Rate Controller HI 4060 - Hardy Process Solutions

Rate Controller HI 4060 - Hardy Process Solutions
Rate Controller
HI 4060
User’s Guide
9440 Carroll Park Drive Suite 150, San Diego, CA 92121
Telephone: 1-800-821-5831
FAX: (858) 278-6700
Web Address: http://www.hardyinstruments.com
Hardy Instruments Document Number: 0596-0307-01 Rev. E
Copyright February 2009, Dynamic Instruments, All Rights Reserved. Printed in the U.S.A.
Local Field Service
Hardy has over 200 field technicians in the U.S., and more positioned throughout the world to
assist you in your support needs. We also have factory engineers who will travel to your facility
anywhere in the world to help you solve challenging applications. We're ready to support you
with:
•
•
•
•
Installation and start-up
Routine maintenance and certification
Plant audits and performance measurement
Emergency troubleshooting and repair
To request Emergency Service and Troubleshooting, Start-up, Installation, Calibration, Verification or to discuss a Maintenance Agreement please call 800-821-5831 Ext. 1757 or Emergency
Service after hours (Standard Hours 6:00 AM to 6:00 PM Pacific Standard Time) and weekends
Ext. 1111.
Outside the U.S
Hardy Instruments has built a network of support throughout the globe. For specific field service options available in
your area please contact your local sales agent or our U.S. factory at +1 858-292-2710, Ext. 1757.
Contents
••••••
Chapter 1
Overview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
HI 4060 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Typical Applications - - - - - - - - - - - - - - - - - - - - - - - - - - Features and Capabilities - - - - - - - - - - - - - - - - - - - - - - - - C2® Calibration - - - - - - - - - - - - - - - - - - - - - - - - WAVERSAVER® - - - - - - - - - - - - - - - - - - - - - - - Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connectivity and Ports - - - - - - - - - - - - - - - - - - - - - Mapped I/O - - - - - - - - - - - - - - - - - - - - - - - - - - Integrated Technician™ - - - - - - - - - - - - - - - - - - - - Secure Memory Module (SMM-SD) - - - - - - - - - - - - - - Automatic or Manual Control Modes - - - - - - - - - - - - - - Continuous or Batch Modes - - - - - - - - - - - - - - - - - - Automatic or Manual Refill- - - - - - - - - - - - - - - - - - - True Two and Five-Point Automatic Rate Calibration - - - - - - Operational and Mode Displays - - - - - - - - - - - - - - - - - Graphics Display Mode - - - - - - - - - - - - - - - - - - - - Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - Reports - - - - - - - - - - - - - - - - - - - - - - - - - - - - Available Communications - - - - - - - - - - - - - - - - - - - - - - - Ethernet/IP - - - - - - - - - - - - - - - - - - - - - - - - - - Modbus/TCP/IP - - - - - - - - - - - - - - - - - - - - - - - - DeviceNet - - - - - - - - - - - - - - - - - - - - - - - - - - - PROFIBUS - - - - - - - - - - - - - - - - - - - - - - - - - - RIO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Interpreting the Model Code Number - - - - - - - - - - - - - - - - - - - - Model Code Breakdown - - - - - - - - - - - - - - - - - - - - - - - Mounting Options - - - - - - - - - - - - - - - - - - - - - - Power Supply Options - - - - - - - - - - - - - - - - - - - - Internal Options (Software Installation Only) - - - - - - - - - External Network Options - - - - - - - - - - - - - - - - - - Enclosure Options - - - - - - - - - - - - - - - - - - - - - - -
Chapter 2
-
2
2
2
3
3
3
3
3
3
4
4
4
4
4
4
4
4
5
5
5
5
5
6
6
6
7
7
7
8
8
Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Basic Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Number of Channels
Update Rate - - - Excitation Voltage Averages - - - - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
9
9
9
9
Contents
•
•
• 3
•
•
•
Input - - - - - - - - - - - - - Display - - - - - - - - - - - - Display Increments (Graduations)Key Pad - - - - - - - - - - - - Non-Linearity - - - - - - - - - WAVERSAVER® - - - - - - - C2® Maximum Cable Length- - Digital Voltmeter (IT) - - - - - Power and Utility Requirements - - - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
9
9
9
9
10
10
10
10
10
Voltage - - - - - - - - - - - Frequency - - - - - - - - - - Power - - - - - - - - - - - - Common Mode Voltage Range Common Mode Rejection - - Environmental Requirements - - - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
10
10
10
10
10
11
Operating Temperature Range
Storage Temperature Range Humidity Range - - - - - - Approvals - - - - - - - - - - - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
11
11
11
11
-
Physical Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Panel Mount - - - - - - - - - Din Rail Mount - - - - - - - Analog Card - - - - - - - - - Current Outputs - - - - Voltage Output- - - - - Resolution - - - - - - - Accuracy - - - - - - - Network Option Cards - - - - - - -
-
-
-
-
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
11
11
12
12
12
12
12
12
Profibus Card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
RIO Card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
Chapter 3
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Disassembly and Reassembly Notes and Cautions - - - - - - - - - - - - - - - 14
Mechanical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
Installing the HI 4060 Rate Controller in a Panel- - - - - - - - - - - - - DIN Rail Installation HI 4060 Rate Controller - - - - - - - - - - Remote Display Installation - - - - - - - - - - - - - - - - - - Installing a remote display or a second display - - - - - - - - - - Installing the SMM-SD Memory Card - - - - - - - - - - - - - - - - - - - - -
14
16
17
18
18
Load Point Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
C2® Load Point Connection - - - - - - - - - - - - - - - - - - - - - - - 20
4
•
•
• Contents
•
•
•
Non-C2 Load Point ConnectionPrinter/Scoreboard Wiring - - Digital Inputs 1-3 - - - Input Power Wiring - - - - - - - - -
-
-
-
-
-
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
21
21
21
22
AC Input Power Wiring (-AC) - - - - - - - - - - - - - - - - - - - - - - 22
DC Power Input (-DC) - - - - - - - - - - - - - - - - - - - - - - - - - - 27
Input Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
Switch Input Defaults - - - - - - - - - - - - - - - - - - - - - - 28
Relay Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - 28
Network: Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
Simple Ethernet Network - - - - - - - - - - - - - - - - - - - - - - - - - 28
Installing a Card in the Option Slot (applies to -4ANB and -DIO) - - - - - - - - 29
Installing Labels - - - - - - - - - - - - - - - - - - - - - - - - - 30
The Analog Output Card - - - - - - - - - - - - - - - - - - - - - - - - - 30
Installing a Card in the Network Slot - - - - - - - - - - - - - - - - - - - - - - 31
Installing a Network Card Label
Wiring the PROFIBUS Card - - - - Wiring the DeviceNet Card - - - - - Wiring the Remote I/O Card - - - - Wiring the Modbus TCP/IP Option - -
Chapter 4
-
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
-
31
32
32
32
32
Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
Front Panel Basics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
Display Area- - - - - - - - - Scroll and Select Buttons - - - Up/Down Arrow Buttons Left/Right Arrow Buttons
Enter Button - - - - - - Function Buttons- - - - - - - START - - - - - - - - Manual (MAN) - - - - MODE - - - - - - - - HOLD - - - - - - - - - STOP - - - - - - - - - EXIT - - - - - - - - - CLR - - - - - - - - - - Summary Display - - - - - - Ethernet Network Configuration - - -
-
-
-
-
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
33
34
34
34
34
34
34
34
34
34
34
35
35
35
36
LAN Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
Blind Units: - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
DHCP Configuration Using the Front Panel - - - - - - - - - - - - - - - - 36
Displaying the Complete DHCP IP Address - - - - - - - - - - - - 37
Contents
•
•
• 5
•
•
•
Fixed IP Configuration Using the Front Panel - - - - - - - - - - - - - - - 37
Direct Connection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38
6
•
•
• Contents
•
•
•
Direct Connect Hardware- - - - Windows PC configuration - - - - - - Windows 2000 - - - - - - - - - Windows XP- - - - - - - - - - Windows 7 - - - - - - - - - - Direct Connect Configuration - HI-4060Web Interface Basics - - - - - - - - - - - -
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
38
39
39
39
40
40
41
Help - - - - - - - - - - Save Parameters - - - - Registering Your HI 4060 - - Network Options Configuration - - -
-
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
41
41
42
43
Configuring DeviceNet- - - - - - - - - - - - - - - - - - - - - - - - Accessing DeviceNet from the Web Interface - - - - - - - - - DeviceNet Baud - - - - - - - - - - - - - - - - - - - - - - - DNET Node - - - - - - - - - - - - - - - - - - - - - - - - - DNET Bytes Input and Bytes Output - - - - - - - - - - - - - DNET No Connection - - - - - - - - - - - - - - - - - - - - Ethernet/IP™ - - - - - - - - - - - - - - - - - - - - - - - - - - - - IP Addresses - - - - - - - - - - - - - - - - - - - - - - - - - No Connection - - - - - - - - - - - - - - - - - - - - - - - - Remote I/O - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Blind Unit Operation Setup - - - - - - - - - - - - - - - - - - Viewing the I/O Card Display - - - - - - - - - - - - - - - - Analog Output Card - - - - - - - - - - - - - - - - - - - - - - - - - Setting Current Channel 2 & 4 Parameters - - - - - - - - - - - Analog Card Help Menu - - - - - - - - - - - - - - - - - - - Configuring ModBus - TCP/IP Over Ethernet (10 socket max.)- - - - - Enabling ModBus in the HI 4060 Module - - - - - - - - - - - Installing Hardy ModBus-Link - - - - - - - - - - - - - - - - Instrument Setup / Entering scale capacity - - - - - - - - - - - ProfiBus® Configuration - - - - - - - - - - - - - - - - - - - - - - - Initialization Process - - - - - - - - - - - - - - - - - - - - - ProfiBus-DP .GSD File- - - - - - - - - - - - - - - - - - - - Pre-Initialization Procedures - - - - - - - - - - - - - - - - - Initialization Procedures - - - - - - - - - - - - - - - - - - - DP State (Read Only) - - - - - - - - - - - - - - - - - - - - WD State (Read Only) - - - - - - - - - - - - - - - - - - - - Baud Rate - - - - - - - - - - - - - - - - - - - - - - - - - - Configuring Rate of Change (ROC) - - - - - - - - - - - - - - - - - - Time Units and Time Base - - - - - - - - - - - - - - - - - - ROC Time Units - - - - - - - - - - - - - - - - - - - - - - - ROC Time Base - - - - - - - - - - - - - - - - - - - - - - - -
-
44
44
45
45
46
47
47
49
50
51
52
52
54
58
58
59
60
60
62
64
65
66
66
67
69
69
69
69
70
70
70
-
-
-
-
Graphing ROC (Front Panel) - - - - - - - - - - - - - - - - - - - 71
Configuring Security - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
Restricting access to the Web interface and front panel Verifying a password from the front panel - - - - - - Setting Parameter Security - - - - - - - - - - - - - Instrument Setup - - - - - - - - - - - - - - - - - - - - -
-
-
-
-
-
-
-
-
-
-
Accessing Instrument setup from the Web Interface - - - - - - - Accessing the Instrument Setup menu from the Front Panel - - - Unit (of Measure) - - - - - - - - - - - - - - - - - - - - - - - Instrument ID - - - - - - - - - - - - - - - - - - - - - - - - - Operator ID - - - - - - - - - - - - - - - - - - - - - - - - - - Weight Decimal Point - - - - - - - - - - - - - - - - - - - - - Rate Decimal Point- - - - - - - - - - - - - - - - - - - - - - - Total Decimal Point - - - - - - - - - - - - - - - - - - - - - - Batch Decimal Point - - - - - - - - - - - - - - - - - - - - - - Grads (Graduation Size) - - - - - - - - - - - - - - - - - - - - Num Averages - - - - - - - - - - - - - - - - - - - - - - - - - WAVERSAVER® - - - - - - - - - - - - - - - - - - - - - - - Low Pass Filter - - - - - - - - - - - - - - - - - - - - - - - - Configuring the Capacity Parameter- - - - - - - - - - - - - - - Use Default I/O? - - - - - - - - - - - - - - - - - - - - - - - - Instrument Usage Help - - - - - - - - - - - - - - - - - - - - - LCD Contrast - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting the Front Panel LCD Display - - - - - - - - - - - - - Configuring a Printer or Scoreboard- - - - - - - - - - - - - - - - - - - Print Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - Baud Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - Parity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Data Bits - - - - - - - - - - - - - - - - - - - - - - - - - - - Configuring Date and Time- - - - - - - - - - - - - - - - - - - - - - - Rate Calibration Configuration - - - - - - - - - - - - - - - - - - - - - Cal Type- - - - - - - - - - - - - - - - - - - - - - - - - - - - Prime Time - - - - - - - - - - - - - - - - - - - - - - - - - - Pause Time - - - - - - - - - - - - - - - - - - - - - - - - - - Feed Time - - - - - - - - - - - - - - - - - - - - - - - - - - - Setting Feed Time - - - - - - - - - - - - - - - - - - - - - - - RateCal Percents - - - - - - - - - - - - - - - - - - - - - - - - Running Rate Cal - - - - - - - - - - - - - - - - - - - - - - - Refills - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Refilling during calibration - - - - - - - - - - - - - - - - - - - Auto Refills - - - - - - - - - - - - - - - - - - - - - - - - - - Initial Refill - - - - - - - - - - - - - - - - - - - - - - - - - - Refill Start (lo) and Stop (hi) - - - - - - - - - - - - - - - - - - Low Shutoff and High Alarm Weight - - - - - - - - - - - - - - -
72
75
76
77
78
78
79
79
80
81
81
82
82
83
84
84
85
86
86
87
87
88
88
88
89
89
90
91
93
93
94
94
95
97
97
99
101
101
101
102
102
103
Contents
•
•
• 7
•
•
•
OP Adjust %/wgt - - - - - - - - - - - - - - - - - - - - - - - OP Adjust and OP Adjust %/wgt during refill - - - - - - - - - - Remote Setpoint - - - - - - - - - - - - - - - - - - - - - - - - - - - - SP HI/LO wgt/time- - - - - - - - - - - - - - - - - - - - - - - Input HI% and Input LO% - - - - - - - - - - - - - - - - - - - Remote Average - - - - - - - - - - - - - - - - - - - - - - - - Analog Input Range Parameter - - - - - - - - - - - - - - - - - Remote Setpoint (SP) Enable - - - - - - - - - - - - - - - - - - Configuring REC Parameters - - - - - - - - - - - - - - - - - - - - - - REC Level % - - - - - - - - - - - - - - - - - - - - - - - - - REC Time - - - - - - - - - - - - - - - - - - - - - - - - - - - REC Shutdown Parameter - - - - - - - - - - - - - - - - - - - Ingredient Configuration - - - - - - - - - - - - - - - - - - - - - - - - Accessing the ingredients forms from the Web interface - - - - - Ingredient Name - - - - - - - - - - - - - - - - - - - - - - - - Selecting an ingredient to rename - - - - - - - - - - - - - - - - Cloning and changing an ingredient from the front panel - - - - - Setting Ingredient Values - - - - - - - - - - - - - - - - - - - - - - - - Rate Setpoint Configuration - - - - - - - - - - - - - - - - - - Selecting Mode - - - - - - - - - - - - - - - - - - - - - - - - Batch (Amount and Preact) - - - - - - - - - - - - - - - - - - - Alarm Delay - - - - - - - - - - - - - - - - - - - - - - - - - - Rate Tolerance / Hi and Lo Shutoff - - - - - - - - - - - - - - - Shutoff Out % - - - - - - - - - - - - - - - - - - - - - - - - - Wait Time - - - - - - - - - - - - - - - - - - - - - - - - - - - Totals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Batch Total (Front Panel only) - - - - - - - - - - - - - - - - - IP Setup Program (necessary for Blind HI-4060 Units) - - - - - - - - - - -
Chapter 5
104
104
105
105
107
108
108
108
109
109
110
110
111
111
112
113
113
115
115
116
116
117
118
119
120
120
121
122
Calibration- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
Pre-Calibration Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - 123
Mechanical Check Procedures
Electrical Check Procedures Load Check - - - - - - - - Calibration Procedures - - - - - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
123
124
125
125
C2 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126
About The Gravitation Correction Factor - - - - - - - - - - - - - 128
Traditional Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - 129
Chapter 6
Mapping - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133
Glossary of Mapping Terms - - - - - - - - - - - - - - - - - - - - - - - 133
How Mapping Works - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 134
Input and Output Tables - - - - - - - - - - - - - - - - - - - - - - - - - 134
8
•
•
• Contents
•
•
•
Local Input - - - - - - - - - - - - Volatile and Non-Volatile Memory - Mapping to an Output - - - - - - - Network Input - - - - - - - - - - - Network Output - - - - - - - - - - Example #2 Mapping an Input - - - Simple Network Mapping - - - - - - - - Mapping to a Network Output - - - Mapping a Network Input for Control More Advanced Mapping - - - - - - - - - - - -
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Boolean Mapping - - - - - - - - - - - - - - - - - - - - - - - - - Analog Mapping - - - - - - - - - - - - - - - - - - - - - - - - - - Mixed Mapping - - - - - - - - - - - - - - - - - - - - - - - - - - Special (Command) Mapping - - - - - - - - - - - - - - - - - - - - The Command Interface - - - - - - - - - - - - - - - - - - - - - - Setting up the Command Interface Mapping - - - - - - - - - Parameter List (Dump) - - - - - - - - - - - - - - - - - - - - - - - Map Dictionary - - - - - - - - - - - - - - - - - - - - - - - - - - -
Chapter 7
-
-
135
135
135
136
136
139
139
139
141
142
-
142
143
143
144
144
144
145
147
Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 153
Operational Displays on the Front Panel - - - - - - - - - - - - - - - - - - - - 153
Selecting Mode Displays from the Front PanelMode Displays - - - - - - - - - - - - Operational displays - - - - - - - - - Setting the Rate Setpoint - - - - - - - - - - - - -
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
153
153
154
155
Setting the Rate Setpoint from the Front Panel - - - - - - - - - - - - - - Setting the Rate Setpoint from the Web Page in Idle Mode - - - - - - - - Ratio Control (Master/Slave) - - - - - - - - - - - - - - - - - - - - - - Description of a Ratio Controlled System - - - - - - - - - - - - Ratio Process Control System- - - - - - - - - - - - - - - - - - Remote Set Points for Ratio Control Applications - - - - - - - - - - - - Setting Remote Set Points for Ingredient B from the Front Panel - - - - - Selecting the Ingredient - - - - - - - - - - - - - - - - - - - - Setting the SP HI wgt/time - - - - - - - - - - - - - - - - - - - Setting SP LO wgt/time - - - - - - - - - - - - - - - - - - - - Setting Input HI% - - - - - - - - - - - - - - - - - - - - - - - Setting Input LO% - - - - - - - - - - - - - - - - - - - - - - - Setting Range - - - - - - - - - - - - - - - - - - - - - - - - - Setting the Remote Setpoints for Ration Control from the Web Page - - - Setting the Averaging Parameter from the Front Panel - - - - - - Setting the Averages from the Web Page - - - - - - - - - - - - -
155
156
156
156
156
157
157
157
157
158
158
158
159
159
161
162
Contents
•
•
• 9
•
•
•
Chapter 8
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 163
Disassembly and Reassembly Notes, Warnings and Cautions - - - - - - - - - - 163
Error Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 164
Trouble Shooting Using Integrated Technician (IT®) - - - - - - - - - - - - - - 165
Stability Test ALL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 165
PASS/FAIL and Variance Test Raw A/D Count - - - - Raw A/D Average Counts
Weight and Voltage ALL - - - - - -
-
-
-
-
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
-
166
166
166
166
Weight - - - - - - - - - - - mV/V and mV - - - - - - - - RTZ (Return to Zero) Test - - - - - IT Test - - - - - - - - - - - - - - Sensor Number - - - - - - - Weight - - - - - - - - - - - Mv/V and MV - - - - - - - - RTZ (Return to Zero) Test - - - - - Audit Trail- - - - - - - - - - General Troubleshooting Flow Chart Index-
-
-
-
-
-
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-
166
166
167
167
167
167
167
167
168
168
A - Guidelines for Instabilities on Formerly Operating Systems - - - - - - - - - 169
A1 - Guidelines for Instabilities on Formerly Operating System (Cont’d)- - - - - 170
B - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) - - - - - 171
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) - - - - 172
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) - - - - 173
C - Guidelines for Instabilities on Formerly Operating Systems - - - - - - - - - 174
E - Non-Return to Zero (Must be connected to an IT® Summing Box - - - - - - 175
F - Verify Individual Load Cell Millivolt Readings - - - - - - - - - - - - - - - 175
G - Calibration Failed: Not Enough Counts Between ZERO and SPAN - - - - - 177
H - Mechanical Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - 178
J - Electrical Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179
K - Load Sharing and Load Sensor Checkout - - - - - - - - - - - - - - - - - - 180
M - (*******) or (- - - - - - -) ERROR - - - - - - - - - - - - - - - - - - - - - 181
N - Rate Controller’s Front Display is Blank - - - - - - - - - - - - - - - - - - 182
P - SD Card Diagnostics and Losing Memory at Power Cycles - - - - - - - - - 183
Erratic Weight or Rate Control - - - - - - - - - - - - - - - - - - - - - - 184
Tests and Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 186
Diagnostic testing from the Web page - - - - - - - - - - - - - - - - - - - 186
Front panel test menu - - - - - - - - - - - - - - - - - - - - - - - - - - 187
Parameters- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 187
•
•
10 ••
•
•
Contents
Chapter
System and Load Cell Tests - - - - - - - - - - - - - - - - - - - - - Overview of Typical Load Cell System - - - - - - - - - - - - INTEGRATED TECHNICIAN (IT®)- - - - - - - - - - - - - - - - - Understanding the Tests - - - - - - - - - - - - - - - - - - - - - - - Stability Test- - - - - - - - - - - - - - - - - - - - - - - - - Weight and Voltage Test - - - - - - - - - - - - - - - - - - - Directory - - - - - - - - - - - - - - - - - - - - - - - - - - Checking Inputs and (Optional) Outputs - - - - - - - - - - - - Viewing System C2 Load Sensors - - - - - - - - - - - - - - Viewing the SMM-SD Card - - - - - - - - - - - - - - - - - Event Log - - - - - - - - - - - - - - - - - - - - - - - - - - Using the Ping Tool to Test the Network Connections and Configuration Selecting the module by number for ping testing - - - - - - - - General Policies and Information - - - - - - - - - - - - - - - - - - - - - -
-
189
189
190
191
191
192
193
194
194
195
195
196
196
196
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Ordering Replacement Parts - - - - - - - - - - - - - - - - - - - - - System Support (Requires Purchase Order or Credit Card) - - - - - - - Software Downloads for Your HI 4060 - - - - - - - - - - - - - - - - Downloading and Installing Firmware Updates (S-19 Files) - - -
-
197
197
197
197
198
Appendix AAbout Time Zones- - - - - - - - - - - - - - - - - - - - - - - - - 201
Greenwich Mean Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - 201
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 205
Contents
•
•
• 11
•
•
•
•
•
12 ••
•
•
Contents
Chapter 1
Overview
••••••
This manual provides users and service personnel with specifications and procedures for
installing, configuring, operating, maintaining, and troubleshooting the Hardy Instruments
HI 4060 Rate Controller with WAVERSAVER.®
NOTE
WAVERSAVER is a registered trademark of Hardy Instruments, Inc.
To ensure good performance and maximum service life, follow all guidelines described in
this manual. Both users and maintenance personnel should understand all cautions,
warnings, and safety procedures. If you find that the information in this manual does not
provide the help you need, contact the HI Customer Service Department at:
Phone: (858) 278-2900
FAX: (858) 278-6700
Web Site: www.hardyinst.com
Support e-mail address: [email protected]
About Hardy Manuals
An overview of each chapter’s contents is listed below:
• Chapter One - Provides an overview of HI 4060 capabilities and features
• Chapter Two - Provides a overview of HI 4060 specifications
• Chapter Three - Describes the steps for installing both the standard and optional HI
•
•
•
•
•
4060 equipment and the HI 215IT series junction box
Chapter Four - Explains how to configure the HI 4060 for network operation
(Ethernet/IP or DeviceNet) using either the front panel or Web interface
Chapter Five - Provides calibration instructions
Chapter Six - Provides mapping instructions
Chapter Seven - Provides procedures for operating the HI 4060
Chapter Eight - Provides troubleshooting procedures for repair of the HI 4060
HI 4060 Overview
The HI 4060 is a single-ingredient, loss-in-weight controller that measures the flow rate
from a feeding device located on a process weighing scale. The user enters the flow
parameters, and an HI 4060 algorithm automatically calculates and adjusts the tuning
parameters needed to maintain the desired rate. After comparing the actual flow rate
Overview
•
•
• 1
•
•
•
(measured by calculating the loss of weight over short intervals) to the desired flow rate, it
computes the adjustments needed to achieve the desired rate and transmits signals to adjust
the speed of the feeding device.
NOTE
While the system rate calibration is designed to automatically fine tune the flow rate
parameters, you can also make manual adjustments.
Typical Applications
The HI 4060 provides closed-loop rate control that can be used in a variety of materialflow applications, such as auger, belt, and vibration-based feeders, converting them from
volumetric to gravimetric.
The Rate Controller can be operated in batch, automatic or manual mode. It can control rate
controllers or can function as a slave device to a master controller, e.g., a PLC, another HI
4060, or a computer.
NOTE
The HI-4060 controls a single ingredient, single feeder, and can transmit control to other
feeder controllers using analog out and communications.
Features and Capabilities
C2® Calibration
Traditional calibration uses certified test weights. C2® Electronic Calibration allows a scale
to be calibrated without the need for test weights. A C2® weighing system consists of up to
eight load cell sensors, a junction box, interconnect cable, and an instrument with C2®
capabilities (e.g., the HI 4060). Each Hardy Instruments C2-certified load sensor outputs
digital information used for calculating the calibration. When the HI 4060 reads the signals
from the load sensors, it calibrates the scale based on the load sensor’s output plus a usersupplied reference point value (from 0 to any known weight on the scale).
2
•
•
•
•
•
•
Chapter 1
WAVERSAVER®
During the measurement of small weight changes, the affects of mechanical vibration and
noise from the feeders and plant environment can introduce substantial interference.
WAVERSAVER factors out vibration, noise, and other interference-related signals from the
load cell so that the rate controller can better decipher the actual weight data.
WAVERSAVER can be configured from either the front panel or Web interface.
While WAVERSAVER can factor out noise with frequencies as low as 0.5 Hz, one of three
higher cut-off frequencies can be selected to provide a faster response time. The default
factory setting is 1 Hz vibration frequency immunity.
NOTE
WAVERSAVER® and C2® are registered trademarks of Hardy Instruments Inc.
Alarms
Two HI 4060 alarms flag deviations from your specified flow rate.
The Rate Tolerance Alarm is used to detect small flow-rate changes. It can be set to trigger
either a visual or sound alarm when the flow rate is above or below the tolerance range you
select for a time that exceeds a limit you set.
The Rate Exception Control (REC) Alarm is triggered by an out-of-tolerance flow rate
using a broader guard band tolerance than the Rate Tolerance Alarm. The REC provides a
user-selectable option when a set threshold is reached to either shut down the feeder system
or just display an "RE+" or “RE-”on the controller screen. During an REC alarm state that
has not resulted in shutdown, the controller will continue to maintain the flow rate while
monitoring the loss in weight until the rate is within tolerance.
Connectivity and Ports
For details, see the Available Communications section of this chapter.
Mapped I/O
Mapped I/O saves wiring costs by distributing the I/O where you need it, either at the
process, using the instrument’s front keypad, or in the control room through the mapping
page on the instrument’s web browser interface.
Integrated Technician™
The HI 4060 INTEGRATED TECHNICIAN™ (IT®) in conjunction with an IT junction
box provides built-in system diagnostics that makes it possible to diagnose weighing
system problems from the front panel or over the available networks. IT reads individual
load sensor voltages and weights and isolates individual system components for quick and
easy troubleshooting.
Secure Memory Module (SMM-SD)
A Secure Memory Module (SMM) in the HI 4060 protects critical data from loss and/or
corruption while increasing system flexibility. Using a Secure Digital (SD) card that
provides non-volatile storage, SMM - SD stores the configuration for hundreds of
Overview
•
•
• 3
•
•
•
ingredients, as well as HI 4060 calibration and setup data. This allows a storedconfiguration
to be activated in a matter of minutes without the need for rate recalibration.
The SD card can be read by a PC with an SD card reader. It is conveniently located on the
rear panel, where it can be quickly replaced, if necessary.
NOTE
Hardy supports Hardy Branded SD Cards and readers only. Other non Hardy branded
products are not supported.
Automatic or Manual Control Modes
Automatic mode corrects for variations in desired flow rates automatically.
Manual Control Mode uses the side-to-side arrows to manually control the flow rate. With
the touch of a button, users can convert to automatic mode when proper flow rate is
achieved.
Continuous or Batch Modes
User selectable operating modes for continuous or batch processing.
Automatic or Manual Refill
Automatic refill uses user selectable refill points to start and stop the refill process without
interrupting the feed process. HI and LO alarms to detect a refill failure.
The Manual Refill option only allows for manual refill at any time.
True Two and Five-Point Automatic Rate Calibration
The 5-point auto rate calibration creates a high feed accuracy for a wide range of feed rates.
It either provides the user with automatically calculated parameters, or it lets the user
manually enter his own derived values.
Operational and Mode Displays
Single button selection of predefined operating displays such as, Rate, Current Weight,
Totalized Weight, Batch data and Output Percentage. This enables the user to view more
functions on the Summary Display, allowing the operator to see at a glance the system
performance.
Graphics Display Mode
Graphs actual feed rate vs. rate setpoint or operating percentage output.
Front Panel
5" x 7" Waterproof when mounted in a NEMA 4 enclosure.
Reports
The HI 4060 automatically prepares batch performance reports that provide:
• Total weight at the time of the report and at the end of the last batch
• The dates and times for the start and end of the batch
• The date and time for the report.
4
•
•
•
•
•
•
Chapter 1
Available Communications
Hardy Instruments provides support for the following network options. See your
installation disk or the Hardy Instruments website to download the support interface
software that best matches your network requirements.
Ethernet/IP
Ethernet has become the de facto standard for both corporate enterprise and factory
networking systems. It enables the user to access device-level data from the Internet.
Ethernet/IP, short for Ethernet Industrial Protocol, is an open industrial networking
standard. It takes advantage of commercial, off-the-shelf Ethernet communication chips
and media and supports both implicit messaging (real-time I/O messaging) and explicit
messaging (message exchange).
Modbus/TCP/IP
TCP/IP is a commonly used set of layered protocols that provide a versatile, scalable, and
reliable data transport mechanism for networked machines with Internet connectivity. By
combining Ethernet with a universal networking standard (TCP/IP) and a vendor-neutral
instruction set /data representation (MODBUS®), Modbus/TCP/IP gives a truly open,
accessible network for exchange of process data that is easy to implement for any device
that supports TCP/IP sockets. If you have a MODBUS® driver and you understand Ethernet
and TCP/IP sockets, you can quickly have a driver up and running and talking to a PC. No
exotic chip sets are required, and you can use standard PC Ethernet cards to talk to your
implemented device.
NOTE
Mod-BUS® is a registered trademark of Schneider Automated Inc.
DeviceNet
The DeviceNet Network is an open, industry-standard communication network protocol
designed to provide an interface through a single cable from a programmable controller or
PC directly to all HI 4000 series instruments as well as smart devices such as sensors, push
buttons, motor starters, simple operator interfaces, drives and other weigh modules.
