
*
12. Wait 12 seconds.
NOTE: Calibration data is automatically saved
to the Secure Memory module (see Section 3.7).
* Display shows actual weight on the scale.
3-22
SECTION 3 - SCALE CALIBRATION
3.8 ENHANCED SECURE MEMORY MODULE (SMM)
The enhanced Secure Memory Module is a secure, non-volatile device. The SMM stores all
calibration data, the configuration of Setpoints (all), and the standard RS-232C Serial Port. It will
also store the configuration of all the options except for Peak Hold (-C1). All data is stored
automatically. During system operation when a new parameter is entered, the enhanced SMM
automatically updates that value in its memory. The enhanced Secure Memory module, a DS1205,
replaces the old DS1201 memory device.
Transferring the Secure Memory Module
CAUTION
These instruments contain static-sensitive components and require careful handling. Use a
static wrist strap for proper grounding protection or touch a grounded surface prior to sliding
the boards out of the case.
NOTE
If the HI2151/20WC is in a wash down area, it is recommended that the front panel gasket be
replaced.
A. From One Enhanced HI2151/20WC to Another
To transfer the Secure Memory Module from one enhanced unit to another, follow the steps below:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Unplug the enhanced unit.
Detach all interconnect cabling and remove the enhanced HI2151/20WC from its mounting.
Remove the four screws holding the rear panel.
Slide the rear panel, including all the boards, out of the case.
The enhanced Secure Memory Module is labeled U19, and is located towards the front of the
top main board.
Unfasten the securing strap, and pull the Secure Memory Module off the board.
Carefully install this module in socket U19 of the new enhanced HI2151/20WC. Match the
beveled edge of the SMM with the diagram on the board. If Soft-Cal is to be used, copy down
the Sticker value found on the hand-written label near U19.
Re-install the boards, hardware, and re-attach the cabling.
The original data is restored to the new unit upon power-up.
B. From One Enhanced HI2151/20WC to an Older HI2151/20WC
To transfer the Secure Memory Module from an enhanced unit to one not enhanced also requires
transferring the E-prom U11. Follow these steps:
1.
2.
3.
4.
5.
Unplug the enhanced unit.
Detach all interconnect cabling and remove the enhanced HI2151/20WC from its mounting.
Remove the four screws holding the rear panel.
Slide the rear panel, including all the boards out of the case.
The enhanced Secure Memory Module is labeled U19 (Chip P/N: DS1205), and is located
towards the front of the top main board.
6. Unfasten the securing strap, and pull the Secure Memory Module off the board.
7. Carefully install this module in socket U19 of the older HI2151/20WC. Match the beveled
edge of the SMM with the diagram on the board.
3-23
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Transferring the Secure Memory Module - Continued
B. From One Enhanced HI2151/20WC to an Older HI2151/20WC - Continued
8
Use a small, flat-blade screwdriver, to gently pry up the Eprom U11, separating it from its
socket on the board.
9. Position the EPROM from the enhanced unit over the socket labeled U11 on the replacement
unit making sure that the notch on the EPROM matches the diagram beneath the socket.
10. Gently insert one row of pins partially into the socket to align the chip. Now, carefully work
the other row of pins into place and gently press the EPROM into the socket.
11. Inspect the pins and verify that there are no bent or misaligned pins as a result of the
installation.
12. Re-install the boards, hardware, and re-attach the cabling.
13. The original data is restored to the new unit upon power up.
C. From an Older HI2151/20WC to an Enhanced HI2151/20WC
This sequence only allows the manual transfer of calibration data from the old SMM to the new
unit, and then the new SMM will be re-installed. The setpoint and option menu data must be reestablished and manually re-entered.
1.
2.
3.
4.
5.
Unplug the older version instrument.
Detach all interconnect cabling and remove the older HI2151/20WC from its mounting.
Remove the four screws holding the rear panel of both instruments.
Slide the rear panel, including all the boards, out of their cases.
The Secure Memory Module is labeled U19, and is located towards the front of the top main
board.
6 Unfasten the securing strap, and pull the Secure Memory Module off the board.
7. Carefully install the older version module in socket U19 of the newer HI2151/20WC. Match
the beveled edge of the SMM with the diagram on the board.
8. Re-install the boards, hardware, and re-attach the cabling (power and load cell) to the newer
unit.
9. Energize the newer instrument. The display should momentarily show Old Tag (OLD tG)and
then continuously sequence through the following parameters at a rate of one per second:
UNIT
GRAD
ZERO COUNTS
SPAN
FULL SCALE COUNTS
SCALE CAPACITY
ZERO TOLERANCE
MOTION
AVERAGES
Note
You will need to write the parameters down before continuing with the installation.
10. De-energize the instrument; remove the old Secure Memory Module and re-install the newer
version.
11. Re-install the boards, hardware, and all the cabling.
3-24
SECTION 3 - SCALE CALIBRATION
Transferring the Secure Memory Module - Continued
C.
From an Older HI2151/20WC to an Enhanced HI2151/20WC- Continued
12. Energize the newer instrument and enter the Calibration menu. In the Set-up portion, enter the
parameters which were copied in step 9.
13. At the Hd CAL prompt press the Mode key. The display will read Zr cnt (zero counts); press
the Enter key followed by the -/Test/Clr key. Using the numeric keys, enter zero counts written
down in step 9.
14. Press the Enter key; the display will read SPAn. Press the Enter key followed by the
-/Test/Clr key. Using the numeric keys, enter the span written down from step 9.
15. Press the Enter key. The display will read FS cnt (full scale counts). Press the Enter key
followed by the -/Test/Clr key. Using the numeric keys, enter the full scale counts written
down from step 9.
16. Press the Enter key. The display will read rEtUrn. Press the Enter key two more times to return
to the weighing mode. The scale is now calibrated.
17. Enter the SETPOINT Menu and input all recorded values.
18. Enter the OPTIONS Menu and input all required parameters.
19. The instrument is now ready for operation.
Table 3-3. Restoring Data from the Secure Memory Module (SMM)*
PROCEDURE
KEY
DISPLAY
1. Press numeric keys 9, 5, and the Enter key.
9 5 Enter
rESEt
2. Press Enter key.
Enter
no
3. Press up arrow.
8
4. Press Enter key.
(It will pause for about 3 seconds before resetting)
YES
Enter
Good
**
CF = 1
***
NOTE
Numeric key entries will not be displayed on LED indicator when restoring data from the Secure
Memory Module.
When restoring information from one Secure Memory Module to another, the HI 2151/20WC will be
within .75% of the original calibration. If closer tolerances are required, a complete re-calibration
with test weights should be performed.
*
This procedure is available for transferring SMM, or restoring existing RAM.
** Display momentarily flashes good if value is a valid entry.
*** Display will count and momentarily flash the Corner Frequency value. This value varies
depending on the Corner Frequency Jumper selected (W0, W1, W2, W3, or W4).
3-25
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
3.9 WAVERSAVER®
WAVERSAVER® is proprietary technology developed by Hardy Instruments, Inc.
WAVERSAVER® is a combination of hardware and firmware which effectively eliminates the
effects of vibration on a scale, to arrive at the true weight. WAVERSAVER® not only rejects the
effects of vibration and extracts the true weight signal, but it performs these functions at high
speed. This allows the accurate weighment of ingredients, including flow cut-off.
The HI 2151/20WC can be configured to reject the signals generated by vibration of frequencies
above 0.25 Hz and respond within one second with stable readings. For applications with higher
frequency components, WAVERSAVER® can be adjusted to reject signals above 7.5 Hz with
virtually instantaneous response.
NOTE
To configure the HI 2151/20WC to NTEP specifications, refer to Section 6 Appendix E - NTEP
Operation.
If you would like a faster performance from the HI 2151/20WC after calibration has been
completed you can move the jumper from W4 to W3. If weight readings are still stable, move the
jumper from W3 to W2. Continue with this method until satisfied with the performance and stable
weight readings. Remember that position W1 provides the fastest final weight reading but the least
amount of vibration immunity. This is important for those applications where it is critical to reach
the final weight reading as quickly as possible. Re-calibration is not necessary after moving
jumpers W1 through W4 and W0. (For a description of WAVERSAVER® Jumper Selections, see
Table 3-4 WAVERSAVER JUMPER SETTINGS).
Also, the number of averages selected in the calibration menu adds to this time, and increasing or
decreasing will also stabilize weight readings or affect performance. For example, with the jumper
in the W4 position and the number of averages set at 20, the final weight reading would not be
reached until 2 seconds (1 second for the WAVERSAVER® and 1 second for 20 averages).
3-26
SECTION 3 - SCALE CALIBRATION
Table 3-4 WAVERSAVER JUMPER SETTINGS
Jumpers are provided for selecting vibration immunity configurations as follows:
JUMPER
*
MIN FREQUENCY
APPROXIMATE RESPONSE TIME
W1
7.5 Hz
Least vibration immunity. Fastest time to reach
the final weight reading (approximately 20mS).
W2
3.5 Hz
100mS to reach the final weight reading.
W3
1.0 Hz
500mS to reach the final weight reading.
W4*
0.5 Hz
Very good vibration immunity requiring
approximately 1 second to reach the final weight
reading.
W0
0.25 Hz
Best vibration immunity requiring approximately
2 seconds to reach the final weight reading.
Factory configuration (default) is with the jumper in position W4.
Instructions for changing the jumpers:
1. Remove power from the unit
2. Remove the four screws from each corner of the rear panel
3. Slide the rear panel and internal circuit cards from the extrusion/display assembly
4. Set the jumpers for your application. The jumpers are located toward the front of the top main
board.
5. Slide the rear panel and internal circuit cards to the extrusion/display assembly
6. Replace the four screws for each corner of the rear panel
7. Restore power to the unit
WARNING
Dangerous voltage is present within the enclosure of the unit and presents the risk of
electrical shock. Always unplug the power cord before opening and servicing the unit.
Follow Electrostatic Discharge (static) procedures when opening the unit.
3-27
3.10 AUTO ZERO TRACKING
Auto Zero Tracking will cause the display to indicate zero, as long as any "live weight" on the
scale is below the set zero tolerance and the scale is not in weight motion. This feature allows the
instrument to ignore material build-up in the weigh system within the set zero tolerance. The time
the module must see these conditions is based on the sum of a constant and the number of averages
set by the user. The minimum time-frame with one average is 2.1 seconds. This time is calculated
as follows:
2 seconds + (Number of Averages + 1) (0.05 seconds)
This feature is enabled when switch eight of S3 (the configuration dipswitch), labeled Config on
the instrument's rear panel, is in the on position.
3-28
SECTION 3 - SCALE CALIBRATION
Figure 3-2. HI 2151/20WC Calibration Menu Structure
3-29
SECTION 4 - OPERATION AND CONFIGURATION
SECTION 4
OPERATION AND CONFIGURATION
4.1 INSTRUMENT CONFIGURATION OVERVIEW
This section provides instructions for installing, configuring, and operating the option boards and the
control options which are available for your HI 2151/20WC.
There are three main menus - Setpoint, Calibration and Option. To enter any of these menus, press
the respective key. Once in a particular menu, use up and down arrow keys to scroll through the
choices of that menu. Some of the menus have sub-menus. To select an item for viewing and/or
changing, press Enter while that menu item is being displayed; the current value or status of that menu
item will now be displayed.
To alter values, use the number keys to change values or press the Exit key for no change. Use the /Test/Clr key when a value is shown on the display to clear the display to all zeros. When clearing the
display, the unit will always keep the decimal location intact by putting zeros to the right and one zero
to the left of the decimal point.
Some menu selections can be toggled using the 8 and 9 keys. Pressing the arrow keys will display all
available selections for the menu item. Whether altering a value or not, when you are ready to stop
viewing this parameter and go on to the next, press the Enter key to accept the value or press the exit
key to keep the original value. This will save the parameter as shown on the display.
The unit will also verify that the value entered is a logical choice. If your parameter has been entered
correctly, "Good" will be displayed and the display advances to the next item in the menu. If it is
desirable to view and/or change this parameter, push Enter. To view a value without changing it, press
the Enter key. If changing a value and then deciding to retain the original value, press the ZERO key
instead of the Enter key. This will save the original value and advance to the next parameter.
Saving Your Configuration Parameters
Option menus are used to set parameters for the various option boards. All option parameters except
for Peak Hold are automatically saved and updated in the Secure Memory Module. The following
sections describe menu operation.
NOTE:
Do not modify ANY Sub menus, while the serial interface or A-B RIO are attempting to modify
information.
4-1
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Figure 4-1. Optional Menu Tree
This section provides instructions for installing, configuring, and operating the option boards and the control options
which are available for your HI 2151/20WC.
4-2
SECTION 4 - OPERATION AND CONFIGURATION
4.2 OPTION BOARDS
The Hardy Instrument option boards add capabilities beyond the standard HI 2151/20WC instrument. They are easily
installed into the option board slots, labeled Option 1 and Option 2 on the back of the instrument.
General Information
NOTE
If your options have already been installed at the factory, move on to section 4.3 Setpoints.
The options are implemented by installation of the appropriate optional circuit board onto the main analog/digital
board in the instrument (top board). In some cases, the specific option is then implemented by installing a custom
Secure Memory Module on the main board.
The following option boards are available for the HI 2151/20WC:
OPTION BOARDS
1. Analog Output board (voltage and current; outputs Net, Gross, Total*, ROC*, or Peak Hold*). P/N 0551-0326,
model HI2151/20xx-B1.
(* if ordered)
2. Parallel BCD board, tri-stated. With 6" cable P/N 0551-0327, model HI2151/20xx-B2. With 24" cable P/N
0509-0389-02, model HI 2151/20xx-B9. With 60" cable P/N 0551-0330, model HI2151/20xx-B5.
3. Serial (RS-232C or 20 mA Current Loop) board. P/N 0551-0328, model HI2151/20xx-B3.
4. Serial (EIA-422/485) board. P/N 0551-0329, model HI2151/20xx-B4.
5. Allen-Bradley RIO. P/N 0551-0351, model HI2151/20xx-B8.
Refer to Section 4.4 Hardware Option Boards - RS-232C through Section 4.5 Parallel BCD Communication for a
description of all option boards.
Option slots are labeled on the top circuit board as follows:
READ PANEL LABEL
26 PIN CONNECTOR NUMBER
Option 1
J5
Option 2
J4
4-3
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Output Option Boards may be ordered and installed into these slots as follows:
BOARD
QUANTITY
OPTION SLOT
Analog
2
1 and/or 2 (Position 1 is preferred due to option cover compatibility)
BCD
1 only
2
RS-232C or
EIA-422/485
1 only
1 or 2
A-B RIO
1 only
1
Only one RS-232C, RS-422/485, or AB RIO may be installed at a time.
WARNING
Dangerous voltage is present within the enclosure of the unit and presents the risk of electrical
shock. Always unplug the power cord before opening and servicing the unit.
CAUTION
Installation and servicing of this unit should be performed by authorized and qualified service personnel
only. Follow Electrostatic Discharge (static) procedures when opening unit.
4.2.1
OUTPUT OPTION BOARD INSTALLATION:
1.
2.
3.
4.
5.
Unplug the enhanced unit.
Detach all interconnect cabling and remove the enhanced HI2151/20WC from its mounting.
Remove the four screws holding the rear panel.
Slide the rear panel, including all the boards, out of the case.
Remove the appropriate option cover from the rear panel (Option 1 or 2 cover) as required. Option 1 cover
has two perforations as shown in Figure 4-2 Optional Label Cover to allow removal for different options.
Refer to Figure 4-3 Output Option Board Installation for installation details of Option Boards. Each Option
Board is furnished with four mounting screws to secure it to the main board. The main board has premounted standoffs which accept any of the Option Boards in either position. Note however, the BCD
board may be installed only in the Option 2 slot which is sized for the BCD connector.
6.
(Continued on page 4-7)
4-4
SECTION 4 - OPERATION AND CONFIGURATION
Figure 4-2. Option Label Cover
4-5
SECTION 4 - OPERATION AND CONFIGURATION
OUTPUT OPTION BOARD INSTALLATION - CONTINUED
7.
8.
9.
10.
Position the Option Board over the standoffs and carefully align the mating connector pins of the Option
Board with the appropriate socket position, J4 or J5, on the main board. Ensure that the connector pins
are guided straight into the socket.
Push down on option board to seat option connector pins into the socket on main board. Visually verify
that all of the pins have been properly seated into the mating connector.
With the option board resting on top of the 4 standoffs on main board, install the four screws, lock
washers, and flat washers.
Finally, re-install the main board set into the instrument.
Figure 4-4. HI 2151/20WC Housing for Main Board, Power and Relay Board Alignment
4-7
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
4.3 SETPOINTS
Each instrument contains 2 standard setpoint relays. These are SPDT (3 Form C) relays internally mounted on the
power and relay board.