PROFIBUS
The PROFIBUS-DP (Decentralized Peripherals) communication profile is designed for
efficient field-level data exchange. The central automation devices, such as PLC/PC or
process control systems, communicate through a fast serial (RS485)connection with
distributed field devices, e.g., I/O, drives, valves, and measuring transducers. Data
exchange with the distributed devices is based on communication functions defined in the
EN 50 170 standard. While these are mostly cyclic functions, DP also offers extended
acyclic communication services for the parameterization, operation, monitoring and alarm
handling of intelligent field devices. To begin communicating weighing parameters
between an HI 4000 Series controller and a PLC, PC or DCS system controller, you need
only to load the *.GSD file and set the node address.
Overview
•
•
• 5
•
•
•
RIO
Under license from The Allen-Bradley Corporation, Hardy Instruments Inc. has developed
a Remote I/O Interface for the HI 4000 Series.
Hardy Instruments worked with substantial customer input from Allen-Bradley to ensure
that the remote I/O communications network best matched the needs of system integrators
and end users for industrial and process applications. The interface is fast, field proven,
requires minimal wiring, requires no special software drivers, and is standard on many
Allen-Bradley programmable controllers. To communicate parameters to and from the
controller, you need only to connect three wires, set the address and baud rate in the
controller, and write some ladder logic.
RIO Information contained in this manual is subject to change. Always check the latest
version of this manual at our web site (http://www.hardyinst.com) before beginning system
design. While this product incorporates technology licensed by Allen-Bradley Company
Inc., Hardy Instruments supplies this product and provides all warranty and technical
support for it.
Interpreting the Model Code Number
Model Code Breakdown
• The model code number can be found on a label that is attached to the top panel of the
HI 4060RC.
• The model code number starts with the base model number (HI 4060). The dash
alphanumeric designations indicate the capabilities of the rate controller. For example:
A model HI 4060RC-PM-AC-EIP-DN is a Panel Mount, AC powered, with Ethernet I/P
Interface, DeviceNet Communications.
6
•
•
•
•
•
•
Chapter 1
Mounting Options
Mounting Options
Option Code
Din Rail Mount (Without Display)
DR
Panel Mount (With Keyboard/Display)
PM
Nema 4 Wall Mount Enclosure (Stainless Steel w/o Display)
DRWS
Nema 4 Wall Mount Enclosure (Stainless Steel with Display)
PMWS
Power Supply Options
Power Supply Options
Option Code
100/240 VAC Operation (Use only with Option DR or PM)
AC
24 VDC Operation (Use only with Option DR or PM)
DC
100/240 VAC Operation (Use only with Option DRWS, PMWP or
PMWS)
ACW
24 VDC Operation (Use only with Option DRWS or PMWS)
DCW
Internal Options (Software Installation Only)
Internal Options
Option Code
No Internal Option
N1
Ethernet I/P Interface
EIP
Modbus TCP/IP
MD
Overview
•
•
• 7
•
•
•
External Network Options (Installed in “Network Option” Slot Location on Rear
Panel)
External Network Options
Option Code
No External Network
N2
DeviceNet Communications
DN
Analog Output, 4 Channel, Network Slot
Profibus DP I/O Interface (Used Only with Option DR or PM)
Profibus DP I/O Interface (Used Only with Option DRWP, DRWS,
PMWP or PMWS)
Remote I/O Interface for A-B Network
Standard
PB
PB60W
RIO
Enclosure Options (Selectable with Mounting Options DRWP, DRWS, PMWP &
PMWS Only)
Enclosure Options
8
•
•
•
•
•
•
Chapter 1
Option Code
No Enclosure Option
N4
IT Summing
IT1
IT Summing, With Trim Pots
IT2
Load Cell Summing
JB1
Load Cell Summing, w/ Trim Pots
JB2
Load Cell Summing, w/ Auxiliary Terminal Block
JB3
Load Cell Summing, W/ Trim Pots & Auxiliary Terminal Block
JB4
Chapter 2
Specifications
••••••
Chapter 2 provides specifications for the HI 4060 rate controller and optional equipment
that may come with the package. The specifications listed are designed to assist in the
installation, operation and troubleshooting of the instrument. All service personnel should
be familiar with this section before attempting an installation or repair of the instrument
Basic Specifications
Number of Channels
• 1 Channel
Update Rate
• 15 Updates per Second
Excitation Voltage
• 0-5 VDC
Averages
• 1 to 31User Selectable in Single Increments
Input
• Up to eight (8) 350 ohm Full Wheatstone Bridge, Strain Gauge Load Sensor/Cells (5
volt excitation) on one vessel.
• Weight Signal Voltage Range 0-15 mV
Display
• 128 x 64 Backlit LCD Graphic Display
Display Increments (Graduations)
• 1, 2, 5, 10, 20, 50, 100, 200, 500, 1000 user selectable via the front panel key pad and
Web Page
• Corresponding weight unit/time unit is dependent on the decimal point location.
Key Pad
• 9 tactile keys
Specifications
•
•
• 9
•
•
•
• 4 Soft Keys (Mappable)
Non-Linearity
• 0.0015% of Full Scale
WAVERSAVER®
• 15 Hz
• 1.0 Hz
• 0.50 Hz
C2® Maximum Cable Length
• 1000’ for C2, Non C2, or JB Card
• 500’ for IT
Digital Voltmeter (IT)
• Accuracy ± 2% of full scale
Power and Utility Requirements
Voltage
• 24 VDC (Standard)
• 100/240 VAC Universal (Optional)
Frequency
• 47/63 Hz
Power
• 10 Watts maximum with options
Common Mode Voltage Range
• ± 2.5 VDC
Common Mode Rejection
• 100dB @ 50-60Hz
•
•
10 ••
•
•
Chapter 2
Environmental Requirements
Operating Temperature Range
• -10 to 40º C (14º to 104º F)
Storage Temperature Range
• DR Type: -40 to 85º C (-40 to 185º F)
• PM Type: -30 to 70º C (-22 to 158º F)
Humidity Range
• 0-90% (non-condensing)
Approvals
• UL (Pending)
• CUL (Pending)
• Hazardous Class I, Division 2, Groups A,B,C,D, T4A and Class II, Division 2, Groups
•
•
•
•
•
•
E,F,G, T4A (Pending)
NTEP (Pending)
CE (Pending)
CB (Pending)
DeviceNet (ODVA)
Ethernet/IP (ODVA)
RIO
Physical Characteristics
Panel Mount
• Depth: 5.125” (130.175mm) Back of the Bezel to rear cable clearance
• Case Dimensions: 4.00”H x 5.65”W x 3.125”D (101.6mm H x 143.51mm W x
79.37mm D)
• Case Material: Aluminum Alloy (6063-T5)
• Weight: 2.45 pounds (1.11 Kilograms)
• Enclosure Rating: Front Panel NEMA 4, 4X Seal
Din Rail Mount
• Depth: 4.0” (101.6mm) Measured from bottom of the Din Rail Mounting Feet to top of
the enclosure)
• Case: 4.00”H x 5.65”W x 3.125”D (101.6mm H x 143.51mm W x 79.37mm D)
Specifications
•
•
• 11
•
•
•
Analog Card
NOTE
On the 4060, the Analog Output Card is standard.
Current Outputs
• 0-20 mA and 4-20 mA
• 0- 500Ω load at 20mA
Voltage Output
• 0-5 V and 0-10 V, max current 10mA
Resolution
• 16K counts over 0 to 20mA and 0 to 10V range
Accuracy
• ≤ 1% initial accuracy, ≤ 1% over temp
• Default settings channel 1-4 = motor speed control
Network Option Cards
Profibus Card
Connector: 9 pin Serial Connector, female
RIO Card
Connector: 9 pin Serial Connector
•
•
12 ••
•
•
Chapter 2
Chapter 3
Installation
••••••
Chapter 3 pertains to unpacking, cabling, interconnecting and installing the HI 4060 Rate
Controller. User and service personnel should be familiar with the procedures contained in
this chapter before installing or operating the HI 4060 Rate Controller.
NOTICE: This equipment is suitable for use in Class I, Division 2, Groups A,B,C,D,
T4A & Class II, Division 2, Groups E,F,G, T4A or Non-Hazardous Locations Only.
WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY
IMPAIR SUITABILITY FOR DIVISION 2.
WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT
UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE
NON-HAZARDOUS
Unpacking
Step 1. Before signing the packing slip, inspect the packing for damage of any kind, and
report any damage to the carrier company immediately.
Step 2. Verify that everything in the package matches the bill of lading. If any items are
missing, damaged, or there are any questions, contact Customer Service at:
Hardy Instruments
9440 Carroll Park Drive Suite 150
San Diego, CA 92121Phone: (800) 821-5831
FAX: (858) 278-6700
Web Site: http//www.hardyinst.com
E-Mail: [email protected]
Step 3. Record the model number and serial number of the HI 4060. Store in a
convenient, secure location for reference when contacting Hardy Instruments
Customer Service Department or to buy parts or firmware upgrades.
NOTE
The HI-4060 front display is optional. Without a front display, a communications IP Setup
disk and Web browser are required to setup and operate the Rate Controller.
Installation
•
•
• 13
•
•
•
Disassembly and Reassembly Notes and Cautions
• Installation of this equipment must be in compliance with any and all International,
•
•
•
•
•
•
•
•
•
National and Local Electrical and Mechanical codes.
Any disassembly must be done in a clean, well ventilated, properly controlled static
environment.
Always make sure that the assemblies and sub-assemblies are well supported and
insulated when doing any repairs on the instrument.
Place small fasteners, connectors and electrical parts in closed containers so as not to
lose parts during reassembly.
Read all the disassembly instructions before any disassembly begins. Be sure that you
are familiar with the procedures. If any of the instructions for disassembly are unclear,
contact Hardy Instruments, Technical Support Department for additional information
and assistance.
Do not disconnect any electrical plug, connector or terminal unless an identification tag
is present or one is attached. Always note where the connector or plug was attached to
the electrical component or wiring harness.
Always install complete hardware groups (Screws, Washers, Lock Washers, Spacers,
Etc.) back to the original point of removal.
Always replace broken or damaged hardware immediately!
Always check to be sure that no loose parts are sitting on printed circuit boards or
electrical connectors or wires when disassembling or reassembling.
Always protect printed circuit boards from electrostatic discharge (ESD). Always use
approved ESD wrist straps and anti-static pads.
Mechanical Installation
Installing the HI 4060 Rate Controller in a Panel
NOTE
CAUTION
Use a torque screw driver and torque each screw to 10 inch/pounds. DO NOT
OVERTIGHTEN!
You must install the HI 4060 in a NEMA 4, 4X or IP 55 rated enclosure or better.
WARNING - YOU MUST INSTALL THE HI 4060 IN A NEMA 4X ENCLOSURE
WHEN USING THIS INSTRUMENT IN A CLASS I or CLASS II ENVIRONMENT.
Step 1. Observe all Electrostatic Discharge (ESD) precautions before and during
installation.
•
•
14 ••
•
•
Chapter 3
.172 THRU, 9 PL
3.100
1.25 THRU
4.05
3.200
3.000
INSTRUMENT
BEZEL OUTLINE
2.590
1.274
.205
.41
.475
.755
5.250
6.200
.44
7.08
Panel Hole Dimensions (drawn from the back and not displayed to scale)
A paper template comes with the product. Copies of that template can be printed from the
Hardy Website. If you print from Hardy Website be sure to note the print instructions. A
copied version may not be correctly sized.
Step 2. Use a Phillips-head screwdriver and install the five (5) 6-32 x 1/2 inch screws that
fasten the bezel to the panel. Use a torque screw driver to torque each screw to 10
inch/pounds. DO NOT OVERTIGHTEN!
Installation
•
•
• 15
•
•
•
Step 3. Put the Display cable and connector
through the 1.25-inch hole in the panel door
or cover and plug the display connector into
the display header in the bezel.
Panel
Step 4. Gently slide the electronic enclosure onto
the threaded rods while making sure the
display cable glides easily and does not
kink.
Step 5. Move the electronic enclosure toward the
panel until it stops. Thread the four 6-32
thumb screws onto the threaded rods until
tight. Do not use pliers on the thumb
screws.
Electrical
Enclosure
Bezel
DIN Rail Installation HI 4060 Rate Controller
Step 1. Snap the DIN rail mounting feet into any two holes on the mounting panel of the
electronic enclosure until you hear a snapping sound. The snap means they are
mounted correctly. Use two mounting feet per enclosure.
Two clips are provided with the instrument. This picture shows one unmounted
sample clip and five clips mounted in vertical and horizontal arrangements.
Step 2. After installation, tug on each mounting foot to ensure it is seated correctly.
•
•
16 ••
•
•
Chapter 3
Remote Display Installation
Remote Display
Electronic
Enclosure
Maximum
Cable Length
100 Ft.
Step 1. Install the Electronic Enclosure on a DIN Rail or in a panel within 100 feet of the
Electronic Enclosure.
Step 2. Remember the maximum length of the Display Cable is 100 Ft. (30.48 meters).
Use shielded 6 wire cable (Minimum 22 AWG).
Step 3. Use the Template that was
shipped with the instrument to
cut the five holes required for
mounting the display on a wall
or on the door of an enclosure.
Step 4. Connect the cable wires to the
display and the Electronic
Enclosure, as shown.
Step 5. Wire the cable connectors as
follows:
Step 6. Plug the cable connector into
the remote display header of
the electronic enclosure.
Step 7. Put the cable through the 1.25inch hole you cut in the surface
where you are going to mount
the display.
Installation
•
•
• 17
•
•
•
Step 8. Use a Phillips-head screwdriver to install the four 6-32 x 1/2 inch screws that
fasten the bezel to the panel or wall. Use a torque screw driver and torque each
screw to 10 inch/pounds. DO NOT OVERTIGHTEN!
NOTE
If you are mounting the remote panel in a wash-down or hazardous area drill the fifth hole
and install with the 6-32 x 1/2 inch screw.
Installing a remote display or a second display
You can connect up to two displays by connecting one display at the front panel and one at
the rear panel. However, the display connected to the rear panel will have no keyboard
functionality. When connecting the display at the front panel (Panel Mount) use the short
cable that comes with the unit.
NOTE
Only one keypad display can be active. With two displays, the ribbon cabled display has the
only active keypad. You can still configure and operate the HI 4060 from the Web Browser.
Step 1. Shielded 4-wire cable (Min 22 AWG) is preferred. If you use 6-wire cable, do not
connect to terminals D3 & D4 on either or both ends of the remote display cable.
Step 2. Wire the cable connectors as follows:
DISPLAY
ELECTRONIC ENCLOSURE
Voltage In (Vin)
Voltage Out (Vout)
D1
D1
D2
D2
D3 Not Used do not Connect
D3 Not Used do not Connect
D4 Not Used do not Connect
D4 Not Used do not Connect
Ground (Gnd)
Ground (Gnd)
Step 3. Connect the cable to the display connector.
Step 4. Plug the connector into the electronic enclosure rear panel header.
Installing the SMM-SD Memory Card
NOTE
The rear panel may have plugs mounted above the SMM-SD slot. When removing these
plugs, avoid accidently disconnecting the SMM-SD card.
Remove and replace the SMM-SD card only when the power is off.
•
•
18 ••
•
•
Chapter 3
Step 1. Slide the SMM-SD
card into the SMMSD slot on the rear
panel.
Step 2. Push in the SMM-SD
card until a snap
indicates that the card
is seated.
SMM-SD
Card
Step 3. To remove the SMMSD card, gently push
the card towards the
instrument and
release it. The card
will pop out a little so
you to remove it from
the housing.
Step 4. Always store the SMM-SD card in a static-free enclosure and in a secure
environment so as not to lose the information stored on the card.
Load Point Installation
Rear panel
Installation
•
•
• 19
•
•
•
C2® Load Point Connection
We suggest that you wire a C2 cable from the instrument to the junction box using the color
code for C2 load points (left to right when facing the rear panel) and that you match the load
sensor color code to ease trouble shooting. There are many color combinations due to the
lack of an industry standard:
Shield Ground Wire
•
•
•
•
•
•
•
•
C2C2+
EXCSENSIGSIG+
SEN+
EXC+
Violet
Grey
Black
Brown
White
Green
Blue
Red
Contro
Output
Shield Ground
Relay Outputs
Switch Inputs
Analog Inputs
Rear panel with network and AC power options
Step 1. Remove the factory-installed jumpers from the terminal block if you are
connecting an 8-wire cable from the junction box.
Step 2. Connect the cable (Recommended load cell cable: Hardy Instruments Prt. # 60200001) wires to the channel terminal block according to the cable color chart.
Step 3. Plug the terminal block into the Channel connector on the rear panel.
•
•
20 ••
•
•
Chapter 3
Non-C2 Load Point Connection
NOTE
Cable Color Codes vary between vendors, check with your supplier for the Color Code for
your Non-C2 load point.
Step 1. Remove the factory-installed jumpers from the terminal block if you have 6-wire
load cell cable that includes sense wires from the load cell or junction box.
Step 2. Connect the cable (Recommended load cell cable: Hardy Instruments Prt. # 60200001) wires to the channel 1 terminal block according to the cable color chart, or
per manufacturer’s specification.
Step 3. Plug the terminal block into the channel connector on the rear panel.
NOTE
If you are using the Integrated Technician summing card, C2 wires are required to
communicate commands to the IT junction card and receive load sensor date in return.
Printer/Scoreboard Wiring
Printer/Scoreboard
Wiring Diagram
Control
Output
Serial Gnd to
Scoreboard Gnd
Serial Tx to
Scoreboard RX
Serial Rx (No
Connection)
Relay Outputs
Switch Inputs
Analog Inputs
Digital Inputs 1-3
The first four pins on the input port, located on the
main controller board at J2, are used for generalpurpose inputs. These inputs can be mapped to read
printer outputs (or switches or buttons to control such
functions as tare, or zero scale). Inputs one through
three can be used only with devices using 5 volts or
less. They are activated by shorting the pins 1, 2, or 3
to the J2 pin 4 COM terminal with a dry contact switch
or relay.
Installation
•
•
• 21
•
•
•
These standard inputs cannot interface with 24v logic directly. To activate the input
contacts sent from a PLC, it is necessary to install a relay device as the dry contact or install
the digital I/O card
Input Power Wiring
NOTE
When you use external over-current protection devices, mount the switch and/or circuitbreaker near the instrument.
WARNING - Do not plug the power connector into the header with live power. To do
so will result in property damage and/or personal injury.
WARNING - If a lithium battery is replaced with an incorrect type it may cause an
explosion which will cause property damage or personal injury.
AC Input Power Wiring (-AC)
WARNING - Operating with incorrect line voltage can result in property damage and/or
personal injury. Make sure that the power source does not exceed 240 VAC.
The AC power should be supplied by a “clean” primary line, directly from the power panel.
This line should not supply any other equipment, including the feeding unit, and should be
supplied with a maximum 20 amp breaker.
WARNING - If an automatic disconnect device is used on the AC input wires, the disconnect
must act on both the line and neutral wires in a double pole, double throw arrangement i.e.
DPDT Relay. Using other automatic disconnect arrangements may cause personal injury
and/or property damage.
Step 1. The HI 4060 is configured with a universal power supply rated from 120 to 240
VAC. Make sure the VAC power is shut off before installing the wires to the
connector.
Step 2. Install a 3-wire, minimum 14 AWG power line to the 3-pin terminal block
connector.
•
•
22 ••
•
•
Chapter 3
DC Power Input (-DC)
WARNING - Do not operate with incorrect line voltage. To do so will result in property
damage and/or personal injury. Make sure that the power source does not exceed 24 VDC.
CAUTION
You must use a power limited DC power supply (Class 2) on the DC input wiring.
The DC power should be supplied by a “clean” primary line, directly from the DC power
source.
Step 1. Make sure the VDC power is shut off before installing the wires to the connector.
Step 2. Connect the 24 VDC voltage wire, ground wire and shield wire to the connector
that plugs into the DC voltage header at the rear panel.
Step 3. Plug the connector into the header at the rear panel.
Step 4. Apply VDC power to the unit.
Input Wiring
The HI 4060 Rate Controller has eight, non-isolated I/O inputs. Three are external inputs
which are not preconfigured. Five are switch inputs with factory-set defaults to functions
(See below) that can be turned on or off from the front panel or the Web interface. If you
turn off the defaults, you can Map other functions to the five 5 preset inputs. See Chapter 6
- Mapping for more information on how to map the switch inputs.
I/O inputs
Installation
•
•
• 27
•
•
•
Switch Input Defaults
•
•
•
•
•
Input 1 = START
Input 2 = STOP
Input 3 = ESTOP
Input 4 = FORCE REFILL
Input 5 = CLEAR TOTAL
Relay Defaults
The relay values below default to the normally open state. To change the defaults you must first
select Defaults = NO on the configuration page.
•
•
•
•
•
1 ON/OFF
2 Shutoff
3 REC
4 Alarm
5 Refill
Network: Installation
The HI 4000 Series Network configurations include:
• DeviceNet
• RIO
• Profibus DP
• Ethernet TCP/IP
• Modbus TCP/IP
• Ethernet/IP
This enables the HI 4000 Series to communicate with virtually every device on the network, including PCs and PLCs. This means that you can map, configure and monitor all
the HI 4000 series products from the front panel or your LAN, Internet, DeviceNet, ControlNet and Wireless Servers that are connected to the Network.
Simple Ethernet Network
You can manage the HI 4060 from any Ethernet network connected computer. Both devices
must be set up for network communication.
All 4000 Series instruments are designed with a selectable 10/100 base T Ethernet connection
which links your PC to an embedded server in the instrument. You can connect to an instrument
via the Internet, Intranet, Extranet, or VPN (Virtual Private Network). Your computer must have
an ethernet card and cable with an RJ45 connector to connect to the instrument (Crossover or
straight are usable with the 4000 Series). Once connected you can, monitor, map and
configure any of the instruments from your web browser from any location in your plant or
•
•
28 •• Chapter 3
•
•
enterprise. Help Dialogs are also available in the browser to assist when performing setup or
troubleshooting of an instrument. In addition the browser connects you to the Hardy Web Site
which connects the user to a full range of customer services and support.
Step 1. Connect one of the RJ45 connectors to the Ethernet connection at the rear panel
of the HI 4000 Series products.
Step 2. Connect the other RJ45 connector to the Ethernet connection on your laptop
Ethernet card or your Ethernet adapter.
Step 3. If the Instrument does not have an IP address, you will need to create one.
See Chapter 4 for details.
Installing a Card in the Option Slot (applies to -4ANB and -DIO)
Installing the Cards
Step 1. Plug the Board Stacker into the Option Slot Header (J9) on the Main Controller
board, as shown below.
Option Slot
header (J2)
2mm Board
Stacker
Option Slot
header (J2)
Step 2. Through holes in the bottom of the option card allow you to plug the board stacker
into the option slot header (J2) on top of the card. Align the card through holes
with the stacker pins.
Installation
•
•
• 29
•
•
•
Step 3. Gently push the card onto the board stacker pins (making sure you align the
through holes on the analog board with the two standoffs on the Main Controller
board) until the pins are seated. Be careful not to bend the pins when plugging the
Analog Board into the board stacker.
Step 4. Slide the board assembly into the chassis until it stops.
Step 5. Use four pan-head screws (6-32 x .1875”) to fasten the rear plate to the chassis.
Installing Labels
Step 1. After removing the protective
cover off the label, align the label
with the through holes on each
side of the Option port.
Step 2. Press the label onto the rear panel
making sure that it sticks evenly.
Step 3. Use the two pan-head screws (440 x .25”) flat and split washers to
fasten the rear panel to the card
assembly, as shown.
The Analog Output Card
The Analog Output card comes standard on the HI 4060. Four independent analog outputs
can be configured to any of the instruments parameters over an adjustable 16,000 counts of
resolution: two current (0-20 mA) and two voltage (0-10 VDC).
NOTE
The analog output is not isolated. A 4-20ma isolator may be required for stable readings
depending on ground conditions.
Analog Wiring
•
•
•
•
Channel 1 -Voltage
Channel 2 - Current
Channel 3 - Voltage
Channel 4 - Current
WARNING - The Voltage and Current outputs are not interchangeable. To interchange
voltage and current will cause personal injury and/or property damage.
WARNING - The Hardy Analog Card is the Analog Source. Do not connect the Analog
card to another internal or external Analog Source. To do so may result in property
damage and/or personal injury.
•
•
30 •• Chapter 3
•
•
Installing a Card in the Network Slot
While some cards use a 16-pin board stacker and others use a or 40-pin board stacker, the
process for installing an optional card in the network slot is basically the same:
Step 1. Plug the 16-pin or 40-pin board stacker into the network option card header.
Network Slot
Header
2mm Board
Stacker
Step 2. Align the board stacker pins with the16 right-side pin holes for the network slot
Header (J41) located on the bottom of the Main Controller board.
Step 3. Using two fingers gently push the board stacker pins into the network slot header
until the standoffs touch the bottom of the main controller board.
Step 4. Use the two pan-head screws (4-40 x .25”) to fasten the option card to the
standoffs attached to the main controller board.
Installing a Network Card Label
Step 1. Peel the protective cover off the label.
Step 2. Align the label with the through holes on each side of the Network port.
Step 3. Press the label onto the rear panel making sure that it evenly sticks to the rear
panel surface.
Step 4. Use the two pan-head screws (4-40 x .25”) split and flat washers to fasten the rear
plate to the board assembly.
Step 5. Slide the board assembly into the chassis until it stops, and use the four pan-head
screws (6-32 x .1875”) to fasten the rear plate to the chassis.
Installation
•
•
• 31
•
•
•
Wiring the PROFIBUS Card
Profibus uses the 40-pin board stacker. Follow the procedure above under Installing
Network Cards.
Connector Terminations:
1
2
3
4
5
6
7
8
9
NO CONNECT
NO CONNECT
RXD/TXD +
RTS
GND BUS STATUS
+5V BUS
NO CONNECT
RXD/TXD NO CONNECT
Wiring the DeviceNet Card
DeviceNet uses the 40-pin board stacker. Follow the procedure above under Installing
Network Cards.
Left to Right facing the HI 4060 rear panel:
VCANShield
CAN+
V+
Black
Blue
Uninsulated
White
Red
Wiring the Remote I/O Card
See the separate Remote I/O User’s Guide for the HI 4000 Series (PN 0596-0306-01) for
setup procedures.
Wiring the Modbus TCP/IP Option
Modbus TCP/IP is a software option that comes preinstalled in the HI4060 upon customer request. A key is
required to enable the software. You can purchase the option
with the Key by contacting your local Hardy Instruments
Representative or Hardy Service Center. Chapter 4
describes the activation procedure.
To connect the HI4060 to a Modbus TCP/IP network, plug
the network cable into the Ethernet port as you would with
any standard Ethernet connection. See the Ethernet sections
above for details.
•
•
32 •• Chapter 3
•
•
Chapter 4
Configuration
Chapter Four provides stepped instructions for configuring the Hardy Instruments HI 4060
Rate Controller and the available network options (e.g., Ethernet/IP, ControlNet, and
DeviceNet) from either the front panel or Web interface. Following these procedures will
help to ensure trouble-free service.
Front Panel Basics
This section provides an overview of the front panel screen functions used to navigate,
make selections, and view and edit the data values displayed.
Rat e
Summary
Operational
Display Area Display area
Left Up/Down
arrow arrows
Enter
Button
Right
arrow
Display Area
The display area has five lines: At the top is a read-only Summary line that shows the
current weight in large print. The next three Operational lines can display either read-only
information or selectable options. And the bottom line names the function currently
assigned to each of the function keys.
Configuration
•
•
• 33
•
•
•
Scroll and Select Buttons
Up/Down Arrow Buttons
The Left/Right arrows move the cursor horizontally left or right. They are normally used to
select a character to change.
Left/Right Arrow Buttons
The Up/Down arrows scroll the options for a cusror location. For example, with the cursor
on the right-most digit of a five-digit number, you can press the Up or Down arrow to select
a number for that digit. Normally, after selecting all of the digits, you must press the Enter
button to save the selection.
Enter Button
Press Enter to save the current selection on a menu or a pick list into non-volatile memory.
Function Buttons
The functions associated with each of up to four function keys (buttons) are subject to
change when you make a different mode selection. The function name appears on the
screen above the button. The function buttons named below are frequently listed
options:
START
The Start button typically starts a motor speed
control that in turn runs a feeder, pump etc.
Manual (MAN)
The Manual button puts the HI 4060 in manual
mode, which allows you to adjust the output
percentage (OP) and/or set or reset the setpoint
when you are developing new process parameters or
adjusting existing processes.
MODE
The Mode button enables you to switch between Gross Weight, Totalized Weight (Total),
Amount (Amt) of weight on the scale and Actual Rate (ROC) modes while operating. The
display outputs the value for the mode selected. For example: ACT lb/m
HOLD
The Hold Button appears as the left-most button after you press the Start Button. Pressing
the Hold Button suspends a process.
STOP
The Stop Button appears as the left-most button after you press the Hold Button. Pressing
the Stop Button stops the output to the motor speed control to stop a process or idle state.
•
•
34 •• Chapter 4
•
•
EXIT
On a lower level menu, the Exit button allows you to return you to the previous menu.
CLR
CLR appears when you enter a menu. It clears the current value and repositions the cursor
for the first entry. To avoid mistakes, you can clear the existing value before entering the
new value.
Summary Display
The Summary screen, shown in the example above, displays gross weight, which can be
displayed in lb, oz, kg, g, Ton, or t (Metric Ton) per Unit/Unit of time and can be expressed
in - m = minutes, hr = hour, s = seconds. It also shows the actual rate of change, total
amount, and batch total. The settings can be toggled using the MODE soft key
The large display area displays:
NOTE
•
The current weight display (large display)
shows that the gross weight of the ingredient
currently in the feeder or scale is: 0.000 lbs
•
OP #% - In our example, 0% indicates that the
system is idle. If the system were active, it
would show the percentage of the available
output signal driving the feeder.
The Actual Rate (ACT) is a heavily averaged Rate of Change that represents the over-all
ROC feed rate. ROC is the raw, unaveraged feed rate for visualization of your flow rate.
The Up/Down arrows allow you to scroll the six top-level options to appear on the front
panel display. They do not always match the order in which they appear on the Web
displays.
1
2
3
4
5
6
Output percentage (OP)
Batch Amount (Amt)
Totalized Weight
Rate of Change (ROC)
Ingredients (This chapter begins with this menu)
Gross Weight
Configuration
•
•
• 35
•
•
•
Ethernet Network Configuration
NOTE
Do not confuse the onboard Ethernet TCP/IP communication with Ethernet/IP®.
Ethernet/IP® is an industrial protocol that does not transmit Web traffic and is a purchased
option.
An embedded Web server in the HI-4060 allows you to easily configure the parameters via
a Web browser. A standard Ethernet network is required to provide the connectivity
between the HI-4060 and your desktop or laptop computer.
The HI-4060 Rate Controller is designed with a standard 10/100 BASE-T Ethernet
connection for linking to any Windows PC. Once connected, the PC can be used to
monitor, configure, or download Hardy software to the HI-4060. A Help function can assist
you in setup or trouble-shooting. The browser also links to the Hardy Web Site where the
user can find additional services and support.
There are two primary ways to connect the HI-4060 to your computer:
LAN Connection:
Connect the HI-4060 to an existing Ethernet-based Local Area
Network (LAN) that has connectivity to your desktop or laptop
computer. See LAN Connection below.
Direct Connection: Make a direct point-to-point connection between the HI-4060 and
your desktop or laptop computer using any standard Ethernet cable.
See Direct Connection below.
LAN Connection
To connect the HI-4060 to a LAN, you simply connect a standard Ethernet cable between
the instrument and the common network hub. Every node on the network must have a
unique IP address or conflicts will result. Contact your Network Administrator for the IP
address to use for the HI-4060.
Blind Units: For controllers without a display, the IP address must be setup using the
IPSetup program. In Section 8 see Software Downloads for Your HI 4060.
The IP address can be set manually (fixed IP), or it can be set automatically by a network
service called DHCP. To use fixed IP addresses, refer to the section Fixed IP Configuration
Using the Front Panel. For automatic IP assignment (DHCP) use the following steps:
DHCP Configuration Using the Front Panel
DHCP works only if a DHCP server installed on your
network. To enable DHCP on the HI-4060, set the current
IP address to ‘0.0.0.0’ at the IP configuration screen.
Step 1. Press Enter to activate the Configuration menu.
Use the down arrow to select Instrument Setup
and press Enter.
•
•
36 •• Chapter 4
•
•
0.000
Configuration
>Instr Setup -->
Options
EXIT CLR
Step 1. From the Setup
menu, select
Ethernet; then press
Enter to display the
Ethernet menu.
Step 2. If the display is not already showing 0.0.0.0 for IP, select IP and press the CLR
button to erase the current IP value.
Step 3. Starting with the right-most digit, enter the value 0.0.0.0 using the up/down
arrows to select each character, and press the left arrow to move to the next digit.
Step 4. Press Enter to save the entry.
Step 5. Press the Exit key four times to exit the IP, Ethernet, Configuration and Setup
menus.
Step 6. Power-cycle the instrument to force the unit to enable the DHCP method for
setting the IP address. (Step not required for HI 4060 software after version
1.7.0.0.)
Step 7. Recall the Configuration / Instrument Setup / Ethernet / IP menu and view the
DHCP page. If the DHCP configuration was successful, the page will include an
IP address provided by the network server. This is the IP address to use in your
web browser to load the Web Interface (See Displaying the Complete DHCP IP
Address). This completes IP setup.
NOTE
If the DHCP: line remains 0.0.0.0, allow the instrument another minute to acquire an
address from the server and re-enter the IP menu. If this doesn’t work, the DHCP server is
not visible to the HI-4060 and you should use a Fixed IP configuration..
Displaying the Complete DHCP IP Address
Read-only screens can display a limited number of characters per line. Follow these steps
to see the complete IP address in DHCP:
Step 1. On the Ethernet menu, select DHCP. If, for example, the screen shows
192.168.100.12 for the DHCP address, the actual address could have one more
digit, e.g., 192.168.100.128. The “8” is not displayed.
Step 2. Press Enter and the DHCP edit form will show the complete IP address.
NOTE
You cannot change the values of the DHCP IP address. Exit returns to the Ethernet Menu.
Fixed IP Configuration Using the Front Panel
The HI-4060 can be configured to use any fixed IP address. Fixed IP addresses must be
carefully selected to avoid accidentally configuring two devices to the same address with
unpredictable results. Since guessing a value could lead to personal or property damage
and/or interrupted network services, your network administrator should provide this
address.
Configuration
•
•
• 37
•
•
•
Step 1. Press Enter to activate the Configuration menu. Use the down arrow to select
Instrument Setup and press Enter.
Step 2. Use the down arrow again to select Ethernet. Finally, select IP to display the IP
screen.
0.000
Configuration
>Instr Setup -->
Options
EXIT CLR
Step 3. If the display is not showing the correct IP value,
press the CLR button to erase the current value.
Step 4. Starting with the right-most digit,
enter the desired IP number using the
standard format shown to the right.
Use the up/down arrows to select each
character, and press the left arrow to
move to the next digit.
Step 5. Press Enter to save the entry.
Step 6. Press the Exit key four times to exit the IP, Ethernet, Configuration and Setup
menus.
The IP address is now saved and the instrument’s embedded web browser is now available
at the entered IP address. This completes IP setup.
Direct Connection
This method of interconnect between an HI-4060 and a standard Windows PC allows you
to configure the instrument using the embedded web browser, even if an Ethernet network
is not part of the normal installation. A desktop or laptop may be used on location as
necessary. Both sides of the link require configuration of their IP addresses to establish a
working connection. The following steps will walk you through the process of connecting
the hardware and configuring the HI-4060 and PC with compatible IP addresses.
Direct Connect Hardware
Any standard Ethernet cable with RJ-45 connectors at each end can be used to connect the
HI-4060 to your PC. A ‘crossover’ cable is not required. Simply connect the cable between
each instrument.
•
•
38 •• Chapter 4
•
•
Windows PC configuration
Windows 2000
Step 1. After starting your computer, click Start.
Step 2. Click on Settings > Control Panel to display the Windows Control Panel.
Step 3. Click the Network icon to display the Network dialog.
Step 4. Click on TCP/IP; then click the Properties button to open the TCP/IP Properties
dialog.
Step 5. Click the IP Address tab. - If the ‘Use the Following IP Address’ box is already
checked, write down the displayed IP Address and jump to the ‘Direct Connect
Configuration – HI-4060’ section below.
Step 6. Click the ‘Specify an IP Address’ check box; then enter the following into the
TCP/IP Properties dialog.
IP Address = 192.168.100.100
Subnet Mask = 255.255.255.000
Step 7.
Select OK on the TCP/IP Properties dialog box. The computer is now fully
configured. To return the computer to the original network settings, return to the
‘Internet Properties (TCP/IP) dialog and select ‘Obtain an IP address
automatically’ and click OK.
Windows XP
Step 1. After starting your computer, click Start.
Step 2. Click on Settings > Network Connections
Step 3. Right-Click on ‘Local Area Connection’ and select Properties.
Step 4. Click on Internet Protocol (TCP/IP) and click on the Properties button to open the
Internet Properties (TCP/IP) Properties dialog. - If the ‘Use the Following IP
Address’ box is already checked, then write down the displayed IP Address and
jump to the ‘Direct Connect Configuration – HI-4060’ section below.
Step 5. Click the ‘Use the Following IP Address’ check box; then enter the following into
the TCP/IP Properties dialog.
IP Address = 192.168.100.100
Subnet Mask = 255.255.255.000
Step 6. Select OK on the TCP/IP Properties dialog box. The computer is now fully
configured. To return the computer to the original network settings, return to the
‘Internet Properties (TCP/IP) dialog and select ‘Obtain an IP address
automatically’ and click OK.
Configuration
•
•
• 39
•
•
•
Windows 7
Step 1. After starting your computer, click Start.
Step 2. Click on Control Panel to display the Windows Control Panel.
Step 3. Click on Network; then click Internet
Step 4. Click on Network; then click Sharing Center.
Step 5. Click on Change Adaptor Settings in the left-hand column.
Step 6. Right-Click on ‘Local Area Connection’ and select Properties.
Step 7. Click on Internet Protocol Version 4 (TCP/IPV4)
Step 8. Click the Properties button to open the Internet Properties (TCP/IP) Properties
dialog. - If the ‘Use the Following IP Address’ box is already checked, then write
down the displayed IP Address and jump to the ‘Direct Connect Configuration –
HI-4060’ section below.
Step 9. Step 7. Click on the ‘Use the Following IP Address’ checkbox then enter the
following into the TCP/IP Properties dialog.
IP Address = 192.168.100.100
Subnet Mask = 255.255.255.000
Step 10. Select OK on the TCP/IP Properties dialog box. The computer is now fully
configured. To return the computer to the original network settings, return to the
‘Internet Properties (TCP/IP) dialog and select ‘Obtain an IP address
automatically’ and click OK.
Direct Connect Configuration - HI-4060
The HI-4060 must now be assigned a unique IP address that will connect to the Windows
PC. There are two simple rules for the IP Address:
It must have the same network identifier as
the computer
It must have a different node identifier than
the computer.
If your Windows PC already had an IP address assigned, simply increment by one the Node
Identifier field of the IP Address you wrote down in the Windows PC configuration steps
above. If your Windows PC was originally set to automatically obtain an IP address
(DHCP), then use 192.168.100.50 for the HI-4060 IP address in step 3 below.
•
•
40 •• Chapter 4
•
•
Setting an IP from the Front Panel
Step 1. Press Enter to activate the Configuration menu. Use the down arrow to select
Instrument Setup and press Enter. Use the down arrow again to select Ethernet.
Finally, select IP to display the IP screen.
_>
_
>
Step 2. Press the CLR button to erase the current IP value.
Step 3. Starting with the right most digit of the new HI-4060 IP address, enter each digit
using the up/down arrows including the decimal-points. Press the left arrow to
move to the next digit.
Step 4. Press Enter to save the entry.
Step 5. Press the Exit key four times to exit the IP, Ethernet, Configuration and Setup
menus.
The HI-4060 in now configured to communicate with the PC. Enter the IP address in any
web browser to access the embedded web browser. For example: http://192.168.100.101
Web Interface Basics
Help
To view a description of
the various parameters on
each of the configuration
pages, click “HELP” to
display the Help dialog.
Save Parameters
Most Save buttons let
you either save entered
parameters at any time
during the configuration
process or wait until you
have configured all of the
listed parameters.
Configuration
•
•
• 41
•
•
•
Registering Your HI 4060
When you receive your HI 4060 Rate Controller be sure to complete the warranty
registration on the Hardy web site.
Step 1. On the HI 4060 Home page click the “Register your rate controller” link to
display The HI 4000 Series Support Site.
Step 2. Click “HI 4000 Series Warranty Registration” to display the Warranty
Registration form.
•
•
42 •• Chapter 4
•
•
Step 3. Fill out the
registration
form, and scroll
to the bottom.
Click Submit to
complete the
registration
process.
Network Options Configuration
The HI 4000 Series Network configurations include:
• DeviceNet
• RIO
• Profibus DP
• Ethernet TCP/IP
• Modbus TCP/IP
• Ethernet/IP
This enables the HI 4000 Series to communicate with many devices on the network,
including PCs and PLCs. This means that you can map, configure and monitor all the HI
4000 series products from the front panel or your LAN, Internet, DeviceNet, ControlNet
and Wireless Servers that are connected to the Network.
To open the Configuration Options
menu from the Web interface,
Select Configuration to display the
Configuration menu and select
Options menu
Configuration
•
•
• 43
•
•
•
What appears on the Options menu depends on the
cards installed in your system.
Configuring DeviceNet
DeviceNet is an open network designed to connect the Rate Controller to higher-level
controllers such as PCs, PLCs or embedded controllers.The DeviceNet Network is an open,
global industry-standard communication network designed to provide an interface through
a single cable from a programmable controller or PC directly to the HI 4060 Rate Controller
as well as smart devices such as sensors, push buttons, motor starters, simple operator
interfaces, drives and other modules.
The user can adjust the number of Bytes In and Bytes Out should their process require a
different configuration than the default 32 Bytes In and/or Out.
Step 1. From the Home Page, select Configuration; then select Options. The
Configuration page appears.
NOTE
The Options Menu varies depending upon what options are installed in the HI 4060.
Accessing DeviceNet from the Web Interface
Select Configuration to display the Configuration menu and
select Options menu, select DeviceNet to open the
DeviceNet Setup page. Accessing
DeviceNet from the Front Panel
From the Configuration Menu, use the Down arrow to select
Options and press Enter to open the Options menu.Use the
Down arrow to select DeviceNet and press Enter to open the
DeviceNet menu.
0.000
Configuration
> Options-->
Map
•
•
44 •• Chapter 4
•
•
EXIT CLR
DeviceNet Baud
See your Network Administrator if you don’t know the correct Baud Rate.
Range: 125k, 250k, 500k (default 125k)
Entering Baud Rate from the Web interface
From the Baud pull-down list, select the Baud rate you need
for your DeviceNet network.
Entering Baud Rate from the front panel
From the DeviceNet menu, select DNET Baud and press
Enter. Press the right or left arrows to select the Baud
Rate you want. Press Enter to save the entry.
DNET Node
Range: 0-63 (default 63)
Entering Node from the Web interface
In the Node text field, type in the Node address of the
instrument.
Entering Node from the front panel
Step 1. From the
DeviceNet menu,
select DNET
Node; then press
Enter to display
the DNET Node
edit screen.
DeviceNet
0.000
> DNET Node-->
DNET Bytes In
0.000
DNET Node
EXIT CLR
20
EXIT CLR
Step 2. Use the right or left arrow to position the cursorand use the up or down arrows to
select the number of the node address.
Step 3. Press Enter to save the entry.
Configuration
•
•
• 45
•
•
•
DNET Bytes Input and Bytes Output
Range: 0-32 (default 32)
Entering DNET Bytes In from the Web interface
Step 1. In the Bytes Input text field, enter the Bytes
Input value you need for your application.
Step 2. In the Bytes Output text field, enter the Bytes
Output value you need for your application.
Step 3. Click Save Parameters to save the configuration.
Entering DNET Bytes In from the front panel
Step 1. Use the Down arrow to select DNET Bytes In and press Enter to open the DNET
Bytes In edit form.
Step 2. Use CLR to clear the current entry and position the cursor on the first value to
change; then use the up or down arrow to scroll to the value.
Step 3. Use the left arrow to move the cursor to the next position, and repeat the process
above until you have entered all the digits for your DNET Bytes In. Our example
shows 16 bytes.
Step 4. Press Enter to save the entry.
Step 5. Use the Down arrow to select DNET Bytes Out and press Enter to open the DNET
Bytes Out edit form.
Step 6. Use CLR to clear the current entry and position the cursor on the first value to
change; then use the up or down arrow to scroll to the value.
Step 7. Use the left arrow to move the cursor to the next position, and repeat the process
above until you have entered all the digits for your DNET Bytes Out. Our
example shows 16 bytes.
Step 8. Press Enter to save the entry.
•
•
46 •• Chapter 4
•
•
DNET No Connection
The Poll Connection entry is read only, telling you
that the instrument is connected and polling. If the HI
4060is not connected to the DeviceNet Network a
“No DNET Connection” message appears.
To resolve the problem and remove the warning, you
must reconnect the DeviceNet cable.
From the Web page
The picture to the right shows the Setup form
displaying the No DNET Connection the message.
When the cable is connected correctly, the “No
DNET Connection LED Off” message should then
be replaced by “Yes DNET Connection. LED On”
message.
From the Front panel
Step 1. If the instrument is not connected to the
DeviceNet Network a “No
Connection” message appears.
Step 2. Reconnect the DeviceNet cable. The
“No Connection” goes away and the
Poll Connection reappears.
Step 3. Press Exit to return to the Setup Menu.
Ethernet/IP™
Ethernet/IP, short for Ethernet Industrial Protocol, is an open industrial networking
standard that takes advantage of commercial, off-the-shelf Ethernet communication chips
and media. Ethernet technology, enables the user to access device-level data from the
network. The Ethernet/IP networking standard supports both implicit messaging (real-time
I/O messaging) and explicit messaging (message exchange). Ethernet/IP is an open
network that takes advantage of commercial technology that already exists.
You will need a key number to enable Ethernet/IP for field upgrades. If the controller was
ordered with EIP, the key should be in place. You can purchase a key number by contacting
the Hardy Service Center or your local Hardy Representative.
NOTE
Ethernet/IP™ is a trademark of ODVA.
Configuration
•
•
• 47
•
•
•
Configuring Ethernet/IP from the Web page
Step 1. Select Ethernet/IP from the Options menu to open the Configuration - Options Ethernet/IP form.
Step 2. Enter the key number you received when you purchased the Ethernet/IP option in
the Key text field.
Step 3. In the Bytes Input field enter the number of bytes you require for your application.
Our example shows 4 bytes.
Step 4. In the Bytes Output field enter the number of bytes you require for your
application.
Step 5. Click on the Save Parameters button to save the settings.
Configuring Ethernet/IP from the front panel
Step 1. From the
Configuration Menu,
select Options and
press Enter; then
select Ethernet/IP
and press Enter.
0.000
Configuration
> Options-->
Map
0.000
Options
>Ethernet/IP -->
EXIT CLR
EXIT CLR
Step 2. On the Ethernet/IP Menu, select EIP Key and press Enter to open the EIP Key edit
form.
0.000
Ethernet/IP
>EIP Key -->
EIP Bytes In
256
EXIT CLR
Step 3. To enter the key number you received from Hardy Instruments Service Center,
use the left or right arrow to position the cursor and the up or down arrow to enter
the value. Repeat the process until you have entered all the digits for your EIP
Key.
•
•
48 •• Chapter 4
•
•
Note that the number displayed is for illustration only. Keys are based on serial
number and do not transfer to other like controllers.
Step 4. Press Enter to save the key entry.
Step 5. You will have to set the following parameters on your PLC in order to
communicate with the HI 4060:
•
•
•
•
NOTE
COMM FORMAT: DATA - SINT
INPUT INSTANCE 100, LENGTH UP TO 256
OUTPUT INSTANCE 112 - LENGTH UP TO 256
CONFIGURATION INSTANCE 150 - LENGTH 0
Minimize the string length to match the application. The input and output ranges must
coincide between the host and the HI 4060.
Step 6. Use the down arrow to select EIP Bytes In and press Enter to display the EIP
Bytes In edit form.
Step 7. Use the left or right arrow to position the cursor and the up or down arrow to enter
the value. Repeat the process until you have entered all the digits for your EIP
Bytes In. Our example shows 10 bytes.
Step 8. Press Enter to save the entry.
Step 9. Use the down arrow to select EIP Bytes Out and press Enter to display the EIP
Bytes Out edit form.
Step 10. Follow the procedures used in steps 7-10 to set the values for Bytes Out. Our
example uses the default value of 10 bytes.
IP Addresses
An IP address consists of 32 bits (4 Bytes) that indicate the network and host numbers.
Follow the steps below to assign a fixed IP address (without DHCP):
Configuration
•
•
• 49
•
•
•
Step 1. From the Setup menu, use the Down arrow to select Ethernet; then press Enter to
display the Ethernet menu with the cursor in front of IP.
0.000
Configuration
>Instr Setup -->
Options
EXIT CLR
Step 2. Press Enter to open the IP edit form. If you are
configuring the instrument for the first time, the
default IP address appears. You must change this
address when starting the instrument for the first
time.
Step 3. Use the left or right arrow to position the cursor and the up or down arrow to enter
the value. Repeat the process above until you have entered a valid IP address.
Range: 0.0.0.0 to 255.255.255.255.
Step 4. Press Enter to save the entry and return to the Ethernet Menu.
It is recommended that you leave the Mask, Gate and DNS settings alone. They
are not listed as options. Contact your Network Administrator if you need to set
these parameters.
No Connection
The Connection message is read only, telling you that the instrument is or is not connected.
If the HI 4060is not connected to the network a “No Connection” message appears.
To resolve the problem and remove the warning, you must reconnect the Ethernet cable.
The picture to the right shows
the Setup form displaying the
No Connection the message.
The picture below shows the
message from the front panel
0.000
Ethernet/IP
>EIP Bytes Out --> 32
No Connection
EXIT CLR
•
•
50 •• Chapter 4
•
•
Remote I/O
NOTE
For complete information about the remote I/O interface, see the HI 4000 RIO Manual.
Step 1. To configure the Remote I/O from the Web Browser, from the HI 4060 Home
page click Configuration; then click Options to display the Options Menu.
Step 2. Click RIO Card to display the
RIO Option Card page.
Step 3. From the Baud pull-down list,
select the Baud rate for this
application.
Step 4. In the Address text field, enter the
address for the HI 4060.
Step 5. From the Rack Size pull down
list, select 1/4 or as required. See
HI RIO manual for definition.
Step 6. From the Quarter (Starting Quarter) pull-down list, select the Starting Quarter you
configured in the PLC to use for this location.
Step 7. The Last Quarter pull-down list is selectable as YES or NO.
Configuration
•
•
• 51
•
•
•
Step 8. Click Save Parameters when you finish. Note that you do not have to wait until
you have configured the all the parameters to save them.
Blind Unit Operation Setup
An HI 4060-DR Rate Controller cannot be configured from the front panel as a blind unit.
In a blind unit, the Remote I/O parameters are configured from the Web browser.
Viewing the I/O Card Display
The I/O Card Menu is not configurable but is read only from the front panel. The menu
indicates whether the I/O Card is connected, A/D Count, Number of Inputs and the Number
of Outputs currently activated. The values are hexadecimal values. A table is provided
below to determine the values listed. The Input and Output values consist of a byte with the
least significant bit equal to the first Input or Output.
Viewing the Controller I/O Card
Option from the Web Page
Select Configuration from the HI 4060
Home Page and select Options to
display the Options menu.
Select Controller I/O
Card on the Options
menu to open the
read-only I/O Card
page. This page
shows the Inputs and
Outputs that are
currently activated.
You may need to
refresh your web
screen to view any
changes to the inputs.
To test the inputs, continuously activate the input and refresh the web page while the input
is activated. Confirm and move on to the next input. Be careful not to cause any false
actions on the system while testing. When an input is activated you will also see the output
percentage of full scale displayed at the bottom of the display.
•
•
52 •• Chapter 4
•
•
Viewing the Controller I/O Card Option from the Front Panel
Step 1. From the Options
menu, use the
down arrow to
select I/O Card;
then press Enter
to display the I/O
Card menu.
NOTE
If the I/O Card Option is not installed the I/O Card Menu does not appear.
Step 2. Select Inputs
and press Enter
to open the
Inputs edit form.
Step 3. The Inputs are displayed as a 5-bit value. (0 0
0 0 0). Note that the least significant (rightmost) digit is input 1 and the most significant
(left-most) digit is input 5. For example, with
Input 1 and Input 3 active, the display reads.
0 0 0 0 0
Input 5
Input 4
Input 3
Input 2
Input 1
Step 4. The Outputs are displayed as a five-bit value.
0 0 0 0 0
Relay 5
Relay 4
Relay 3
Relay 2
Relay 1
The relay outputs default settings are Relay 1
ON, Relay 2 SHUTOFF, Relay 3 REC, Relay
4 ALARM, and Relay 5 REFILL. Relay 1 is
on the right of the bit value and Relay 5 is on
the left. For example, if Relay 4 and Relay 5
are active, the binary value is (1 1 0 0 0). If the
relay output defaults are selected, the alarm
and refill relays are activated.
Configuration
•
•
• 53
•
•
•
Analog Output Card
NOTE
The Analog Output Card comes standard on the 4060.
The analog parameters configure the analog output channels. The channels are hard
configured as voltage or current outputs. Channels 1 and 3 are voltage output channels (010 VDC). Channels 2 and 4 are current outputs (0-20 mA). Although the analog board
comes as standard equipment, it is configured via the Options menu.
Configuring the Analog Output Card from the Web Page
Step 1. From the Home Page, click Configuration to open the Configuration menu.
Although the Analog Output Card comes standard, it is accessed under Options,
so select Options to open the Options menu; then select Analog Output Card.
Step 2. Click Analog Output Card to open the Configuration - Options - Analog Output
page.
NOTES
The Voltage Low and High and Current Low and High are set to the default values. 0-10
Volts Output and 4-20 mA Output. If you don’t want to change the values start with the Low
and High Weight values for your application.
For assistance in configuring the Analog Output Card you can click on ‘HELP” at the top
of the page.
•
•
54 •• Chapter 4
•
•
Analog out channel 1-4 are default mapped as OP% for motor speed control. To change the
analog out source, you need only to map it and that will change the default setting.
To change a value, rapidly click in the text field until the entire value is highlighted. It may
take a few clicks
You can click on the Set button to save the parameters as you enter values or wait until all
the channels are configured.
To Configure Channel 1 (Voltage Output):
Step 1. Type the value for your low voltage output in the Chan 1 V LOW text box.
Step 2. Type the value for your high voltage output in the V HIGH text box.
Step 3. Type the value for your Low Weight Setting.
Step 4. Type in the value you want for your High Weight Setting.
If you want to refine a reading of say 10.02 and you want an output reading of 10, you will
need to adjust the 0-10 values to get the correct output. The formula to do this is as follows:
Step 1. Expected Output/Actual Output x Expected Output = New Number.
For example: (10/10.02) = .998 x 10 = 9.98
Step 2. Reset your input numbers to 0-9.98.
Step 3. This formula can be used on all four channels.
Step 4. To Configure Channels 2, 3 and 4 repeat the procedures above. Remember that
Channels 2 and 4 are current outputs.
Step 5. Click on the Set button to save the configuration.
Step 6. Click on “Home” to return to the Home Page.
Step 7. You can assign the input data to that analog output channels being used by going
to the Mapping page and following the Instructions for Mapping in Chapter 6.
Configuration
•
•
• 55
•
•
•
Step 8. The analog output card's
Output Settings are
configured in MAPPING
via the symbols HFO28,
HFO29, HFO30, and
HFO3. Use these rules to
scale the settings:
• If the setting is less
•
•
NOTE
than the Low Weight,
the analog output is set
to V (or I) Low.
If the setting is greater
than the High Weight,
the analog output is set
to V (or I) High.
Otherwise, the output
is "V (I) Low" +
(Setpoint - "Low
Weight")*("V(I) High"-"V(I) Low")/("High Weight" - "Low Weight")
The Loopback Debug Values are estimates only and may not match the actual outputs.
Configuring the Analog Output Card from the Front Panel
Step 1. From the Options menu, use the down arrow
to select Analog Card; then press Enter to
display the Analog Card Sub-Menu.
Step 2. Press the right or left arrow to select the
channel you want to view and/or configure.
Range: 1- 4 (default 1)
Setting Channel 1 & 3 Output Voltage Parameters
Keep in mind that Channel 1 and Channel 3 are 0-10
Voltage Channels.
•
•
56 •• Chapter 4
•
•
0.000
Options
>Analog Card -->
Ethernet/IP
EXIT CLR
0.000
Analog Card
> Chan Number -->
1
V/I Out Low
0.00
EXIT CLR
Step 1. Use the down arrow to select V/I Out Low
and press Enter to open the V/I Out Low edit
screen.
Range: 0- 10V (default 0- 10V)
Step 2. Use the left arrow to position the cursor and
the up and down arrow to set the value. Our
example shiws 0.00 as out Low Output
voltage value.
If you want to narrow the total range from 010 V to 0-5, change the V/I Out Low value
to 5.00. You can adjust the low output
voltage to any value to fit your application
requirements.
Step 3. Press Enter to save the setting. A brief message “Entry Accepted” appears if the
value is between 0-10 Volts. If the value is not between 0-10 Volts, the V/I value
reverts to 0.00.
Step 1. To Set or Change the Voltage Out High, use the down arrow to select V/I Out High
and press Enter to display the V/I Out High edit screen.
Step 2. Use the left arrow to position the cursor and the up and down arrow to set the
value. Our example leaves the High Voltage value at 10.00 Volts.
Step 3. Press Enter to save the entry.
Step 4. Use the Down arrow to select Low Value and press Enter to open the Low Value
edit screen.
Step 5. Use the left arrow to position the cursor and the up and down arrow to set the
value. Press Enter to save the entry.
Configuration
•
•
• 57
•
•
•
Step 6. Use the Down arrow to select High Value and press Enter to display the High
Value edit screen.
Step 7. Use the left arrow to position the cursor and the up and down arrow to set the
value. Press Enter to save the entry. Our example sets the High Weight Value at
10.00. You have already set the weight units when you configured the Instrument.
The High Value displays in whatever units you selected.
Step 8. Press the right or left button to change the
Channel number.
Step 9. The process for configuring Channel 2 is the
same.
Setting Current Channel 2 & 4 Parameters
The process for configuring Channel 4 is the same.
NOTES
When you finish with the configuration from the front panel, if you selected the defaults and
want a signal other than motor control you will need to map that input signal to the Analog
Channel, as described in Chapter 6.
To set the Analog Card Parameters, see Configuring the Analog Output Card from the Web
Page.
Analog Card Help Menu
The Help Menu provides a description of all the
Analog Card parameters.
Step 1. Press the down arrow until the cursor is in
front of Help.
Step 2. Press Enter to view the Help Menu.
Step 3. To read the complete descriptions and see
other parameters press the down arrow.
Step 4. Press the Exit button once to return to the
Help menu or twice to return to the Options
menu.
•
•
58 •• Chapter 4
•
•
Configuring ModBus - TCP/IP Over Ethernet (10 socket max.)
ModBusModBus is an application layer messaging protocol, positioned at level 7 of the
OSI model and enabled to communicate with up to ten different hosts. It provides
client/server communication between devices connected on different types of buses or
networks. Support for the simple and elegant structure of ModBus continues to grow. The
Internet community can access ModBus at a reserved system port 502 on the TCP/IP stack.
ModBus is a request/reply protocol and offers services specified by function codes.
ModBus function codes are elements of ModBus request/reply PDUs. The objective of this
document is to describe the function codes used within the framework of ModBus
transactions.
ModBus is an application layer messaging protocol for client/server communication
between devices connected on different types of buses or networks. It is currently
implemented for the HI 4060 product line using: TCP/IP over Ethernet.
Modbus Application Layer
Modbus
on TCP
TCP
IP
Other
Other
ModBus +/ HDLC
Master/Slave
Ethernet II/802.3
Physical Layer
EIA/TIA - 232 or
EIA/TIA - 485
Ethernet
Physical Layer
Configuration
•
•
• 59
•
•
•
Enabling ModBus in the HI 4060 Module
ModBus is an optional network communication protocol and requires a Key to enable. If it
was not ordered with your system, you can purchase the option with the Key by contacting
your local Hardy Instruments Representative or Hardy Service Center.
Enabling ModBus TCP/IP from the Web page
Step 1. From the HI 4060 home
page, click
Configuration to open
the Configuration
menu, select Options to
open the Options menu.
Step 2. Select ModBus TCP/IP.
On the ModBusOptions page, enter the
ModBus Key in the ModBus Key text field.
Step 3. Click Set Parameter.
Step 4. This procedure activates the ModBus option in the instrument.
Step 5. The HI 4060 module is ModBus enabled.
Step 6. You can now map from your client (PLC) to the HI 4060 module via ModBus.
Installing Hardy ModBus-Link
If you do not have a PLC or other client, Hardy has provided the Hardy ModBus-Link
Client to communicate with the HI 4060 module. For the sake of clarity the Client/Server
definitions are as follows:
•
•
•
•
•
60 •• Chapter 4
•
•
Client - The module asking for data.
Server - The module providing the data.
1-10 host socket connections available on link
This Hardy ModBus software is used to setup and test the link and is not a full protocol
packaged software.
Step 1. On the Documentation CD you received with your HI 4060 Instrument you will
find a copy of the Hardy ModBus-Link Software. If you do not have the CD that
came with your instrument you can go to the HI 4060 Resources Web page and
download the application from there.
Step 2. Double click on the Hardy ModBus-Link .exe file to install the software on your
PC. Once the Installation is complete a Hardy ModBus-Link icon appears on your
Desktop.
Step 3. Double click the Hardy ModBus-Link icon to open the display shown below.
Step 4. From the Connection pull down menu, click
“Connect” to display the TCP/IP Connection
page.
Configuration
•
•
• 61
•
•
•
Instrument Setup / Entering scale capacity
Step 5. To verify that you have twoway communication, on the
Mapping web page of the HI
4060 instrument you want to
ping, select “ModBus Float
Out” (MFO) on the Destination
Network pull down menu.
Step 6. For Float Variable under
Scratchpad, use the default
word 0. “MFO0=” appears in
the Map: text field.
Step 7. From the Select Source
Scratchpad pull down list,
select the Float Variable 0
(HFO0), as shown below. Keep
the default word 0.
Step 8. A Select button appears.
Click this button.
The Destination and Source appear in the Map: text field. (MFO0=HFO0). Click
the Map button to open the HFO - Float Variables form, shown below. Thus far
we have mapped the Float Variable 0, word 0 to ModBus Float Out, Word 0).