Six additional TTL outputs, rated at 300 ma per line, are available as a software option. Six triac relays are also
available on an externally mounted option card. The relays used on the setpoint relay option board (Figure 4-5
Setpoint Relay Option Board) are 115 VAC, solid state triacs. Each relay has a fuse on the board rated at 5 amperes.
The relays are rated at 3 amperes continuous duty and 5 amperes intermittent duty. The minimum load current is 20
milliamperes. Each relay may be configured by a dipswitch (on the board) either normally open or normally closed.
The interface to the relays must draw a minimum of 20 ma.
WARNING
The contacts on the solid state relay will open if a power failure occurs. A lit LED indicates that the
relay has been activated.
This board is equipped with six relay outputs. All relays operate in the same manner. There are three values
associated with each relay. They are the setpoint value, the preact value, and the deadband value. These values are
set using the setpoint menu.
Figure 4-5. Setpoint Relay Option Board
4-8
SECTION 4 - OPERATION AND CONFIGURATION
The setpoint value is the target weight or level. It may be set in either net, gross, ROC, total, or peak hold weight
units. When entering this value, the corresponding LED flag will appear on the display. The operator may toggle this
flag to the desired mode using the MODE key. Refer to the Setpoint Limits section following installation for a
description of setpoint limits.
Setpoint Relay Installation:
The setpoint relay option board must be installed outside of the HI 2151/20WC as follows:
a.
b.
c.
d.
e.
f.
Locate a clear, flat mounting area within five feet cable distance of the HI 2151/20WC.
Use the measurements shown in Figure 2-1 HI 2151/20WC Installation Details to make four mounting holes.
Drill 3/16-inch holes where marked.
Install four P/N 2815-0063 standoffs in holes.
Install relay option board on standoffs.
Connect P/N 0509-0390 ribbon cable between relay option board jack J1 and J4 on the rear panel of the HI
2151/20WC (refer to Figure 2-2 HI 2151/20WC Rear Panel Connections).
Figure 4-6. Setpoint Relay Option Board Installation and Wiring
4-9
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
SETPOINT LIMITS
The deadband value can be set as a positive or negative value. It is used to prevent relay chatter once the setpoint is
reached. For example: if a setpoint value was 1000 pounds and the deadband was set to -5 pounds, the relay would
close at a 1000 pounds but not open until the weight dropped to 995 pounds. This would be used if a setpoint is a high
trip limit. A positive deadband would be used for a low trip limit. Examples are shown in Figure 4-7 Low and High
Trip Limits. Using a setpoint of 1,000 pounds and a deadband of -800 pounds will cause the level to remain between
200 and 1,000 pounds.
NOTE
The deadband should be numerically larger then the preact.
Figure 4-7. Low and High Trip Limits
The preact value is the number of units below (negative value) or above (positive value) the setpoint value at which
the relay will trip. It can be used as an "in-flight" compensation value when filling a vessel. If set to zero, there will
be no compensation. This would be the normal setting if a setpoint were used as a level indication.
4-10
SECTION 4 - OPERATION AND CONFIGURATION
SETPOINT MENU (For Standard and Optional Setpoint Configuration)
This menu is used to enter the setpoint, deadband, and preact values for the two standard internal relays. It is also
used to enter the associated values for the six optional, external relays when installed.
NOTE:
To scroll forward or reverse through the Setpoint Menus, press the Up or Down arrow keys.
PROCEDURE
KEY
DISPLAY
6/Set Pt
rLy-1
1. Enter Setpoint Menu
NOTE: Previously assigned setpoint value will be
displayed. For this example, the setpoint value will
be set to 500.
a. Press 6/SetPt key to select setpoint menu.
b. Press Enter key to select setpoint #1.
SPnt-1
Enter
c. Press Enter Key to select setpoint
value.
100
Enter
NOTE: The mode status display indicator flashes on
the present setpoint mode. To change modes, press
the round mode button until the desired mode display
flashes.
d. To enter a new setpoint value,
press -/Test/Clr key.
-/Test/Clr
0
e. Press the number keys to enter new
setpoint value.
500
500
f.
Enter
Good
Press Enter key.
*
* Display momentarily flashes good if value is a valid entry.
4-11
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Setpoint Menu - Continued
PROCEDURE
KEY
dbnd-1
2. Enter Deadband Tolerance
a. Press Enter key to select deadband #1.
-0.01
Enter
b. To enter a new deadband value, press the
-/Test/Clr key.
c. Press the -/Test/Clr key for a negative
value.
DISPLAY
0
-/Test/Clr
-/Test/Clr
-0
d. Press number keys to enter new deadband
value.
125
-125
e. Press Enter key.
Enter
Good *
PrE - 1
3. Enter Preact value.
a. Press Enter key to select preact value.
0.00
Enter
NOTE: Previously set preact value will be displayed.
For this example, the preact value will be set to 20.
b. To enter a new value, press -/Test/Clr key.
c. Press the -/Test/Clr key for a negative value.
-/Test/Clr
-0
d. Press number keys to enter new preact value.
20
-20
* Display momentarily flashes good if value is a valid entry.
4-12
0
-/Test/Clr
SECTION 4 - OPERATION AND CONFIGURATION
Setpoint Menu - Continued
PROCEDURE
KEY
e. Press Enter key.
Enter
f.
Press 0/Exit key to advance to relay 2.
DISPLAY
Good
Spnt- 1
*
rLy-2
Exit
g. Repeat above procedure to enter relay 2
parameters.
h. IF the option for 8 relays is active, enter relay
3-8 at this time.
i.
Press Exit key to resume normal operation
or enter parameters for optional relays.
Exit
-
4-13
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
4.4 SERIAL COMMUNICATIONS
The standard serial port is compatible with RS-232C signals and may be configured as a printer output port or as a
bi-directional communication port. Transmission speed is selectable from 600 to 19.2K baud and may be configured
for a continuous data output mode. The port allows host computer control using ASCII character commands and
supports multiple weight controllers via the multidrop configuration.
RS-232C SPECIFICATIONS
4-14
SPECIFICATION
DESCRIPTION
High Level Output
+11V at 5 mA
Low Level Output
-11V at -5 mA
High Level Input
+4V to +15V
Low Level Input
+1.6V to -15V (Schmit trigger input disallows logic changes with voltages
between these ranges.)
Slew Rate
15V per microsecond maximum
Input Impedance
20K ohms
Clear to Send
(Input) A high level indicates the receiving device is ready to accept data. In the
(J3-1) print mode, CTS must be wired to printer BUSY. Connecting RTS and
CTS is insufficient. In the bi-directional mode a CTS signal (high level) must be
furnished by the receiving device.
Request to Send
(Output) A high level indicates the instrument is ready to receive data.
RXD (Data In)
Accepts RS-232C data signals.
TXD (Data Out)
Between characters, the transmission level will show a start bit or binary 0.
GND
SIGNAL GND
Update Time
10 updates/sec.
SECTION 4 - OPERATION AND CONFIGURATION
Serial port connections are made to J3, located on the rear panel, through the mating plug P3. The pin-out designations
are:
PIN
SIGNAL NAME
1
CTS
2
4
RTS
_____
RXD
_____
TXD
5
+5v
6
GND
3
The standard RS-232C port is located on the main board inside the unit and may be configured through the option
menu. It is identified as SER P1. Refer to Section 4 Serial Port 1 (Standard) and Port 2 (Optional) Menu Setup
Procedure for menu operation.
4.4.1 BI-DIRECTIONAL COMMUNICATIONS
HARDWARE OPTION BOARDS - RS-232C
Description
One RS-232C Option Board (Figure 4-9 RS-232C Board) may be installed in either Option Slot 1 or 2 (an RS422/485 or A-B RIO Option Board may not be installed in the other Option Slot, only one optional serial
communication board per unit). This Option Board supports RS-232C serial data transmission and current loop
communications. The board is user-selectable as a print-output only port or as a bi-directional control port through
the Option Menu. The outputs are electrically and optically isolated from the main board.
RS-232C SIGNALS
DESCRIPTION
High Level Output
11 volts at 5 milliamperes
Low Level Output
-11 volts at -5 milliamperes
High Level Input
+2 volts to +15 volts with 20k ohms input resistance
Low Level Input
+0.8 volts to -15 volts with 20k ohms input resistance
Slew Rate
15 volts per microsecond maximum
Isolation
300 VAC or 450 vdc
4-15
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
RS-232C SIGNALS
DESCRIPTION
Clear to Send
A high level input indicates the receiving device is ready to accept data, connecting
RTS and CTS is insufficient.
Request to Send
A high level out indicates the instrument is ready to receive data.
TXD (Data Out)
Between characters it is in a mark condition: LOW. A start bit or binary 0 bit in
a character will be logic HIGH at this pin.
RXD (Data In)
Accepts RS-232C data signals
CURRENT LOOP
SIGNALS
4-16
DESCRIPTION
I Out
Marks at 20 mA minimum with compliance of 10 volt (at 500 ohms maximum).
Logic 0 current is less than 20 microamperes.
I In
Accepts from 10 to 50 mA as logic 1. Logic 0 is less than 3 mA. Moving the RCV
jumper from the W3 to the W4 position enables current input for transmitted data.
DIS (Transmit Disable)
If TREN jumper W1 is installed, positions 2, 3, 4, and 5 will only be active when
a TRANSMIT DISABLE signal is present at position 6. If TREN jumper W2 is
installed, the TRANSMIT DISABLE signal at position 6 will not affect the output
of positions 2, 3, 4, and 5.
SECTION 4 - OPERATION AND CONFIGURATION
Installation
Follow the instructions in Section 4 General Installation for board installation.
The cable is connected to the RS-232C option board at P1 (Figure 4-9 RS-232C Board). The connector can be pulled
off the header posts for ease in connecting the cable. The pinouts for serial and current loop transmission are:
SERIAL TRANSMISSION
PIN
1
2
3
4
5
6
8
9
SIGNAL NAME
GND
TXD
RXD
RTS
CTS
DIS (Transmit Disable)
Ground
Ground
CURRENT LOOP TRANSMISSION
PIN
5
7
8
9
10
SIGNAL NAME
CTS tied HI
Current Out (Transmit)
Return
Return
Current In (Receive)
4-17
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
The following table describes transmission mode switch settings:
Table 4-1 RS-422/485 Option Board Mode Configuration
MODE
JUMPERS
W1
W2
4 WIRE 2 WIRE
DIP SWITCHES
S1 & S3
Tx+/- PULL
UP/DOWN
S4
MULTIDROP
INDUSTRY STANDARD
"EIA" MODES
EIA-485 2 wire
X
ON
ON (one unit
only)
multidrop
EIA-422 4 wire
X
OFF
X
ON
ON (one unit
only)
singledrop
ADDITIONAL NON-STANDARD
TRANSMISSION MODE
Used most frequently.
Only one "host" permitted.
EIA-485 4 wire /
ON (one unit
only)
EIA-422 multidrop
INDUSTRY STANDARD "EIA" MODES
EIA-485
The option board will be operating in true RS-485 mode when configured as two wire (2 wire jumper) with the transmitter
enabled (S4 off).
EIA-422
If the board is in the four wire (4 wire jumper) mode with the transmitter always enabled (S4 off), then the board operates
in a true RS-422 mode. This flexibility allows compatibility between the host computer and the HI 2151/20WC.
ADDITIONAL NON-STANDARD TRANSMISSION MODE
Used most frequently. Only one "host" permitted.
Four wire RS-485 or multidrop RS-422 mode
When configured in four wire mode with the transmitter selectively tri-stated (S4 on), the board is operating in a four wire
RS-485 or multidrop RS-422 mode. This configuration doesn't meet either specification but can be easier to program than
either true specification.
4-20
SECTION 4 - OPERATION AND CONFIGURATION
RS-422/485 Wiring and Electrical Specifications
Serial communication signal configuration and wiring is dependent on how the board is configured. The following
notes are typical methods of connection. It should be realized that these methods vary and are only furnished to offer
a starting point for configuration:
SIGNAL GROUNDS
A direct connection between signal grounds of the different devices is not desirable, rather a connection with
approximately 100 ohms of resistance is recommended. This resistor is provided in the HI 2151/20WC circuit.
Signal ground should NOT be used as a shield.
EARTH GROUND CABLE SHIELD
Typically, cable shields are tied to ("frame") ground at the end that is the best earth ground.
Pick up frame ground on the HI 2151/20WC with the phillips head screw on the rear of the instrument labeled
Shield.
CABLE TYPE
The Tx+/Tx- and Rx+/Rx- wires are twisted pair (with outer shield).
SERIAL CONNECTOR
Each function is wired to two pins to allow only one wire to be put in each terminal position. (The same
electrical signal is routed to pins one and two on the board.)
EIA-422/485 CONFIGURATION WIRING
OPTION
CONNECTOR
PINS
TWO WIRE
FOUR WIRE
1, 2
Tx- & Rx-
Tx-
3, 4
Tx+ & Rx+
Tx+
5, 6
Not Used
Rx-
7, 8
Not Used
Rx+
9, 10
SIGNAL GROUND
SIGNAL GROUND
See the diagram on the next page.
4-21
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
EIA-422/485 ELECTRICAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Receiver Impedance
12 k ohm
Receiver Common Mode Range
+12 to -7 V
Maximum Input Threshold
+200 mv
Minimum Input Hysteresis
50 mv
Driver Output Capability
+60 ma at 2 V differential
Driver Short Circuit Limit
250 ma to +12 or -7 V
Bus Loading By Unpowered Board
One Receiver Load
For menu setup procedure, see Section 4.4 Serial Communications.
4-22
SECTION 4 - OPERATION AND CONFIGURATION
INSTRUMENT SERIAL COMMUNICATIONS
The HI 2151/20WC's serial options provide the user with a full complement of RS-232C, current loop RS-422, and
RS-485 communications. There is a standard RS-232C serial port on the main board which may be configured as an
output only port to drive a printer or similar device, or as a bi-directional port for both status and control.
Additionally, a RS-232C or RS-422/485 serial option board may be installed in the instrument.
PRINTER OUTPUT
Below is an example of the printout with the weight controller formatted for Gross, Net and Tare.
>
GROSS
1.430 LB
NET 0.430 LB
TARE 1.000 LB
SERIAL PROTOCOL - RING AND MULTIDROP MODES
Hardy Instruments' 2100 family of weight and batch controllers employ an ASCII command protocol and
accompanying command set, described in the following paragraphs. The protocol is via RS-232 or RS-422 hardware,
with the network being called Hardy Link. Hardy Link supports a ring or multidrop configuration.
Serial Protocol - Multidrop Mode
Multidrop is a configuration denoting that there are multiple HI 2151/20WC units connected to a host computer
whereby each HI 2151/20WC receives and sends data through a unique address. The fastest possible instrument
response will be from the multidrop configuration. The multidrop configuration also lends itself well to host computer
control of multiple weight and batch controllers. An RS-422/485 option board is utilized and provides excellent noise
immunity and drive capability supporting long cable runs.
NOTE:
The 2100 family of weight and batch controllers contain intelligent front ends to a distributed system, therefore
network speed is not usually critical.
Serial Protocol - Ring Mode
The ring mode configuration is an RS-232C optional configuration whereby the HI 2151/20WC relays each serial
message received onto the next unit. This configuration is not as flexible as the multidrop configuration, and is
typically used only when requiring a simple printed output from two or more instruments.
To send a command to the third controller in a ring of five controllers, the command must be passed on by the first
two controllers. The third controller receives the command, acts on it and transmits the response to the fourth
controller. The response then gets passed to the fifth controller, then finally back to the host.
It is advisable to limit periodic requests to commands that will result in short responses. For instance, if gross and net
are both required, the format on the HI 2151/20WC could be set up as GN and the request made with an X (transmit)
command.
4-23
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
The time to complete a request is approximately (time of transmission + 0.1 sec) X (number of units). The 0.1 second
is the approximate internal worst case processing time of each received and transmitted message.
The ring configuration may utilize the standard Serial port or the optional RS-232C option. The wiring configuration
for multiple controllers sharing a printer would be as follows:
MULTIPLE CONTROLLER CONNECTION TO SERIAL PRINTER - RING CONFIGURATION
Controller #1
Controller #2... Controller #32
Printer
TXD )))))))))))))))))))))> RXD
TXD )))))))))))> RXD
TXD ))))))))))))))))> RXD
CTS <))))))))))))))))))))) RTS
CTS <))))))))))) RTS
CTS <))))))))))))))))) BUSY
GND )))))))))))))))))))))) GND )))))))))))) GND )))))))))))))))))) GND
The last controller is configured to strip all checksums and End Of Text bytes before passing information to the printer.
This configuration is accomplished in the serial port format menu by specifying an "A" in the print location.