•
•
62 •• Chapter 4
•
•
Step 9. The HFO - Float Variables form, type in a value. For our example we used the
value “555.0000.” Double click in the HFO (Hardy Float Out) text field 0 and
click Enter.
Step 10. Go to the Hardy ModBus-Link Display. Minimize the Web Page, but do not close
the browser. On the Display pull down, select Float Inverse.
Step 11. The value we entered from the Mapping page appears to the right of the 00000 =
which is 555.0000. Click button 23, as shown below to open the Read/Write
Multiple Registers page.
Step 12. Double click on
“555.0000.”
Configuration
•
•
• 63
•
•
•
Step 13. The Enter Value display appears with the value 555 which was sent from the HI
4060 module (In our example 555). Enter a new number. We entered 999.”
Step 14. Click OK. The Write
Multiple Registers
display appears with
999.0000 in place of
555.0000. Click the
Send button.
Step 15. A Response pop up
appears indicating
that the Response
from the HI 4060
module was received.
Click on OK.
Step 16. Should you get an error message, check the following:
•
•
•
•
•
Function Not Supported - You cannot use the selected function. Use a
different function.
Address Error - Wrong IP address of the register you want to send the data
to. Get and enter the correct IP address. See your Network Administrator.
Byte Count Error - The Byte count is incorrect. Enter the correct byte count.
Value Error - The Value entered does not match the variable type. Enter the
correct a value that is equal to or less than the variable type.
Request Error - Your want to Read and you select Write. Make sure you
select the correct Request Error.
ProfiBus® Configuration
ProfiBus DP operates using a cyclic transfer of data between master(s) and slave(s) on an
RS485 network. An assigned master periodically requests (polls) each node (slave) on the
network. The HI 4060 is a slave device. All data communication exchanges between a
master and the HI 4060 originate from the master device. Each HI 4060 is assigned to one
master and only that master may write output data to that HI 4060. Other masters may read
information from any slave, but can only write output data to their own assigned slaves.
•
•
64 •• Chapter 4
•
•
Because ProfiBus uses a cyclic (periodic) polling mechanism between masters and slaves,
it is also deterministic. Therefore behavior of a ProfiBus system can be reliably predicted
over time. ProfiBus is designed to guarantee a deterministic response.
The length (and timing) of the I/O data to be transferred from a single slave to a master is
predefined in the slave's device data base or GSD file. The GSD files of each device
connected via the network (slaves and class 1 masters only) are compiled into a master
parameter record which contains parameterization and configuration data, an address
allocation list, and the bus parameters for all connected stations. A master uses this
information to set up communication with each slave during startup. Slaves can only
acknowledge the messages they receive or transfer messages to a master when the latter
requests a slave to do so. Slaves are also designated as passive nodes.
Configuring ProfiBus From the Web Interface
Step 1. From the Configuration menu select Options to open the Options menu; then
Click on ProfiBus Card. to open the Click on ProfiBus Card form.
Double click in the Node text field to highlight the current entry. Type in the HI 4060 Node
address. Range: 1-125 (default 5) Our example uses the default address #5.
NOTE
ProfiBus Node Address #5 is the lowest number that can be used by a slave device.
Step 2. Click Save Parameters to save the entry.
Step 3. You can also read the communication status of the instrument.
Step 4. Click Home to return to the Home Page.
Initialization Process
To be able to add an HI 4060 to a ProfiBus-DP network, you need a PC and software such
as Siemens Step 7™, Simatic Manager or equal, that allows the ProfiBus-DP PLC and the
HI 4060 to exchange data.
Configuration
•
•
• 65
•
•
•
ProfiBus-DP .GSD File
All devices connected to a ProfiBus-DP network require a *.gsd file. The *.gsd file contains
all the parameters including the baud rate, table formats and necessary data required by the
network PLC when an HI 4060 is connected to the network.
A copy of the *.gsd file can be found on the CD that comes with the instrument or at the
Hardy Website or at http://www.ProfiBus.com/libraries.html.
Whichever Simatic Manager you select, you must go through these three steps:
Step 1. Connect the HI 4000 Series Instrument to the ProfiBus DP network and verify the
address. (See the Installation Section for Installation and Cabling Instructions. )
Step 2. Connect the PC to the Trunk Line. Load the configuration properties to the
initialization software on the PC and transfer them to the PLC.
Step 3. Install the *.gsd file, and map I/O data table properties to the instrument.
Pre-Initialization Procedures
Step 1. Inspect the network cables and make sure that the cables have been installed
correctly and satisfy the ProfiBus-DP guidelines for the data transmission baud
rate(s) required. (See the Cabling Chapter/ProfiBus Installation in this manual for
ProfiBus-DP cable specifications and cabling guidelines.)
Step 2. Select the Node address for the HI 4060. (See below) This can be done before or
after Initialization.
Step 3. Cycle power, or perform the two previous steps before powering up your network.
Address selection can only occur after cycling the power. Make sure that the
software you use will detect the values as you have set them.
Caution:
The address should never be changed during operation. If the address is modified
while on line, an internal error could be generated and the module disconnected from
the network.
NOTE
ProfiBus-DP provides a very flexible network solution. In addition to the basic guideline
provided in this manual, your installation could require procedures that are beyond the
scope of this manual. For more information and to locate lists of links to other sources of
ProfiBus-DP information, check the ProfiBus website at http://www.ProfiBus.com.
Step 4. Complete any additional configuration that is required by your PLC for
initialization. Our initialization example is for a Siemens PLC. Your PLC
initialization requirements may differ.
Step 5. Install the *.GSD file for the instrument you connected to the ProfiBus Network.
•
•
66 •• Chapter 4
•
•
Initialization Procedures
NOTE
The examples come from the Siemens Step 7™, Simatic Manager Software. Your software
will vary from these procedures. Step 7™ is a trademark of the Siemens Corporation.
Step 1. In the Siemens Step 7™, Simatic
Manager open the Hardware Catalog.
Step 2. Click on the “+” to expand the
Additional Field Devices Folder.
Step 3. Click + to expand the General Folder.
Step 4. Highlight the CPU you selected in the
UR dialog box.
Step 5. Double Click on “HI4000” or drag and
drop the “HI4000” folder to the
Profibus-DP Network.
Step 6. This opens the HI 4000 PDP
Parameters dialog box where you can
set the address of the instrument, if
necessary.
NOTE
The HI 4060 Series Input and Output Sizes are expressed in words. 16 words input and 16
words output.
Configuration
•
•
• 67
•
•
•
Step 7. Click OK to set the Node Address.
Step 8. The HI 4000 Series module appears in
the Profibus Network.
Step 9. Click the Download Icon to download
the configuration to the PLC and open
the Select Destination Module dialog
box.
Step 10. Click OK to open the Select Station Address Dialog box; then click OK again. A
status box will show the progress of configuration download to the PLC.
Step 11. When the download is complete the
HW Config dialog box should look
something like this.
Step 12. Initialization is complete.
Configuring Profibus from the Front Panel
Step 1. Select Options
from the Configuration menu, then
Profibus from the
Options menu.
•
•
68 •• Chapter 4
•
•
Step 2. Select Profibus Node to open the Profibus Node
edit screen.
Step 3. Press CLR to clear the current entry and position
the cursor, then use the up or down arrow to
select the number for the right-most digit.
Step 4. Press the left arrow to move the cursor to the next
digit, and use the up or down arrow to select the
number for the left digit. Our example sets the
Node Address at #7.
Step 5. Press Enter to save the entry.
Step 6. The other parameters are status indicators and
are read only. The status indicators indicate the state of communications between
the Master and the HI 4060.
DP State (Read Only)
• 00 = Status “Wait_ Prm” (HI 4060 waiting for
communications from the Master Device.)
• 01 = Status “Wait_Cfg” (HI 4060 configuring for Data
Exchange)
• 10 = Status “DATA_EX” (HI 4060 Exchanging Data
with Master)
WD State (Read Only)
•
•
•
00 = Status “Baud_Search”. (HI 4060
searching for baud rate.)
01 = Status “Baud_Control”. (HI 4060 found
the baud rate.)
10 = Status “DP_Control”. (HI 4060
communicating at the current baud rate.)
Baud Rate
Reads the baud rate at which the HI 4060 communicates with the Master Device. If “Error”
appears it means that no data is being exchanged between the HI 4060 and a Master device.
Press the Exit button until you return to the Summary display
Configuring Rate of Change (ROC)
ROC measures and displays the rate at which a material enters or is dispensed from the
scale over a period of time. The 4060 uses a minimum of one second’s worth of updates to
calculate the change. The register used for ROC data holds 15 entries. New weight values
are written to the register at the rate of 1/15th of the time base; then the first register is
subtracted from the 16th Register. Thus, the 16th register is one-time base older than the
1st register.
Configuration
•
•
• 69
•
•
•
Time Units and Time Base
The HI 4060 calculates and optimizes the flow rate. However, you enter values within an
appropriate range to use as a starting point for auto rate calculation.
ROC Time Units
ROC time units are the units of time (seconds, minutes or hours) you want for the Rate of
Change. The ROC display on the summary display will read in these units. Auto rate
calibration uses a minimum of 10 ROC Time periods to make the rate calculation.
Units: SEC, MIN, HR (default SEC)
Range = 1 - 1800
ROC Time Base
The Time Base is the length of time in seconds between two weight readings that are
subtracted to determine the initial flow rate. By increasing the time base, you increase the
time between weight readings. This allows more material to be dispensed during the time
base period. Low flow rates require a longer time base than high flow rates. The HI 4060
measures weight to about 1 part in 10,000. The formula below provides a minimum.
TIME BASE > (SCALE CAPACITY/5000)/LOW SETPOINT (units per sec.)
SCALE CAPACITY/5000 = determines minimum weight increment
Example: (440/5000) = 0.088 lb
lowest setpoint in units per second @ 3 lb per min is: 3 lb/60 sec = 0.05 lb/sec
Thus:
TIME BASE = 0.088/0.05
TIME BASE = 1.76 (rounded to 2)
MINIMUM TIME BASE = 2 seconds
Configuring ROC (Time Units and Time Base) from the Web interface
To display the ROC page, click the right green arrowhead at the bottom or the ROC link at
the top of the Configuration - Ingredient or Refill form. Sample screens are displayed below
under Configuring the Time Base from the Web interface.
Step 1.
•
•
70 •• Chapter 4
•
•
From on the Time Measure pull
down, select the Time Measure
to use for this ingredient. Our
example uses minutes.
Step 2. In the time base field, enter the
Timebase you want for the
interval between weight
readings.
Step 3. Click Save Parameters to save
the parameter settings.
Configuring ROC (Time Units and Time Base) from the Front Panel
Step 1. From the Ingredient
menu, select ROC
and press Enter to
display the ROC
sub-menu.
Step 2. Select Time Units;
then press Enter to
display the Time
Unit edit page.
0.000
Time Units
Step 3. Press the left or right
arrow to toggle
between seconds, minutes, or hours.
Seconds
EXIT CLR
Step 4. Press Enter to save the entry and return to the ROC Menu.
Step 1. Use the down arrow
to select Time Base;
then press Enter to
display the Time
Base edit form.
Step 2. Use the left or right arrow to position the cursor and use the up or down arrow to
select the value.
Step 3. Press Enter to save the entry
Step 4. Press Exit to return to the Ingredient Sub-Menu.
Graphing ROC (Front Panel)
You can graph the Actual Rate of Change (ACT) compared to the Rate Setpoint or the
Control Output Percentage on the front panel display. ACT is a heavily averaged ROC used
for over-all performance. During setup, you can make the plot easier to see by adjusting the
Max and Min parameters. The default values for the Actual ROC graph include the Max
Rate that was set during a rate calibration and zeroing. For the Control Output Percentage,
the max is 100 and the min is 0.
Configuration
•
•
• 71
•
•
•
Step 1. From the
Configuration
menu, select
Graph and press
Enter to open the
Graph menu.
Step 2. Press the up or down arrows to toggle between OFF and ON, and press Enter to
save the setting.
Step 3. Select Graph var and use the up or down arrows to toggle between ACT and OP
(Control Output Percentage).
Step 4. Press Enter to save the selection.
Step 5. Use the down arrow to select Max.
Step 6. If you selected the Actual (ACT) option, the
default Max rate is whatever the Max rate
Configuring Security
The security system can be used to:
• Protect the entire Web interface and front panel from unauthorized access
• (front panel only) Limit access to selected functions by those who have basic access
To gain access to protected interfaces and functions, the user must enter a security code.
NOTE
Web page security can be assigned to require either the medium or high level code for
access, but not both, while security for the front panel can be set to one level and access to
specific functions via the front panel can be set do a different level.
Restricting access to the Web interface and front panel
If security is currently in place and you want to change any security settings, logon using
the high security code.
•
•
72 •• Chapter 4
•
•
Restricting access to the Web interface and front panel from the Front Panel
Step 1. If you want to require a high-level password to access the Configuration Menu,
use the down arrow to select Security and press Enter to open the Security menu;
then select High Password and press Enter to open the High Password edit form.
Step 2. The field defaults to 0, which indicates that no
password protection is required. Use the up or
down arrow to change to a value for your High
security code (Allowed Range 0- 65535). Our
example (for illustration only) shows 123.
Step 3. Press Enter to save the password and return to the
Security Menu.
Step 4. To set up a medium-level password, use the same process described in steps 1-3.
Step 5. To apply security for
the front panel, from
the Configuration
menu select Security
and press Enter to
open the Security
menu.
Step 6. Select FPSecurity, and press the Right or Left arrows to select NONE, MEDIUM,
or HIGH. Using the same procedures, you can setup a NONE, MEDIUM, or
HIGH password requirement for the Calibration Section and to the Web Page.
0.000
Security
>Web Sec -->
NONE
High Password
EXIT CLR
Step 7. Press the Exit button to return to the Summary Display.
Configuration
•
•
• 73
•
•
•
Restricting access to the Web interface and front panel from the Web Page
Step 1. From the Configuration menu, click Security to open the Security page.
NOTE
The field allows only numbers in any combination. Be sure to write down the codes you use
and store them in a secure location in case you need to refer to them again.
Step 2. In the High and/or
Medium Security
Code text fields,
type in the number
codes you want
(Allowed Range
0- 65535).
Step 3. Our example
shows 123 for
High and 456 for
Medium. To not
set a code, enter 0.
Step 4. On the “Front Panel Security pull-down list, select the level of security you want
for the front panel.
If other than NONE, there must be a security code for that level or the security
system will not require a code to be entered.
•
•
74 •• Chapter 4
•
•
Step 5. From the “Front Panel Calibration Security pull-down list, select the level of
security you want for calibrating the instrument. If other than NONE, there must
be a security code for that level or the security system will not require a code to
be entered.
Step 6. From the “Web Page Security” pull down list, select the level of security you want
for the Web Pages.If other than NONE, there must be a security code for that level
or the security system will not require a code to be entered.
Step 7. Click Save Code to save the security settings.
NOTE
You can save your settings at any time during the Security setup process.
Verifying a password from the front panel
For front panel access, the user’s password is used to derive the user’s ID. Users who must
enter passwords to operate or configure the instrument from the front panel should follow
these steps:
Step 1. Select Verify Password
and press Enter to open
the edit page.
Step 2. Use the left or right arrow to position the cursor
and the up or down arrow to enter the value.
Step 3. Repeat the process until you have entered the
whole password; then press Enter to open the
window.
Configuration
•
•
• 75
•
•
•
Setting Parameter Security
The setup for High and Medium security code can be applied to functions accessed through
the front panel. Three security levels apply to parameters: NONE, MEDIUM, and HIGH.
The security level for a parameter is indicated by the addition of dollar signs or zero to the
parameter name, as described below:
• None: A security code of 0 disables all security, whether the $ sign is present on a
•
•
parameter or not.
Medium: If a parameter has medium security, insert a $ before its name.
High: If a parameter has medium security, insert $$ before its name.
For example, this Decimal Point parameter has a medium security level:
00000002 $Decimal Point=1 [1]
This manual system allows a system administrator to selectively set security restrictions for
selected parameters.
Setting Parameter Security from the Web Interface
You can access the parameters by
editing the Parameter Dump.
Select Operation from the Home
page to open the Operation menu;
then select Diagnostics to open the
Operation- Diagnostics form.
Click the Parameters link to
display a list of parameters.
For each function you want to protect, enter the $ (medium security) or $$ (high security)
in front of the parameter name.
For example, if you want a high security code for Units, enter the following: 00000001
$$Unit=0 (lb)
•
•
76 •• Chapter 4
•
•
Our examples show two dollar signs, High Security for the Weight Decimal Pt and one
dollar sign for Rate Decimal Pt.
NOTE
You must first enter a High or Medium security password or both in order for the Parameter
Security to work.
Click the Save button to save the security changes.
NOTES
The Mode and Operational Display on the Summary display work even if a HIGH or
MEDIUM password has been assigned.
Pressing Enter makes the Configuration Menu reappear so you can proceed. This is true
for all Sections that are assigned a password.
Instrument Setup
This section describes how to setup values such as Instrument ID, Operator ID, Unit of
Measure and other values that are basic to HI 4060 operation. The outline will follow the
Configuration - Instrument Setup form on the Web interface, but the procedure for using
the front panel display will also be explained for each value.
The configuration process sets up the instrument to operate as a scale. This includes
configuring WAVERSAVER®, Scale Capacity, Units of Measure, Motion tolerance and
Configuration
•
•
• 77
•
•
•
other instrument parameters required for your process. Here is where the global parameters
are entered. All of the configured parameters and mappings except the IP Address are
stored in the Secure Memory Module (SMM-SD).
Accessing Instrument setup from the Web
Interface
Step 1. From the HI 4060 Home Page click
on Configuration to open the
Configuration Menu.
Step 2. Select Instrument Setup to open the
Configuration - Instrument Setup
form.
Accessing the Instrument Setup menu from the Front Panel
Step 1. Configuration is a top-level menu which can
be accessed from any lower level menu by
clicking the Exit button one or more times, or
press Enter from the Summary display.
Step 2. Use the down arrow to select Instrument
setup, and press Enter to open the setup menu
•
•
78 •• Chapter 4
•
•
0.000
Configuration
>Instrument Setup –>
Options
EXIT
CLR
Unit (of Measure)
The Unit parameter sets the scale and related displays to one of the following options:
•
•
•
•
•
•
Pounds (lb) - Default
Ounces (oz)
Ton (Ton) short ton
Kilograms (Kg)
Grams (G)
Metric Tonnes (t) long ton
Range: LB, OZ, LB/OZ, TON, KG, G, T (default LB)
Configuring Unit from the Web interface
Step 1. Select a weight type from the Unit
pull-down selection list.
Step 2. Click on the Change Unit button
to make the change. You must
click Save Parameters to save any
value set from this form
Configuring Unit from the front panel
Step 1. From the Setup menu, use the down arrow to
select Unit.
Step 2. Press the left or right arrows to select the Unit of
measure you want.
Step 3. Press Enter to save the selection.
Instrument ID
The Instrument ID parameter provides a specific identification for a Rate Controller. This
is important when using several HI 4060’s for different applications. A unique Instrument
ID allows you to distinguish one HI 4060 from another.
Range: 19 characters (default HI 4060)
Configuring the Instrument ID from the Web interface
Enter an instrument ID from the keyboard. You
must click Save Parameters to save any value set
from this form.
Configuration
•
•
• 79
•
•
•
Configuring the Instrument ID from the Front Panel
Step 1. From the Setup
menu, select Inst.
ID; then press Enter
to open the Inst. ID
edit form.
Step 2. Use the right or left arrow to position the cursor and the up or down arrow to
change the value for your instrument ID. Our example changes the default value
to Cake Mix, which makes this instrument easy to recognize by its application.
Step 3. Press Enter to save the entry and return to the Setup Menu.
Operator ID
The Operator ID is the ID of the user logged into the system using security. Select three
letters or numbers or any combination of the two that adequately identifies the user. We
have provided some examples for your assistance.
Range: 3 characters (default none)
Some examples of Operator IDs are Joe, 312, J15, or JD7
Viewing the Operator ID from the Web interface
Enter an operator ID from the keyboard. Use Save
Parameters to save any value set from this form.
Configuring the Operator ID from the Front Panel
Step 1. To open the Operator
ID edit form from the
Setup menu, use the
down arrow to select
Operator ID; then
press Enter.
Step 2. Use CLR to clear the current entry and position the cursor on the first value to
change. Use the up or down arrow to scroll to the value, first from 1-10 and then
from A-Z.
Step 3. Use the right or left arrow to move the cursor to the next position, and repeat the
process until you have entered all of the characters (up to 3) for your operator ID.
Step 4. Press Enter to save the entry and return to the Setup Menu.
•
•
80 •• Chapter 4
•
•
Weight Decimal Point
Set the Weight Decimal Point parameter to indicate the location of the decimal point within
the weight values, which are based on the selected unit of measure. The higher the number,
the farther to the left the decimal point moves and the more precisely the rate is displayed.
However, setting the decimal point far to the left does not ensure that the weight value will
be accurate enough to distinguish the requested level of precision from interference factors.
Range: 0-5 (default 2)
Setting the decimal point from the Web interface
Step 1. From the Decimal Point pull-down list, select the number of digits from
the right edge of the displayed number before which the decimal point
should appear.
Step 2. You must click Save Parameters to save any value set from this form.
Setting decimal point from the front panel
Step 1. From the Setup menu, use the down arrow to select
Weight Decimal Pt.
Step 2. Press the Right or Left arrows to select the number
of digits from the right side of the displayed
number before which you want the decimal point
inserted.
Step 3. Press Enter to save the selection.
Rate Decimal Point
The Rate Decimal Point Parameter sets the location of the decimal point within the Flow
Rate value. If there is a limit on the totalizer, the decimal point can determine its range. The
higher the number, the farther to the left the decimal point moves and the more precisely
the rate is displayed. However, setting the decimal point far to the left does not ensure that
the total weight measurement will be accurate enough to distinguish the requested level of
resolution. Adding decimals does not increase the precision. Maximum precision is
1:10,000. Increasing the decimal point beyond that only produces unstable readings.
Range: 0-5
Setting the Rate decimal point from the Web interface
Step 1. From the Rate Decimal Point pull-down list, select the number of digits
from the right edge of the displayed number before which the decimal
point should appear.
Step 2. You must click Save Parameters to save any value set from this form.
Configuration
•
•
• 81
•
•
•
Setting Rate decimal point from the front panel
Step 1. From the Setup menu, use the Down arrow to
select Rate Decimal Pt.
Step 2. Press the Right or Left arrows to select the
number of digits from the right side of the
displayed number before which you want the
decimal point inserted.
Step 3. Press Enter to save the selection.
Total Decimal Point
The Total Decimal Point parameter sets the location of the decimal point within the Total
weight value, which is based on the selected unit of measure. For example, with a six-digit
range (e.g., 999,999), the totalizer would start over at one million, but with three decimal
points (e.g., 999.999), it would start over at one thousand. (See note in specification.)
Range: 0-5 (default 1) In most applications a decimal setting of 0 or 1 is recommended.
Setting the Total decimal point from the Web interface
Step 1. From the Total Decimal Point pull-down list, select the number of digits
from the right edge of the displayed number in front of which the decimal
point should appear.
Step 2. You must click Save Parameters to save any value set from this form.
Setting Total decimal point from the front panel
Step 1. From the Setup menu, use the Down arrow to
select Total Decimal Pt.
Step 2. Press the Right or Left arrows to select the
number of digits from the right side of the
displayed number before which you want the
decimal point inserted.
Step 3. Press Enter to save the selection.
Batch Decimal Point
The Batch Decimal Point parameter sets the location of the decimal point within the batch
weight value, which is based on the selected unit of measure. The higher the number, the
farther to the left the decimal point moves. However, setting the decimal point far to the left
cannot ensure that the scale is accurate enough to distinguish the requested level of
precision.
Range: 0-5 (default 1)
•
•
82 •• Chapter 4
•
•
Configuring the Batch Decimal Point from the Web interface
Step 1. From the Batch Decimal Point pull-down list, select the number of digits
from the right edge of the displayed number in front of which the decimal
point should appear.
Step 2. You must click Save Parameters to save any value set from this form.
Configuring the Batch decimal point from the front panel
Step 1. From the Setup menu, use the Down arrow to
select Batch Decimal Pt.
Step 2. Press the Right or Left arrows to select the
number of digits from the right side of the
displayed number before which you want the
decimal point inserted.
Step 3. Press Enter to save the selection.
Grads (Graduation Size)
The Graduation Size is the minimum increment or decrement used in the display of HI 4060
weight values. The HI 4060 can repeatedly distinguish changes of up to one ten thousandth
of the total load cell capacity, so graduation values set smaller than that would probably
reflect noise variations rather than accurate weight readings. The value applies to the rightmost digit(s), which may be at the sub-decimal level. For example, with a graduation size
of two applied to the final digit of 10,000.00, the minimum change allowed to the displayed
number would be.02, allowing for values of 9999.98, 10,000 or 10,000.02.
Range: 1, 2, 5, 10, 20, 50, 100, 200, 500, 1000 (default 1)
Configuring Grads from the Web interface
Step 1. From the Grads pull-down list, select the minimum increment or
decrement to use in the display of HI 4060 weight values.
Step 2. You must click Save Parameters to save any value set from this
form.
Configuring Grads from the front panel
Step 1. From the Setup menu, select Grads.
Step 2. Use the Right or Left arrows to select the minimum
increase or decrease to allow in the display of HI
4060 weight values; then press Enter to save.
Configuration
•
•
• 83
•
•
•
Num Averages
A number of weight readings are averaged to reduce the affect of material impact and/or
vibration as material moves on and off the scale. The Rate Controller takes 15 readings per
second. If you average enough weight readings, the weight loss or gain remains smooth and
the displayed value shows little or no fluctuation, although it is actually recalculated (by
sliding average) with each reading. If a weight reading fluctuates too much, increase the
number of readings in the average, but for applications that require a very quick weight
reading, do not set this value too high. See also WAVERSAVER for information on filtering
unstable weight readings.
Range: 1-31 (default 10)
Configuring Number of Averages from the Web interface
Step 1. In the Number of Averages edit box, enter
the number of weight readings to average
in the display of HI 4060 weight values.
Step 2. You must click Save Parameters to save any value set from this form.
Configuring Number of Averages from the front panel
Step 1. From the Setup
menu, select Num
Averages and press
Enter to open the
Num Averages edit
form.
Step 2. To enter the number of weight readings to average in the display of HI 4060
weight values, use CLR to clear the current entry and position the cursor on the
first value to change, and use the up or down arrow to scroll to the value.
Step 3. Use the left arrow to move the cursor to the next position, and repeat the process
above until you have entered all the digits for your Num Averages value.
Step 4. Press Enter to save.
NOTE
The number entered in Figure above is for illustration purposes only. Yours will vary
depending on your application.
WAVERSAVER®
Chapter One provides a detailed description of WAVERSAVER’s function and purpose. In
short, WAVERSAVER helps to mitigate the effects of vibratory forces, allowing the HI
4060 to distinguish between actual weight data and mechanical noise in the signals the load
cell sends it. WAVERSAVER can be configured to ignore noise with frequencies as low as
0.5 Hz. Two higher frequencies may be selected to provide a faster instrument response
time.
•
•
84 •• Chapter 4
•
•
High values allow faster readings, while the lower values raise the degree of filtration. The
function is user selectable and can be turned off.
Range: 15 HZ, 1.0 HZ, .50 HZ (default 1.00 Hz)
Configuring WAVERSAVER from the Web interface
Step 1. From the WAVERSAVER pull-down list,
select the number of Hz to use for the filter.
Step 2. You must click Save Parameters to save any
value set from this form.
Configuring WAVERSAVER from the front panel
Step 1. Select WAVERSAVER with the Down arrow.
Step 2. Use the Right or Left arrows to select the number of
Hz to use for the filter.
Step 3. Press Enter to save the selection.
Low Pass Filter
The Low Pass (LP) filter can be toggled on or off. It provides a more stable weight reading,
but at the expense of some reaction time. For an application that requires very stable weight
readings and the reaction time poses no problem, the Low Pass filter allows for a more
precise adjustment. High-speed weight readings will be better with the low-pass filter off.
Range: ON/OFF (default ON)
Configuring Low Pass Filter from the Web interface
From the Low Pass Filter pull-down list, select ON or
OFF. You must click Save Parameters to save any value
set from this form.
Configuring Low Pass Filter from the front panel
We recommed setting the low-pass filter to ON mode for
most applications. Off is used for the control of liquids.
Step 1. Use the Down arrow to select Low Pass Filter
and press Enter.
Step 2. Press the Right or Left arrows to toggle between
ON or OFF.
Step 3. Press Enter to save the selection.
Configuration
•
•
• 85
•
•
•
Configuring the Capacity Parameter
For optional use in noting the scale capacity.
Configuring Capacity from the Web interface
Step 1. In the Capacity edit box, enter the total
capacity of the scale system.
Step 2. You must click Save Parameters to save any value set from this form.
Configuring Capacity from the front panel
Step 1. Use the Down
arrow to select
Capacity; then
press Enter to open
the edit form.
Step 2. Use the right or left arrow to position the cursor on the first value to change and
the up or down arrow to change to the Capacity value. Our example shows
1,500.0 lbs. Press Enter to save the entry and return to the Setup Menu.
Use Default I/O?
Use Default I/O refers your choice to use or not use the factory-set defaults of five switch
inputs. Deselecting the defaults requires you to map any control function to the inputs and
analog outputs.
Range: YES/NO (default YES)
NOTE
The Switch Input defaults are:
•
•
•
•
•
Input 1 = START
Input 2 = STOP
Input 3 = ESTOP
Input 4 = FORCE REFILL
Input 5 = CLEAR TOTAL
The Relay Output defaults are:
•
•
•
•
•
Relay 1 = MOTOR ON
Relay 2 = SHUTOFF
Relay 3 = REC
Relay 4 = ALARM
Relay 5 = REFILL
Analog Output channels 1-4 are set by default for motor speed control OP%:
•
•
86 •• Chapter 4
•
•
Configuring Use Default I/O? from the Web interface
Step 1. Select YES or NO from the Use Default
I/O? pull-down list.
Step 2. You must click Save Parameters to save
any value set from this form.
Configuring Use Default I/O? from the front panel
Step 1. From the Setup menu, use the down arrow to
select Use Default I/O? and press Enter.
Step 2. Press the right or left arrow to toggle between
YES and NO.
Step 3. Press Enter to save the entry.
Instrument Usage Help
Help provides descriptions of all the parameters in the Instrument Setup Menu.
Step 1. Use the down
arrow to select
Help, and press
Enter to display
the help screen.
Step 2. The Help Display appears with a description for *Units* of Measure.
Step 3. To view a parameter, press the down arrow until the parameter appears with the
description. To read the entire Parameter description continue to press the down
arrow until the next parameter appears.
Step 4. Press Exit to return to the Instrument Setup Menu.
Step 5. Press Exit to return to the Configuration Menu.
LCD Contrast
Use the LCD Contrast or CONTRAST option to increase or decrease the contrast of the
display.
Adjusting contrast from the Web interface
Step 1. To make the display lighter, click Lighter,
or to make the display darker, click
Darker.
Configuration
•
•
• 87
•
•
•
Adjusting the Front Panel LCD Display
Step 1. Select CONTRAST from the Setup menu.
Step 2. Press the right arrow to increase the contrast.
Press the left arrow to decrease the contrast. This
completes the Instrument Configuration.