The wiring configuration for a host computer communicating with multiple controllers in a ring configuration would
be as follows:
HOST COMPUTER CONNECTION TO MULTIPLE CONTROLLERS - RING CONFIGURATION
Computer
Controller #1
Controller #2... Controller #32
TXD ))))))))))))> RXD
TXD )))))))))))> RXD
TXD )))))))))))))> RXD
RXD <)))))))))))))))))))))))))))))))))))))))))))))))) TXD
HANDSHAKE LINES
INPUT (OK to send) <)))))))) RTS
CTS <))))))))))) RTS
CTS <)))))))))))) RTS
OUTPUT (Ready to receive) ))))))))))))))))))))))))))))))))))))> CTS
GND ))))))))))))) GND )))))))))))) GND ))))))))))))) GND
4-24
SECTION 4 - OPERATION AND CONFIGURATION
DATA FORMATS
Relays, dip switches and LED data along with weight data have their own special format for transmission. These
formats are described in the following two sections.
Data Formats - Binary Representation
Relay, dipswitch and LED numbers are represented by the binary bit position. In the case of a relay, 0 disables the
relay and a 1 enables the relay.
binary bit position:
7
6
5
4
3
2
1
0
relay, dipswitch
or LED number
(binary bit position +1):
7
6
8
1
2
3
4
5
For example, to enable relays
4 and 8, the following would
be the binary representation:
0
0
1
0
0
0
1
0
This would be 22 hex, hence the command to enable relays 4 and 8 would be E 22.
Data Formats - Weight Data Format
Weights are transmitted according to the following rules:
A. Positive numbers: Maximum of 6 numeric + decimal point.
B. Negative numbers: Maximum of 5 numeric + minus sign + decimal point.
EXAMPLES:
TRANSMITTED
CORRECT?
RECEIVED
REASON
-123.45
Y
-123.45
5 numerics + minus sign + decimal point (B above).
1234.56
Y
1234.56
6 numerics + decimal point (A above).
-12345
Y
-12345
5 numerics + minus sign (B above)
-123456
N
-12345
The "6" would be truncated since only 5 numerics + the
minus sign is legal (B above).
12345.67
N
12345.6
The "7" would be truncated since only a maximum of 6
numerics + decimal point is legal (A above).
4-25
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
SERIAL COMMANDS
Serial commands are transmitted to the instrument in ASCII format. Each command has a single letter corresponding
to the command. The instrument will accept command strings up to 40 characters (the 40th will internally default to
a carriage return).
The front panel serial port menu allows setup of serial communication parameters, i.e. BAUD, parity, etc. Refer to
Section 4.4 Serial Port 1 (Standard) and Port 2 (Optional) Menu Setup Procedure for details.
Serial Commands - Data Transmission Format
The following table uses the following mnemonics corresponding to the outgoing command format (some of which
are optional):
MNEMONIC
MEANING
CMD
SUB-CMD
DATA-n
MODE
CR
Command
Subcommand
Data byte n
Mode
Carriage return
NUMBER OF ASCII BYTES
1
1 to 3
1 to 7
1
1
Serial commands are transmitted from the host to the instrument (in ASCII bytes) in the format:
Control characters are transmitted in HEX. (See the ASCII to HEX table in Appendix G)
An example using the "x" transmit command with Hardy Link and an address of 10 is:
START
CHAR
INSTRUMENT
ADDRESS
>
10
CM
D
X
2 BYTE CHECKSUM
SUB-CMD
G
CR
CR
EOT
CHK-1
CHK-2
CHK-1
CHK-2
EOT
NOTE
The example uses decimal and mnemonic abbreviation format for clarity, however, the actual data
would be in ASCII format. A leading zero (i.e. 01) is required for single digit addresses for serial port
#2.
There is one space (20 hex) required between each type of data following the INSTRUMENT
ADDRESS, hence, the outgoing command represented in hex format would be:
4-26
3E
31
30
>
1
0
20
58
X
20
47
0D
34
44
04
G
CR
4
D
EOT
SECTION 4 - OPERATION AND CONFIGURATION
An example using the "x" transmit command without Hardy Link is:
START
CHAR
>
CM
D
2 BYTE CHECKSUM
SUB-CMD
X
G
CR
CR
EOT
CHK-1
CHK-2
CHK-1
CHK-2
EOT
Serial Commands, Command Set
The checksum is computed by totaling the bytes in the command stream starting with the
INSTRUMENT ADDRESS through (and including) the CR and then subtract 256 from the total until
the remainder is less than 256 (to achieve a one byte maximum). The result is then represented as two
ASCII bytes and appended to the command, followed by an EOT (04).
VALUE
DESCRIPTION
31
30
20
58
20
47
0D
--------------= 14d
100
--------------= 4d
address - instrument number 10 - ASCII "1"
address - instrument number 10 - ASCII "0"
space
X
space
G
CR
Serial commands are transmitted from the instrument back to the host in the format they were
received from the host with the return data (and units) added to the message and a LF added to the CR.
Using the above example, the return data would be:
START
CHAR
INSTRUMENT
ADDRESS
CMD
>
10
X
SUB-CMD
G
7 BYTE DATA
D-7 ... D-1
D-7 ... D-1
2 BYTE CHECKSUM
MODE
Lb or Kg*
CR
CRLF
EOT
CHK-1
CHK-2
CHK-1
CHK-2
EOT
* Lb or Kg follow data.
4-27
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Serial Commands, Command Set - Continued
In the case where return data is appropriate for the command, an A is returned by the instrument in the
form of:
2 BYTE CHECKSUM
START
CHAR
INSTRUMENT
ADDRESS
CMD
>
10
A
SUB-CMD
CR
CRLF
EOT
CHK-1
CHK-2
CHK-1
CHK-2
EOT
In the case of an error, the message returned would be:
2 BYTE CHECKSUM
START
CHAR
INSTRUMENT
ADDRESS
CMD
>
10
N
CMD
9
SUB
9
CR
CRLF
EOT
CHK-1
CHK-2
CHK-1
CHK-2
EOT
where 99 is the error number (see Section 6 Appendix D Error Codes and Definitions for a
breakdown of error codes).
NOTE
The example uses decimal and mnemonic abbreviation format for clarity, however, the
actual data would be in ASCII format.
The following section describes all of the instrument's serial commands. Commands new to the
HI 2151/20WC and unavailable in the HI 2151WC are marked "---> NEW TO HI 2151/20WC".
COMMAND
X
MEANING
Xmit. When this command is issued without a subcommand, the type of data specified in
the format command will be transmitted to the port issuing the request. When this
command is issued with a subcommand only, the subcommand data will be transmitted.
Only one subcommand per command is allowed.
Transmit data specified in SUB-CMD as follows:
SUB-CMD
none
A
G
N
T
DE
P
S
DI
L
REL
REM
C
4-28
MEANING
Default to data setup by the format command
Accumulated total
Gross
Net
Tare
Deadband
Preact
Setpoint
Dipswitch
LED Status
Relay
Remote
ROC
SECTION 4 - OPERATION AND CONFIGURATION
Serial Commands, Command Set - Continued
X
Xmit - Continued
SUB-CMD
REL
SUB-CMD
L
MEANING
Relay
Bit
RELAY
01
02
04
08
5
4
3
1
10
20
40
80
2
8
7
6
MEANING
The L command returns a two-byte status, each bit describing the
LED status.
The values returned are the hex values of the two bytes.
SUB-CMD
DI
Byte 1: LED STATUS, BYTE 1
Byte 2: LED STATUS, BYTE 2
Bit 0 - Pounds led
Bit 1 - Zero track led
Bit 2 - Not used
Bit 3 - Center zero led
Bit 4 - Motion led
Bit 5 - Gross led
Bit 6 - Net led
Bit 7 - Kilograms led
Bit 0 - Rate of change led.
Bit 1 - Alarm #2 led.
Bit 2 - Alarm #1 led.
Bit 3 - Peak led.
Bit 4 - Total led.
Bit 5 - Not used
Bit 6 - Not used
Bit 7 - Not used
MEANING
The HI 2151/20WC will return two bytes for the dip switches. Dip
switch #1 is the one on the rear panel and Dip Switch #2 is internal
to the unit located on the bottom power relay board.
4-29
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Serial Commands, Command Set - Continued
X
Xmit - Continued
SUB-CMD
MEANING
DI - continued
Dip Switch #1 (S3)
Position
Bit
Function ("ON" position)
1
80
Multi-drop
2
01
Calibrate toggle (Non NBS
applications)
3
40
Serial command lockout (Requests
OK)
4
02
Option menu lockout
5
04
Setpoint menu lockout
6
20
Spare
7
08
Lb/Kg, N/G, Tare and Zero lockout
8
10
Zero track
Dip Switch #2 (S2)
Position
Bit
Function ("ON" position)
1
08
Ignore incoming checksums
2
10
On is averaged peak hold, Off is
instantaneous peak hold
3
20
NBS
4
04
NBS Re-Cal toggle switch
5
40
Spare
6
80
Spare
7
02
Spare
8
01
Spare
SUB-CMD
I
SUB-CMD
REM
4-30
MEANING
Load cell input command. Used primarily to check the analog
input section of the unit. The command will return the number of
averaged counts that is currently being read from the load cell
input.
MEANING
Level status of the Remote Input connector (J2) pins.
Bit
Remote Function
Bit
Remote Function
01
02
04
08
Rate of change
Totalizer
Display Hold
Option Hold
10
20
40
80
Net
Lbs/Kgs
Tare
Print
SECTION 4 - OPERATION AND CONFIGURATION
Serial Commands, Command Set - Continued
X
Xmit - Continued
SUB-CMD
Q
MEANING
The query command obtains a block of information as follows:
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
COMMAND
F
Gross weight (6 bytes plus label)
Net weight (6 bytes plus label)
Peak gross value reached (6 bytes plus label)
Internal counts (6 bytes)
Total net accumulation (6 bytes plus label)
Rate of change value (6 bytes plus label)
Not Used (6 bytes set to 000000)
Not Used (6 bytes set to 000000)
LED status (4 bytes)
Relay status (2 bytes)
MEANING
Format the output data. Used to configure data to be sent on a TRANSMIT or PRINT
request. The SUB-CMD letters can be issued in any combination or order and are as
follows:
SUB-CMD
G
N
T
R
S
MEANING
Gross
Net
Tare
ROC
Setpoint, Deadband, Preact
The last (6th) position is one of the following (must be
accompanied by at least one of the above SUB-CMDs):
- Continuous printing.
P Key on front panel "triggers" output.
The default FORMAT is GNTRSP.
M
Monitors the specified SUB-CMD data as follows by requesting a report whenever a
change in the type of status occurs.
CAUTION:
Do not use this command if the system is configured in ring or multidrop
modes. If used in multidrop mode, it will cause data transmission problems.
It is intended only for single units.
4-31
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Serial Commands, Command Set - Continued
M
Monitors - Continued
SUB-CMD
MEANING
R xx
D xx
L xx
Relay number where xx is a two ASCII digit value.
Dipswitch number where xx is a two ASCII digit value.
LED number where xx is a two ASCII digit value.
This command is used to request a report whenever a change in
status occurs in the subcommand selected. You may request the
status of the Relays, Dipswitches, or LED's. Only one MONITOR
subcommand may be issued per command. After the command is
received, the instrument immediately sends back the present status
of the subcommand requested followed by a # sign and a bell
character (cntrl G). This can be used to mark the beginning of the
MONITOR command. To select which particular Relays,
Dipswitches, or LED's you want to monitor, enter the appropriate
2 byte Hexadecimal number after the subcommand. To shut off a
MONITOR command; enter MONITOR command, subcommand
and Hex 00.
COMMAND
S
MEANING
Set specified SUB-CMD data as follows:
SUB-CMD
MEANING
S y xxxxxxx
D y xxxxxxx
P y xxxxxxx
Setpoint value.
Deadband value.
Preact value.
xxxxxxx is up to a seven digit ASCII value.
y is the Setpoint Relay number.
Note that the above xxxxxx data may be followed by a MODE
as follows:
Mode
N
G
R
4-32
Meaning
Net
Gross
ROC
Mode
T
P
Meaning
Total
Peak
SECTION 4 - OPERATION AND CONFIGURATION
Serial Commands, Command Set - Continued
For example, to set setpoint one to 1000 Lbs gross on instrument number 10, the outgoing
command would be as follows:
START
CHAR
INSTRUMENT
ADDRESS
CMD
>
10
S
SUB
S
CMD
1
2 BYTE CHECKSUM
7 BYTE DATA
D-7 ... D-1
MODE
1000
G
CR
CR
EOT
CHK-1
CHK-2
CHK-1
CHK-2
EOT
NOTE:
The example uses decimal and mnemonic abbreviation format for clarity, however, the actual
data would be in ASCII format.
COMMAND
C
MEANING
Allows you to change modes between Net/Gross, lb/kg, or Hold/Unhold Display.
SUB-CMD
MEANING
M
U
H
A
Used to auto tare or auto zero the instrument.
SUB-CMD
T
Z
P
Toggles between Net and Gross weight mode.
Unit (toggles between Lbs. and Kg.)
Toggles between display hold and unhold.
MEANING
Auto tare the instrument. (Scale must not be in motion.)
Auto zero the instrument.(Scale must not be in motion and mode
must be set to Gross)
Print command. Functionally the same as the print key on the keyboard.
The data setup through the format command will be sent to the port configured as a printer.
4-33
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Serial Commands, Command Set - Continued
COMMAND MEANING
P1 or P2
Print to either ports 1 or 2.
An optional "subcommand" of up to 37 ASCII characters may be entered and will be printed
before the formatted data.
SUB-CMD
MEANING
37 ASCII characters maximum.
H
The ASCII characters supplied in the subcommand (maximum of 20 characters) will be
printed as a heading and saved for each subsequent X - transmit or P - print command
requested. Heading is not stored in the Secure Memory Module.
To remove the heading, transmit H with no subcommand.
H1 or H2
The ASCII characters supplied in the subcommand (maximum of 20 characters) will be
printed as a heading and saved for each subsequent X - transmit or P - print command
requested.
To remove the heading, transmit H1 or H2 with no subcommand.
N
Adds the current net weight to the accumulated total.
E
A two ASCII digit hex number is transmitted with this command to enable a relay to be under
the control of it's setpoint value. The power-on default is all relays enabled.
!
This command is used to reset instrument communication. It is typically used when an error
or unintelligible response is received from the instrument and should used sparingly. It is
recommended that it not be used during "normal" communication retries (i.e. unintelligible
response), but instead be used as a last resort (no response after retries are exhausted).
Internally, it performs the same operations as done on instrument power-up. Refer to the REL
Sub-Command under the X (Xmit) Serial Commands Command Set.
4-34
SECTION 4 - OPERATION AND CONFIGURATION
SERIAL PORT 1 (STANDARD) AND PORT 2 (OPTIONAL) MENU SETUP PROCEDURE
The standard and optional serial ports are configured through the option menu and are identified as
SER P1 or P2 respectively. Following is a brief description of each parameter, followed by details
on menu operation.
DISPLAY
SERCON
BAUD
MEANING
Serial port configuration. The port can be used as either a print output port or as
a bi-directional communication port.
Baud rate selection. The baud rates that can be selected are: 300, 600, 1200,
2400, 4800, 9600, or 19,200 with the following exceptions:
The standard port cannot communicate at 300 BAUD.
The option port cannot communicate at 600 BAUD.
(Using 300 and/or 600 baud communications may cause intermittent errors)
PARITY
Parity selection for transmission error detection. Allows parity to be set at even,
odd, or no parity.
STOPS
Stop bit selection. Sets number of bits used to indicate end of a transmission
frame. The number of stop bits can be set to 1 or 2.
LENGTH
Word length selection. Sets the number bits for each data word. Word length can
be set to 7 or 8 bits.
FORMAT
Formats the serial data output. To configure the output use the left arrow key to
select the code letter corresponding to the specific parameter(s). When the letter
is flashing use the up or down arrow keys to toggle the code letter on the display.
To enable a specific parameter, the code letter must be shown on the display.
Pressing the -/Test/Clr key will restore all code letters. The codes are:
G
N
T
R
S
Gross Weight
Net Weight
Tare Value
Rate of Change (ROC)
Setpoint, Deadband, Preact Values
PRINT
Selects print mode. P sets print trigger and "-" sets continuous print.
BI-DIR
Selects bi-directional mode. The bi-directional codes are:
A Altered print (removes checksums)
P Bi-directional with print trigger
- Bi-directional without print trigger.
ADDRESS
Selects the instrument address. This is a two digit value, being 01 to 99.
4-35
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Serial Port 1 (Standard) and Port 2 (Optional) Menu Setup Procedure - Continued
DISPLAY
MEANING
ECHO
Selects whether instrument commands are returned or displayed. Echo can be
turned on or off. If the (bi-directional only) Echo is turned on, commands sent to
the instrument are returned. If turned off, only data transmitted from the
instrument will be displayed.