Configuring a Printer or Scoreboard
The Printer Parameters are set to operate a Printer or Scoreboard which can print out or
display on a Scoreboard whatever appears in the front panel display. The Printer parameters
also include a Batch Report (Batch Rep) which prints out the following:
•
•
•
•
•
NOTE
Current Date and Time
The Date and Time the last batch started.
The Date and Time the last batch ended.
The Total Weight.
The Batch Total Weight
If the Scoreboard is configured, the Print button does not function.
Opening Configuring - Printer from the Web interface
To display the Configuration - Printer form from
the Configuration - Instrument Setup page, click
the Printer link at the top of the page or one of the
green arrows at the bottom.
If you are using a scoreboard, the scoreboard will
display similar screens to those pictured in Chapter
7 under Mode Displays (without the function key
names). The content of each display depends on
the operating mode.
Configuring Printer Setup from the front panel
From the Setup menu, use the
down arrow to select Printer
Setup and press Enter to open
the Printer Setup menu.
Print Mode
Range: Batch Rep - Scoreboard (default Batch Rep - i.e., Batch Report)
•
•
88 •• Chapter 4
•
•
Configuring Mode from the Web interface
Step 1. From the Print Mode pull-down menu,
select the mode you want, either a Batch
Report or printing to a Scoreboard.
Configuring Mode from the front panel
Step 1. From the Printer Setup menu, select Print
Mode and press Enter.
Step 2. To select the Print Mode use the Left or
Right arrows to toggle between Batch
Report or printing to a Scoreboard.
Step 3. Press Enter to save the entry.
Baud Rate
See your Network Administrator if you don’t know the correct Baud Rate.
Range: 300, 1200, 2400, 4800, 9600, 19200 (default 19200)
Configuring Baud Rate from the Web interface
Step 1. Click on the Baud Rate pull down list.
Step 2. Click on the Baud rate for the printer
connected to this instrument.
Configuring Baud Rate from the front panel
Step 1. From the Printer Setup menu, select Baud
Rate and press Enter.
Step 2. To select the Baud Rate, press the left or right
arrow until the baud rate you want appears.
Step 3. Press Enter to save the entry.
Parity
See your Network Administrator if you don’t know the correct parity.
Range: NONE, ODD, EVEN (default NONE)
Configuration
•
•
• 89
•
•
•
Configuring Parity from the Web interface
From the Parity pull down list, select the Parity required
for the printer connected to this instrument.
Configuring Parity from the front panel
Step 1. From the Printer Setup menu, select Parity and
press Enter. The current Parity value is
displayed.
Step 2. To select the Parity option you want, press the
Left or Right arrows until it appears.
Step 3. Press Enter to save the entry.
Data Bits
Most printers are set for eight bits. A seven-bit option is also available. See your printer
manual if you think your printer could might require a seven-bit setting.
Range: 7 or 8 (default 8)
Resetting the Data Bits default from the Web interface
Step 1. From the Data Bits pull-down menu, select the
Data Bits required for the printer connected to
this instrument.
Step 2. Click on Save Parameters to save the entries.
Resetting Data Bits default from the front panel
Step 1. From the Printer Setup menu, select Data Bits
and press Enter. The current Data Bits value is
displayed.
Step 2. To select the Data Bits press the Left or Right
Arrow to toggle between 8 and 7.
Step 3. Press Enter to save the entry.
Step 4. Press the Exit button to return to the Setup Menu.
•
•
90 •• Chapter 4
•
•
Configuring Date and Time
HI 4060s are set with a default time, which you will need to change to the time in your area.
NOTE
To set up Greenwich Mean Time (GMT), see Appendix A.
Configuring Date and Time Setup from the Web interface
Step 1. To display the Configuration - Date and
Time page from the Instrument Setup
page, click the Time link at the top of the
or an arrow at the bottom.
Step 2. In the Minute field, enter the
current minute in the format
shown (leading 0 not required).
Step 3. In the Hour field, enter the current
hour (1-24) in the format shown
(leading 0 not required).
Step 4. In the Day field, enter the current
Day of the month in the format
shown (leading 0 not required).
Step 5. In the Month field, enter the
number of the current month
(leading 0 not required).
Step 6. In the Year field, enter the current
year in the format shown.
Step 7. From the time zone pop-up menu,
select the time zone in your area.
GMT = Greenwich Mean Time
Step 8. Click Save Parameters to save the
Date and Time settings.
Configuration
•
•
• 91
•
•
•
Configuring Date and Time Setup from the front panel
Step 1. From the Setup menu,
select Time and press
Enter to display the
Time menu with the
cursor in front of
Zone. Press Enter to
select Zone.
Step 2. Press the Left or Right arrows to select the time zone in your location. Press Enter
to save and return to the Time menu.
Step 3. Use the down arrow
to scroll to Timeyear and press Enter
to open the TimeYear edit page.
Step 4. Use the left arrow to position the cursor and the up or down arrow to select the
value. Repeat the process above until you have entered all the numbers for Timeyear. Note: Use only four numbers. Other options cannot be saved.
Step 5. Press Enter to save the entry and return to the Time Menu.
Step 6. Use the Down arrow
to select Time Month and press
Enter to display the
Time - Month edit
page.
Step 7. Use the left arrow to position the cursor and the up or down arrow to select the
value. Note: Use only up to two numbers. Other options cannot be saved.
Step 8. Press Enter to save the entry and return to the Time Menu.
Step 9. Use the Down arrow
to select Time - Day
and press Enter to
open the The Time Day Menu edit page.
Step 10. Use the left arrow to position the cursor and the up or down arrow to select the
value. Note: Use only up to two numbers. Other options cannot be saved.
Step 11. Press Enter to save the entry and return to the Setup Menu.
•
•
92 •• Chapter 4
•
•
Step 12. Use the Down arrow
to select Time - Hours
and press Enter to
display the Time Hours Menu.
Step 13. Use the left arrow to position the cursor and the up or down arrow to select the
value. Note: Use only up to two numbers. Other options cannot be saved.
Step 14. Press Enter to save the entry and return to the Setup Menu.
Step 15. Use the Down arrow
to select Time Minutes; then press
Enter to display the
Time - Minutes edit
page.
Step 16. Use the left arrow to position the cursor and the up or down arrow to select the
value.. Note: Use only up to two numbers. Other options cannot be saved.
Step 17. Press Enter to save the entry and return to the Time Menu.
Step 18. Press Exit to return to the Setup Menu.
Rate Calibration Configuration
This section describes how to set the parameters for Rate Calibration. It begins with
information that applies to entries made from either the Web interface or front panel. See
Chapter 5 for additional instructions on running Rate Calibration.
Use Rate Calibration to calibrate the system starting flow rate, either manually or using
Auto Rate Cal calculator. Rate calibration establishes the feeder maximum rate, PI settings,
and the starting OP% for a given rate setpoint. From that starting point, the controller
adjusts the OP% to maintain an optimized setpoint. Environment and product conditions
require monitoring and adjustment to meet the requested setpoint target.
NOTE
You must calibrate the scale prior to rate calibration.
The P and I values
The PI controller calculates an output percentage based on the parameters P - Proportional,
and I - Integral. The rate calibration process can set the values for P and I automatically. D
(Derivatve) is set to 0 and cannot be changed.
The output percent is determined by the formula:
P*((Setpoint - ActualRate)/MaxRate + I * (integral of the proportional term)).
Cal Type
There are three types of calibrations to determine the rate per output percentage:
Configuration
•
•
• 93
•
•
•
• Two-point rate calibration (default) for Auto RateCal, where two flow rates are
•
•
selected (points 2 and 4).
Five-point rate calibration for Auto RateCal, select starting % point 1 where five
flow rates are performed.
Advanced Cal, used when you cannot do an Auto RateCal and you know the flow
rate for 2 output percentage selections (points 2 and 4).
The known flow rates can come from experience with the material, often through trial and
error. When these known values have been entered, the HI 4060 RC calculates the rates for
seven output points: Minimum %, projected maximum rate at 100%, and five linear
percentage points.
If a two-point Auto Rate Calibration is selected, the unit will go to the high rate output
percent for a period of feed time plus prime time. When this period is complete, it will save
the actual rate as the high cal rate and will then pause for a period of pause time before
going to the low rate output percent for a period of feed time When this period is complete,
it will save the actual rate as the low cal rate.
After doing the auto rate calibration at the low and high rates, the unit will estimate the zero
rate output percent and the Max rate cal rate and will fill values for the first, third, and fifth
five-point calibration rate pairs.
Five-point measurement provides tighter flow rate control. Enter the point one output
percent, which must be between 10.0 and 30.0 percent. The next four calibration output
percents are fixed at cal point 1 + 10.0, cal point 1 + 20.0, cal point 1 + 30.0, and cal point
1 + 60.0. The unit will then run at each of these output percents, starting with the highest
one, for a period of feed time or feed time plus prime time on the first run. It saves the actual
rates it observes into the cal rates and estimates the MaxRate and zero output rates.
We recommend that you select output percentage points where your control set point falls
between pt 2 and pt 4.
If an Advanced calibration is selected, you must enter calibration pairs for the low rate and
the high rate. The unit will fill in the other calibration pairs based on linear extrapolation
from the two entered points.
Prime Time
The time in seconds it takes to get the system up to full flow for the first calibration point.
(The feeder must prime the feeding system and the feeding system must smoothly feed
product at an OP % selected rate.) This only occurs on the first test OP% run of the rate
calibration.
Range: 1-999 (default 5 sec)
Pause Time
This is the time you want the feeder to wait between Auto Rate Calibration cycles. If
necessary, more material may be added to the feeder. Note that this parameter should be set
long enough to allow the operator to press the "hold" button in between feed runs..
•
•
94 •• Chapter 4
•
•
We recommend that you make the Pause Time equal to or greater than the Timebase value
you entered for the ROC.
NOTE
If a feeder is manually paused before a cycle starts, or during a cycle, when the test is
restarted it will run from the beginning.
Feed Time
Feed Time is the test duration at each rate. Set this to a minimum of 10 X ROC time base.
Range: 1-999 (default 0)
Configuring Rate Calibration from the Web interface
NOTE
The information in the section above defines and explains the fields on this form.
To open the Rate Calibration
form, click the green right
arrow at the base of the
Configuration - Ingredient
form or click on the Rate
Calibration link at the top of
the form.
Configuring P, I, Values
The Rate Calibration process
automatically sets the values
for P and I of the PI algorithm,
but you can adjust them on
this screen.
Selecting Cal Type
On the Cal Type pull-down
menu, select the Cal type for
this ingredient. Our example
uses five-point Cal Type.
Configuration
•
•
• 95
•
•
•
Entering Prime, Pause, and Feed Time
Step 1. Enter the value for Prime Time you need for
this ingredient.
Step 2. Enter the Pause Time you want between runs.
Our example shows five seconds.
Step 3. Enter the Feed Time value in seconds. Our
example shows 40 seconds.
Configuring Cal Type from the Front Panel
NOTE
This subsection describes the procedure for entering the values. The information at the
beginning of this section defines each value and explains what it does.
Step 1. Use the down
arrow to select Rate
Cal and press
Enter, then select
Cal Type.
Step 2. Use the right or left arrow to toggle between 2 pt, 5 pt and advance Cal Types.
Step 3. Press Enter to save the entry and return to the Rate Cal sub-menu.
Setting the Prime Time
Step 1. Use the down
arrow to select
Prime Time and
press Enter to
display the Prime
time edit page.
Step 2. To change the Prime Time value, use the left or right arrow to position the cursor
and the up or down arrow to change the number. Our example shows 10 sec.
Step 3. Press Enter to save the entry and return to the RateCal Menu.
•
•
96 •• Chapter 4
•
•
Setting Pause Time
Step 1. Use the down
arrow to select
Pause time; then
press Enter to
display the Pause
Time edit form.
Step 2. To enter the numeric value you want for the Pause Time: Press the left arrow until
the cursor is at the first character entry for the Pause Time, and use the up or down
arrow to select the number or punctuation you want.
Step 3. Press the right arrow to move the cursor one place to the right, and repeat the
above process until you have entered all the numbers for your Pause Time value.
In our example we selected 10 seconds.
Step 4. Press Enter to save the entry and return to the RateCal Menu.
Setting Feed Time
Step 1. Press the down
arrow to select Feed
Time; then press
Enter to display the
Feed Time edit
form.
Step 2. To enter the numeric value you want for the Feed Time: Press the left arrow until
the cursor is at the first character entry for the Feed Time, and use the up or
down arrow to select the number or punctuation you want.
Step 3. Press the right arrow to move the cursor one place to the right, and repeat the
above process until you have entered all the numbers for your Feed Time value.
In our example we selected 30 seconds.
Step 4. Press Enter to save the entry and return to the RateCal Menu.
NOTE
Make sure you have enough material to do a Rate Cal at the highest OP%. If, for example,
30 seconds at 90% would empty the hopper, reduce the Rate Cal to a lower rate.
RateCal Percents
RateCal Percents sets the output percentage for the three cal types.
• For the 2 pt Cal Type (%Lo & % Hi), make sure that the Hi % is higher than the Lo
% and that there is a separation of at least 10%. You enter Pt2 and Pt4.
• For the 5 pt Cal Type (Pt1, Pt2, Pt3, Pt4, Pt5), you select only Pt1,the first RateCal
percentage, and the HI 4060 will select the remaining percentages, which are read
only and cannot be changed except by changing the first output value.
Configuration
•
•
• 97
•
•
•
• For the Advanced Cal Type, you need to know the flow rates for two output
percentage setpoints. You enter the output percentages and the known flow rates and
the instrument does the rest.
Range: 0-100
RateCal Percents from the Web Page
Use the seven rate calibration pairs of output
percent and output rate
to set the initial output
percent when the unit
starts. The zero output
rate is fixed at 0.0, and
the "max output
percent" is fixed at
100%.
You can edit the other parameters.
You can change the values in the highlighted OP% (and/or Cal Rate) fields. With 5 pt Cal
Type, the OP% number for Pt 1 is highlighted. With 2 pt Cal Type, the OP% values for pt
2 and pt 4 are highlighted. With Advanced, both the OP% values for pt 2 and pt 4 and Cal
Rates are highlighted .
Example: A calibration pair Output percent of 25% and a cal rate 250 means that a rate of
250 weight units per unit time will be obtained when the output percent is 25 %.
NOTE
Internet Explorer is a registered trademark of the Microsoft Corporation
RateCal Percents from the Front Panel
Step 1. Select RateCal Percents and press Enter to display the RateCal Percents edit
screen for the Cal Type you selected. For our example we selected 2pt Cal Type.
Select the 2PtLo (OP2) and press Enter to open the 2PtLo (OP2) edit page.
Step 2. Press the right arrow to position the cursor and the up or down arrow to change
the number. Repeat the process until you have entered all the numbers for your
2PtLo %(OP2) value. Our example shows 40 percent.
Step 3. Press Enter to save the entry and return to the RateCal Menu.
•
•
98 •• Chapter 4
•
•
Step 4. Use the down
arrow to select
2PtHi %(OP4) and
press Enter to
display the 2PtHi
%(OP4) edit page.
Step 5. To change the 2PtHi %(OP4) value, use the left or right arrow to position the
cursor and the up or down arrow to change the number or punctuation. Our
example shows 60 percent.
Step 6. Press Enter to save the entry and return to the RateCal Menu.
Running Rate Cal
The Auto Rate Cal will prime the system, then run for the selected feed time based on the
calibration type, pause time, and RateCal Percents you selected. In each case, the display
will show the flow rates for five output percentage points plus the MIN and MAX OP%
rates to give you the calibration performance curve.
• For the 2 pt Cal Type (Pt2 and Pt4) the two flow rates for the percentages you
•
•
selected are the actual flow rates. The instrument calculates the remaining three flow
rates .
For the 5 pt Cal Type, where you provide Pt1, the first RateCal percentage, the
display will show the actual flow rates for 5 output percentage points between the
Low and High output percentages.
For the Advanced Cal Type, where you provide known flow rates for two output
percentage setpoints (Pt2 and Pt4) and the output percentages, the HI 4060
calculates the remaining three output percentage points. The feeder does not operate
during this process.
Running Rate Cal from the Web interface
Step 1.
In the Feed Time field, enter the amount of
time you want for each feed run.
Step 2. Click the Do Rate Calibration button.
The result depends on the Cal Type you selected. With five-point, the instrument cycles
through each of the OP% listed for the 5 pt calibration. With two-point, it cycles through
each of the OP% listed for the 2 pt calibration.
As the calculation runs, the instrument will cycle through
the feed time and display the OP% RCAL percent
remaining below the STOP button at the base of the
form. (e.g. 80%, 50%, 40%, 30%, 20%). 80% represents
the point 5 OP %, which is the first stage of the cycle.
Configuration
•
•
• 99
•
•
•
The new values will appear in the
display.
Running Rate Cal from the
Front Panel
Step 1. From the Rate Cal menu, use the down arrow to select Do Auto Rate Cal, then
press Enter to display the Do Auto Rate Cal form.
Step 2. To start the Auto RateCal press the Start button.
Step 3. After the display says RCAL, you are exited to the main display screen.
Reading RateCal Results
Step 1. To read the results of the Rate Cal, use the down arrow to select RateCal Results
and Press Enter to display the Rate Cal menu listing the OP stages
Step 2. Select an OP stage number and press Enter to view the Rate and units.
Step 3. Press Exit to return to the RateCal Results menu.
Step 4. You can continue to read the results for all 5 points on the curve.
Step 5. Select OP 100%,
and press Enter to
see the read-only
details.
Step 6. Press Exit until you return to the Ingredients sub-menu.
•
•
100 •• Chapter 4
•
•
Refills
Refilling during calibration
If you need to refill the feeder hopper to complete a rate calibration, you can do this during
the pause between cycles.
Step 1. After one cycle the instrument will pause and the OP% goes to 0%.
Step 2. Click the STOP button.
Step 3. The RCAL changes to RHOLD.
Step 4. Complete your refill at this time.
Step 5. Click on the Do Rate Calibration button and
the Calibration process begins again.
Auto Refills
Automatic refill uses user selectable refill points to start and stop the refill process without
interrupting the feed process. HI and LO alarms to detect a refill failure. Manual Refill
allows for manual refill at any time.
Configuring Auto Refill from the
Web page
Set Auto Refill to YES on the
Configuration - Refill page.
Configuring Auto Refill from the front panel
Step 1. Use the down arrow
to select Auto Refill.
The left / right
arrows toggle from
Yes to No.
Configuration
•
•
•101
•
•
•
Step 2. To Select Auto Refill select Yes. The Initial Refill parameter appears.
Initial Refill
Initial Refill ensures that the filler contains enough material to safely begin operation. It
works only when Auto refill is active. It can help to decrease the number of refills during a
run. Review how the initial refill works before you make this selection.
After selecting Initial Refill, when you press the start button the feeder starts to run, and the
instrument checks to see if the material in the hopper is below the HI Setpoint weight. If it
is, the instrument fills the hopper until the HI Weight Setpoint is reached..
Range YES or NO (default NO)
NOTE
If Initial Refill is on with Auto Refill off, Initial Refill still activates the refill relay and fills
the hopper to the stop high amount. If you wish to prevent this, turn off Initial Refill when
you turn off Auto Refill.
Configuring Initial Refill from the Web interface
From the Initial Refill pull-down list, select YES or
NO. You must click Save Parameters to save any value
set from this form.
Configuring Initial Refill from the front panel
Step 1. From the Ingredient
menu, use the down
arrow to select Refill
and press Enter.
Step 2. Use the down arrow to
select Initial Refill.
Step 3. Use the right or left arrow to use (YES) or not use (NO) this function and Press
Enter to save. Initial Refill begins when you press the Start button.
Refill Start (lo) and Stop (hi)
The Start (lo), which is set in mass units (actual weight), triggers a signal to begin the refill
process. You need to determine when you want the refill to automatically begin (or an alarm
to trigger so an operator can refill the feeder). The Start (lo) value must be higher than the
Lo Shutoff value. Stop(Hi) signals when the weight in a hopper goes above the high
setpoint.
Range Lo >0.0 (default 10.0) . . Range Hi >0.0 (default 110.0)
•
•
102 •• Chapter 4
•
•
Configuring Start (Lo) Stop (Hi) from the Web interface
Enter the low and high values in the named fields.
You must click Save Parameters to save any value set
from this form.
Configuring Start (Lo) and Stop (Hi) from the front panel
To set the weights you want to trigger the start and stop refill signals.
Step 1. From the Refill menu,
use the down arrow to
select Start (lo), and press
Enter to open the Start
(lo) edit page.
Step 2. Use the right or left arrow to move position the cursor and the up or down arrow
to select the value.
Step 3. When you have selected all the values, press Enter to save the Start Lo value. Our
example shows 10 pounds.
Step 4. Press Enter to save the entry and return to the Refills sub-menu.
Step 5. Use the same procedure to set the Stop (Hi) weight that, when reached, will signal
to stop the refill process.
Low Shutoff and High Alarm Weight
The Low Shutoff setting stops the process when there is insufficient or no material in the
hopper. This setting can be 0 weight indicating nothing in the hopper or a weight setting
somewhat above the 0 weight and the Start (lo) value. The Low Shutoff value must be
below the Start (lo) value. The weight you enter for High Alarm will trigger an alarm should
the flow rate go above this value while refilling.
Low Shutoff Range >0 (default 0)
High Alarm Range >0 (default none)
Configuring HI Alarm from the front panel
Step 1. From the Refill
submenu, use the
down arrow to select
Hi Alarm, and press
Enter to display the
HI Alarm edit page.
Step 2. To enter the weight you want to trigger an alarm should the flow rate go above
this value while refilling, use the right or left arrow to move the cursor and the
upor down arrow to change the value.
Configuration
•
•
•103
•
•
•
Step 3. Repeat the process until you have entered all the numbers or punctuation for your
High Alarm value. Our example shows 120 lbs. Press Enter to save.
Step 4. In the Low Shutoff Weight field, use the same process to enter the weight at which
you want to stop the flow should the flow rate go below this value while refilling.
Step 5. Press Enter to save the entry.
OP Adjust %/wgt
OP (Output Percentage) Adjust % per unit of wgt. The weight of an ingredient in a hopper
can affect the rate of feed. For example, a liquid at the base of a full hopper is under greater
pressure than a liquid at the base of a near empty hopper. If no adjustment is made, the
liquid flows out faster when the hopper is full than when it is low. When the OP Adjust
parameter is ON (i.e., not set to OFF), the OP Adjust %/wgt value will adjust the refill rate
to compensate for any change in weight of the ingredient in the hopper. OP Adjust On
Learn is used to calculate this value.
Range: -100 to +100 up to six decimal places (Default 0.0)
OP Adjust %/wgtfrom the front panel
Step 1. OP Adjust %/wgt is
described above.
Select it with the
down arrow.
0.000
OP Adjust %/wgt
Step 2. Press Enter to
display the OP
Adjust %/wgt edit form.
0.000000E.00
EXIT
CLR
Step 3. Use the right or left arrow to move the cursor and the up or down arrow to change
the value.
Step 4. Repeat the process until you have entered all the numbers or punctuation for your
OP Adjust %/wgt value. Our example shows a typical calculated value in a
machine-readable format.
Step 5. Press Enter to save and return to the Refill Menu.
Step 6. Pressing the Exit button returns to the Ingredient Sub-Menu.
OP Adjust and OP Adjust %/wgt during refill
OP = Output Percentage. If you use OP Adjust, it uses the OP Adjust %/wgt value to
allocate the refill. There are thee options:
OFF: (default) Turns off the function.
•
•
104 •• Chapter 4
•
•
ON-LEARN: (works only with Auto Refill) The HI 4060 saves the % output and change
in weight values from previous refills and continuously calculates the optimal Output %
based on these values. This allows the instrument to adjust as conditions and the material
or refill characteristics change over time.
ON-FIXED: With Auto Refill, you can use ON-FIXED to either lock in an effective
learned value or enter a noted value that has worked well on previous applications.
Configuring OP Adjust and OP Adjust
%/wgt from the Web interface
Select one of the three options (explained
above) from the OP Adjust pull-down. You
must click Save Parameters to save any value
set from this form.
Configuring OP Adjust and OP Adjust %/wgt from the front panel
Step 1. From the Refill menu, select OP Adjust. The left and right arrows toggle between
ON,LEARN, ON, FIXED and OFF, which are described above.
Remote Setpoint
The standard Remote (Rate) Setpoint can be set up as 0-5 VDC, 0-10 VDC, 0-20 mA or 420 mA. We will refer to these as the “signals.” A signal can come from a variety of Host
Controllers (PLC, computer, a flow meter, etc.). The Remote Setpoint function gets its
input from an Analog I/O Card installed in the HI 4060.
Ingredient #1 is the Master ingredient where the actual flow is measured and transmitted.
Other ingredients may be Slave ingredients with flow rates that are proportional to the flow
rate of Ingredient #1. For example, if ingredient #1's flow rate is 10 gallons/minute and
ingredient #2 must be fed at 10% of the flow rate of ingredient #1; ingredient #2 must be
fed at a flow rate of 1 gallon/minute (a 10/1 ratio). To maintain a flow rate for ingredient
#2 that is 10% of Ingredient #1, the HI 4060 uses the flow rate signal for ingredient #1 to
adjust its output signal to the feeder motor for ingredient #2. Even if ingredient #1's flow
rate varies, the rate controller must maintain the 10% proportional feed rate.
SP HI/LO wgt/time
When configuring, the user can scale the input signal by entering flow rates that are
represented by the Low and Hi inputs. This allows tight rate scaling for precise control.
Noise can be averaged out by selecting from an averaging range of 1-20.
Configuration
•
•
•105
•
•
•
The SP HI wgt/time setting is the input signal referenced as the maximum rate setpoint,
depending on the signal range selected, and the SP LO wgt/time setting is the minimum
signal input to be referenced as the minimum rate setpoint depending on the signal range
selected (i.e., 0-20 milliamps, 4-20 milliamps, 0-5 volts, 0-10 volts). The SP HI wgt/time
setting corresponds to 20 milliamps or 5 or 10 volts input. For example, if you set the SP
HI to be 100 lbs/min at the max input of 20 milliamps and 5 or 10 VDC, the controller will
request 100 lbs/min (assuming that the feeder can achieve that rate).
The SP LO wgt/time setting corresponds to 0 milliamps or 0 volts input; so if you want the
min rate to be 0.00 lbs/min, the min input needs to be 0 milliamps 0VDC. Your minimum
rate may not be zero. You may set the lowest rate for the application by raising the SP LO
to reflect the minimum ratio.
Range: 0-99999 (default High 100.0 Low 0.0)
Configuring the Remote Setpoint from the Web interface
Step 1. To open the Configuration- Remote Setpoint
form from any form in the Configuration Ingredient series, click the Remote Setpoint
link (top of form) or the green right arrow
(base of form).
Step 2. In the SP HI weight/time (lb/m) field, enter
the High Setpoint for this ingredient. Our
example uses 100 lb/m.
Step 3. In the SP LO weight/time (lb/m) field, enter
the Low Setpoint for the ingredient. Our
example uses 0.000 lb/m.
Configuring the Remote Setpoint from the front panel
Step 1. To open the Remote
Setpoint menu,
select Remote
Setpoint from the
Ingredient menu and
press Enter.
0.000
Ingredient
> Remote Setpoint -->
Help
EXIT CLR
Step 2. Select SP HI wgt/ time and press Enter to open the
SP HI wgt/ timeedit page.
Step 3. Use the left or right arrow to position the cursor
and the up or down arrow to change the number or
punctuation. Repeat the process until you have
entered all the numbers for your SP HI wgt/time
value. Our example shows 80 lbs/min.
•
•
106 •• Chapter 4
•
•
0.000
Step 4. Select SP LO wgt/
time from the Remote
Setpoint menu, then
press Enter to open
the edit page.
SP LO wgt/time
0.0
lbs/min
EXIT CLR
Step 5. Use the left or right arrow to position the cursor and the up or down arrow to
change the number or punctuation for your SP HI wgt/time value. Our example
shows 80 lbs/min. In our example we selected 0.000 lbs/min. Setting the Setpoint
LO to 0.0 provides a ratio of 00% to 80% of the master flow rate.
Input HI% and Input LO%
The HI 4060 Input HI% parameter allows the operator to quickly change the input signal
in order to reduce the flow rate, without changing the HI and LO Output Signal parameters.
The master flow rate and the slaves can have the same SP HI and SP LO parameter settings.
By setting percentage you can control the ratio.
For Example: The master and this slaves HI output signal setting are 10.00 lbs/min. The
slave feed rate required is only 9 lbs/min. You can set this slave Input HI Percentage at 90%
and the HI 4060 recalculates the feeder rate to 0 to 9 lbs/min. If the process requires a
maximum 5.7 lbs/min, set the percentage for 57%, 6.3 lbs/min, set the percentage for 63%,
etc. Your rates probably will not be an even percentage as our example, but a percentage
of the HI and LO SP rates can be use for the control, rather than differing SP HI and SP LO
setting from controller to controller.
The HI 4060 Input LO% parameter allows the operator to quickly change the input signal
in order to meet the new flow rate without changing the LO or HI SP Output Signal.
Range: 0-100 (default High 100.0 Low 0.0)
Configuring the Input HI and Input LO from the Web interface
Step 1.
For Input HI %, enter the High
Output Percentage to maintain the SP
HI setpoint. Our example uses 100%.
Step 2. For Input LO%, enter the Low Output Percentage to maintain the SP LO setpoint.
Our example uses 0.000 percent.
Configuring the Input HI and Input LO from the front panel
Step 1. Select Remote Setpoint on the Ingredient menu. Press Enter to open the Remote
Setpoint menu. Select Input HI% and press Enter to open the Input HI% edit form.
0.000
Ingredient
> Remote Setpoint -->
Help
EXIT CLR
0.000
Remote Setpoint
> Input HI% --> 100.000
Input LO%
0.000
EXIT CLR
Configuration
•
•
•107
•
•
•
Step 2. Use the left or right arrow to position the cursor and the up or down arrow to
change the number or punctuation for your Input HI% value. Our example shows
90 percent.
Step 3. Press Enter to return to the Remote Setpoint menu
and select Input LO% and press Enter to open the
Input LO% edit form.
Step 4. Use the left or right arrow to position the cursor and
the up or down arrow to change the number or
punctuation for your Input LO% value.
Our example shows 0.0 percent. Setting the LO rate to zero provides a ratio of
90% of the master flow.
Remote Average
This is the number of samples for the I/O card to average when determining a value. The
averaging parameter is most often set when using any device that outputs an erratic signal
(e.g. a flow meter). The averaging function takes a number of input (voltage or amperage)
readings and averages the input signal to improve stability. However, this improvement
comes at the expense of response time. A setting of one average takes 100 milliseconds. A
setting of 100 averages takes 1 second. The averaging function is a running average, where
the input signals are totaled and the total is divided by the number of set averages (1-20).
The Default setting is 20. The instrument reads one new signal plus the last 99 signals and
repeats the averaging process again.
For example: with a setting of 20 the instrument reads 20 of the most current input signals
(amps or voltages), totals the signals, divides by 20, drops down one, reads one new signal
along with 19 of the old readings, totals the signals, divides by 20, drops down one, etc.
Range: 0-20 (default 20)
NOTE
When setting averaging parameters, set the smallest value that provides stable set point
readings.
Analog Input Range Parameter
The Range parameter selects the input that matches the analog device connected to the
analog card on the HI 4060.
Value Range: 0-5 V, 0-10 V, 0-20 Milliamps, 0-24 Milliamps (default 0-5 V)
Remote Setpoint (SP) Enable
In order to use the Remote Setpoint you have to enable it. This parameter enables you to
send signals to the Analog card on the HI 4060.