CONTRL
Selects hardware and software handshaking control. The hardware mode controls
Request to Send (RTS) lines. In this mode the receiving device must set Clear to
Send (CTS) lines to high to enable transmission. The software mode controls the
transmission by the following control codes:
XOFF - (CTRL-S) halt transmission
XON - (CTRL-Q) resume transmission
When a serial port is configured for bi-directional communication with a Print
Trigger format, the control port will respond to the remote function print or serial
print command just like a print port.
COMMAND LOCKOUT
The following commands/functions may be disabled via the dipswitch labeled S3 Config on the instrument
rear panel:
1.
2.
3.
4.
Format
Set
Change
Auto
Set dipswitch S3, position 3 (labeled Serial) to the ON position (down) to lockout the commands from the
serial interface.
NOTE
If you have a problem with weight readings not changing or not being able to exit from a menu, check to see
that the instrument has not been set in the Display Hold mode by a serial command. A C H (change hold)
command will toggle between Hold and Unhold. There is no visual indication showing the present mode.
4-36
SECTION 4 - OPERATION AND CONFIGURATION
Serial Port 1 (Standard) and Port 2 (Optional) Menu Setup Procedure - Continued
PROCEDURE
KEY
1. Enter Option Menu Setup by pressing 7/Option key.
DISPLAY
ROC
7/Option
*
8
SER P1 or
SER P2
3. Press Enter key.
Enter
SERcon
4. Press Enter key (bi-directional or Print will be displayed).
Enter
or
bi - dir
2. Press up arrow until the desired serial port (1 or 2) is
displayed on the screen.
Print
5. Use up or down arrows to choose between bi-directional
or print. Use bi-directional for the example.
8 9
bi - dir
6. Press Enter key.
Enter
bAUd
7. Press Enter key.
Enter
9600
8. Use up or down arrow keys to select 300, 600, 1200, 2400,
4800, 9600, or 19,200 with the following exceptions:
8 9
19200
Enter
PARIty
The standard port cannot communicate at 300 BAUD.
The option port cannot communicate at 600 BAUD.
This example uses 19,200 BAUD.
9. Press Enter key.
*
Display may show an option other than "ROC", depending upon the options installed. The HI
2151/20WC will show the first available option, in this case, ROC.
** The current preset BAUD rate is displayed.
4-37
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Serial Port 1 (Standard) and Port 2 (Optional) Menu Setup Procedure - Continued
PROCEDURE
10. Press Enter key
(none, even, or odd will be displayed).
KEY
DISPLAY
Enter
nonE
or
EVEn
or
odd
11. Use up or down arrow keys to select
(no parity for the example).
8 9
nonE
12. Press Enter key.
Enter
StoPS
13. Press Enter
(1 bit or 2 bits will be displayed).
Enter
1 bit
or
2 bitS
14. Choose either 1 or 2 stop bits by pressing up or down
arrows (1 bit is used for the example).
8 9
1 bitS
15. Press Enter key.
Enter
LEnGtH
16. Press Enter key (7 or 8 bits will be displayed).
Enter
7 bitS
or
8 bitS
8 9
17. Choose either 7 or 8 by pressing up or down arrows
8 bitS
(8 bits are used for the example).
18. Press Enter key.
Enter
FORmAt
19. Press Enter key.
Enter
GntrSP
a. Use up arrow to select "P" (to print on demand),
or "_" (to print continuously).
8
GntrSP
or
GntrS -
4-38
SECTION 4 - OPERATION AND CONFIGURATION
Serial Port 1 (Standard) and Port 2 (Optional) Menu Setup Procedure - Continued
PROCEDURE
KEY
DISPLAY
b. Use left arrow to move cursor one space to the left so
that the "S" is flashing.
7
GntrSP
c. Use up arrow to select "S" (to send setpoints to the
printer), or "_" (setpoints will not be sent to the
8
GntrS-P
or
Gntr-P
printer).
d. Use left arrow to move cursor one space to the left
so that the "r" is flashing.
7
GntrSP
e. Use up arrow to select "r" (to send rate of change to
the printer), or "_" (rate of change will not be sent
8
GntrSP
or
Gnt-SP
to the printer.
Use left arrow to move cursor one space to the left
until the "t" is flashing.
7
GntrSP
g. Use up arrow to select "t" (to send tare value to the
printer), or "_" (tare value will not be sent to the
8
GntrSP
f.
or
Gn-rSP
printer).
h. Use left arrow to move cursor one space to the left
until the "n" is flashing.
7
GntrSP
i.
8
GntrSP
Use up arrow to select "n" (to send net weight to the
printer, or "_" (net weight will not be sent to the
or
G-trSP
printer).
j.
Use left arrow to move cursor one space to the left
until the "G" is flashing.
k. Use up arrow to select "G" (to send gross weight to
the printer), or "_" (gross weight will not be sent to
the printer).
7
GntrSP
8
GntrSP
or
-ntrSP
NOTE: At least one of the letters "G", "n", "t", "r",
or "S" must be selected or an Error 54 will be displayed.
4-39
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Serial Port 1 (Standard) and Port 2 (Optional) Menu Setup Procedure - Continued
PROCEDURE
KEY
DISPLAY
20. Press Enter key.
Enter
ContrL*
21. Press Enter key.
(software or hardware control will be displayed).
Enter
SOFtrE
or
HArdrE
22. Choose either parameter by pressing up or down arrows
(example: software control).
8 9
SoftrE
23. Press Enter key.
Enter
ECHo*
OFF
24. Press Enter key. (on or off will be displayed).
Enter
On
or
8 9
OFF
26. Press Enter key.
Enter
AddrES**
27. Press Enter key.
*(the current two digit address will be displayed).
Enter
*
28. Press -/Test/Clr key to clear the display.
-/Test/Clr
0
29. Enter the desired instrument address, 99 maximum
(unit 10 is used for this example).
10
10
30. Press Enter key.
Enter
good
SErcon
31. Press Exit key.
Exit
SEr P1
25. Choose either parameter by pressing up or down arrows
(off is used for the example).
NOTE: If the Hardy Link configuration is enabled, the
address selection appears, otherwise skip to item 30:
or
SEr P2
33. Press Exit key again to return to normal operation.
*
4-40
Available only when "Bi-dir" mode is selected, ** and the HardyLink option has been enabled.
SECTION 4 - OPERATION AND CONFIGURATION
4.5 PARALLEL BCD COMMUNICATION
Description
The BCD option board (Figure 4-11 Parallel BCD Board) is installed in option slot 2 and will provide
parallel output of the sensed gross, net, or tare weight.
The board connector is a 40 pin right angle connector terminating to either a 37 pin D-subminiature
assembly (option B-2) or a 40 pin connector and a 60-inch cable (option B-5). The B-5 option
provides flexibility of terminating BCD signal lines to the terminal board options B-6 and B-7.
The pin designations for the BCD output are noted in Table 4-2 Cable Pinouts - Parallel BCD Board
Connector to BCD Connector. All data outputs have a drive capability of 15 LSTTL loads (6 mA
total) and use positive true logic. PRINT/NOT-PRINT has a drive capability of 10 LSTTL loads
(4mA). This option board is electrically and optically isolated from the main board.
Figure 4-11. Parallel BCD Board
NOTE:
To transmit BCD signals more than 50 feet, order the HI 120S0 Serial to BCD Converter.
4-41
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Installation
Refer to Section 4.2.1 Output Option Board installation.
Operation
This option is configured by first entering the Option Menu and selecting the BCD menu. Refer to
Section 4.5 BCD Menu Setup Procedure for detailed menu operation. The menu will show a
combination of "Gntd P" (G = gross, n = net, t = tare, d = display, p = print). The user may select
which data will be present at the output. If the "P" or print flag is selected, the data will only change
at the output once the PRINT key is pressed or the remote functions print has been activated.
Otherwise, the output will be continuous.
The output can be triggered by any one of the following methods:
1. By pressing the PRINT key.
2. By sending a command over the serial port.
3. By connecting the remote functions print to the remote functions ground.
The output can be tri-stated if the OUTPUT DISABLE is brought low. This is useful for multiple
parallel outputs to be connected to the same device. Once this input is brought high, the latched data
will be accessible again. The PRINT output is normally low and goes high for 25 milliseconds. If the
opposite polarity (normally high, pulsed low) is desired, move jumper from W1 to W2.
BCD PRINT
The weight select mode tells the output device which type of data is present. The user selects
which type of data is desired by toggling "Gnt" under the option BCD sub-menu. If all three types
of data are requested, then all three will appear on the output one after the other, 10 milliseconds
apart. If "d" is selected, the output will follow the mode being displayed.
CONNECTOR REQUIREMENTS
The BCD interface requires a 40 pin right angle connector. One cable assembly with a 37 pin DSubminiature connector is supplied with each BCD option board when option B-2 is ordered.
Option B-5 provides a 60-inch cable terminated to a 40-pin connector. The pin out signals are
identical to the Parallel BCD PWA P1.
TIMING CONSIDERATIONS
When the BCD is in the continuous print mode the data will be updated on an average of every 100
milliseconds. Additional considerations are shown on BCD Timing Diagram (Table 4-2).
OUTPUT DISABLE
Data output is discontinued if the OUTPUT DISABLE, pin 22 on the PWA (pin 30 on the DSubminiature connector), is low. The data pins will be tri-stated even though print pulses will be
sent.
4-42
SECTION 4 - OPERATION AND CONFIGURATION
Table 4-2 BCD Timing Diagram
4-43
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 4-3 Cable Pinouts - Parallel BCD Board Connector to DB Connector
BCD BOARD
*
*
*
*
*
*
4-44
DB CONNECTOR
SIGNAL
VALUE
1
3
5
7
9
1
2
3
4
5
GND
BCD digit 1, bit 0
BCD digit 1, bit 1
BCD digit 1, bit 2
BCD digit 1, bit 3
1 x 10E
2 x 10E
4 x 10E
8 x 10E
11
13
15
17
6
7
8
9
BCD digit 2, bit 0
BCD digit 2, bit 1
BCD digit 2, bit 2
BCD digit 2, bit 3
1 x 101
2 x 101
4 x 101
8 x 101
19
21
23
25
10
11
12
13
BCD digit 3, bit 0
BCD digit 3, bit 1
BCD digit 3, bit 2
BCD digit 3, bit 3
1 x 102
2 x 102
4 x 102
8 x 102
27
29
31
33
14
15
16
17
BCD digit 4, bit 0
BCD digit 4, bit 1
BCD digit 4, bit 2
BCD digit 4, bit 3
1 x 103
2 x 103
4 x 103
8 x 103
35
37
2
4
18
19
20
21
BCD digit 5, bit 0
BCD digit 5, bit 1
BCD digit 5, bit 2
BCD digit 5, bit 3
1 x 104
2 x 104
4 x 104
8 x 104
6
8
10
12
22
23
24
25
BCD digit 6, bit 0
BCD digit 6, bit 1
BCD digit 6, bit 2
BCD digit 6, bit 3
1 x 105
2 x 105
4 x 105
8 x 105
14
16
18
20
22
24
26
28
30
32
34
36
38-40
26
27
28
29
30
31
+/- (- = +5V) (+ = OV)
OVR
WEIGHT SELECT - LSB {SEE CHART BELOW}
WEIGHT SELECT - MSB {SEE CHART BELOW}
+)))))))))))))),
OUTPUT DISABLE
*
Pin 28 & 29
not used
*
Weight
not used
*
Mode
MOTION (+5V = in motion)
/)))))))0))))))1
PRINT/ PRINT
*
Pin
*
not used
/)))0)))1
Mode
LB/KG
* 28 * 29 *
GND
/)))3)))3))))))1
not used
* 0 * 0* Gross*
33
34
36
37
/)))3)))3))))))1
SECTION 4 - OPERATION AND CONFIGURATION
Hardware Option Boards - Parallel BCD Option Boards - BCD Termination Board
The HI 2151/20WC Binary Coded Decimal (BCD) terminal boards provide easy termination of signal lines
from the -B5 BCD option. The option boards may be ordered to provide termination of a single BCD port
(-B6 option) or termination of four discrete BCD ports (-B7 option) in a tri-state configuration. The terminal
boards consist of one to four connector sockets (depending on which board is ordered) ready to receive the
cables from the -B5 option board in the HI 2151/20WC. All terminal positions will accept cable sizes 20
to 26 gauge. Additional terminal boards may be interconnected to allow multiple BCD ports to exist in the
tri-state arrangement.
Figure 4-12. BCD Quad Termination Board Option (P/N 0535-0384-1 shown)
4-45
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
The BCD terminal board is an interconnect board that contains no active components. Ribbon cables,
P/N 0509-0389-01, route signals from the HI 2151/20WC BCD outputs to BCD board jacks J1 through
J4. Control lines from the computer are routed to BCD board terminal block TB1. Data from the
HI 2151/20WC is returned to the computer through TB2. For installations with more than four
HI 2151/20WC units, a second BCD terminal board can be added to connect four additional
HI 2151/20WCs. In these installations the expansion jacks on both BCD boards must be connected
using a P/N 0509-0389-02 ribbon cable. Figure 4-13 BCD Termination Board Installation Block
Diagram shows a block diagram of an installation using two BCD terminal boards to interface eight
HI 2151/20WCs with a computer.
Figure 4-13. BCD Termination Board Installation Block Diagram
4-46
SECTION 4 - OPERATION AND CONFIGURATION
Installation
Install BCD termination board as follows:
1. Locate a clear, flat mounting area within five feet of all HI 2151/20WCs.
2. Use the measurements shown in Figure 4-14 BCD Termination Board Installation Drill Template
Illustration or P/N 0596-0117 drill template to mark five mounting holes.
3. Drill 3/16-inch holes where marked.
4. Install five P/N 2815-0053 standoffs in holes.
5. Install BCD terminal board on standoffs.
6. Connect P/N 0509-0389-01 ribbon cables between the BCD output (option 2) of up to four
HI 2151/20WCs and BCD terminal board jacks J1 through J4.
7. Connect control lines from computer to TB1.
8. For installations with more than four HI 2151/20WCs, proceed as follows:
a) Install a second BCD terminal board within two feet of installed BCD terminal board. Refer
to steps a through g.
b) Connect P/N 0509-0389-02 ribbon cable from J5 on one BCD terminal board to J5 on the other
BCD terminal board.
9. Connect data/status lines from BCD terminal board to computer.
Figure 4-14. BCD Termination Board Installation Drill Template Illustration
4-47
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Control lines on TB1 are arranged as follows: terminals 1 through 6 are for HI 2151/20WC unit 1,
terminals 7 through 12 are for unit 2, terminals 13 through 18 are for unit 3, and terminals 19 through
24 are for unit 4. Each set of control lines has the following signals:
CONTROL LINE
DESCRIPTION
GND
BUSY
PRINT
PRTDIS
PRTTRIG
OUTENBL
Signal ground
not used
A pulse which indicates when data is changing in the output register
not used
not used
Enables HI 2151/20WC BCD data output.
Only one HI 2151/20WC can be selected at a time. The data from the selected HI 2150/20WC is
output through BCD board TB2. TB2 terminals 1 through 24 contain the BCD format data. TB2
terminals 25 through 30 contains status information for the selected HI 2151/20WC. TB2 terminal
signal values are as follows:
BCD TERMINAL BOARD - BCD DATA FORMAT
TB2
4-48
BCD BIT POSITION
VALUE
1
2
3
4
5
6
7
8
BCD digit 1, bit 0
BCD digit 1, bit 1
BCD digit 1, bit 2
BCD digit 1, bit 3
BCD digit 2, bit 0
BCD digit 2, bit 1
BCD digit 2, bit 2
BCD digit 2, bit 3
1 x 10E
2 x 10E
4 x 10E
8 x 10E
1 x 101
2 x 101
4 x 101
8 x 101
9
10
11
12
BCD digit 3, bit 0
BCD digit 3, bit 1
BCD digit 3, bit 2
BCD digit 3, bit 3
1 x 102
2 x 102
4 x 102
8 x 102
13
14
15
16
BCD digit 4, bit 0
BCD digit 4, bit 1
BCD digit 4, bit 2
BCD digit 4, bit 3
1 x 103
2 x 103
4 x 103
8 x 103
SECTION 4 - OPERATION AND CONFIGURATION
BCD TERMINAL BOARD - BCD DATA FORMAT- continued
TB2
BCD BIT POSITION
VALUE
17
18
19
20
BCD digit 5, bit 0
BCD digit 5, bit 1
BCD digit 5, bit 2
BCD digit 5, bit 3
1 x 104
2 x 104
4 x 104
8 x 104
21
22
23
24
BCD digit 6, bit 0
BCD digit 6, bit 1
BCD digit 6, bit 2
BCD digit 6, bit 3
1 x 105
2 x 105
4 x 105
8 x 105
25
26
27
28
29
30
+ or Overload (OVR)
Weight Selected LSB
Weight Selected MSB
Motion Tolerance (MOTION)
Pounds or Kilograms Display (LB/KG)
4-49
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
BCD Menu Setup Procedure
PROCEDURE
KEY
1. Enter Option Menu Setup by pressing 7/Option key.
DISPLAY
7/Option
ROC
*
2. Press up arrow until BCD is displayed on the screen.
8
bcd P1
3. Press Enter key.
Enter
Gntd-P
a. Use up arrow to select "P" (to print on demand),
or "_" (to print continuously).
8
Gntd-P
or
Gntd-NOTE: Only ONE letter of "G","n","t", or "d", should be
turned on for an output of that value. If continuous output
is desired, select "_".
b. Use left arrow to move cursor one space to the left so
that the "d" is flashing.
7
Gntd- P
c. Use up arrow to select "d" (to send BCD data as
registered on the HI 2151/20WC display), or "_".
8
Gntd-P
or
Gnt - - P
d. Use left arrow to move cursor one space to the left so
that the "t" is flashing.
7
e. Use up arrow to select "t" (to send tare to the printer),
or "_" (tare will not be sent to the printer.)
8
Gntd-P
Gntd-P
or
Gn - d - P
f.
Use left arrow to move cursor one space to the left
until the "n" is flashing.
g. Use up arrow to select "n" (to send net weight to the
printer, or "_" (net weight will not be sent to the printer).
7
Gntd - P
8
Gntd - P
or
G-td - P
*
Display may show an option other than "ROC", depending upon which options were installed.
The HI 2151/20WC will show the first available option, in this case, ROC.
4-50
SECTION 4 - OPERATION AND CONFIGURATION
BCD Menu Setup Procedure - Continued
PROCEDURE
KEY
DISPLAY
h. Use left arrow to move cursor one space to the left
until the "G" is flashing.
7
Gntd-P
i.
8
Gntd-P
Use up arrow to select "G" ( to send gross weight to
the printer), or "_" (gross weight will not be sent to
or
- ntd-P
to the printer).
4. Press Enter key.
Enter
BCD P1
5. Press Exit key to return to normal operation.
Exit
SER P1 *
6. Press Exit key again to return to normal operation.
*
Display may show an option other than "SER P1", depending upon which option boards were installed.
4-51
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
4.6 ANALOG OUTPUT
Description
The analog output option allows the user not only to output gross, net, ROC, Peak, or total weight as
0-5V, 0-10V, 0-20 mA or 4-20 mA (or the reverse of these via the front panel), but makes it possible
to span these ranges over a portion of the weight data. A full analog output is obtained over the range
desired. Resolution of the analog out is 16,000 counts, or the number of display counts available in
the range selected, whichever is less. All of this is accomplished via the front panel or the serial port.
Two analog option boards may be installed in each unit.
Installation
Refer to Section 4.2.1 Output Option Board Installation.
Operation
The analog transmitter (Figure 4-15 Analog Output Board) will output an analog representation of
either net, gross, ROC, total, or peak hold weight data. The transmitter has over 16,000 counts of
resolution limited to the resolution calibrated on the display. The outputs are electrically and optically
isolated from the main board.
VOLTAGE OUT
Maximum Current
Temperature Stability
5 mA (2K ohm load at 10 V)
10 ppm/C or 5 mV total from 30 degrees F to 120 F
CURRENT OUT
Maximum Voltage (compliance) 12 V allowing 0-600 ohm load at 20 mA
Temperature Stability
20 ppm/C or 20 microampere total from 30 to 120 F
EITHER OUTPUT
Linearity
Response Time After Update
Isolation from Main Board
Update Rate
* with 1 average selected.
4-52
0.01%*
1 millisecond
300 VAC or 450 Vdc
50 milliseconds (20 times/sec)
SECTION 4 - OPERATION AND CONFIGURATION
The analog board has one output connector. The connector, J1, uses pins 1 and 2 for voltage outputs
and pins 5 and 6 for current outputs. Both current and voltage outputs may be used. The output is
selected by configuring the jumper block "W" (Figure 4-15 Analog Output Board) which determines
the selection of one current range and one voltage range. To select the range desired, position the
jumper plugs as follows:
OUTPUT
CONFIGURATION
JUMPER
CONNECTION
Remove 4 mA offset
Set current span to 16 instead of 20 mA
Change voltage out scale to 5 V
Set voltage output scale to 10 V
W1
W2
W3
W4
(0-20 mA)
(4-20 mA, default)
(0-5V)
(0-10V, default)
A reversed output (i.e. 20-4 mA) can be selected via the menu by setting the Lo weight to a higher
value than the HI weight, for example: Lo = 5000 lbs, HI = 3000 lbs.
Once the board is installed, the analog parameters can be set through the option menu. The analog
output can represent a window of the span set in the CAL MENU. For example, if the cal span is 5000
lbs, the analog output span can be set for 1000 lbs.
The Analog Menu is accessed through the OPTION MENU key. When in the menu, select ANOUT
1 or ANOUT 2 and then press the Enter key. (ANOUT 2 will only appear if a second analog board
is installed). Values for analog Lo and analog HI can be entered at this time. The NET/GROSS mode
is selected while in the Option Menu (the mode can be changed anytime before the Enter key is
pressed). To select net, gross, peak, rate of change, or total output press the MODE key until the
appropriate LED status indicator is lit.
Analog Card Adjustment
Slight adjustment may be necessary to insure that the display on your Programmable Logic Controller
reads precisely with the display on your weight controller. Use the procedure below which
corresponds to the input card in your PLC.
Ensure the Analog Option card is programmed correctly prior to performing any adjustments.
Voltage
If 0 volts represents other than empty put weight on your load cells equal to your 0 volt selection.
Otherwise, with the hopper empty adjust R4 for the correct reading.
Put weight on your load cells equal to your 10 volt selection. Adjust R16 for the correct reading.
4-53
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Current
Put weight on your load cells equal to your 4 ma selection, if 4 ma represents other than empty. Adjust
R19 for the correct reading.
Put weight on your load cells equal to your 20 ma selection. Adjust R5 for the correct reading.
Figure 4-15. Analog Output Board
4-54
SECTION 4 - OPERATION AND CONFIGURATION
Analog Output Menu Setup Procedure
PROCEDURE
KEY
1. Enter Option Menu Setup by pressing 7/Option key.
DISPLAY
7/Option
ROC *
2. Press up arrow until Analog Output 1 or 2 is displayed.
8
AnOut 1
3. Press Enter key.
Enter
An - Lo
4. Press Enter key.
Enter
0 **
5. Press -/Test/Clr key.
-/Test/Clr
a. Enter numerical value desired.
(Enter (-) for loss-in-weight systems.)
b. The value displayed will equal 4 milliamps, 0 milliamps, or
0 volts, depending on which output and configuration is used.
c. Use mode button to select which mode is to be sent
out: GROSS, NET, ROC, TOTAL, OR PEAK.
6. Press Enter key.
Enter
Good ***
An - HI
7. Press Enter key.
Enter
35000
8. Press -/Test/Clr key.
a. Enter numerical value desired.
(Enter (-) for loss-in-weight systems.)
b. The value displayed will equal 20 milliamps, 10 volts, or 5
volts, depending on which output and configuration is used.
9. Set mode by pressing MODE key until cursor is flashing
under desired option. Select from total, gross, net, ROC,
or peak. The default is gross.
Mode
10. Press Enter key.
Enter
Good ***
An - Lo
11. Press Exit key.
Exit
AnOut 1
12. Press Exit key again to return to normal operation.
Exit
*
**
***
Display may show an option other than "ROC", depending upon the option boards installed.
Previously set numerical value will be displayed. "0" is the default.
Display momentarily flashes good if value is a valid entry.
4-55
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
4.7 BAR-GRAPH
PROCEDURE
KEY
1. Enter Option Menu Setup by pressing 7/Option key.
DISPLAY
7/Option
ROC
2. Press up arrow until "bar Gr" is displayed.
8
bar
3. Press Enter key.
Enter
bAr - Lo
4. Press Enter key.
Enter
0.00
*
5. If you need to change this number, press -/Test/Clr key.
-/Test/Clr
0.00
*
Enter
Good **
bAr - HI
8. Press Enter key.
Enter
10,000
9. Press -/Test/Clr key to change this number.
-/Test/Clr
0.00
Enter
Good **
SEr P1 ***
Gr
6. Enter lowest numerical value to be displayed on bar-graph.
7. Press Enter key.
NOTE: MODE may be selected at this point by pressing
MODE key (total, gross, net, ROC, or peak) and viewing
the status LEDs. Default is gross.
*
11. Enter highest numerical value to be displayed
on bar-graph.
12. Press Enter key to end Bar-Graph Option Setup,
and to return to the first menu option.
*
**
***
4-56
Previously set numerical value will be displayed. "0" is the default.
Display momentarily flashes good if value is a valid entry.
Display may show an option other than "SER P1", depending upon the option boards installed.
SECTION 4 - OPERATION AND CONFIGURATION
4.8 RATE OF CHANGE (ROC)
The Rate of Change Option is to measure the rate at which a material enters or is dispensed from a
vessel over a given period of time.
To develop ROC data, a Register is used that is 21 entries in length. New weight is inputed to the
register at the rate of 1/20th of the Time Base. The 1st register is subtracted from the 21st register.
The 21st register is one Time Base older than the 1st register. The results of this subtraction are
divided or multiplied, as necessary, to equal the appropriate measurement time for display, U-SEC,
U-MIN, U-HOUR.
In the example below, the units of display are units per minute (U-Min) with a Time Base of 10
seconds. New data is inserted into the 1st register every 1/2 second and all old data is shifted down
one register. The 1st register is subtracted from the 21st register and the results are multiplied by
6 to make the Time Base results of 10 seconds correspond to Units per Minute.
1st
ROC REGISTER
+)))))))))),100
/))))))))))1102
/))))))))))1104
/))))))))))1106
/))))))))))1108
/))))))))))1110
/))))))))))1112
/))))))))))1114
/))))))))))1116
/))))))))))1118
/))))))))))1120
/))))))))))1122
/))))))))))1124
/))))))))))1126
/))))))))))1128
/))))))))))1130
/))))))))))1132
/))))))))))1134
/))))))))))1136
/))))))))))1138
.))))))))))-140
[ 21ST - 1ST (x) 6 = ROC ]
140 - 100 = 40 (x) 6 = 240
At time one there is 100 lbs
on the scale. One half second
later there is 102 lbs one the
scale. At time twenty one, 10
seconds later there is 140 lbs
on the scale. A 40 lb change in
10 seconds converts to 240 lbs
per minute.
Rate of change data can be transmitted through the standard or optional serial ports or the analog
output. It can also be displayed numerically or as a bar graph.
To select Rate of Change Mode: Push the MODE key until the ROC indicator is illuminated.
4-57
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
4.8 RATE OF CHANGE (ROC) - Continued
PROCEDURE
1. Enter Option Menu Setup by pressing the 7/Option key
.
KEY
DISPLAY
Option
Option
R0C *
2. Press Enter key.
Enter
UnitS
3. Press Enter key.
Enter
U-Sec
8 9
U-Sec
U-min
U-HoUr
5. Press Enter key.
Enter
t-bASE
6. Press Enter key.
Enter
1
7. Use up or down arrow to select time base from one of
the following: 1, 2, 3, 4, 5, 6, 10, 12, 15, 30, 60, 120,
240, 450, 900, or 1800.
8 9
8. Press Enter key.
Enter
UnitS
9. Press Exit key to end Option Menu setup and go to the
next available menu option, in this case, Serial Port 1.
Exit/0
SEr P1
NOTE: Previously set time value will be displayed.
For this example, the time value will be set to seconds.
4. Press up or down arrow key to select appropriate
measurement of time (seconds, minutes, or hours).
*
Display may vary depending on which options were installed in your instrument. The HI 2151/20WC
will show the first available option, in this case, ROC.
4-58
SECTION 4 - OPERATION AND CONFIGURATION
4.9 PEAK HOLD MODE
Peak Hold Option, when selected, will display the highest gross value that has been measured or the
averaged peak gross value. (Highest gross or averaged gross is selectable on dip switch S1 position
number 2, located internally on the power/relay board.) Peak does not need to be displayed in order
to capture the peak value.
To display PEAK HOLD: Press the MODE key until the "PEAK" indicator is illuminated. The value
displayed is the highest gross value that has been measured since last RESET.
To reset the Peak Value to zero: With the Peak Value displayed, press the TEST/CLR key.
To exit Peak Hold mode: Press the MODE key until desired mode is indicated.
4.10 TOTALIZER MODE
When Total Option is selected, the display will indicate the accumulated total net weight stored in the
total register.
To set up TOTAL: Via the Calibration Menu (Section 3), select the desired decimal point position.
To add weight value to the Total Register: The current net weight displayed will be added to the net
weight accumulated in the total register when the total remote function input is detected (this is
accomplished by providing a momentary switch to the remote function connector between J2, Pin 8
and J2, Pin 9 or 10.
To display the Total Value: Press MODE key until the "TOTAL" indicator is illuminated. The value
displayed is the total accumulated net weight.
To print the Total Value: With the Total displayed, press the PRINT key.
To clear the Total: With the Total displayed, press the TEST/CLR key. The Total Register will now
be reset to zero.
To exit the Total Mode: Press the MODE key until the desired mode is indicated.
NOTE: The Peak Hold and Totalizer modes do not support the LB/KG key or LB/KG remote input.
They will display and transmit only the mode the instrument was calibrated in.
4.11 ALLEN-BRADLEY REMOTE I/O
Refer to Installation and Operation Manual (P/N 0596-0173)
4-59
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
SECTION 5
TROUBLESHOOTING AND MAINTENANCE
5.1 INTRODUCTION
This section provides instructions for running and interpreting the self-test diagnostics, and locating
possible causes of minor malfunctions.
Instrument malfunctions are due to any of the following:
1. Internal malfunction of the equipment. Return unit to Hardy Instruments for repairs.
2. Faulty external cabling connections and/or peripheral devices which interface with
the HI 2151/20WC. Assistance from Customer Support may be required.
3. Operator Error. This may occur with the start-up of the new system, or when the user is required
to re-configure or enter new parameters in the Setpoint, Calibration, or Option menus. Refer to
the manual to gain a better understanding of the instrument.
Any problems which cannot be resolved by using the following instructions should be referred to Hardy
Instruments' Customer Support (refer to Section 5.4 Customer Support).
5.2 SYSTEM INTEGRITY CHECK AND FAULT DETERMINATION
To determine if an instrument or cabling problem exists, verify the basic operation of the system by
performing the following system checks.
Self-Test
Self-test can be entered only from the net, gross or rate of change operating modes. To initiate self-test,
press the -/Test/Clr key on the keypad. The name of each test is displayed for about 2 seconds after
which the result is displayed for another 2 seconds. The self-test program automatically steps through
each test and continues through any failed tests until all are completed. When the self-test program has
completed all tests, the instrument returns to the keyboard test, which can be ended by pressing the 0/exit
button.
Speed up the self-test by holding down the UP arrow key. Pause the self-test display by pressing the
down arrow key. To resume the self-test, press the up arrow key. To exit the self-test at any time, press
the exit key.
Write down the test results and compare them to Section 6 Appendix B System Data Survey Sheet.
Determine if any differences are due to system modifications, and update Appendix B.
Following are the sequential tests conducted by the self-test program:
5-1
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 5-1. Self-Test Program
DISPLAY
TEST
FAILURE SOLUTIONS
tESt
Indicates beginning of self-test.
--
06500062
Part number of EPROM installed.
--
Version of EPROM installed.
--
8.8.8.8.8.8
Display Test - All segments and words
on display turned on.
1. Main card not seated properly
in display board.
2. Contamination on connector
pins.
3. LED display not functioning.
ramtSt
Ram Test - Writes to each location
in RAM & reads back and verifies data.
Test is non-destructive.
--
PASS
FAIL
Indicates whether RAM test passed
1. With most RAM failures
failed.
system will not operate.
2. Check that EPROM (U13)
on main board is seated.
3. Consult for help.
C SUm
Checksum Test - indicates that EPROM
checksum is being calculated.
--
OE OE
Two hex numbers displayed; right one
is actual checksum, left one is
calculated from test. The two numbers must
match. For each revision to EPROM
numbers will be different.
Discrepancy between two
numbers indicates EPROM
faulty.
If the two numbers matched, test will
If failed, replace EPROM.
pass; otherwise fail is indicated. It is
possible for EPROM to loose one or more
bits & still operate.