Range: YES/NO (default NO)
•
•
108 •• Chapter 4
•
•
Remote Average, Range, and Remote Setpoint (SP) Enable from the Web interface
Step 1. In the Remote AVG field, enter the
number of samples to average when
calculating a value for this ingredient.
Step 2. On the Analog Input range pull-down
menu, select the Input Range that
matches the Analog input to the HI
4060 I/O Card.
Step 3. Our example shows 0-20 Milliamps range.
Step 4. On the Remote SP Enable pull-down list, click YES to enable or NO to disable
Remote SP function.
NOTE
You must select YES if you want to use the Remote SP Function.
Step 5. Click on the Set Parameter button to save the settings.
Remote Average, Range, and Remote Setpoint (SP) Enable from the front panel
Step 1. Select Remote Setpoint on the Ingredient menu to open the Remote Setpoint
menu; then select Remote AVG and press Enter to open the Remote AVE edit
form.
0.000
Ingredient
> Remote Setpoint -->
Help
EXIT CLR
0.000
Remote Setpoint
> Remote AVG --> 1
Range
0-5V
EXIT CLR
Step 2. Use the left or right arrow to position the cursor and the up or down arrow to
change the number or punctuation for your Remote AVE value. Our example
shows 4.
Configuring REC Parameters
REC Level %
The REC Level % (RECPERCENT or REC LEVEL% parameter) is a percentage of Max
Rate. It is the level of error above or below the Setpoint Rate that you can accept before the
instrument goes into REC mode. For example: If the rate calibration Max Rate is 5.0
lb/min, and the REC level % is 20%, the allowable deviation is 1.0 lb/min from the Rate
Setpoint before a Rate Exception error occurs.
Range: 0-100 (default 20%. However, this allows for a very large error. We recommend a
setting between 5% and 10% and allowing a RE+ or RE- indication about every five min.)
Configuration
•
•
•109
•
•
•
REC Time
The time the unit must remain in the REC mode to get an alarm condition or if the
Shutdown parameter is selected to shutdown the operation.
Range: 0-999 (default 10)
REC Shutdown Parameter
The REC Shutdown enables you to shutdown your operation if the system operates in REC
mode beyond the time limit set in REC Time. If you select YES for REC Shutdown and the
RE error goes beyond the REC Time, the HI 4060 shuts the system down. If you select NO,
once the deviation goes beyond the REC Time, the system only displays an alarm.
Range: NO/YES (default NO)
Configuring Rate Exception Control (REC) from the Web interface
Step 1. To open the REC page from any form in the Configuration - Ingredient series,
click the REC link at the top of the page or the green right arrow at the bottom of
the page.
Step 2. In the REC Level % field, set the Max deviation your process can tolerate from
the Setpoint Rate for this ingredient. Our example shows 20.0%.
Step 3. In the REC Time (sec) field, enter the amount time you want the deviation to
occur before an REC alarm occurs. Our example shows 30 seconds.
Step 4. Select YES or NO for REC Shutdown.
Step 5. Click Save Parameters to save your changes.
•
•
110 •• Chapter 4
•
•
Configuring Rate Exception Control (REC) from the Front Panel
Step 1. Select REC on the Ingredient menu and press Enter to open the REC menu; then
select REC Level % and press Enter to open the REC Level % edit form.
0.000
Ingredient
> REC -->
Remote Setpoint
EXIT CLR
0.000
REC
> REC Level% --> 20.0
REC Time 30
EXIT CLR
Step 2. Use the left or right arrow to position the cursor and the up or down arrow to
change the number or punctuation. Our example shows 10 % for REC Level %.
Step 3. Press Enter to save the entry and return to the REC menu.
Step 4. Select REC Time;
then press Enter to
display the REC
Time edit page.
Step 5. Use the left or right
arrow to position the cursor and the up or down arrow to change the number.
Repeat the process until you have entered all the numbers for your REC Time
value; then press Enter to save the entry and return to the REC menu. Our example
shows10 seconds.
Step 6. From the REC menu,
use the down arrow
to select REC
Shutdown.
Step 7. Press the right or left
arrow to toggle
between Yes and No.
Step 8. Press Enter to save the entry, and use Exit to return to the Ingredient menu.
Ingredient Configuration
Each ingredient is configured with a name, rate setpoint, preact and other parameters to
deliver the exact amount of material for your process, whether you are working in batch or
continuous mode. You can configure and store more than 100 ingredient names from either
the front panel or the web interface.
Configuration
•
•
•111
•
•
•
Accessing the ingredients forms from the Web interface
On the HI 4060 Home Page
click Configuration to open the
Configuration menu and select
Ingredient.
This will ddisplay the
Configuration - Ingredient form set for the last
selected ingredient.
Several parameters, e.g., ingredient name, unit
(of measure), and time (set on the ROC page) are
set from forms that are accessed via the links
listed at the top of the page.
Ingredient Name
Before you can configure an ingredient, it
must have a name in the database. However,
you cannot select or create ingredient names
from the Configure - Ingredient page. Click
either the Ingredient Name link at the top of
the page or the right arrow at the bottom of
the page to open the Ingredient Name form.
Name of Parameter: INGRED
Range: 1-7 alphanumeric characters (default: none)
Before you configure your first ingredient name, the Configuration - Ingredient form and
other forms accessed from that form, display a set of default values. After the first name has
been configured, these forms will display the values for the last selected ingredient.
•
•
112 •• Chapter 4
•
•
Selecting an ingredient to rename
Since the configuration file for that name inherits the existing values of the last selected
ingredient, to simplify the task when you create a new ingredient, select an ingredient that
is very close to the one you currently want to configure, enter a new name, and modify the
inherited values as needed.
NOTE
The ingredient name is a file name for the ingredient configuration file. You must enter DOS
file names and follow what is called the 8.3 file naming convention. Make the name
descriptive but brief because you have only seven characters. The characters you cannot
use in a file name are: * / + | \ = ? [ ] ; : . < > ,
Cloning and changing an ingredient from the Web interface
Step 1. From the Other Ingredients pulldown list, click the name of the
ingredient you want to use as a
model for your default parameters.
That name will appear in the
Ingredient Filename box.
Step 2. Type in the new name you want for
this ingredient. Our example uses
Cement.
Step 3. Click Change file to save the new
Filename with inherited values from
the ingredient you first selected. To
distinguish the new ingredient, you
must change values, as appropriate
on one or more of the other
Ingredient configuration forms.
Cloning and changing an ingredient from the front panel
Step 1.
From the Configuration menu (top level), use the down arrow to select Ingredient
and press Enter to open the Ingredient menu.
Step 2. Use the down
arrow, if
necessary, to
choose Select
Ingredient and
press Enter.
0.000
Configuration
> Ingredient –>
Graph
EXIT CLR
Configuration
•
•
•113
•
•
•
Step 3. On the edit page,
press the right or
left arrow until
the name of the
ingredient you
want to use as a
model for your
parameters appears.
0.000
> Select Ingredient
File: Sugar
EXIT
Step 4. Our example uses Sugar, so our new ingredient name will inherit the values for
sugar when the configuration screens are opened.
CAUTION
When you enter the Ingredient sub-menu, unless you change the name of the
ingredient, the new parameters will be written over the current ingredient
parameters. To create a new ingredient you must change the current ingredient name.
Step 5. Press CLR to clear the current name and position the cursor for entering a new
name; then enter the first character of the alphanumeric name for the new
ingredient by using the up or down arrows to select the letter or number you want.
0.000
Ingred
B3
EXIT CLR
Step 6. Press the right arrow once to move the cursor to the next character entry position,
then use the up or down arrows to select the next letter or number. Repeat this
process until you have entered all of up to seven total characters.
Step 7. Press Enter to save the ingredient. The display
returns to the Ingredient sub-menu with the
new ingredient displayed.
0.000
Ingredient
> Ingred –> B3
Select Ingredient
Step 8. To change the parameters for this ingredient,
EXIT CLR
press the down arrow until the cursor is in front
of the parameter(s) you want to change. To
change to a higher level menu with this ingredient selected, press Exit.
Step 9. When you finish changing parameters, press Exit to overwrite the inherited
default parameters. The Ingredient name is not saved until you exit to the
summary display.
NOTE
•
•
114 •• Chapter 4
•
•
When you save a configured ingredient, the HI 4060 creates an ingredient file that is stored
in non-volatile memory on the SMM SD memory card.
Setting Ingredient Values
After selecting an ingredient, as described above, we will next configure the ingredient.
This section will explain how to configure the values from either the Web interface or the
front panel.
Rate Setpoint Configuration
The Rate Setpoint is the ingredient target flow rate (Loss in or Gain Weight) you want to
maintain for your process. Either medium or high security should be set for this menu so
that non-authorized personnel cannot inadvertently change this parameter.
CAUTION
Changing the Rate Setpoint changes the currently loaded ingredient setup.
From the Web interface
After you select an ingredient as described above,
the Configuration - Ingredient page will display the
ingredient name. To change the Rate Setpoint for
this ingredient, enter the value in the Rate Setpoint
field (default 10). Our example shows 2.00 lb/m.
To save changes on this page, click Save
Parameters.
From the Front Panel
Step 1. From the Configuration or Ingredient
menu, select Rate Setpoint and press
Enter.
Step 2. Use the left or right arrow to position the cursor and the up or down arrow to
change the value.
Step 3. When you have selected all the values for rate setpoint, press Enter.
Selecting Mode
You can operate either in continuous or batch mode depending on the process.
Range continuous/batch (default continuous)
Configuration
•
•
•115
•
•
•
From the Web interface
Select the mode from the Mode pull-down list.
To save changes, click Save Parameters. Our
example shows CONTINUOUS.
From the front panel
Step 1. Select Mode from the Ingredient menu.
Step 2. Press the left or right arrow to toggle the
mode, and press Enter to save.
Step 3. If you select Continuous mode, saving the
setting takes you directly to the Totals
Menu.
Batch (Amount and Preact)
If there are values for Batch Amount and Batch Preact in continuous mode, the HI 4060
ignores these parameters. But if you select Batch mode, you must enter these parameters.
The Batch Amount sets the amount of ingredient in weight units used per batch for the
selected ingredient. The preact value is the difference between the batch amount and when
you stop feeding. In some cases the feeders coast to a stop so the preact should be set
accordingly so that the batch amount is reached when the feeder comes to a complete stop.
Batch Amount Range >0.0 (default 0.0)
Batch Preact Range >0.0 (default 0.0)
It is not necessary to enter 0.00 for these parameters)
From the Web interface
In Batch mode, enter the batch amount for this
ingredient in the Batch Amount field. (Our
example shows 4.54 kg.), and enter the Batch
Preact value for this ingredient in the Batch
Preact field. To save changes on this page, click
Save Parameters.
From the front panel
Step 1. Select Batch with the down arrow and press Enter to display the Batch menu.
•
•
116 •• Chapter 4
•
•
Step 2. Select Batch Amount with the down arrow and press Enter to display the Batch
Amount edit form.
Step 3. Use the left or right arrow to position the cursor and the up or down arrow to
change the value.
Step 4. When you have selected all the values for your Batch Amount, press Enter to save
the entry and return to the Batch sub-menu.
Step 5. Use the down
arrow to select
Preact and press
Enter to open the
Preact edit page.
Step 6. Use the left or right arrow to position the cursor and the up or down arrow to
change the value.
Step 7. When you have selected all the values for your preact amount, press Enter to save
the entry and return to the Batch sub-menu.
Alarm Delay
The Alarm Delay is the amount of time you want the instrument to delay before setting off
either a HI shutoff or LO shutoff alarm after detecting a flow rate that is out of tolerance.
This avoids nuisance alarms and gives the system time to clear a problem.
If a product is easily liquefied, set a very short delay to prevent large spills. If a product
tends to plug or bridge set a longer delay.
Alarm Delay Range >0.0 (default 10.0sec.)
From the front panel
Step 1. From the Configuration menu, use the down arrow and press Enter to select Rate
Tolerance. Use the Rate Tolerance menu to set the Alarm parameters: The Alarm
Delay and the HI and LO shutoff alarm values notify you of unacceptable rates of
flow. When you change the setpoint rate, the alarm tolerance bands follow the
new setpoint automatically.
Configuration
•
•
•117
•
•
•
Step 2. Use the down arrow
to select Alarm
Delay, and press
Enter to open the
Alarm Delay edit
page.
Step 3. Use the left or right arrow to position the cursor and the up or down arrow to
change the value.
Step 4. When you have selected all the values for rate setpoint, press Enter to save the
entry and return to the Rate Tolerance sub-menu, and use Exit to return to the
Ingredient Menu.
Alarm Delay From the Web interface
In the Alarm Delay field, enter the delay in seconds you
want before the instrument signals an alarm condition.
To save changes on this page, click Save Parameters.
Rate Tolerance / Hi and Lo Shutoff
If the ACT flow rate is above the setpoint beyond the alarm delay time, the Hi and Lo
Shutoff alarms can be configured to signal an alarm condition that can either shut the
process down or lower the output to a set percentage (See Shutoff % Out below).
NOTE
The Lo Shutoff alarm value must be ≤ the lowest set point value.
HI Shutoff Range undefined (default 100)
Lo Shutoff Range undefined (default 0.0)
From the Web interface
In the Hi Shutoff field enter the high shutoff value you
want, and in the Lo Shutoff field enter the low shutoff
value you want. To save changes, click Save Parameters.
From the front panel
Step 1. From the Ingredient menu, use the down arrow and Enter to select Rate Tolerance;
then from the Rate Tolerance submenu, use the down arrow to select Hi Shutoff,
and press Enter to open the Hi Shutoff edit form.
•
•
118 •• Chapter 4
•
•
Step 2. Use the left or right arrow to position the cursor and the up or down arrow to
change the value.
Step 3. When you have selected all the values for rate setpoint, press Enter to save and
return to the Rate Tolerance menu. Our example shows 102.0 lb/m. for a setpoint
of 100.00 lb/m.
Step 4. Use the same procedure
to set the Lo Shutoff.
Our example uses 98.0
lb/m assuming a setpoint
of 100.00 lb/m.
Shutoff Out %
If the unit shuts down, the output percentage (OP) will be set to the value of the Shutoff Out
% parameter. If your process must continue to operate, you can preset the percentage output
so that the process does not completely shut down. If the flow rate goes outside the rate
tolerance, the system goes into Rate Exception Control. The REC timer starts and, if the
REC times out the system output goes to the preset Shutoff Out % until the system problem
is corrected, clear the alarms and press the Start button again.
CAUTION
If you want the system to stop be sure to set the Shutoff Out % to 0.0. Otherwise the
controller will go to a preset output and continue operating which may result in a
malfunction of the system.
Shutoff Out % Range 0.0> (default 0.0 You cannot set fractions of a second.)
From the Web interface
In the Shutoff Out % field enter the percentage. To save
changes on this page, click Save Parameters.
From the front panel
Step 1. From the Rate Tolerance
menu, use the down
arrow to select Shutoff
Out % and press Enter to
open the Shutoff Output
% edit form.
Step 2. Use the left or right arrow to position the cursor and the up or down arrow to
change the value.
Step 3. When you have selected all the values for rate setpoint, press Enter to save and
return to the Rate Tolerance sub-menu. (Exit returns to the Ingredient Sub-Menu.)
Our example shows 10.0 %.
Configuration
•
•
•119
•
•
•
Wait Time
Wait Time is the time the controller waits for the material to settle before it calculates the
batch total.
Wait Time Range 0 - >65,500 seconds (default 0.0 Very high values not recommended)
From the Web interface
Enter the wait time n the Wait Time field. To save
changes on this page, click Save Parameters.
From the front panel
Step 1. From the Ingredient
menu, select Wait
Time, then press
Enter to display the
Wait Time edit page.
Step 2. Use the left or right arrow to position the cursor and the up or down arrow to
change the value.
Step 3. When you have selected all the values for rate setpoint, press Enter to save and
return to the Ingredient Menu. Our example shows 5 seconds.
Totals
The HI 4060 records the total amount dispensed. The Total number displays the amount of
material that has been processed from the start of the process until the process completes
or is interrupted. For error correction, the Total parameter can be cleared (in either
continuous or batch modes) from the Web interface or changed from the front panel. For
example, if a power failure shuts the system down during a process, before you resume
operation you can re-enter the lost total from the front panel.
CAUTION
If you change the total or batch total, stop the system.
Total Range 0 - >99,999.0 wt units (default 0.0)
Batch Total (Front Panel only)
The Batch Total reads the total amount of material for the selected batch that has been
processed from the start of a batch process until the batch process ends (by intent or other
reason). When the Batch is complete, the Batch Total resets to 0.0 for the next batch. The
Batch Total parameter can be changed from the front panel should there be an error in the
batch total amount while processing. We recommend that you stop the system when
changing this parameter.
Batch Total Range 0 - >99,999.0 wt units (default 0.0)
•
•
120 •• Chapter 4
•
•
From the Web interface
You may view or clear the total for all batches
from the Web interface.
Whether the HI 4060 is in Continuous or Batch
mode, the Clear Total button will remove the
total weight accumulated in a process and
return the value to 0.00. To save the new
parameters click the Save Parameters button.
You can clear the Total at anytime during the process even when the system is running.
Changing the total from the front panel
Changing this value is not normally recommended, but if you know the value is wrong and
needs changing, start from the Ingredient Menu.
Step 1. Select Totals and press Enter to display the Totals menu, then select Total and
press Enter to display the Total edit screen.
Step 2. Use the right or left arrow to move position the cursor and the up or down arrow
to select the value.
Step 3. When you have selected all the values for Total, press Enter to save and return to
the Totals sub-menu. Our example shows 310.00 pounds.
Changing the Batch Total From the front panel
Changing this value is not normally recommended, but if you know the value is wrong and
needs changing, start from the Totals Menu.
Step 1. Select Batch with the
down arrow and press
Enter to display the
Batch edit form.
Step 2. Use the right or left arrow to move position the cursor and the up or down arrow
to select the value.
Step 3. When you have selected all the values for Batch Total, press Enter to save and
return to the Totals sub-menu. In our example we entered 100.00 pounds.
Configuration
•
•
•121
•
•
•
IP Setup Program (necessary for Blind HI-4060 Units)
The Netburner IP Setup program comes on the installation disk or it can be downloaded or
run from the Hardy Instruments Web site (See Software Downloads for your HI-4060
above). To run the program, you must be on the same network as the HI-4060 and your
firewall must be set to allow the process.
When you run the
Netburner IP Setup
program from a
network computer, it
will find the HI4060 and allow you
to set its IP address.
•
•
122 •• Chapter 4
•
•
Chapter 5
Calibration
••••••
Chapter 5 pertains to the calibration procedures for the HI 4060 Rate Controller. It is
important that both users and service personnel know and follow the procedures contained
in this chapter before installing or operating the HI 4060 Rate Controller. To ensure that the
rates read by the controller are accurate, we recommend that the Rate Controller be recalibrated periodically or when it has not been in use for extended periods of time. All
calibration is done in the Gross mode.
Pre-Calibration Procedures
NOTE
FOR NEW INSTALLATIONS
It is recommended to install 80-100% of the load several times to exercise the scale. This
settles the mounts and any piping prior to the final calibration.
Mechanical Check Procedures
Step 1. Check to determine if the load cells have been installed properly. Refer to your
load cell I&M manual for proper installation instructions.
Step 2. On some load cells an arrow
indicates the direction of the applied
load. If the arrow points in the wrong
direction, change the position of the
load cell so that it is mounted in the
direction of the applied load.
Direction of
applied load
Step 3. Check for binding on the load cell or
other parts of the system. A load cell
must be mounted so that 100% of the
load (vessel + contents) pass through
the load cell vertically.
Step 4. Verify that nothing is binding the
load cell or other parts of the
weighing system. nothing should be
draped over the scale/vessel or the
load cell, such as a hose, electrical
cord, tubes, or other objects.
Vessel
Properly installed load cell/no binding
Calibration
•
•
•123
•
•
•
CAUTION
Binding on a Scale/Vessel or Load Cell does not allow the load cell free vertical
movement and may prevent the instrument from returning to the original zero
reference point.
Step 5. Check to see that nothing comes in contact with the scale/vessel other than service
wires and piping that have been properly mounted with flexible connectors.
Electrical Check Procedures
Step 1. Check to see that there is power to the Rate Controller. If there is power, the front
panel display should be lit, and if the display appears with a value, the unit is
ready for calibration.
Step 2. Typical Load Cell/Point Input/Output Measurements (EXC & SIG outputs)
•
•
•
The HI 4060 Rate Controller is designed to supply 5 VDC excitation to as
many as eight 350 ohm load cells/points.
The expected output from each load cell/point depends on the mV/V rating
of the load cell/point and weight. For example, a 2 mV/V load cell/point will
respond with a maximum of 10 mVDC at the system’s full weight capacity,
which includes the weight of the vessel and the weight of the product as
measured by the load cell/point.
If the load cell/point weight capacity is rated at 1000 pounds, the load
cell/point output will be 10 mVDC at 1000 pounds, 7.5 mVDC at 750
pounds, 5 mVDC at 500 pounds and so on..
10
MAXIMUM LOAD CAPACITY
9
MILLIVOLTS DC
8
7
6
5
4
DEAD LOAD 500#
ZERO REFERENCE POINT
3
2
1
250
500
750
WEIGHT IN POUNDS
Millivolts/Weight Scale
•
•
124 ••
•
•
Chapter 5
1000
A zero reference point will vary on different systems depending on the “Dead Load” of the
vessel. Dead Load is the weight of the vessel and appurtenances, with no product loaded.
Our example assumes the dead load to be 500 lbs. In this example, the operating range for
this scale is 5-10 mVDC with a 500 pound weight. After zeroing the instrument, the 0
reading refers to the zero reference point and not absolute 0 mVDC or absolute 0 weight.
NOTE
Load cell/point measurements can be checked with a digital voltmeter at the J1 connector
on the rear panel or at the summing box of the HI 4060 or use Integrated Technician if you
are using the IT Junction Box.
Step 3. Allow the instrument to warm up for about 15 minutes before doing the
calibration procedures.
Load Check
Step 1. Put a load (weight) on the scale or vessel. For a full load test you can put 80% to
100% of the expected weight you will see in your process on the scale or vessel.
Step 2. Check to see if the weight reading changes on the display in the proper direction.
•
•
•
For example, if the display reads 100 pounds and a 20 pound load is placed
on the vessel or scale, the display should read 120 or some value over 100.
If the display reads 80 pounds and a 20 pound load is placed on the vessel or
scaled, the reading is going in the wrong direction and indicates some
problem with the system. (See Chapter 8, Troubleshooting for corrective
action)
If the display is reading improperly or shows no change there is something
wrong with the configuration or the load cells.
Step 3. If the display changes in the proper direction, remove the weight and proceed to
calibrate the Rate Controller.
Calibration Procedures
NOTES
When calibrating the HI 4060 for the first time, go from one sub-menu to the next in
sequence.
Any example settings are for illustration only. Your setting requirements will vary.
Make sure you have configured the instrument for your application. This includes setting
the units, decimal point, scale capacity, averages etc. For instructions please see Chapter
4, Configuration.
Calibration
•
•
•125
•
•
•
C2 Calibration
C2® Electronic Calibration enables a scale system to be calibrated electronically without
using certified test weights. A C2® weighing system consists of up to eight load sensors, a
junction box, interconnect cable and an instrument with C2® capabilities such as the HI
4060 Rate Controller. The HI 4060 reads the performance characteristics of each load
sensor and detects the quantity of load sensors in the system.
Reference Weight is the total live load on the scale. The calibration process uses a
reference point that can be entered from either the front panel or the Web page. The
reference can be zero (no weight on the scale) or a known weight, such as a container, that
will be on the scale. With no weight on the scale, the Reference Weight is 0.00. With 5 lbs
on the scale, the Reference Weight is 5.00 lbs.
C2 Calibration Procedures From the Web page
Step 1. Perform all of the pre-calibration procedures listed above.
Step 2. Make sure you have configured the instrument for your application. This includes
setting the units, decimal point, scale capacity, averages etc. For instructions
please see Chapter 4, Configuration.
Step 3. From the home page select Configuration to display the Configuration menu, then
select Scale Calibration to open the Configuration - Scale Calibration page.
Step 4. This step establishes the gross zero reference.
Enter the reference weight for your
application in the C2“Ref Weight” text field.
Our example shows 0.000 lbs.
Step 5. You can enter a gravity correction factor. (For
Gravity Correction information see the
section About Gravity Correction and the
correction factor selection table later in this
chapter.
Step 6. Click on the “Do C2 Calibration” button.
•
•
126 ••
•
•
Chapter 5
Step 7. The results will appear in a few seconds. If
the Calibration succeeds, a Cal completed
OK appears. If no load points are
connected to the instrument, a Cal Failed:
A to D Converter Error appears. To correct
this error check the cable and connectors
of the load point(s) and re-calibrate.
You will also see that the Load Sensor
Number reads 0. If no C2 load points are
connected to the instrument, a Cal Failed:
No C2 sensors found appears. This
requires a traditional instrument
calibration or connect C2 load sensors to
the instrument.
Step 8. Click on “Back” to return to the
Calibration page.
C2 Calibration Procedures From the Front Panel
Step 1. From the Configuration Menu, select Calibration and press Enter to open the
Calibration menu; then select C2 Cal and press Enter to open the C2 Cal menu
with the cursor in front of Num C2.
Step 2. Check the C2 Load Cell count. The read-only Num C2 lists the number of C2 load
cells installed on the system that the instrument detected. Verify that the load cells
detected match the number of C2 load cells actually installed.
Step 3. If the load cells detected do not match the load cells installed in the system, verify
that each load cell/point cable connection is securely fastened and in good
condition. Also, on the HI 4060 web page the information concerning
Operations/Diagnostics/C2 and Weight and Voltage can help you to determine
which load cell/point is malfunctioning.
Step 4. Select Ref Weight
(Reference Weight)
and press Enter to
open the Ref Weight
Menu edit screen.
Calibration
•
•
•127
•
•
•
Step 5. This step establishes the gross zero reference. Press the CLR button to clear the
current value and position the cursor and use the up or down arrows to scroll the
number for the right-most digit.
Step 6. Use the left arrow to select the next position and the up or down arrows to scroll
the number or punctuation. Repeat the process to enter the Reference Weight
value.
Step 7. Press the Enter button to save the Reference Weight.
About The Gravitation Correction Factor
The table below shows the gravitation correction factor for various cities around the world.
Objects weigh about 0.06% less at the equator than they weigh at each pole because the
force of gravity is less at the equator than at the poles. For example an object weighing 100
pounds at the North Pole on a spring scale would weigh 99.65 pounds at the equator.
Depending on the latitude of your location, your scales would measure somewhere in
between. Mexico City (1.002102) is the lowest and Oslo (0.998726) and Helsinki
(1.001405) are the highest.
City
Grav. Accel
City
Grav. Accel
City
Grav. Accel
Amsterdam
0.999369
Istanbul
1.000406
Paris
0.999048
Athens
1.000684
Havana
1.001872
Rio de Janeiro
1.001884
Auckland NZ
1.000782
Helsinki
1.001405
Rome
1.000326
Bangkok
1.002392
Kuwait
1.001405
San Francisco
1.000702
Brussels
0.999503
Lisbon
1.000615
Singapore
1.00269
Buenos Aires
1.001004
London
0.999445
Stockholm
0.99877
Calcutta
1.00191
Los Angeles
1.001028
Sydney
1.00104
Cape Town
1.00104
Madrid
1.000461
Taipei
1.001741
Chicago
0.99922
Manila
1.000461
Tokyo
1.000886
Copenhagen
0.999075
Mexico City
1.002102
Vancouver BC
0.999653
Nicosia
1.00093
New York
1.000433
Washington DC
1.000601
Jakarta
1.002631
Oslo
0.998726
Wellington NZ
0.999399
Frankfurt
0.999579
Ottawa
1.000007
Zurich
0.999821
In general if your location is between the 45th parallel and the equator, the gravity
correction is greater than 1.0. For example, because the gravity is less at these latitudes, you
factor the scale by 1.0006 for an error that is .06%. For locations between the 45th parallel
and the North or South Pole, your correction factor will be less than 1.0. For example .9994
for an error that is -.06%.
•
•
128 ••
•
•
Chapter 5
NOTE
If you do not want to enter a Gravitation Correction Factor go to Step 16, C2 Cal.
You must calibrate C2 after setting the Gravity Correction for the correction factor to work.
Step 8. Select Gravity
Correction from
the C2 Cal Menu
to display the
Gravity Correction
edit screen.
0.000
C2 Cal
> Gravity Correction -->
1
C2 Cal
Do Cal
EXIT CLR
Step 9. Use the left arrow to position the cursor and the up or down arrows to change the
value until you have entered all the characters for the Gravity Correction Factor.
Our example shows 1.006.
Step 10. Press the Enter button to save the Gravity Correction Factor.
Step 11. Use the Down Arrow to select C2 Cal . . Do Cal
and press Enter to perform the C2 Calibration. A
“Cal Completed OK” briefly appears on the screen
indicating the C2 calibration was successful.
A “Cal Failed” message briefly appears with the
error number if the C2 Calibration was not
successful. Check Chapter 8, Troubleshooting for
corrective action.
0.000
C2 Cal
> C2 Cal
A/D Average
Do Cal
65535
EXIT CLR
A “Security Violation” message briefly appears if the user does not have the
security level required to do a calibration.
Step 12. Use the down arrow to select A/D Average. This
is a read only display of the Average A/D counts.
Step 13. Press the Exit button to return to the Calibration
Menu.
Traditional Calibration
Traditional Calibration is the method of calibration that uses test weights. We recommend
that the test weights total 80 to 100% of the scale live load capacity.
Traditional Calibration normally uses a zero point and the physical placement of test
weights on the scale. To set the scale value. The scale is normally empty, but not
necessarily. The reference weight must be the amount of live load weight on the scale. With
no weight on the scale, the Zero Value would be 0.00. Wait 12 seconds or more.
Calibration
•
•
•129
•
•
•
Traditional Calibration from the Web page
Step 1. In the Ref Weight text field enter the
reference weight you want. In our
example we entered 0 lbs. If you want the
reference weight to be 5.0 lbs enter 5.0.
Step 2. Cal low weight is a reference for the
weight of any product on the scale that is
not removed during calibration (derived
from actual measured weight used at cal
low or C2 cal). Normally, you would
remove all “live load” weight from the scale to obtain a CalLow Weight of 0.0.
Click on the Do Cal Low button to do the Trad Cal Zero. A “Cal Completed OK”
message appears briefly if the calibration was successful. If not, an Error number
appears. See Chapter 8, Troubleshooting. for help with error correction.
Step 3. To set the Span Weight, place a certified
test weight on the scale.
Step 4. In the Span Weight text field, enter the
weight of the certified weight. Our
example shows 5 lbs.
When you click the Do Cal High button,
a “Cal Completed OK” message appears
briefly if the calibration succeeds, or an
error message appears if the calibration
fails. See the Error list in Chapter 8 for
help with error correction.
Traditional Calibration from the Front Panel
Step 1. From the Configuration menu select Calibration and press Enter button to display
the Scale Calibration Menu; select Trad Cal and press Enter to display the Trad
Cal menu: then press Enter to open the Reference Weight edit screen.
Step 2. Traditional Calibration requires a zero point and the physical placement of test
weights on the scale. The Ref Weight would normally be 0.0 (but not necessarily).
Enter a reference weight equal to the weight on the scale.
Step 3. Wait 12 seconds or more.
•
•
130 ••
•
•
Chapter 5
Step 4. Use the Left and Right Arrow buttons to position the cursor. Use the Up or Down
Arrow buttons to enter the Reference Weight for this instrument.
Step 5. Press the Enter button to save the entry.
Step 6. Select Cal Low Do Cal with the Down arrow, and
press Enter to show the Cal Low value. A “Cal
Completed OK” message appears briefly if the
calibration succeeded. If not, you will see an Error
number. See the Error list in Chapter 8,
Troubleshooting for help in correcting the error.
Step 7. From the Scale Calibration menu, select Trad Cal with the Down arrow to view
the A/D Averages. This is used to tell when the scale settles.
Step 8. From the Trad Cal menu, use the Down arrow to select Span Weight and press
Enter to open the Span Weight Menu edit screen showing the last Span Weight.
Step 9. To set the Span Weight: Place a certified test weight on the scale and use the Left
and Right arrows to position the cursor and the Up or Down arrows to enter the
value of the test weight; then press Enter to save. For a 10 lb. weight, enter 10.00.
Step 10. Select Do Cal High, and press Enter to do the Cal
High. A “Cal Completed OK” message appears
briefly if the calibration succeeded. If not, you will
see an Error number. See the Error list in Chapter 8,
Troubleshooting for help in correcting the error
Step 11. The scale is now calibrated.
Calibration
•
•
•131
•
•
•
•
•
132 ••
•
•
Chapter 5
Chapter 6
Mapping
••••••
NOTE
Default mapping predefines the I/O and analog signals. (Default functions for the five I/O
card inputs HI5.0-HI5.4 are listed under Control.) If you use these defaults, it is necessary
to map only commands sent over the communication links.
Mapping allows you to set up certain monitoring and control activities to meet your process
requirements without programming. Whether the input is digital data to be routed to a
display or a signal used to trigger a command to a PLC, mapping is often the easiest way
to achieve the desired result. HI 4060 mapping is more flexible than the typical I/O
addressing used in a PLC. You can either use the predefined I/O default mapping or tailor
custom mappings to meet the unique requirements of your application. To prevent
unintended action with your inputs when you reset the defaults, be sure to set Use Default
I/O to NO on the Configuration - Instrument Setup page.
Glossary of Mapping Terms
Assignment Statement - The assignment statement tells the computer to change the value
stored in the memory address named as a variable on the left side of an = sign. (The = sign
is called an assignment operator). For example: i = a + b, means get the values stored in
memory locations a and b, add them together, then store the sum in location i.
Destination - This is the destination memory address to which data will be moved. left side
I/O Interface - The section of the instrument that communicates with the “outside world”.
Input Contact - Inputs interface selector and limit switches, push buttons, and sensors to
the HI 4060. An address assigned to each input identifies the location of the input device.
Input Table - Defined in the section Input and Output Tables.
Local Mapping - See the section Local Input.
Network Mapping - This is mapping to and from network devices.
Node Number - This is the physical address of a device in a network.
Output Table - Defined in the section Input and Output Tables.
Source - This is the memory address of the data (Right side of the equation) you want to
assign to the destination.
Word - When mapping the value selected for Network on the Mapping page, you can
specify a value for Word. Data passed to a table must be formatted to match the allocated
space. Words are groups of bit locations that can be identified by a sequence number. The
default word 0 indicates that data sent to that memory location will occupy the allocated
space starting from the first available bit. Entering a different value in the Word field allows
Mapping
•
•
•133
•
•
•
you to specify a different starting point for storing the data input. This may be done to avoid
overriding data that already exists in certain locations. For example, with ControlNet and
RIO some tables have assigned word 0 (or both 0 and 1) to other uses, so they should not
be used for a new mapping. You may need to track where information is stored. For
example, if both weight and Setpoint 1 are assigned to Word zero in the same table, the
overlapping input values would override one another. Note too that Int and Float consume
two words, so both the word selected and the word to follow must be available for mapping.
How Mapping Works
Mapping (Addressing I/O) creates assignment statements. The destination is on the left side
of the = sign and is a memory address (variable). The Source is the data on the right side of
the = sign at a memory address. The = sign assigns the data on the right side of the
assignment statement to the memory address on the left side of the assignment statement.
Any reference to the right side of the assignment statement refers to the data only and not
the address, even though the address is listed.
Memory Address (Variable) = Data (Values, states)
Input and Output Tables
To transfer values from node to node during the I/O scan, each node has an Output table,
that contains the values to be read by other nodes, and an Input table, where incoming
values from other nodes are received. Generally, the transferred values are current states or
other variables. The output tables and input tables are data arrays where data are stored (i.e.
a set of memory locations of tailored sizes based on the type assigned to the variable and
having an address). Mapping specifies what to do with HI 4060 input.
HI 406 0
Mapping
Equation
HI 4060
Internal
Process
Input
Table
Short Word 11
Output
Table
External
Device
Input
Table
External
Device
Output
Table
Short Word 11
Often, more than two devices are involved, so separate output tables and input tables having
different addresses may be set up for data exchanges with each device.
The HI 4060 scans through the I/O tables 110 times a second and reads any values they
contain. If state or other values are stored in the tables, the firmware processes the data and
outputs it to an output device or the screen. If nothing is stored to output, no output is sent.
When an I/O scan occurs, the state of each input is transferred from the input point to the
input table for the receiving device, as shown in the graphic below.
•
•
134 ••
•
•
Chapter 6
The left side of an assignment statement is for output table data, and the right side of an
assignment statement is for input table data. Memory address (variable) = Data (values,
states).
Output variables are also further identified by the first two letters of the variable:
•
•
•
HO - Hardy output table
DO - DeviceNet output table
EO - Ethernet/IP output table
If the items in the table are only permitted on the right side of an Assignment Statement,
we call it an input table:
•
•
•
HI - Hardy input table
DI - DeviceNet input table
EI - Ethernet input table
Local Input
This is mapping where the input side of the equation is a digital signal entering the HI 4060
via a connector (other than a network connection feeding into an input table). The source
of such inputs would be an interface with a limit or selector switch, push button, or some
other sensor feeding voltage signals into the HI 4060. The mapping output normally goes
to an HI 4060 internal process or one of its output tables.
Remember Local Inputs = User Switches.
Input
0
Input Device
HI 4060
Mapping
Equation
HI 4060
Internal
Process
1
2
Output
Table
Volatile and Non-Volatile Memory
The data stored in the output tables and input tables are stored in volatile memory. This
means, when you power off the HI 4060 you lose the data. The Addressing I/O (Mapping)
is saved in non-volatile memory and is not lost when you power off.
Mapping to an Output
In English we might say: Connect Gross Weight to Ethernet/IP Float Out.
• Ethernet/IP Float Out is the Destination.
Mapping
•
•
•135
•
•
•
• Gross Weight is the Source.
In Assignment Statement form this mapping would look like this:
• Destination = Source or
• Ethernet/IP Float Out (EFO) = Gross Weight (HF10)
Network Input
Like the HI 4060, PLCs have output tables and input tables. The HI 4060 is a network node
that you can assign a node address so the Network scanner can identify the instrument.
WARNING: YOU CANNOT ASSIGN THE SAME ADDRESS TO TWO DIFFERENT
NODES. THE PLC CANNOT DETERMINE WHICH NODE IT IS COMMUNICATIING
WITH. THIS CAN RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY.
The Network scanner, scans each node’s output table and reads the values to the PLC’s
input table which makes the data available to the PLC for processing.
Here again you can assign the data in the node’s output table to an address in the PLC input
table. For example, to display a Gross Weight on the PLC’s output (screen), you assign the
Gross Weight value in the HI 4060’s input table to its output table where the PLC Scanner
can read it and moves it to its input table (where it can then be output to the PLC screen).
Network Output
The Network Scanner writes data in a PLC’s output table to the input table of any network
node that is setup to receive it. This data then becomes a source that can be mapped to any
destination in the HI 4060.
Mapping from the Web Browser
Step 1. From the HI 4060 Home Page, click
Configuration to view the
Configuration menu.
Step 2. Select Mapping to view the
Configuration Mapping Setup form.
The pull-down menus list both
Destination and Source setup
options.
•
•
136 ••
•
•
Chapter 6
Step 3. For our destination, from the Network
pull-down list we select an option
based on three factors:
•
Type of network, e.g., CNET
(Control Net ), “Ethernet/IP,
Modbus, etc.
• Message data type based on the
number of bits to be sent or
received, e.g., Int, Float, short Int,
or Boolean (see Data Types below).
• Whether the value is an input or an output. Note that the listed options for
destination show mainly output options.
In our example, we select “Ethernet/IP Float Out (EFO) as our destination.
Step 4. This causes Ethernet/IP Float Out
(EFO) to appear in the text box and a
Select button appear to the right of the
Network box.
Mapping
•
•
•137
•
•
•
Step 5. When we click Select, an address appears in the text box below. You will have to
scroll down to see it. In our example we selected Ethernet/IP Float Out, which has
an address of: EFO0. An equal sign also appears.
Step 6. You have now selected the Destination. Now we want to select the source Gross
Weight, which is Process Data.
Step 7. From the Process
Data pull down,
select “Gross
Weight.” A Select
button appears to
the right of the
Process Data box.
Step 8. Click the Select
button to select
“Gross Weight as
the Source.
Step 9. The Assignment Statement is complete. You now see in the Mapping text box:
“EFO0=HFI0”
Step 10. Click the Map button. You have now mapped Gross Weight to Ethernet/IP Float
Out. The Gross Weight that is stored in the input table is now assigned to the
Ethernet/IP Float Out output table and to the Ethernet/IP Network. Notice that the
new mapping is included in the Map list.
•
•
138 ••
•
•
Chapter 6
Example #2 Mapping an Input
To connect a remote switch for starting a process, you can map “User Switch 1” (1 of 3
inputs to the HI 4060) to the Start (HO3.0) option. The Assignment Statement is:
•
•
Destination = Source
Start (HO3.0) = User Switch 1 (HI0.4)
Step 1. On the Control pull-down menu
under Destination, select Start. A
Select button appears.
Step 2. Click the Select button.
Step 3. The Destination address appears
in the Mapping text field.
Step 4. Under the Source Section click on the Control pull-down menu. Click on User
Switch 1. A Select button appears.
Step 5. Click the Select button. The Source address appears in the Map text field.
Step 6. The Mapping Assignment Statement is complete. Start (HO3.0) = User Switch 1
(HI0.4). Click the Map button. The Input Contact is now mapped to Start.
Simple Network Mapping
Mapping to a Network Output
To send data to a PLC from the HI 4060, you need to map the data to a network output. For
example, to map the weight to an Ethernet/IP output, the process is:
Step 1. From the
Network pull
down, select
Ethernet/IP
Float Out.
Mapping
•
•
•139
•
•
•
Step 2. In the Word text box, enter the number 2. See Glossary of Mapping Terms for an
explanation on how the Word text box is used.
Step 3. Click on the Select button to set the Destination. The “Ethernet/IP Float Out”
address appears on the left side of the Assignment Statement.
NOTE
The 2 in Ethernet/IP Float Out address EFO2 refers to Word 2.
Step 4. Click on the Process Data pull-down list.
Step 5. Click on Total (HFI7).
Step 6. Click the Select button to enter Total as the source of the Assignment Statement.
Step 7. The total address appears on the right side of the assignment statement.
Step 8. The total weight is now available to the PLC via the DeviceNet Scanner.
•
•
140 ••
•
•
Chapter 6
Mapping a Network Input for Control
NOTE
PLC output that is input to the HI 4060 can be mapped for HI 4060 local control.
When the PLC sends information to the
HI 4060, this mapping process clears
alarms when word 2 bit 0 is set high.
Step 1. Under Destination on the
Mapping page, select Clear
Alarm (HO3.6) on the Control
pull-down list.
Step 2. When you click Select, the Clear Alarm (HO3.6) address appears on the left side
of the Assignment Statement.
Step 3. From the Networks pull down, select a Boolean option as the Source for the
Assignment Statement.
Step 4. In the Word text box, type in the number 2. See Glossary of Mapping Terms for
an explanation on how the Word text box is used.
Step 5. Click on the Select button to assign the source to the right side of the assignment
statement; then click the Map button.
Mapping
•
•
•141
•
•
•
Step 6. The new mapping, clears alarms when word 2 bit 0 is set high from the PLC.
More Advanced Mapping
This section is for those who have experience Addressing I/O (mapping) or for those who
want more information as to how the mapping works locally and on the network. It includes
instructions for Boolean, Analog, Mixed and Special Command mapping procedures.
Unlike the addressing of PLC input and output, you do not map the physical location of an
I/O module terminal to a bit location in the processor. HI 4060 mappings are not predefined.
Instead, you map values or states in an input table to an output table location. HI 4060
mapping is nothing more than assigning data from an address (Source) to another address
(Destination) to be used by the controller in ways that meet your process requirements. The
HI 4060 has default mapping for the Addressed I/O.
For each input, e.g., the state of the input device, an associated input table address identifies
the physical location for the data. When you map an input to a destination, you assign the
input table value to an output table Address. For example: Clear Alarm = Input #3 means
assign the state (Open (0) or Closed (1)) of Contact #3, contained in the Contact Closure
input #3 input table address, and move it to the Clear Alarm address in the output table.
Boolean Mapping
In a Boolean equation, the destination (left side of the equation) is a Boolean term. A
Boolean variable is a variable that can have the value 0 (FALSE) or 1 (TRUE). In the HI
4060 there are 3 Boolean operations supported:
•
•
•
AND - The symbol for “AND” in a Boolean Assignment Statement is “*”.
OR - The symbol for “OR” in a Boolean Assignment Statement is “+”.
NOT - the symbol for “NOT” in a Boolean Assignment Statement is “~”.
The Boolean tables are arrays of short (2 byte) integers. An individual Boolean variable in
the table is located by its word offset and its bit offset. Boolean tables are given two letter
names as follows:
•
•
•
•
DI is the DeviceNet input table.
DO is the DeviceNet output table.
HI is the Hardy input table.
HO is the Hardy output table.
DeviceNet input tables and output tables are mapped to physical external devices using a
DeviceNet configuration software like Rockwell Software’s RS NetWorx®.
•
•
142 ••
•
•
Chapter 6
NOTE
RS NetWorx® is a registered trademark of the Rockwell Corporation.
A Boolean variable is addressed with the syntax below:
[tablename][word offset].[bit offset]
Example: DI0.3 is bit #3 in the DeviceNet input table, word #0.
Analog Mapping
Analog equation mapping is defined as the destination in an analog term. Analog variables
can have different values in different formats:16-bit integer, 32-bit integer, and 32-bit float.
Three analog operations are supported. The symbols are the same as the Boolean
operations, but with different meaning.
1: Multiply. The symbol for “multiply” is '*'
2: Add. The symbol for "add" is '+'
3: Negate (logical NOT). The symbol for "NOT" is '~'
Analog tables are given three letter names as follows:
DFI,DFO,DSI,DSO,DII,DIO all refer to network tables, where the item is a float, a short
integer, or a 32-bit integer, depending on the second letter in the table name.
•
•
•
S - 16 bit signed integer
F - float
I - 32 bit signed integer
An analog variable is addressed with the syntax below:
[tablename][offset]
The offset in DeviceNet tables is measured in words. See Glossary of Mapping Terms for
an explanation on how the Word text box is used. The offsets in Hardy tables have various
predefined meanings. When an analog equation is evaluated, all terms get converted to
float. The final result is then converted to the type of the LHS (destination).
Mixed Mapping
An equation is said to be an analog equation if the term on the left side of the equals sign
is an analog variable. The equation is said to be a Boolean equation if the term on the left
side is a Boolean variable. It is permissible to have analog variables appear in Boolean
equations and Boolean variables in analog equations. (We call a mixed equation “Boolean”
if its LHS is a Boolean term and “Analog” if its LHS is an analog term).
A Boolean variable in an analog equation is converted to 1.0 or 0.0.
An analog variable in a Boolean equation is TRUE if it is greater than zero and FALSE if
it is less than or equal to zero.
Mapping
•
•
•143
•
•
•
Special (Command) Mapping
A command interface can be used to read or write a parameter value. The table CMD can
appear only on the left side of an equation. The right side has one or two terms. The first
one defines (in words) the offset where the command data comes from in the table, and the
second term defines the table and offset where the response to a command is written.
The Command Interface
A command interface can be used to read or write a parameter value. The HI 4060 may
receive commands over any of its network interfaces. A command consists of a four-byte
command which it receives through its network input data. The instrument responds with
a four-byte response. We need to set the upper two bytes of the parameter ID into the
location for this, as described below.
Setting up the Command Interface Mapping
Use an equation of the form CMD0 = (in_table)*(out_table)
In_table is an input table defining where the command is written. Out_table defines where
the replay data is written.
Example: CMD0=DSI0*DSO0
This equation says the command will be written to the DeviceNet input table at word offset
0 and the reply data is written to the DeviceNet output table at word offset zero.
The upper two bytes of PARAMETER ID (JSO15) and the upper two bytes of the
parameter value (JSO14) can also be mapped, which removes the need to do steps 1 and 2
above. Instead, you would write the 0000 and 0001 into JSO15 and JSO14, respectively.
Example: JSO15 = DSI2 and JSO14 = DSI3
By doing this you can set four-byte parameter values using a single command rather than
the three commands required above.
To read the value of any parameter, send the four-byte PARAMETER ID. The byte order is
LITTLE ENDIAN, that is least significant byte first. Verify that the upper two bytes are set
correctly. To verify what they should be, either see the parameter list at the end of this
section or look on the OPERATION/DIAGNOSTICS/PARAMETERS web page to find the
parameter IDs. Use the special parameter ID (0x4001 or 0xC001 with the upper bit set) to
set the upper bytes. The value the instrument returns for the parameter will be either an
integer or float.
When writing the value of a parameter, the PARAMETER ID is four bytes long, and the
parameter value is also four bytes long if it is a floating-point number. However, each
command is only four bytes long, while most integer valued parameters are only two bytes
long. Also the most significant two bytes of a PARAMETER ID is usually zero.
To setup a two-byte parameter with a four-byte PARAMTER ID, send these four bytes:
•
•
•
•
144 ••
•
•
Chapter 6
byte 0: The least significant byte of the PARAMTER ID
byte 1: The next byte of the PARAMTER ID but with the highest order bit set.
•
bytes 2,3: The value you want to set the parameter to.
For example, to set the value of NumAverages to 3, if the first two-bytes are set to 0, send
this hex command <0x8007><0x0003>.
Here the <0x0007> is the lowest 2 bytes of the PARAMETER ID or NumAverages which
becomes 0x8007 after you set the most significant bit and <0x0003> is the value you want
to set the parameter to.
If the parameter is 4 bytes long, as all floating-point values are, first set the upper 2 bytes.
A special PARAMETER value (0x4000 or 0xC000 with the upper bit set) does this.
The first two bytes of the response to a write command echo the first two bytes of the
command. The next two bytes are either the TWO MOST SIGNIFICANT bytes of the
parameter or, if the parameter was in fact a command like CLEAR ALARM or TARE, a
status code indicating whether the command succeeded or failed.
If the PARAMETER ID is not valid, the instrument will return four zero bytes.
A parameter writing example: Setting Rate Setpoint Target to 1.0
Rate Setpoint Target has a PARAMTER ID of 0x00010012 (hexadecimal). The number 1.0
in float format is 0x3F800000.
Step 1. Set the upper two bytes of the parameter value with the command
<0xC000><0x3F80>
Step 2. Set the upper two bytes of the PARAMETER ID with the command
<0xC001><0x0001>
Step 3. Write the Rate Setpoint Target with the command <0x8012><0x0000>
Parameter List (Dump)
Step 1. To display the Operation menu from the
Home Page, click Operation.
Step 2. Select Diagnostics to display the Diagnostics
Page, and click on Parameters to display list
of the parameters and their settings.
Mapping
•
•
•145
•
•
•
NOTE
* The dollar signs indicate that the parameters have a security code. One (1) dollar sign
for Medium Security and two (2) dollar signs for High Security. 00000001 $$Unit=0 [lb]
00000002 $Weight Decimal Pt=3 [3]
00010002 Rate Decimal Pt=3 [3]
00020002 Total Decimal Pt=2 [2]
00030002 Batch Decimal Pt=3 [3]
00000003 Grads=0 [1]
00000004 Operator ID=Me!
00000005 Instrument ID=HI 4060
00000006 WAVERSAVER®=3 [1.00 Hz]
00000007 Num Averages=10
00000009 Low Pass Filter=1 [ON]
0000000A Gain In Weight=0 [NO]
0000000F Capacity=130.000
00000201 Span Weight=6.001
00000202 Ref Weight=0.000
0000002A Baud Rate:=5[19200]
0001002A Data bits:=1[8]
0002002A Parity:=0[NONE]
0003002A PrintMode=0[BATCH REP]
000002F2 scratchpad=0.000000
000102F2 scratchpad=30.000000
000202F2 scratchpad=0.000000
000302F2 scratchpad=0.000000
000402F2 scratchpad=0.000000
000502F2 scratchpad=0.000000
000602F2 scratchpad=0.000000
000702F2 scratchpad=0.000000
00000036 DNET Baud=2[500k]
00010036 DNET Node=6
00020036 DNET Bytes In=32
00030036 DNET Bytes Out=32
00000037 EIP Bytes In=4
00010037 EIP Bytes Out=4
00020038 Analog Weight Low=0.000000
00030038 Analog Weight High=100.000000
00040038 Analog Output Low=0.00
00050038 Analog Output High=5.00
10020038 Analog Weight Low=0.000000
10030038 Analog Weight High=130.000000
10040038 Analog Output Low=4.00
10050038 Analog Output High=20.00
20020038 Analog Weight Low=0.000000
20030038 Analog Weight High=130.000000
20040038 Analog Output Low=0.00
20050038 Analog Output High=10.00
30020038 Analog Weight Low=0.000000
30030038 Analog Weight High=130.000000
30040038 Analog Output Low=4.00
30050038 Analog Output High=20.00
00000040 Profibus Node:=5
00000041 RIO Baud Rate=0 [57.6k]
00010041 RIO Address=0
00020041 RIO Rack Size=0 [ 1/4]
00030041 RIO Quarter=0 [0]
00040041 RIO Last Quarter=0 [NO]
00000208 Calibration Date=C2 Cal 23 Dec 2008
00000203 Cal Low Counts=3033020
00000204 Cal High Counts=3455028
00000205 Cal Span Factor=2.883120214392E-05
00000206 Zero Counts=3033020
0000020A ITECH=0 0 0 0 0 0 0
0000020B Gravity Correction=1.000000
0000001D zone=3[PST(GMT-8h)]
•
•
146 ••
•
•
Chapter 6
000002F0 MAP:=MFO0=+HFO0
000002F1 Use Default I/O?=1 [YES]
00000300 Display Mode=1
00000301 Display Line=2
0000002D High Security Code=0
0001002D Medium Security Code=0
0000002E FPSecurity=0[NONE]
0000002F Calibration Security=0[NONE]
00000030 Web Page Security=0[NONE]
00000061 Modbus Key=1417817
00020037 EIP key=1264930
00000505 Ingr Filename=INGRED
00010060 ROC Time Units:=1 [min]
00020060 ROC Time Base:=5
00810500 Rate at percent=1.170
00820500 Rate at percent=2.340
00830500 Rate at percent=2.711
00840500 Rate at percent=3.083
00050500 Rate at percent=3.547
00860500 Rate at percent=4.012
80000500 Rate Cal Percent=0
81000500 Rate Cal Percent=10
82000500 Rate Cal Percent=20
83000500 Rate Cal Percent=35
84000500 Rate Cal Percent=50
85000500 Rate Cal Percent=75
41000500 Prime time=0
42000500 Pause time=5
43000500 Feed time=40
44000500 Cal type=0 [2 point]
00000501 Rate Setpoint=3.000
00000502 PID P=50.0
00000503 PID I=16.1
00000506 Alarm Delay=10
00010506 Lo Shutoff=0.000
00020506 Hi Shutoff=100.020
00000508 Batch Amount=6.000
00010508 Preact=0.000
00000509 Mode=0[CONTINUOUS]
00000507 Auto Refill=0 [NO]
00010507 Initial Refill=0 [NO]
00020507 Start(lo)=10.000
00030507 Stop(hi)=99.999
00040507 Hi Alarm=110.000
00050507 Low Shutoff=2.000
00060507 OP Adjust=2 [ON,FIXED]
00070507 OP Adjust %/wgt=0.000000E+00
0000050B Wait Time=2
0000050C REC Level%=20.0
0001050C REC Time=30
0002050C REC Shutdown=0 [NO]
0000050D Shutoff Out%=0.0
0002050E Input LO%=0.000
0003050E Input HI%=100.000
0004050E SP LO wgt/time=0.000
0005050E SP HI wgt/time=100.000
0006050E Remote AVE=1
0007050E Remote SP Enable=0 [NO]
0008050E Range=0 [0-5 V]
00000098 Total=290.31
00000099 Batch=14.500
000002F4 Graph var=0 [ACT]
Map Dictionary
CMD0 - Specifies input and output locations for the command interface
e.g. CMD0=ESI25*ESO20
Th unit will look for commands starting at EtherNet/IP input word 25 and send
acknowledgements to output word 20
Be careful to distinguish between digit zero "0", and upper-case letter "O".
DFI - DeviceNet Input, regarded as floats
DFO - DeviceNet Output, regarded as floats
DSI - DeviceNet Input, regarded as 16 bit integers
DSO - DeviceNet Output, regarded as 16 bit integers
DII,DIO - DeviceNet Input,Output, regarded as 32 bit integers
DI,DO - DeviceNet Boolean input and output
EFI,EFO,ESI,ESO,EII,EIO,EI,EO - Ethernet I/P, similar to DeviceNet
PFI,PFO,PSI,PSO,PII,PIO,PI,PO - Profibus
RFI,RFO,RSI,RSO,RII,RIO,RI,RO - RIO. Words 0-63 for block transfer, Words 64-71
for discrete transfer
MFI,MFO,MSI,MSO,MII,MIO,MI,MO - Modbus
HSI - Hardy Short Input Table. This table allows the things in HI to be mapped as 16-bit
words.
HSI0 - Digital Input
• HSI0 bit 0 (HI0.0) - Digital Card Input 1
• HSI0 bit 1 (HI0.1) - Digital Card Input 2
• HSI0 bit 2 (HI0.2) - Digital Card Input 3
• HSI0 bit 4 (HI0.4) - User Switch 1
• HSI0 bit 5 (HI0.5) - User Switch 2
• HSI0 bit 6 (HI0.6) - User Switch 3
HSI1 - Status Word
• HSI1 bit 0 (HI1.0) - A/D Conversion Error
• HIS1 bit 1 (HI1.1) - A/D Failure
• HIS1 bit 3 (HI1.3) - Weight Overrange
• HIS1 bit 7 (HI1.7) - Real Time Clock failure
• HIS1 bit 8 (HI1.8) - SD memory card read failure
• HIS1 bit 9 (HI1.9) - Display error
• HIS1 bit 11 (HI1.11) - SD memory card write failure
HSI2 - Default Relay Output, as determined by the state machine (can be overridden
by mapping HSO4)
• HSI2 bit 0 (HI2.0)ON/OFF relay
• HSI2 bit 1 (HI2.1)Shutoff relay
• HSI2 bit 2 (HI2.2)REC relay
• HSI2 bit 3 (HI2.3)Alarm relay
• HSI2 bit 4 (HI2.4)Refill relay
Mapping
•
•
•147
•
•
•
HSI3 - State machine operating mode
• 0 = IDLE
• 1 = AUTO
• 2 = MANUAL
• 3 = START
• 4 = STOP
• 5 = SHUTOFF
• 6 = PAUSE
• 7 = RATE CAL
• 8 = REFILL
• 9 = REFILL FULL
• 10 = MANUAL HOLD
• 11 = RATE CAL HOLD
• 12 = INITIAL REFILL
HSI4 - Rate Status Word
• HSI4 bit 0 (HI4.0) Low Alarm
• HSI4 bit 1 (HI4.1) High Alarm
• HSI4 bit 2 (HI4.2) Control lost
• HSI4 bit 3 (HI4.3) Refill overflow
• HSI4 bit 4 (HI4.4) Not OK to Feed
• HSI4 bit 5 (HI4.5) ON/OFF
• HSI4 bit 6 (HI4.6) Rate Range Error - Rate is below zero, or above MAX
RATE
• HSI4 bit 11 (HI4.11) RE- (rate exception condition, low rate)
• HSI4 bit 12 (HI4.12 Batch Complete
• HSI4 bit 13 (HI4.13)Request Refill
• HSI4 bit 14 (HI4.14)REC (rate exception condition)
• HSI4 bit 15 (HI4.15)Shutoff
HSI5 -Digital input from I/O card. These 5 inputs do not have to be mapped if the
parameter Use Default I/O is set to YES. The default functions are listed below.
• HI5.0 Start
• HI5.1 Stop
• HI5.2 Abort
• HI5.3 Force Refill
• HI5.4 Clear Total
HSI10 -Analog input counts from I/O card
HSO - Hardy Short Output table. This table allows the things in HO to be mapped as 16bit words.
HSO0 - Digital Output
• HSO0 bits 0-3 (HO0.0-HO0.3) - Digital Card Output 1-4
HSO1 - Command Status - value returned after a command (see HSO2) is done. Nonzero status means the command failed.
• Status 1,2 = Calibration failed due to ADC error, or ADC failure
•
•
148 ••
•
•
Chapter 6
•
Status -8 (0xFFF8) = Hard Calibration failed, not enough ADC counts
between high and low steps
• Status -6 (0xFFFA) = C2 Calibration failed, no C2 sensors detected
HSO2 - Command Word. Commands are performed on a 1-shot basis when this word
changes from 0 to 1. An error code is returned in the "command status" word HSO1.