(If this doesn't eliminate
the problem, there could be a
BUS problem.)
Option ID - Checks for and displays
status of the two option slots.
--
VEr
1.10
or
(example)
PASS
FAIL
OPt ID
5-2
or
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
Table 5-1. Self-Test Program - Continued
DISPLAY
TEST
FAILURE SOLUTIONS
SLOt 1
Indicates next display is for slot 1.
--
nOnE or
SerIAL or
Indicates which type of option card is
1. Check connector for proper
installed in slot 1, if any.
mating.
AnOUt
2. Try card in other slot.
SLOt 2
Indicates next display is for slot 2.
--
nOnE or
SerIAL or
AnOUt or
bCd
CALdAt
Indicates which type of option card is
1. Check connector for proper
installed in slot 2, if any.
mating.
2. Try card in other slot.
3. Swap with spare option card.
Calibration Data Test - The contents
of the user-calibrated parameters are
displayed. The display first shows
the heading of each parameter and then
the value or configuration at which it is set.
If value or calibration is other
than desired, re-enter value into
menu and retest.
CALtyP
How instrument was calibrated
H CAL
Hardware Calibration
S CAL
Software Calibration
C2 CAL
C2TM Second Generation Calibration
UnitS
Indicates next parameter will be units
of measure.
--
Kilograms or pounds.
Default is Lb.
Gr
or
LB
CF = 4
Indicates Corner Frequency jumper position
(W0, W1, W2, W3, or W4).
GrAD
Indicates next parameter will be graduation size.
Default is 4.
--
5-3
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 5-1. Self-Test Program - Continued
DISPLAY
TEST
FAILURE SOLUTIONS
1 or 2 or 5 etc.
Graduation size calibrated in unit (least
significant digit on display will change by
this amount).
Default is 1.
SPAn
Indicates next parameter will be Span.
--
10000
Span value calibrated in unit.
Default is 10,000.
Indicates next parameter will be A to D
counts representing the Zero Count.
--
(example)
Zr Cnt
36780
A to D counts that indicate the calibrated
Zero.
Default is 36780.
FS Cnt
Indicates next parameter will be Full Scale
Count. 0 in most significant digit indicate
value >1,000,000.
--
992000
A to D counts that indicate the Calibrated
Span Value.
Default is 992000.
Sc CAP
Indicates next parameter will be Scale
Capacity.
--
999999
Scale capacity value calibrated in unit.
Default is 10,000.
0 tOL
Indicates next parameter will be Zero
Tolerance.
--
10
Zero Tolerance value calibrated in unit.
Default is 10.
mOtion
Indicates next parameter will be
motion value.
---
3
Motion value calibrated in unit.
Default is 3.
(example)
(example)
(example)
(example)
(example)
5-4
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
Table 5-1. Self-Test Program - Continued
DISPLAY
TEST
FAILURE SOLUTIONS
AVrAGE
Indicates next display will be number of
values set in the running average table
(1 - 200).
--
100
Number of values set up to be averaged.
Default is 100.
LIncor
Indicates next display will be single point
linear correction.
--
0
If 0, linear correction is not used. Number
other than 0 indicates single-point calibrated
value.
Default is 0.
(example)
(example)
SthVAL
330,000
(example)
dIP 1
00
thru FF
dIP 2
Sticker Value. Instrument normalization
number for C2TM Second Generation
Calibration and Soft CAL.
Indicates next display will be settings of
rear panel Config dipswitch S3 segments.
Settings represented by hexadecimal notation.
SWITCH
POSIT.
VALUE
2
4
5
7
01
02
04
08
8
6
3
1
10
20
40
80
If value is other than desired,
reset dipswitch segment and
retest.
ON
OFF
Cal toggle
Opt menu lock
S.P. menu lock
Tare, lb/kg, N/G, zero
lock
Zero track on
Spare
Serial requests only
P2 multidrop
Cal toggle
No opt menu lock
No S.P. menu lock
Keys not locked
Indicates next display will be settings of
internal dipswitch S2 on power relay board.
Settings represented by hexadecimal notation.
Zero trk off
Spare
All serial I/O
Not multidrop
If value is other than desired,
reset dipswitch segment and
retest.
5-5
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 5-1. Self-Test Program - Continued
DISPLAY
TEST
00
Dip Switch #2
thru
FF
SWITCH
POSIT.
FAILURE SOLUTIONS
VALUE
8
7
4
1
2
01
02
04
08
10
3
5
6
20
40
80
ON
Spare
Spare
NBS Re-Call toggle switch
Ignore incoming checksums
On is averaged gross,
Off is instantaneous gross
NBS
Spare
Spare
LC Cnt = 0-8
Sn1 xxxx-xxxx
Sn8 xxxx-xxxx
tAG 1
Indicates next display will be value of software
00
thru FF
tAG 2
00
5-6
thru
OFF
control options. Settings represented by
hexadecimal notation.
If options are not as desired,
another memory key must be
ordered. Consult
Customer Support.
VALUE
01
02
04
08
10
20
40
80
OFF
No bar-graph
No ROC
No peak hold
No Hardy link
No optional relays
No real time clock
Normal CAL mode
No totalizer
ON
Bar-graph
Rate of change
Peak hold
Hardy link
Optional relays
Real time clock
CAL SW override
Totalizer
Indicates next display will be value of software control options.
FF
VALUE
ON
OFF
01
02
04
08
10
20
40
80
Spare
Remote clear total
Remote clear peak
Spare
Spare
Spare
Spare
Spare
Spare
No remote clear total
No remote clear peak
Spare
Spare
Spare
Spare
Spare
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
Table 5-1. Self-Test Program - Continued
DISPLAY
TEST
FAILURE SOLUTIONS
kEY - bd
Indicates next display will be the keyboard
test. Ensure the keyboard operates properly
by pressing each key, starting with the ZERO
key in the upper left corner of the keypad and
moving from left to right. The LED will display
each key as it is pressed. Do not press the 0/exit
key until you are ready to leave the keyboard test.
Consult Customer Support.
Check Cabling and Inputs
Moving the unit may cause loose or improperly installed cabling. Inspect all connectors and cabling for
loose contacts or damage. Verify each wire is in its correct position on the connector, and each connector
is in the right jack on the rear panel. See Table 5-2 Troubleshooting Solutions for additional
troubleshooting assistance.
5-7
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
5.3 INTERPRETING DIAGNOSTIC/ERROR MESSAGES
This section lists some possible system problems along with recommended troubleshooting techniques.
(Refer to Section 6 Appendix D Error Messages and Definitions for a listing of error messages). These
techniques are limited to external observations. Checking of internal test points and voltages requires
special test equipment and exposure of the circuit cards during normal operation. This should only be
done by qualified technicians.
Overview of Typical Load Cell System
The typical system consists of one or more load cells/points, a summing junction box, and a weight
controller (the HI 2151/20WC). See Figure 5-1.
Figure 5-1. Typical Load Cell System
5-8
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
A. LOAD CELL/POINT is a force transducer, which generates an electrical signal proportional to the
load applied to the scale. Load cells/points can be used any place a person needs to measure
pressure, load, or torque. This can be accomplished by either Tension or Compression type load
cells/points. The load cell/point takes as an input the 10 volts DC Excitation Voltage generated by
the HI 2151/20WC, and depending upon how much weight is applied to the scale, generates a
millivolt output (proportional to the weight, 0-20mv DC for 2mv/V load cells/points or 0-30mv DC
for 3mv/V load cells/points).
B. SUMMING JUNCTION BOX provides a tie point for the cabling when the distance between the
load cell/point and the weight controller exceeds the cable length provided with the load cell/point.
Also, in applications where two or more load cells/points are required, it ties the load cells/points
in parallel to give one output cable to the weight controller.
C. WEIGHT CONTROLLER is an electronic instrument which, among other functions, is used
primarily to power the load cell(s)/point(s), take the millivolt signal output from the load
cell(s)/point(s), and digitize, interpret, and display the results as a weight indication.
Please refer to the following pages which may be useful in troubleshooting Load Cell/Point Systems.
5-9
PROBLEM 1: NO DISPLAY
NO
Measure A.C. power. S)))))))))))))Q 1. Check for proper power
OK?
connections at J-6 connector
*
and the source of A.C. power.
* YES
2. Check circuit breaker at the
*
source.
R
Measure the excitation
NO
Fuse Blows again - call
voltage between -EXC S)))))))))))Q
Hardy Instruments Customer
and +EXC of J-1.
Support at (619) 535-8200.
+10VDC?
*
*
*
*
YES
continuity.
*
* NO
.)))Q
BAD
F-1 located inside S)))))))))))))Q
the HI 2151/20WC on the Power
Replace F-1 with a
BAD
1/2 amp Slo Blow fuse S))))))))))))Q
and power up.
and Relay Board (0535-0405).
T
*
*
*
YES
Verify proper Load Cell
signal. Measure between S))),
+SIG and -SIG on J-1. Is
*
it > 0 mvDC and < 30 mvDC?* *
T
*
*
*
*
Check the power fuse for
GOOD
Call Hardy Instruments Customer
Support (619) 278-2900.
Connections on J-1 +/- Sig. and
at the Summing Junction Box OK? S)))))))))))))Q
T
*
Possible Causes
1. Defective Load Cell(s)
2. Overloading of the Load Cells
3. Defective Load Cell cable (J-Box
to
R
Call Hardy Instruments
Customer Support
(619)278-2900.
NOTE:
*
*
NO
Improper Load Cell Signals to the
HI 2151/20WC can cause unpredictable
results. Make connections as tight as
possible to insure a good metal to metal
bond that is less prone to oxide build-ups
which will change the resistivity. Hardy
Instruments recommends that all connections
be crimped and soldered. Connections should
be shielded as best as possible from drafts
or sudden air currents.
Less than 30 mvDC for 3 mv/V load cells and
less than 20 mvDC for 2 mv/V load cells.
weight controller cable).
4. Defective summing junction box.
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
PROBLEM 2: ERROR 18
This error occurs when insufficient positive load cell/point signal change occurs during calibration
between zero and span.
YES
+ and - signal leads (+/- sig) at
J-1 or summing junction box
reversed.
T
*
* NO
*
*
R
Insufficient test weight applied
calibrate.
to the load cell.
T
*
* NO
*
*
R
Load cell wired improperly.
S)))))))))))))Q
Repair problem and calibrate.
YES
S)))))))))))))Q
Add additional test weight and
YES
S)))))))))))))Q
Check load cell wire color code in
accordance with the manufacturer's
documentation, correct the problem
and
calibrate.
T
*
* NO
*
*
R
Contact Hardy Instruments.
5-11
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
PROBLEM 3: DRIFTING WEIGHT INDICATIONS
BAD
Check for proper connections on
connected to the + and + and - sense at J1.
instrument, or
T
*
*
*
*
R
excitation at either the back of the
GOOD
NO
S)))))))))))))Q
YES
If the display is stable, the cause
of the problem is likely to be
external to the HI 2151/20WC. Check
the
following:
1)
*
Ensure the + and - sense are
in the junction box.
Install the jumper shown
in Box 1. Is the display
stable?
T
*
*
*
*
*
R
S)))))))))))))Q
Vibration may be causing the
problem.
Select another vibration immunity
frequency. Refer to paragraph
3.7 for WAVERSAVER® JUMPER
SELECTION.
+EXC
+SEN
+SIG
-SIG
-SEN
-EXC
-C2
+C2
Call Hardy Instruments Customer
Support (619) 278-2900.
+))),
+))))))),
* O /))))))1
/))))))),
* O *
.)))))))*
* O /))))))
)))))))1
* O /))))))
)))))))1
* O *
+))))))),
*
* O /))))))1
/)))))))* O *NC
.)))))))* O *NC
*___*
BOX 1
2)
Load cells/points must make good
electrical contact. Avoid splicing cables.
3)
Use proper load cell/point cable shielding
and connect shield to ground at only
one end.
4)
Use separate conduits for load cell/point cables.
5)
Ensure vessels/hoppers/scales etc. are not
binding. Piping and conduit that makes contact
with the vessel or hopper should be flexible.
6)
Cables that do not have anti-moisture
wicking capabilities and may have been
subjected to significant amounts of moisture,
could have moisture inside the cable which can
cause signal drift and erratic readings.
NOTE:
5-12
175 ohm resistor
1/2 watt
Ensure that you remove the jumper at the conclusion of this testing.
175 ohm resistor
1/4 watt
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
PROBLEM 4: WEIGHT INDICATION FROZEN
Weight indication reaches a value and does not increase as additional weight is added to
the load cells/points.
With the weight indication locked, check millivolt reading at J1 Pin 3 to Pin 4.
Is the reading
less than 30 mV?
YES
S))))))))))))))))))))Q Contact Hardy Instruments
*
* NO
*
*
Trouble is in the
Load Cell/point system.
5-13
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
Table 5-2. Troubleshooting Solutions
SYMPTOM
POSSIBLE SOLUTION
NO POWER
Check power cord at J6 and at the power source outlet
for loose connections.
NO DISPLAY
Check for blown fuse; replace if necessary.
INTERMITTENT DISPLAY
Check for dirty or loose connections or noise on ac
power line.
NO KEYPAD OPERATION
1. Config dipswitch S3 set to keypad lockout;
reposition switch.
2. Check for "HI" on display. Whenever "HI" is
displayed, the keypad will be disabled except for the
Cal Menu key.
"HI" ON DISPLAY
1. Check scale capacity. If gross weight is greater than
105% of calibrated scale capacity, this message will
persist. Remove excess load from scale.
2. If calibrated span is greater than scale capacity, this
message will also occur. Enter Cal menu to increase
Scale Capacity value.
3. If "HI is still displayed, check ± EXC voltage on J1
for 10 vdc , and ± SIG for a voltage between 0-20
mvdc with a 2 mV/V load cell, or 0-30 mvdc with a
3 mV/V load cell.
REMOTE FUNCTIONS
NON-OPERATIONAL
1. Check wiring at J2.
2. Ensure correct ground is used (J2 pins 9 or 10).
3. Check for correct setting of Config dipswitch S3
(Figure 6-1, Appendix A).
5-14
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
Table 5-2. Troubleshooting Solutions - Continued
SYMPTOM
POSSIBLE SOLUTION
SYSTEM NON-LINEARITY
1. Perform linearity check and verify displayed weight
tracks actual weight added.
2. Check mechanical structures, piping, and material
conveying components to ensure no appreciable or
non-repeatable forces are added to the load cells.
3. Re-calibrate system and examine linearity plot. Plot
a graph displaying weight versus mv readings from
load cells. Make linearity correction at the point of
maximum error. Reference full calibration table 3-1
to set midpoint linearity.
NOTE:
This piece of equipment, as with all microprocessor-based instruments, should have a
quality power conditioning product installed between the HI 2151/20WC and the AC.
Power source to lesson the likelihood of faults caused by poor or intermittent AC power.
5-15
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
5.4 OPERATION - USING SOLID STATE RELAYS WITH LIGHT LOADS
(Optional Set Relays)
There have been installations where solid state relays have been used and failed to shut off a solenoid
or relay when de-energized.
The actual problem comes from the internal snubbing network in parallel with the Silicon Controlled
Rectifier (SCR) which does the actual switching. This network presents an impedance of 30K ohms,
which means with 120 volts across, it will pass 4mA of AC current.
Figure 5-2. SCR Switching Load Circuit.
The SCR itself presents no leakage current. Some solid state relay manufactures specify 20mA
minimum load. This is based on the presumption a relay or solenoid will drop out with only 4mA
through it, which is not always true. That may not be true. When switching a light load with a solid
state relay across the line, you must look at the rated drop-out current of the load, and if it is less than
4mA it may not turn off. The solution is to put a loading resistor in parallel with the light load, to be
sure leakage current is sufficiently shunted away from the coil.
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.
5-16
SECTION 5 - TROUBLESHOOTING AND MAINTENANCE
5.5 CUSTOMER SUPPORT
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.
System Support
Customer support is provided as follows:
1. New system start-up: Ensure that the installation is checked and correct; instruments are
calibrated, and operators trained.
2. Service: Engineers are trained and qualified to provide on-site installation, calibration, and
maintenance.
3. 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.
NOTE:
Before returning any product to Hardy Instruments, call the Customer Support Department
listed below for a Return Authorization Number. Have your company name, address,
telephone, equipment model number, S/N, and a brief description of the problem ready to
give to him. In addition, please have Appendix A completed and ready to FAX to us before
calling.
FOR FURTHER INFORMATION CONTACT:
Customer Support Manager
Hardy Instruments, Inc.
3860 Calle Fortunada, San Diego, CA 92123-1825
Telephone: (619) 278-2900
FAX: (619) 278-6700
Web Address: www.hardyinst.com
Ordering Replacement Parts
Consult the Hardy Instruments Sales Department to order replacement parts and option boards. Have
your equipment model number ready, as well as your completed System Data Survey Sheet (Section
6 Appendix B System Data Survey Sheet).
5-17
SECTION 6 - APPENDIX A
SECTION 6
APPENDIX A
KEYPAD, DIPSWITCH AND REMOTE FUNCTION DEFINITIONS
6.1
KEYPAD DESCRIPTIONS.
KEY
KEY FUNCTION DESCRIPTION
ZERO
Used in the gross mode to zero the display within the zero tolerance level.
The user may zero the instrument as many times as desired as long as the total does
not exceed the value entered as the zero tolerance.
A special function of ZERO is to exit a numeric entry in a menu in order to retain
the original value.
MODE
Sets the display to gross or net weight and, if installed, this key will change to total,
peak hold or rate of change optional modes.
Note that the Remote Functions Connector on the rear of the instrument may also
be used to trigger mode changes. See Section 6.4 Remote Functions Connector for
details. Additional access to these modes is available through the serial ports. See
Section 4.3 Instrument Serial Communications for details.
MODE
Standard Modes
Net/Gross Mode Change
Optional Modes
Total Mode
DESCRIPTION
Activating this function causes the
instrument to change modes from net to
gross or gross to net.
When the total mode is selected, the
display indicates the accumulated total
weight. The instrument adds the current
net weight to the total net weight when a
remote function input is entered. This
value is then available for displaying,
clearing or printing.
6-1
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
6.1
Keypad Descriptions - Continued
KEY
KEY FUNCTION DESCRIPTION
MODE (cont.)
MODE
DESCRIPTION
Peak Hold Mode (peak)
When the peak hold mode is selected, the
display indicates the highest measured
average gross weight. The peak value is
continuously monitored and stored in any
mode of operation.
Reset is
accomplished in the peak hold mode by
pressing the clear key. The peak value is
stored in memory but will not be retained
in the event of power failure.
Rate-Of-Change Mode (ROC) When the ROC mode is selected, the display
indicates the rate-of-change of the input with
respect to a pre-selected time base. ROC unit and
time base values can be configured as follows:
Units:
Time-base
seconds:
seconds, minutes, or hours
1, 2, 3, 4, 5, 6, 10, 12, 15, 30, 60,
120, 240, 450, 900, or 1800
ROC mode is useful for rate-by-weight
applications, early warning fault conditions, such
as clogged feeder tubes and trend indication.
TARE
Pressing this key allows the instrument to capture the current GROSS weight and
place it in the tare register.
The tare value is the difference between the NET and GROSS weights. For
example, if your scale is at zero and you place 10 pounds on it and then press
TARE, the instrument will store that 10 pounds in its tare register. Then in the net
mode your display will now read zero, and in the gross mode it will read 10 pounds.
NOTE:
An identical TARE function may be obtained by activating the appropriate remote
function pin. See Section 6.4 Remote Functions Connector for details.
6-2
SECTION 6 - APPENDIX A
6.1
Keypad Descriptions - Continued
KEY
KEY FUNCTION DESCRIPTION
PRINT
Transmit data to the printer.
This may be accomplished over the standard serial port, remote functions connector,
or the optional serial and BCD ports. If this key is pressed and the ports have not
been configured as a printer port, the action will be ignored. No printing will occur
if the weight is "In Motion", or over scale capacity.
-/Test/Clr
"Test" functional
description
This function initiates the instrument's automatic self-test.
The program automatically steps through each test until all are completed. When
the self-test is complete the program will return to the operate mode. The down
arrow key will pause the display until the up arrow key is pressed. To get out of the
program before it has finished press the Exit key. The self-test does not stop on a
failure, therefore the operator must watch the display while the test is being
performed. Refer to Section 5.2.1 Self-Test for a description of the self-test.
-/Test/Clr
"Clr" functional
description
The clear function operates only when in one of the three menus (Setpoint, Option,
or Calibration) and fills the display with zeros.
Use this key to clear the display before entering a new value. In the CAL set up
menu, pushing this key while a subheading is displayed will take the display back
to the unit sub-menu heading.
-/Test/Clr
"-" functional
description
1/Tare Val
This function inserts a minus sign in preparation for entry of a negative value. This
function operates only when the display reads a numeric zero.
Enters the digit "1". Also displays the current value stored in the tare register.
To enter a new value press the clear key, enter the new value using the numeric
keys, and then press enter.
6-3
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
6.1
Keypad Descriptions - Continued
KEY
KEY FUNCTION DESCRIPTION
2/Status/Bar
Enters the digit "2". Also changes 30 segment LED functions.
Pressing this key will cause the 30 segment LEDs to indicate HI 2151/20WC status
settings or display an optional bar-graph representation of a selected mode.
3/Lb kg
Enters the digit "3". Also selects between pounds and kilogram modes.
4/8
Enters the digit "4". Also advances each step through a menu when pressed. Will
wrap through the end step of a menu to the start step when reached.
5/7
Enters the digit "5". Also selects either of the following:
a. decimal point position
b. format position for the Serial Port and BCD options.
c. enter time/date options
6/Set Pt
Enters the digit "6". Also displays the setpoint option menu.
The setpoint menu is used to enter the setpoint, deadband, and preact values. This
menu is used to enter values for the standard internal relays and optional relays.
Successive pressing of the up arrow (8) key causes the menu items to be displayed.
To select one of the menu items, press the Enter key when it is displayed. The
display will then show the value of the item. Use the numeric keys to enter a new
value.
7/Option
Enters the digit "7". Also displays the option menu.
The option menu items allow the operator to configure those standard features
which require setup as well as any installed hardware and software options. The
option menu items are:
a.
b.
c.
d.
e.
f.
g.
Rate-of-change
Analog transmitter(s)
Serial port(s)
BCD port
Bar-Graph
Real time clock
Remote I/O
As the menus are advanced (up/down arrow keys), an option menu item will only
show on the display if the respective option is installed.
6-4
SECTION 6 - APPENDIX A
6.1
Keypad Descriptions - Continued
KEY
KEY FUNCTION DESCRIPTION
7/Option (cont.)
Option numbers on the menu are determined in the order they are scanned by the
instrument. You must be sure you configure the correct menu number to the proper
option board. Lack of an option on the menu may indicate an improper installation
of the option.
Once the desired item is displayed, press the Enter key to view/modify the item.
Some items require the entry of a number, whereas others require selection of one
of several alternatives.
The alternatives take the form of a sub-menu under the selected item. The options
sub-menus are shown in Figure 4-1 Optional Menu Tree.
8/Cal
Enters the digit "8". Also opens the calibration set up menu.
The CAL segment on the Config dipswitch (S3) on the rear panel must be toggled
before entering the Cal Menu. If the CAL switch is not toggled, the display will
read ERR8. When changing the dipswitch to the CAL mode, CTR ZERO,
MOTION and ZERO TRACK will flash on the display to indicate that calibration
is not sealed.
To review the calibration values without changing them, press the -/Test/Clr key
to begin displaying the calibration values.
To change any calibration value, enter the gross mode, toggle the CAL dipswitch
and press the Cal key.
9/9
Enters the digit "9". Also steps backwards through menus.
Will wrap through the start step of a menu to the end step when reached. Also
chooses format in the serial and BCD menus, and pauses display in self-test.
0/Exit
Enters the digit "0". Also exits from menus and returns to normal operating mode.
In a sub-menu the Exit key will display the next higher level. If the ZERO key is
used during data entry, the new value will not be entered and the menu will advance
to the next item.
6-5
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
6.1
Keypad Descriptions - Continued
KEY
KEY FUNCTION DESCRIPTION
Enter
Accepts the selection shown on the display.
This selection may be a numeric value or a menu item selection. Whenever a value
is changed, the Enter key must be pressed in order for the new value to be accepted.
Also, for numeric values, once the Enter key is pressed, the message "Good" or
"Err" will be displayed for one-half second, indicating the acceptance or rejection
of the value by the instrument.
In the case of "Good" being displayed, the display will then show the name of the
next item in the menu.
In the case of error, the value entered will be re-displayed so that the operator may
correct the error. A listing of ERROR codes are in Appendix D Error Messages and
Definitions.
6.2 DESCRIPTION OF REAR PANEL.
See Section 2.3 Cabling Connections for a description of the rear panel and electrical connections.
6.3 INSTRUMENT CONFIGURATION DIPSWITCH.
The Configuration dipswitch labeled Config on the instrument's rear panel (see Figure 2-2
HI 2151/20WC Rear Panel Connections) provides a means to configure the instrument to your needs by
being able to lock out portions of the keypad from operator intervention and lockout calibration. Each
of the dipswitch functions is described below: ("ON" position is down, and "OFF" is up):
Figure 6-1. "Config" Dipswitch S3
NOTE:
For internal dip switch (S2) functions and settings, see table 5-1 located under dip switch 2 display.
6-6
SECTION 6 - APPENDIX A
SWITCH
PANEL
LABEL
1
MultDp
Multidrop. When the switch is ON, the multi-drop switch function
is selected. The system must include the Hardy Link software
option for this to apply. When OFF, the system defaults to the
serial ring configuration. Multidrop is only available when using
the EIA-422/485 option board.
2
Cal
Calibration Menu. This switch must be toggled (i.e., position
changed) to enter calibration with the Cal key. (This dipswitch not
used in wall mount version.)
3
Serial
Serial Port Lockout. When the switch is ON, the following
commands: Format, Set, Change, Auto and Enable, cannot be
executed over the serial interface. When OFF, those serial port
commands are enabled.
4
Option
When the switch is ON, access to the option menu is denied.
When OFF, the full option menu is available.
5
Setpt
Setpoint Menu. When the switch is ON, access to the setpoint
menu is denied. When OFF the setpoint menu is available.
6
DESCRIPTION
Not used.
7
Lock
Lockout. When ON, locks out the Tare, Mode, Zero, and lb/Kg
keys.
8
0 Trk
Zero Track. ON enables the zero track feature, OFF disables the
feature.
6.4 REMOTE FUNCTIONS CONNECTOR.
This section describes the control available by using the remote functions connections (labeled J2
Remote Functions on the rear panel of the instrument).
The functions assigned to the Remote Function connector pins are illustrated in Figure 6-2 Remote
Function (J2) Connection. All of the function pins are normally-high CMOS levels.
A function is activated by connecting it with the remote functions ground pin.
6-7
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
NOTE:
The remote functions ground, J2-9 or 10, must be used.
Two ground pins are provided for your convenience. The power earth ground is entirely different and
the option grounds are floating with respect to the remote function circuitry. Some functions are level
conditions and some are activated by momentary grounding. Momentary functions must pull the
desired pin low for at least 100 milliseconds (0.1 seconds). The following paragraphs give a detailed
description of each remotely controlled function.
Figure 6-2. Remote Function (J2) Connection.
NOTE:
LB/KG for cal switch in wall mount unit.
REMOTE
FUNCTION
6-8
PIN
DESCRIPTION
Tare
1
Activating this pin is exactly the same as pressing the Tare key on the front
panel.
Print
2
Activating this pin is the same as pressing the PRINT key. Note that, as in
the case of the PRINT key, the request for a print is only acknowledged
while the unit is not already involved in a print cycle.
Net
3
Activating this pin causes the instrument to change modes from current
mode to net. It is recommended that the NET/GROSS key on the keypad
be disabled using Config dipswitch Lock (S3-7) when this remote function
is being used.
Lb/Kg
4
Activating this pin causes the instrument to change modes from lb to kg or
kg to lb. It is recommended that the lb/kg key on the keypad be disabled
using the Config dipswitch Lock (S3-7) when this remote function is being
used. Used for cal switch in the wall mount "WS" version.
SECTION 6 - APPENDIX A
REMOTE
FUNCTION
PIN
Displ
5
This function causes the display to be frozen. All outputs to options such
as the BCD continue to be updated with new readings.
Opt
6
This function causes data to the option slots to be halted. If Pin 6 is
grounded no new data will be sent to the option slots.
DESCRIPTION
In addition, two options are available to change the function of this
pin. Only one of the following two options can be used:
1. Clear total accumulator from remote.
2. Clear peak value from remote.
These functions must be activated at the factory.
Roc
7
Activating this pin causes the instrument to change mode from current
mode to ROC.
Total
8
Activating this function causes the instrument to add the current net weight
to the accumulated net weight. The level must go high and low again to
add the next net weight.
Gnd
9,10
Remote functions ground.
GROUND!
SEPARATE FROM AC OR OPTION
6.5 INTERNAL DIP SWITCH.
The internal dip switch an eight position slide type is found on the power relay (lower) board.
SWITCH
DESCRIPTION
1
With this switch on incoming checksums are ignored.
2
When this switch is on, the Peak hold signal read is averaged. When in the off
position the Peak hold signal is instantaneous.
3
In the on position the instrument is in the NBS mode of operation. Resolution is
limited to 1:10,000 counts. In the off position is 1:985,000.
4
This switch must be toggled (i.e. position changed) to enter NBS calibration from
the front panel CAL key.
5-8
Not used.
6-9
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX B
SYSTEM DATA SURVEY SHEET
TO:
Hardy Instruments, Inc.
FROM:
ATTN:
Customer Support
COMPANY:
FAX NO:
858-278-6700
DATE:
Retain a copy of this page in a safe place. This information will help us assist you if, for any reason,
you need to consult Hardy Instruments.
DATE OF INSTALLATION:
INSTRUMENT MODEL NUMBER:
INSTRUMENT SERIAL NUMBER:
(located on the back of the instrument)
CORNER FREQUENCY SELECTED:
LOAD CELLS:
Model #:
Rated Capacity:
Number of Load Cells:
mv/V Rating:
Type of Vessel/Hopper:
Deadload or weight of vessel:
RESULTS OF SELF-TEST: Press the -/Test/Clr button on the keypad while in the operating mode,
and record the results on the following page. Use the down arrow to pause the display, and the up
arrow to resume the self-test.
6-10
SECTION 6 - APPENDIX B
Self-Test Program Results
Self-Test
Display
Your
Results
tESt
VEr
C SUM
CALdAt:
CALtyP
UnItS
CF =
grAd
SPAn
Zr cnt
FS cnt
SC CAP
0 tOL
Motion
AVrAgE
LIncor
SthVAL
dIP 1
dIP 2
tAG 1
tAG 2
6-11
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
OPTIONS: Press the 7/Option key to enter the options menu and record the results. (The order of
parameters may vary from this list, depending on which options were installed.)
Options
rOC
UnitS
tbASE
bArGr
bAr - Lo
bAr - HI
bcd
FOrMAt
An OUt 1
An OUt 2
SEr P1
SEr P2
An Lo
An HI
[ ] Print
[ ] bi-dir
[ ] Print
[ ] bi-dir
[ ] odd
[ ] even
[ ] odd
[ ] even
[ ] none
[ ] none
StoPS
[ ] 1 bit
[ ] 2 bits
[ ] 1 bit
[ ] 2 bits
LEnGtH
[ ] 7 bit
[ ] 8 bits
[ ] 7 bit
[ ] 8 bits
FOrMAt
) ) ) ) ) )
ContrL
[ ] softre
[ ] hardre
[ ] softre
[ ] hardre
ECHo
[ ] On
[ ] Off
[ ] On
[ ] Off
SERcon
bAUd
PArIty
AddrES
rIO
rAtE
rAC no
otr no
L-otr
6-12
) ) ) ) ) )
SECTION 6 - APPENDIX B
SETPOINT MENU: Press the 6/Set Pt key to enter the Setpoint menu and record settings.
Setpoint Menu
SEtPnt/rLy
1
2
3
4
5
6
7
8
M0dE
SPnt dbnd PrE PRINTER INFORMATION
Make and Model #:
Baud Rate:
Parity:
Stop Bits:
Length:
Format:
MISCELLANEOUS INFORMATION
Format:
Control:
Echo:
* Address:
* Configured with Hardy-Link Option.
3860 Calle Fortunada
San Diego, CA 92123-1825
Phone: (619) 278-2900
FAX: (619) 278-6700
6-13
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX C
DISPLAY MESSAGES
DISPLAY
DEFINITION
AddrES
ADDRESS
(only available in Hardy Link Applications)
AVrAgE
AVERAGE NUMBER OF READINGS
bArgr
BAR GRAPH
bar-Hi
BAR GRAPH HIGH END VALUE
bar-Lo
BAR GRAPH LOW END VALUE
bAUd
BAUD RATE
bcdP1
PARALLEL BCD PORT
bi-dir
BI-DIRECTIONAL
C2 CAL
C2TM SECOND GENERATION CALIBRATION
CAL
CALIBRATION MENU
CALdAt
CALIBRATION DATA
CF = 0, 1, 2, 3, or 4
CORNER FREQUENCY
Contrl
CONTROL
C SUM
CHECK SUM TEST
6-14
SECTION 6 - APPENDIX C
APPENDIX C - DISPLAY MESSAGES - Continued
DISPLAY
DEFINITION
dAtE
DATE
dbnd - 1
DEADBAND TOLERANCE
#1 through #8 (Deadband #1 shown)
dEcPnt
DECIMAL POINT POSITION
dIP 1
DIPSWITCH #1 & #2
(Dipswitch #1 shown)
ECHo
ECHO
EndCAL
CALIBRATION COMPLETE
EntEr
ENTER
ERROR NUMBERS
(see Appendix D - Error Messages and Definitions)
EVEn
EVEN (PARITY)
FOrMAt
FORMAT
FScnt
FULL SCALE COUNT
GntrSA
GROSS, NET, TARE, RATE OF CHANGE,
SETPOINT, ALTERED PRINT
or
GntrSP
GROSS, NET, TARE, RATE OF CHANGE,
SETPOINT, PRINT
6-15
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX C - DISPLAY MESSAGES - Continued
DISPLAY
DEFINITION
Good
GOOD
Gr
KILOGRAMS
grAd
GRADUATION SIZE
HArdrE
HARDWARE
kEy - bd
KEYBOARD
L - Otr?
LAST QUARTER?
Lb
POUNDS
LEnGtH
7 bitS
LENGTH
LInCor
MIDPOINT LINEARITY CORRECTION
Motion
MOTION TOLERANCE
Mode
MODE
no
NO
nOnE
NONE (PARITY)
odd
ODD (PARITY)
OFF
OFF
On
ON
OPt
OPTION MENU
6-16
7 OR 8 BITS (7 bits shown)
SECTION 6 - APPENDIX C
APPENDIX C - DISPLAY MESSAGES - Continued
DISPLAY
DEFINITION
OPt Id
OPTION ID
Otr no
QUARTER NUMBER
PArIty
PARITY
PASS
PASS
PrE - 1
PREACT #1 through #8 (Preact 1 shown)
Print
PRINT
rAC No
RACK NUMBER
rAMtSt
RAM TEST
rAnGE
LOAD CELL/S CAPACITY
rATE
RATE
rEF Pt
ZERO OR USER SELECTED VALUE FOR S-CAL
rEStOr
RESTORE DATA FROM SECURE MEMORY
MODULE TO INSTRUMENT RAM.
rEv
REVISION LEVEL X <R>
(X denotes revision level of software)
X
rIO
REMOTE INPUT OUTPUT
rOC
RATE OF CHANGE
rLy - 1
RELAY #1 through #8
(Relay #1 shown. Relays #3 through #8 are external
optional relays)
6-17
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX C - DISPLAY MESSAGES - Continued
DISPLAY
DEFINITION
SAVE
SAVE DATA FROM INSTRUMENT RAM TO
SECURE MEMORY MODULE
S CAL
SOFTWARE CALIBRATION
Sc CAP
SCALE CAPACITY
SErcon
SERIAL CONFIGURATION
SEr P1
SERIAL PORT #1 & #2
(Serial Port #1 shown)
SEtPnt
1
SETPOINT #1 through #8
(Setpoint #1 shown)
SLOt 1
SLOT #1 & #2 (Slot 1 shown)
SnStUy
LOAD CELL FULL SCALE OUTPUT MV/V
SOFtrE
SOFTWARE
SPAn
SPAN
Stichr
INSTRUMENT NORMALIZATION VALUE
StoPS
STOP BITS
1 bit
1 & 2 BITS (1 bit shown)
TAG 1
TAG #1 & #2 (Tag #1 shown)
tAre
TARE
tbASE
TIMEBASE
tESt
TEST
6-18
SECTION 6 - APPENDIX C
APPENDIX C - DISPLAY MESSAGES - Continued
DISPLAY
DEFINITION
tiME
TIME
totAL
TOTAL
tot dP
TOTALIZER DECIMAL POINT
U-HOUr
UNITS IN HOURS
Units
UNITS (LB OR KG)
U-Min
UNITS IN MINUTES
U-SEC
UNITS IN SECONDS
yES
YES
ZErO
ZERO
Zr cnt
Zero Count
0 toL
ZERO TOLERANCE
6-19
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX D
ERROR MESSAGES AND DEFINITIONS
ERROR MESSAGE
DEFINITION
- - HI - -
Load cell/point signal represents a weight higher than scale capacity.
Error
Invalid character entry.
Err 1
Invalid grad size. Grad size must be 1, 2, 5, 10, 20, 50, 100, 200, 500.
Err 2
NTEP grad size error. Grad size must be greater than the full scale
divided by the range.
Err 3
Average out of range. Average must be from 1 to 200.
Err 4
Instrument in motion when value entered.
Err 5
Not in Gross mode when trying to enter CAL menu.
Err 6
Invalid zero. Zero must be less than zero tolerance.
Err 7
Invalid grad size. Grad size must be greater than the full scale divided
by the range minus one valid grad size.
Err 8
Unable to enter Calibration Menu without toggling ReCal segment on
S3.
Err 9
Invalid zero. When the instrument is in NTEP mode, the zero must be
within the zero tolerance.
Err 10
Invalid motion tolerance. Motion must be greater than 0 and greater then
or equal to Grad Size.
6-20
SECTION 6 - APPENDIX D
APPENDIX D - ERROR MESSAGES AND DEFINITIONS - Continued
ERROR MESSAGE
DEFINITION
Err 11
Negative gross weight during acquire tare. (NTEP only)
Err 12
All decades after decimal point must be active. (NTEP only)
Err 13
Full scale calibration of zero or negative value not allowed.
Err 14
Scale capacity of zero or at negative value not allowed.
Err 15
Zero tolerance of zero or a negative value not allowed.
Err 16
Tare greater than span. (NTEP only)
Err 17
Acquire tare cannot be used with zero gross weight. (NTEP only)
Err 18
Difference between zero and span less then 100 counts.
Err 19
Occurs when configuring Serial Port 1 and entering a negative address.
Err 20
Option held when a print command was requested. Option hold active
on remote functions TB when print command from serial port requested.
(Serial Port only)
Err 24
Clock malfunction.
Err 25
Invalid total decimal point.
Err 26
Faulty time or date entry.
6-21
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX D - ERROR MESSAGES AND DEFINITIONS - Continued
ERROR MESSAGE
DEFINITION
Err 40
Software Cal sticker value too small.
Err 41
Software Cal reference point weight out of range.
Err 42
Software Cal load cell overloaded.
Err 43
Software Cal range is zero error.
Err 44
Sensitivity out of range.
Err 45
No Software Cal in NBS range.
Err 50
Too many BCD Options.
Err 52
Too many Serial Options.
Err 54
Invalid serial or BCD format entry.
(_ _ _ _ _ _ P or _ _ _ _ _ _)
Err 55
Illegal analog weight span. Analog span weight minus analog zero
weight must be larger than 2% of the calibrated span.
Err 60
The number of load points found did not match the number entered.
Err 61
No load points found.
Err 62
Load point capacities or sensitivities do not match.
Err 63
Check Sum Error on 1 or more load points.
6-22
SECTION 6 - APPENDIX D
APPENDIX D - ERROR MESSAGES AND DEFINITIONS - Continued
ERROR MESSAGE
DEFINITION
Err 64
Too many significant digits, after the decimal point, to be displayed.
Err 97
Checksum error.
Err 99
Bad command sequence. (Serial Port only)
6-23
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX E
NTEP OPERATION
This instrument has been approved for NTEP applications. An NTEP kit is available from the factory
that includes special screws for sealing the instrument and NTEP labels. Consult the factory for further
information on this kit.
There are some differences in how the instrument operates when in the NTEP mode.
1. To configure the instrument for NTEP mode, set DIP switch S2 position 3 to the ON position.
This switch is inside the instrument located on the Power and Relay board (bottom board).
Calibrate the instrument as follows:
a. Remove power cable from HI 2151/20WC rear panel POWER jack J6.
b. Slide HI 2151/20WC assembly from housing.
c. Ensure DIP switch S2 position 3 is set to ON.
d. Move DIP switch S2 position 4 to the opposite of its current setting. This is the Cal toggle
switch.
e. Slide HI 2151/20WC assembly into case as shown in Figure 3-4 HI 2151/20WC Housing
for Main Board, Power and Relay Board Alignment.
f. Ensure load cell or loading device cable is connected to jack J1.
g. Connect power cable to rear panel POWER jack J6.
h. Observe the center zero, motion, and zero track LED's flash.
i. Calibrate HI 2151/20WC, refer to detailed calibration procedure Section 3.3 Full
Calibration Procedure.
j. Observe CTR ZERO, motion, and zero track no longer appear on display.
6-24
SECTION 6 - APPENDIX E
APPENDIX E - NTEP OPERATION - Continued
2.
The "CTR ZERO" message indicator is illuminated when the weight reading is within
one-quarter of a graduation of the calibrated zero value.
3.
The maximum allowable resolution in the NTEP mode is 10,000 counts.
4.
The following ERR codes are applicable to NTEP only.
ERROR MESSAGE
DEFINITION
Err 2
NTEP grad size error. Grad size must be greater than the
full scale divided by the range.
Err 9
Invalid zero. When the instrument is in NTEP mode,
the zero must be within the zero tolerance.
Err 11
(NTEP only) Negative gross weight during acquire tare.
Err 12
(NTEP only) All decades after decimal point must be
active.
Err 16
(NTEP only) Tare greater than span.
Err 17
(NTEP only) Acquire tare cannot be used with zero
gross weight.
Err 45
Soft-Cal not available in NTEP mode.
6-25
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX F
GLOSSARY OF TERMS
ACCURACY
Closeness of a reading to the actual value of the quantity being measured.
ALARM
Indication of a tolerance deviation.
ANALOG SHIELD CAN
A metal enclosure placed over the analog section of the electronics to prevent radio frequency
interference.
ANALOG TRANSMITTER
An option card which outputs an analog representation of net, gross, total weight or rate of change data.
BAUD RATE
Baud rates are used as a measure of how fast serial data is transmitted, (BIT/SEC).
BCD
Binary Coded Decimal - a type of positional value code in which each decimal digit is binary coded into
4-bit "words".
BI-DIRECTIONAL
A capability used to transmit data in either direction at the same time, for example: to or from the
instrument.
CLEAR KEY
A key used to clear data or formats entered into a menu.
CTS
Clear to send an RS-232C level signaling a readiness to accept data.
DEAD BAND
A value used to prevent relay chatter once the setpoint is reached.
DEAD LOAD
Weight of hopper assembly or platform assembly sitting on top of load cells.
6-26
SECTION 6 - APPENDIX F
APPENDIX F - GLOSSARY OF TERMS - Continued
DECIMAL POINT POSITION
Menu item used to set the decimal point position for all display readouts.
DIP-SWITCH
A switch installed in a circuit card with several individual switches built in. Used to set different options
in a system.
DISPLAY
A device used to show information from the instrument.
ENGINEERING UNITS
Pounds or Kilograms
ELECTROSTATIC DISCHARGE (ESD)
Electrostatic Discharge is an electric charge (static electricity) which occurs when an electrically charged
object, such as a person, touches the HI 2151/20WC. To avoid damage to personnel and to the unit, a
grounded static control wrist strap should always be worn when opening and/or servicing the HI
2151/20WC.
ENTER KEY
This key is used to accept user input into the memory.
EPROM
Electrically programmable read-only memory.
ERROR
A message that indicates an unacceptable input has been entered.
EVEN
A parity configuration.
EXCITATION
D.C. voltage supplied to the load cell for power.
FULL-SCALE
Full scale input as defined by instrument and load cell parameters. Example: 3MV/V load cell @ 10
volts = 30mV full scale.
6-27
HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX F - GLOSSARY OF TERMS - Continued
GRADUATION SIZE
Minimum increment displayed by the instrument.
GROSS WEIGHT
An overall weight exclusive of tare deductions. Weight of material plus container.
INPUT AVERAGE
The number of readings averaged into a displayed value.
KEYPAD LOCKOUT
A selectable switch used to prevent input from the keyboard.
KILOGRAMS
A unit of mass in the metric system. Equal to 1000 grams or 2.2046 pounds. "Gr" represents kilograms
on the seven segment display.
LED
Light Emitting Diode. These are used in the front panel displays and indicators.
LOAD CELL
A device which produces output signal proportional to the applied weight or force.
MENU
A set of prompts used to configure the instrument.
MENU DRIVEN
Operational prompts supplied in common language statements via the system display to guide an
operator through a procedure.
MICROPROCESSOR
A semiconductor device that performs control, input/output, arithmetic, and logical operations by
executing instructions obtained from memory sources.
MIDPOINT LINEARITY CORRECTION
Allows operator to "BEND" the response of an instrument to match a non-linear input.
6-28
SECTION 6 - APPENDIX F
APPENDIX F - GLOSSARY OF TERMS - Continued
MOTION
The amount of allowable deviation between consecutive readings before a weighment is accepted as
being complete.
NEMA 4
An enclosure that is watertight, dust-tight, and usable both indoors and outdoors. Will protect the
enclosed equipment against splashing water, seepage of water, falling or hose-directed water, and severe
external condensation.
NET WEIGHT
Gross Weight minus the Tare value.
NEXT KEY
A key used to step through menus or increase the value of a digit.
NON-LINEARITY
A deviation of an instrument response from a straight line.
NUMBER OF READINGS PER AVERAGE
The number of weight readings used to compute the displayed weight.
ODD
A parity configuration.
OPTION
A device not supplied with a basic instrument.
OPTION SLOT
A location on the main board used to install an option card.
PARITY
A binary digit error correction appended to an array of bits to make the sum of all the bits always odd or
always even.
POUNDS
A unit of mass in the Avoirdupois System. Equal to 16 ounces or 0.4536 kilograms.
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HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX F - GLOSSARY OF TERMS - Continued
PREACT
The number of units above or below the set point value of which the relay will trip. Use as an "in flight"
compensation value.
PREVIOUS KEY
A key used to step back through menus.
PROMPTS
Instructions or options presented, in a menu, by the instrument.
RAM
Random-Access-Memory. Read/write memory out of which the microprocessor can both write and read
data.
RATE OF CHANGE
A measure of the rate at which weight is changing. For example, if 100 pounds were dispensed in 1
minute the rate of change would be 100 lb/minute.
RELAY SENSE SELECTION
Optional procedure which reverses the relay sense from normally energized to normally de-energized, or
back again.
REMOTE FUNCTION
A function in the instrument that can be accessed away from the instrument.
REPEATABILITY
The maximum difference between readings for repeated readings under identical conditions.
ROM
Read-Only-Memory. This permanent, non-volatile memory gives the processor instructions and cannot
be altered.
RTS
Request to send an RS-232C level, signaling a readiness to send.
RXD
Received data at a serial port. Accepts RS-232C data signals.
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SECTION 6 - APPENDIX F
APPENDIX F - GLOSSARY OF TERMS - Continued
SCALE CAPACITY
The maximum amount of weight the scale is capable of supporting, (Live load plus deadload).
SECURE MEMORY MODULE (SMM)
The Secure Memory Module stores and protects vital information from corruption, including calibration,
configuration of setpoints, RS-232C Serial Port, Optional Serial, BCD, Bar-graph, and Rate of Change.
Also allows the transference of data from one unit to another, with no re-calibration or re-configuration
necessary.
SET POINT
Ordered weight of a particular ingredient. Weight reading at which a relay will be actuated.
SPAN
The total amount of test weights used (placed on the scale) when performing a "Hard Calibration".
TAG
Another name for Secure Memory Module.
TARE
Artificial zeroing of the weight hopper so that a net weight can be displayed. Also, the action of adjusting
out the known weight of the container from the total indicated weight, so that the indicator reads net
weight directly.
TEMPERATURE COEFFICIENT
The change in indication due solely to a change in temperature from a reference temperature. Expressed
as a percentage of span value for a specified temperature change.
TIME BASE
Time in seconds between values subtracted to determine rate of change.
TRANSMITTER SPAN
Value the transmitter puts out with the maximum weight on the load cell.
TRANSMITTER ZERO
Value the transmitter puts out with minimum weight on the load cell.
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HI 2151/20WC OPERATION AND INSTALLATION MANUAL
APPENDIX F - GLOSSARY OF TERMS - Continued
TTL
Transistor-transistor Logic
TXD
Transmit Data
UPDATE RATE
Number of times per second a new weight reading is taken.
ZERO
Weight reading once the dead load has been offset.
ZERO CALIBRATION
Offset of the value of the dead load of the weight hopper.
ZERO TOLERANCE
The number of graduations from zero that will be accepted as zero by the instrument.
ZERO TRACK
Logic command used to adjust the instrument automatically from small variances in zero readings.
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