• HSO2 bit 0 (HO2.0) - Clear Total
• HSO2 bit 2 (HO2.2) - Hard Cal Low
• HSO2 bit 3 (HO2.3) - Hard Cal High
• HSO2 bit 4 (HO2.4) - C2 Cal
• HSO2 bit 5 (HO2.5) - Write Parameters to SD card
• HSO2 bit 6 (HO2.6) - Print
• HSO2 bit 7 (HO2.7) - Do 2 point Rate Calibration
• HSO2 bit 8 (HO2.8) - Do 5 point Rate Calibration
• HSO2 bit 10 (HO2.10) - Enter Manual Mode
• HSO2 bit 11 (HO2.11) - Exit Manual Mode
HSO3 - Mapped Switch
• HO3.0 Start
• HO3.1 Stop
• HO3.2 Abort
• HO3.3 Force Refill
• HO3.4 Clear Total
• HO3.5 Print
• HO3.6 Clear Alarm
• HO3.7 Clear Hopper
• HO3.8 Not OK to Feed
HSO4 - Relay Output- defaulted to the values below, unless re-mapped
• HO4.0 Relay1-ON
• HO4.1 Relay2-SHUTOFF
• HO4.2 Relay3-REC
• HO4.3 Relay4-ALARM
• HO4.4 Relay5-REFILL
JSO Hardy Short Integer Parameters
JSO0 - WAVERSAVER®
JSO1 - Num Averages
JSO2 - Unit
JSO3 - Weight Decimal Point
JSO4 - Wait Time
JSO5 - Grad Size
JSO6 - Remote Key
JSO7 - Auto Refill
JSO8 - Initial Refill
JSO9 - Alarm Delay
JSO10 - REC Time
JSO11 - REC Shutdown
Mapping
•
•
•149
•
•
•
JSO13 - Rate Decimal Point
JSO14 - Param Value MSW
JSO15 - Param ID MSW
JSO16 - Remote Setpoint Averages
JSO17 - Remote Setpoint Enabled
JSO18 - Remote Setpoint Analog Input Range
JSO19 - Total Decimal Point
JSO20 - Gain in Weight
JSO21 - PrintMode
JSO22 - Batch Decimal Point
HFO Hardy Float Parameters
HFO0..HFO7 - Scratchpad variables
HFO8 - Max Rate
HFO12 - Span Weight
HFO13 - Cal Low Weight
HFO14 - Scale Capacity
HFO15 - Remote Setpoint in
HFO16-19 - Remote Setpoint configuration: RateLow, RateHigh, InputPercentLow,
InputPercentHigh
HFO20-23 - Input to one of 4 channels of analog output card
HFO24-27 - Analog output channel 1 configuration: Low Value, High Value,
OutputVoltsLow, OutputVoltsHigh
HFO28-31 - Analog output channel 2 configuration: Low Value, High Value,
OutputMilliampsLow, OutputMilliampsHigh
HFO32-35 - Analog output channel 3 configuration: Low Value, High Value,
OutputVoltsLow, OutputVoltsHigh
HFO36-39 - Analog output channel 4 configuration: Low Value, High Value,
OutputMilliampsLow, OutputMilliampsHigh
HFO41-42 - Initial and Final gross weights of a run
HFO43 - ROC noise
HFI Hardy Float Parameters (read only)
HFI0 - Gross weight
HFI1 - OP Output Percent
HFI2-5 - Analog Output setpoints, calculated from scaling HFO28-31
HFI6 - Rate of Change, not averaged
HFI7 - Total
HFI8 - Batch Total
HFI9 - Remote Setpoint Value
•
•
150 ••
•
•
Chapter 6
HFI10 - ACT (Rate of Change, heavily averaged)
IFO Rate parameters
IFO0 - Controlled variable, usually rate of change (ROC)
IFO1 - Rate Setpoint
IFO2 - PID P
IFO3 - PID I
IFO5 - RefillStartWgt
IFO6 - RefillStopWgt
IFO7 - RefillOverloadWgt
IFO8 - RefillLowShutoff
IFO9 - LowAlarmShutDownRate
IFO10 - HighAlarmShutDownRate
IFO11 - Batch Amount
IFO12 - Batch Preact
IFO13 - Manual Mode OP
WSI
WSI0 - A/D convertor raw counts
WSI1 - A/D convertor average counts
WSI2 - A/D running count
Mapping
•
•
•151
•
•
•
•
•
152 ••
•
•
Chapter 6
Chapter 7
Operation
••••••
Chapter 7 pertains to the operation of the HI 4060. This section includes instructions for
selecting Operational displays, ratio control, setting operating parameters. We recommend
that maintenance personnel and operators read and understand this chapter before operating
the controller. Make sure that all configuration and setup procedures are completed before
operating the controller.
Operational Displays on the Front Panel
There are two types of displays: Summary and
Operational. The Summary display is the large
weight readout that the user can see from a
distance. The Operational Displays appears at the
bottom of the front display.
Operational
Status Display
Weight/Rate
Summary
You can select the display to show what is useful
during an operation. For example you might want
to select the Gross Mode Display and the Rate of
Change Operational Display.
Operational
Display
Mode Display
Selecting Mode Displays from the Front Panel
Step 1. Any mode can be selected at any time. Selecting mode or operational displays will
not effect the a currently running process.
Step 2. From the Summary display press the Mode button to select the mode you want.
Mode Displays
There are five modes that can appear in the mode display area.
• The Gross Weight Mode display shows the gross
weight which includes anything put on the
permanent scale structure.
Operation
•
•
•153
•
•
•
• Amount (AMT) of weight that has been processed
since the last start when in Continuous operation
mode. When you completely stop the process this
value goes to 0.00 and begins again when you press
Start.
• Batch lists the amount of weight that has been
processed since the last start when in Batch operation
mode. When you completely stop the batch process,
this value goes to 0.00 and begins again when you
press Start.
• Actual (ACT) feed rate in weights units per unit of
time (lb/m) whether in Continuous or Batch mode.
This is a heavily averaged ROC and is indicative of
your current run rate.
• Total weight accumulated during a continuous or
batching process.
Operational displays
NOTE
Selecting operational displays will not effect the a currently running process.
There are six options for what can appear in the operations display area.
• Ingredient display lists the current selected ingredient.
• Rate of Change (ROC) display shows the change rate
in weight units/time units. This is the lightly averaged
or Raw rate of change.
• Total display shows the total amount of an ingredient
processed.
•
•
154 ••
•
•
Chapter 7
• In batching mode, the Batch display shows the actual
weight processed on the left and the rate setpoint for
the current batch on the right. In continuous mode, the
Batch amount shows the total material fed since the last
idle mode.
Idle
OP 20%
Batch
ACT
lb/m
SP
10.00
125.00/5.00
START
• Output display shows the output in percentage with
one decimal point for a finer definition of the control
activities.
5.000
Idle
OP 20%
OP
includes anything put on the permanent scale structure.
Idle
OP 20%
GROSS
MODE
8.000
ACT
SP
START
• Gross weight display shows the gross weight which
MAN
lb/m
10.00
20.0
MAN
MODE
8.000
ACT
SP
START
MAN
lb/m
10.00
11.00
MODE
Setting the Rate Setpoint
Setting the Rate Setpoint from the Front Panel
Step 1. Press the down arrow until the cursor is in front of
“Rate Setpoint.”
Step 2. Press Enter. The Rate Setpoint sub-menu appears.
Step 3. Press CLR to clear the current entry and position
the cursor on the first digit to change.
Step 4. Use the up or down arrow to select the number you want, then use the left arrow
to move to the next character, and repeat the process until you have entered all the
characters for your rate setpoint.
Step 5. Press Enter to save the new rate setpoint.
Step 6. Press the Exit button to return to the Configuration Menu.
NOTE
You can change the active setpoint from the front panel in the active state, but you cannot
change the remote setpoint from the Ingredient menu while in the Remote Setpoint state.
Operation
•
•
•155
•
•
•
Setting the Rate Setpoint from the Web Page in Idle Mode
Step 1. To open the Ingredient
Configuration page from the HI
4060 Home page, click
Configuration to display the
Configuration menu; then click
Ingredient.
Step 2. In the Rate Setpoint field, enter the
new Rate Setpoint.
Step 3. Press the Save Parameters button.
Ratio Control (Master/Slave)
Description of a Ratio Controlled System
The Host Controller monitors and/or controls the flow rate of the main ingredient
(Ingredient #1). The process requires that ingredient #2, #3, #4 etc. be fed into the main
ingredient or vessel at a certain percentage (proportion) of the flow rate of ingredient #1.
For example, if ingredient #1's flow rate is 10 gallons/minute and the process requires that
ingredient #2 be fed at 10% of the flow rate of ingredient #1; ingredient #2 must be fed at
a flow rate of 1 gallon/minute (a 10/1 ratio). However, ingredient #1's flow rate is not
constant. The rate controller for ingredient #2, must maintain the 10% proportional feed
rate no matter what the flow rate of ingredient #1 may be.
Ratio Process Control System
The Host Controller is fitted with an Analog Output Option card that generates a 0-5 VDC,
0-10 VDC, 0-20 milliamp or 4 to 20 milliamp output signal that is proportional to the actual
flow rate of ingredient #1.
The Slave Controller is fitted with a Remote Set Point Analog Input Option card to receive
a 0-5 VDC, 0-10 VDC, or 4 to 20 milliamp signal. The slave controller receives the signal
from the host and adjusts the output signal to the feeder motor to maintain a ratio of
ingredient #2.
The flow rates of all ingredients can be monitored by Host (PLC or Computer).
New desired flow rates should not be continuously transferred to the Rate Controllers over
communications. When new rate information is received, existing rate information in
memory is written over and the instrument will not enter closed loop control for a minimum
of one Time base periods plus the averages (20 averages per second).
The Timebase default is four seconds.
•
•
156 ••
•
•
Chapter 7
• The Master Ingredient is where the actual flow is measured and transmitted. A signal
•
can come from a variety of Host Controllers including a flow meter.
Different Slave ingredients can track the flow of the master ingredient. The remote set
points for slave ingredients is proportionally calculated from the rate of the master
ingredient.
Remote Set Points for Ratio Control Applications
The Remote Set Point Input enables the user to set a range that is used to receive rate set
point values from another unit's analog outputs. The Set Point parameters can be set
remotely from the Remote I/O and PROFIBUS Interface Card, but cannot be remotely set
via the serial communication.
Setting Remote Set Points for Ingredient B from the Front Panel
Selecting the Ingredient
This is an example. Your setpoint number may be different.
Step 1. To open the SP HI wgt/time edit from the Configuration menu, use the down
arrow to select Ingrd.
Step 2. Press the right arrow to scroll through the listed ingredient names, and press Enter
Setting the SP HI wgt/time
Step 1. From the Ingredient
menu, select
Remote Setpoint,
and press Enter to
display the Remote
Setpoint menu.
Step 2. Use the down arrow to select SP HI wgt/time,
then press Enter.
Step 3. Press the left or right arrow to position the cursor
and the up or down arrow to select the number.
Our example shows 25 lb/m you want for the SP
HI wgt/time.
Step 4. Press Enter to save the entry and return to the Remote Setpoint menu.
Operation
•
•
•157
•
•
•
Setting SP LO wgt/time
Step 1. To display the SP
LO wgt/time edit
form for Ingredient
B, use the down
arrow to select SP
LO wgt/time and
press Enter; then select SP LO wgt/time and press Enter
Step 2. Press CLR to clear the current entry and position the cursor on the first digit.
Step 3. To enter 1.0 pound for the SP LO wgt/time: use the up or down arrow to select the
number; then press the left arrow until the cursor is at the next character and select
the number or punctuation you want. Repeat the process above until you have
entered all the numbers for your SP LO wgt/time value. In our example we
selected 1.000 lbs/min.
Step 4. Press Enter to save the entry and return to the Remote Setpoint menu.
Setting Input HI%
Step 1. To display the Input
HI % edit form, use
the down arrow to
select Input HI %,
then press Enter.
Step 2. Press CLR to clear the current entry and position the cursor on the first digit to
enter, then use the up or down arrow to select the number you want.
Step 3. Press the left arrow to move the cursor to the next character, and use the up or
down arrow to select the number or punctuation you want. Repeat the process
above until you have entered all the numbers for your Input HI% value. In our
example we selected 100 percent.
Step 4. Press Enter to save the entry and return to the Remote Setpoint menu.
Setting Input LO%
Step 1. To display the Input LO
% edit form from the
Remote Setpoint menu,
select Input LO % and
press Enter.
Step 2. Press CLR to clear the current entry and position the cursor on the first digit to
change.
Step 3. To enter 0 for the Input LO%: Use the up or down arrow to select the number.
•
•
158 ••
•
•
Chapter 7
Step 4. Use the left arrow to move the cursor one place to the left, and use the up or down
arrow to select the number or punctuation you want. Repeat the process until
you have entered all the numbers for your Input LO% value.
Step 5. Press Enter to save the entry and return to the Remote Setpoint menu.
Setting Range
Step 1. From the Remote Setpoint menu, use the down
arrow to select Range.
Step 2. Press the right or left arrow to toggle between the
range selections.
Step 3. The range options are 0-5v, 0-10v, 0-20mA, or 4-20
mA. Our example uses 4-20 mA.
Step 4. Press Enter to save the entry.
Step 5. This completes the configuration process for Ingredient B.
Step 6. Repeat to Set the Remote Setpoint for the Next Ingredient
Setting the Remote Setpoints for Ration Control from the Web Page
Step 1. On the HI 4060 Home Page, click Configuration to display the Configuration
page.
Step 2. Click Ingredient to display the Configuration Ingredient page.
Step 3. At the top of the page click on Ingredient Name.
Step 4. If you have not created an ingredient name for Ingredient B, enter the name in the
Ingredient Filename field.
Step 5. Click on Change File to save the ingredient name.
Operation
•
•
•159
•
•
•
Step 6. If you have selected an ingredient
name for Ingredient B, click on the
“Other ingredients” pull down list.
Step 7. Click on the name you gave for
Ingredient B. In our example we
selected INGRDB.
Step 8. At the top of the page click on Remote
Setpoint to display the Remote
Setpoint page
Step 9. Enter the values we selected for
Ingredient B
Step 10. Click on the Set Parameter button to
save the Remote Setpoint parameters
for Ingredient B.
•
•
160 ••
•
•
Chapter 7
Step 11. Click on Ingredient Name to open the
displayed screen.
Step 12. On the Ingredient Name pull down list,
select the name you gave for
Ingredient B. In our example we
selected INGRDB.
Step 13. Click on Remote Setpoint to display
the Remote Setpoint Page.
Step 14. Enter the Remote Setpoint parameters
for Ingredient C.
Step 15. Press the Set Parameter button to save
the settings.
Step 16. Your Ratio Control settings are
complete.
Setting the Averaging Parameter from the Front Panel
When using any device that output an erratic signal (e.g. a flow meter). The averaging
function takes a number of input (voltage or amperage) readings and averages the input
signal to improve stability. The improvement in stability however, is at the expense of the
response time. A setting of 1 average takes 100 milliseconds. A setting of 100 averages
takes 1 second.
Step 1. When in the Remote Setpoint sub-menu
press the up or down arrow until the cursor is
in front of Remote AVG.
Step 2. Press Enter to display the Remote Setpoint
(AVG) sub-menu appears.
Step 3. Press CLR to clear the current entry.
Step 4. Press the left arrow until the cursor is at the
first character entry for the Remote
Setupoint, and use the up or down arrow to
select the number or punctuation you want.
Operation
•
•
•161
•
•
•
Step 5. Press the right arrow to move the cursor one place to the right, and repeat the
process above until you have entered all the numbers for your averaging value. In
our example we selected 4 averages.
Step 6. Press Enter. the Remote Setpoint Sub-Menu appears.
Step 7. Press the Exit button to return to the Summary Display.
Setting the Averages from the Web Page
Step 1. From the HI 4060 Home Page, click Configuration to display the Configuration
page.
Step 2. Click on Ingredient to display the Ingredient Page.
Step 3. At the top of the page click on
Remote Setpoint. The Remote
Setpoint appears.
Step 4. Click in the Remote AVE field
until the value is highlighted.
Step 5. Enter the Average value you want
for the selected ingredient. In our
example we selected 1.
Step 6. Press Set Parameter to save the
settings
•
•
162 ••
•
•
Chapter 7
Chapter 8
Troubleshooting
••••••
Chapter 8 provides procedures for troubleshooting the electrical, mechanical and firmware
elements of the HI 4060 and for using Hardy’s Integrated Technician (IT®) software utility
to isolate problems. Flow charts provide troubleshooting steps for the rate controller, load
cells, and cabling. Chapter Eight also provides
Disassembly and Reassembly Notes, Warnings and Cautions
WARNING - EXPLOSION HAZARD - DO NOT REPLACE COMPONENTS
UNLESS POWER HAS BEEN SWITCHED OFF OR AREA IS KNOWN TO BE NONHAZARDOUS.
WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT
UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE
NON-HAZARDOUS
• Always disconnect the power cord before disassembling.
• Ensure that any disassembly is done in a clean, well ventilated, properly controlled
static environment.
• Ensure that the assemblies and sub-assemblies are well supported and insulated when
doing any repairs on the HI 4060.
• Place small fasteners, connectors and electrical parts in closed containers so as not to
lose parts during reassembly.
• Read the disassembly instructions before any disassembly begins. If any of the
•
•
•
•
•
instructions for disassembly are unclear, contact Hardy Instruments, Technical Support
Department for additional information and assistance.
Do not disconnect any electrical plug, connector or terminal unless an identification tag
is present or one is attached. Always note where the connector or plug was attached to
the electrical component or wiring harness.
Always install complete hardware groups (Screws, Washers, Lock Washers, Spacers,
Etc.) back to the original point of removal.
Always replace broken or damaged modules or hardware immediately!
Always check to be sure that no loose parts are sitting on printed circuit boards or
electrical connectors or wires when disassembling or reassembling.
Always protect printed circuit boards from electrostatic discharge (ESD). Always use
approved ESD wrist straps and anti-static pads.
Troubleshooting
•
•
•163
•
•
•
• Always perform a final inspection after completing any reassembly to be sure that all
fasteners are tight, all connectors are secure and there are no loose parts on any of the
printed circuit boards in the Rate Controller.
• Always follow proper safety procedures when working on or around the Rate
Controller.
This chapter describes several tests that can shorten the time for troubleshooting. Most
problems require the use of two or more tests to determine the cause.
If a problem is isolated to a load cell, it may not mean the load cell is the damaged
component. Mechanical imbalances and system piping stress (lack of piping vibration
isolators, cables draped over pipes etc.) can make a load cell seem to be the problem.
If you are in doubt as to how to resolve a problem or if you need assistance, look for Hardy
Instruments Web-tech at http://www.hardyinst.com. Web-tech is updated often and is
available 365 days a year 24/7. It contains several frequently asked questions to aid you in
troubleshooting, and it provides a form for requesting additional information and answers
to questions, with no waiting on hold.
Customer Service is available from 6 AM to 5:30 PM Pacific Standard Time.For direct
factory support call Hardy Instruments Customer Service at:
1
2
Factory Technical Support in the US and Canada:1-800-821-5831, Ext.1757.
Technical Support outside the US and Canada:1-858-278-2900 Ext.1757.
Error Messages
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
164 ••
•
•
Chapter 8
A/D Failure Error! - Internal Electronics Error, Retry.
A/D Convert Error! - Load Cells input out of range.
Motion Error! - Check Motion Tolerance Settings and Retry
Trad Cal Error! - Error occurred during calibration, re-calibrate.
C2 Cal Error! - Error occurred during calibration, re-calibrate.
Too Lo Error! - Verify that the load cell signal level is 0-15 mV. Verify that there is
enough weight on the scale. Perform Span than go back and Zero.
Too Hi Error! - Verify that the load cell signal level is 0-15mV. Verify that there is
enough weight on the scale. Perform Span than go back and Zero.
No C2 Sensor! - Instrument did not detect a C2 Load Sensor
CAL Failed! - Too few counts between Zero and Span.
C2 Caps Unequal! - Different load cell capacities (For example 50 lbs capacity load cell
and 100 lbs capacity load cell on one system. Make the load cells even be removing the
uneven load cell and replacing it with a load cell that is equal to the others capacity.
HI/LO Too Close! - Zero and Span are not more than 1,000 counts from each other or
there is no change or negative change. Reset either so the counts are more than 1,000
counts of each other.
Function Error! - Pressed a function button and the Function did not work. Try again.
Cycle power.
Not Allowed! - Value entered is outside the range allowed. Try another value.
• Security Violation! - User signed in with a password that does not allow performance
•
•
of a certain function or entry to certain menus. Security level of the user identified in
the User ID, too low for the menu or function.
Overrange - Weight over the setpoint target.
Need Cal with ITJBOX - IT summing card is not installed. Install an IT summing card
then do a Calibration with the card installed to access the IT information.
Trouble Shooting Using Integrated Technician (IT®)
Press the Enter
(Center Button)
and arrow to Test
START
Diagnostic
Serial Number
HI 40xx Dignostic and
Troubleshooting
Firmware Rev
Weigh Vessel/SCALE
Model Number
Load Sensor
Program Number
Pass/Fail and Variance
Stability Test
ALL
Integrated Technician
Summing Junction Box
Raw A/D Count
Raw A/D Average Count
Weight
Mv/V
RTZ
MV
Weight and Voltage
ALL
IT Test
Weight
Mv/V
RTZ
MV
Sensor
Number
Audit Trail
A more detailed explanation of each section of the test follows below:
Stability Test ALL
Pass/Fail and Variance
Stability Test
ALL
Raw A/D Count
Raw A/D Average Count
Troubleshooting
•
•
•165
•
•
•
PASS/FAIL and Variance Test
This test computes the variation of the A/D counts. The results show the variance and
indicate pass or fail. The test is valid to help break down the problem into smaller divisions.
Unstable test results can be caused by an internal A/D processor fault, grounding, power
connection EMI/RFI above specified CE limits or noise to load cell input.
Raw A/D Count
These numbers reflect a weight change at the smallest measurement, the internal analog-todigital converter computer register.
Raw A/D Average Counts
These numbers also reflect weight change at the smallest measurement, the internal analogto-digital converter computer register - except that this reading is averaged using the
AVERAGES setting parameter from the controller’s configuration. Using the maximum
number of internal averages and the 10ms update equals a maximum delay of 2.55 seconds
Weight and Voltage ALL
This test section looks at the readings from ALL the load cells to test overall system
performance and signal voltage readings. This test works for all varieties of load cell
connection systems.
Further investigation to
isolate system problems
requires the use of hand
tools and multi-meters or
the Integrated Technician
Summing Junction Box
and using the IT© Test
section.
NOTE
Weight
Mv/V
RTZ
MV
Weight and Voltage
ALL
IT ®is a registered trademark of Hardy Instruments Inc.
Weight This displays the amount of force seen by all load cells installed in the summing
junction box. Further investigation to isolate system problems will require the use of hand
tools and Multi-meters or the Integrated Summing Junction box and using the IT test
section.
mV/V and mV DC voltage signals are between 0-15 millivolts. Overloads and negative
millivolt readings are not shown as actual readings but 15.3 for over voltage and 0.0 for
negative voltage. You will need to use a multimeter with a 200 or 300mVDC range to view
the out of range voltages. Millivolt/Volt equals the output from a load cell per each volt of
excitation. The HI 4060 reads the load cell output in mV/V which is a higher resolution (4
decimal places) reading than a mV reading, thereby providing more sensitivity to enable
you to troubleshoot the condition of the load cell in question under certain conditions. Load
Cells are rated in Millivolts/Volts.
•
•
166 ••
•
•
Chapter 8
RTZ (Return to Zero) Test
Run this test only when the scale is empty. When the scale is calibrated at the ZERO or
Reference zero, there is a WAIT period during which the WEIGHT readings are collected.
After a valid calibration has been completed, the test compares the original weight reading
with collected and current readings. If the difference is more than the combined Motion and
the Zero Tolerance parameters the test will fail.
IT Test
IT Test
Weight
Mv/V
RTZ
MV
Sensor
Number
If your system has an Integrated Technician Summing Junction box, the IT test can help
identify individual load cell problems up to a maximum of four load cell selections.
Sensor Number Indicates which sensor is under test. Using the up or down arrow selects
the target sensor to be tested.
Weight Displays the force seen by a selected load cell. This force can show an imbalance
or weight distribution problem. Review your system to insure proper balance. Motors can
account for this problem. Piping should not apply any appreciable force on the scale.
Mv/V and MV DC voltage signals are between 0 and 15 millivolts. Overloads and
negative millivolt readings are not shown as actual readings, but 15.3 for over voltage and
0.0 for negative voltage. You need to use a multi-meter with a 200 or 300mV range to view
the out of range voltages.
RTZ (Return to Zero) Test
Run this test only when the scale is empty. When the scale is calibrated at the ZERO or
Reference zero there is a WAIT period. During this WAIT period the WEIGHT readings
are collected for each load point. When this test is run, after a valid calibration has been
completed, there is a comparison of the original weight reading collected and current. If the
difference exceeds the combined Motion and the Zero Tolerance parameters the test fails.
Use this test to determine which load cell is malfunctioning in a drifting weight problem.
NOTE
Warning: Do not install your HI 215IT summing board in areas susceptible to high
vibrations. The relays on the board can chatter and affect your weight readings.
Troubleshooting
•
•
•167
•
•
•
Audit Trail
A list of parameters and successful calibration
events is logged into the audit trail section. Event
listings are formatted with a time and date stamp.
Log entries cannot be erased and are stored in the
Secure Memory Module.
Audit Trail
General Troubleshooting Flow Chart Index
•
•
168 ••
•
•
Chapter 8
Drifting or unstable weight readings
A
Electrical, Mechanical and
Configuration reviews
B
Drifting or unstable weight readings
C
Weight indication will not return to
zero
E
Verify individual load sensor operation
F
Trad. Cal - A/D Failure Error
G
Mechanical Inspection
H
Electrical Inspection
J
Load Sensor Installation
K
Exceeds the Millivolt range.
Out of range condition.
M
Blank Display
N
SD Card Diagnostics and losing
memory at power cycles
P
A - Guidelines for Instabilities on Formerly Operating Systems
A
Press the ENTER Button and arrow to the TEST
prompt and press ENTER.
Select the Stability Test and press ENTER
This is a Pass or
Fail test with the
Variance displayed.
The variance is the
difference between
the low and high
counts over 100
readings.
Monitor the Test
results
PASS?
A1
No
Yes
Verify wiring and connectors
are solid and clean
EXIT to the
Summary Display
Monitor the
display for stability
No
STABLE?
Yes
No
Replace IT summing
card
STABLE?
Yes
Cont.
C
Yes
STABLE?
No
B1
Troubleshooting
•
•
•169
•
•
•
A1 - Guidelines for Instabilities on Formerly Operating System (Cont’d)
A1
UNSTABLE RATE CONTROLLER
Disconnect external signal cables and
shields, except AC Power
Monitor the Display
for stability
Yes
STABLE?
Reconnect signal
cables one at a
time
No
Problem could be in
the instrument. Contact
Hardy Customer Support
PH: 800-821-5831
Monitor the
display for stability
If installing any cable causes
unstable readings
REVIEW TROUBLESHOOTING
SECTION B: B1.1-B1.7
•
•
170 ••
•
•
Chapter 8
Go to
B
B - Guidelines for Instabilities on Formerly Operating Systems (Cont’d)
B
Check for
Electrical Stability
OK?
No
B1
No
B2
No
B3
Yes
Check for
Mechanical Stability
OK?
Yes
Check Configuration
settings for
stability
OK?
Yes
Go To
A
Stability
Troubleshooting
•
•
•171
•
•
•
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d)
B1
B1.1
B1.2
Physical Grounding All common equipment share a common ground point.
Keep the ground cable length to earth ground as short as possible.
Install a new ground rod if the cable length is excessive.
Cable Cuts or breaks in the load cell insulation allow moisture to wick into the
cable and load points. This can setup stray capacitance charges and allow
ground currents to exist. This could create a highly intermittent situation.
B1.3
Vessel, Fill and discharge piping Ground all to a common point to eliminate electrical differences in potential
and static build-up.
B1.4
Load Cells Ground straps must be installed to provide a direct discharge path to ground
around the load points.
B1.5
Cable Routing Separate high voltage sources and cables form low voltage signal cables.
Stay a minimum of 14 inches from magnetic fields and SCR controls.
Avoid parallel high voltage and signal cable runs.
B1.6
B1.7
•
•
172 ••
•
•
Electrical
Chapter 8
Cable Shielding Ground low voltage cable shields only at the controller end.
Grounding both cable ends produce ground currents.
Verify, with and ohm meter, the shield is only grounded at the rate controller.
Disconnect eh shield at the controller and check for an open circuit between ground
and shield. Reconnect the shield to ground and confirm a proper ground path from
the IT Junction box to the controller.
Verify the shield is not connected to ground at the IT Junction Box.
Load cell shields only pass thru the IT Junction boxes and are not connected
ground at that pont.
Rate Controller - Common AC ground and Chassis grounds.
Go to
B
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d)
B1
B2
OK?
No
Vessel When inspecting a vessel, keep in mind the Center of Gravity (COG)
should be low and centered equally over all the load cells.
Insure the load is directly over or under the load point to avoid side-loading.
Make sure there isn’t any side loading from piping or external forces.
Install flexures on all piping to insure a free floating vessel.
Make sure the vessel and load cell mounts are mechanically stable and
fixed.
Large changes in individual load cells indicate a shift in the COG or
faulty load cells.
Piping and motors can effect the individual load cell readings.
Allow for a higher reading on load cells that support motors and piping.
Insure pneumatic lines are not applying pressure to the vessel when
energized.
Yes
Use check (stay) rods to minimize vessel movement.
Make sure the check rods are loose and not interacting with the vessel.
Power down all vibration, vacuum and pressurization equipment during the
test process.
Configuration Settings
B3
OK?
No
Incorrect WAVERSAVER settings can cause unstable weight readings.
Adjust to the lowest WS setting that gives you a stable reading.
Higher frequencies with low amplitude vibrations - Use WS settings 1 or 2
Lower frequencies with high amplitude vibrations - Use WS setting 3 or higher
Incorrect number of decimal places. Reading weight increments beyond the
equipment applications level. (Sed Guideline Calculations below)
Yes
Repeatability Divide the total load cell capacity, including decimal points by 10,000.
(Expected stable weight reading)
Resolution Divide the total load cell capacity, including decimals points by 30,000.
(The amount you can expect to see but not necessarily stable
Return to
A
STABILITY
C
Troubleshooting
•
•
•173
•
•
•
C - Guidelines for Instabilities on Formerly Operating Systems
C
Weight
Mv/V
RTZ
MV
Weight and Voltage
ALL
IT Test
Weight
Mv/V
RTZ
MV
At the IT Junction Box
Remove and Replace
the load sensor(s) determined to be faulty.
Sensor
Number
No
Yes
STABLE?
STABLE?
No
Replace summing card
Re-install all load
sensors
Yes
TEST
COMPLETE
Yes
STABLE?
No
If you are unable to isolate the instability:
Compare your results by testing the vessel when empty
and then re-testing under load.
Go to B for additional system checks
Or
Contact Hardy Instruments
Customer Support
PH: 800-821-5831
•
•
174 ••
•
•
Chapter 8
E - Non-Return to Zero (Must be connected to an IT® Summing Box
NOTE
Return to Zero is run during the Weight and Voltage tests.
Review the individual
sensor values for out of
range or non-performance
LS1?
Yes
ERROR? Check load sensor ONE
Yes
ERROR? Check load sensorTWO
No
LS2?
F
No
LS3?
Yes
ERROR? Check load sensor THREE
Yes
ERROR? Check load sensor FOUR
No
LS4?
No
TEST COMPLETE
Additional Testing Suggestions
Verify cable connections and cable integrity.
REVIEW TROUBLESHOOTING SECTION
F Individual load cell Millivolt readings
A Verify Sensor readings are stable
B Electrical and Mechanical Guidelines
F - Verify Individual Load Cell Millivolt Readings
Testing an individual load cell signal output requires an IT Summing Junction box or
millivolt meter.
Use the load cell certificate to verify the millivolt per volt (mV/V) rating:
Example: 3mV/V load cells produce approximately 15mV at full load. That is 5 volts
excitation x 3 mV/V. A scale capacity of 1,000 lbs. with 100 lbs. of deadload when
empty, the load point mV reading should measure 1.5mV.
Troubleshooting
•
•
•175
•
•
•
.
F
Press ENTER and arrow to
TEST menu and run
ITECH TEST Program
Select
IT
TEST MV
Zero mV
reading
IT TEST Checks
individual load
sensor output
mV readings
Press ENTER
to check load
sensor
Record load
sensor mV output
level for
comparison
High mV
reading
mV
readings
acceptable?
Yes
TEST COMPLETE
Chapter 8
1) Stressed load cell, remove
all load and re-test.
2) Excessive loading
For additional
testing go to:
H
No
Repeat for all load
sensors
•
•
176 ••
•
•
1) No dead load
Apply load and re-test.
2) Wiring error
Verify color code using the
load cell certificate
3) Open bridge circuit
Disconnect power and verify
load point bridge resistance
reading with an Ohmmeter
High mV
reading
K
Unstable
reading
A
Defective load Cell
Replace and repeat
TEST F
G - Calibration Failed: Not Enough Counts Between ZERO and SPAN
• This error only occurs at the SPAN parameter. You may ZERO out chains and
temporary calibration equipment to hold or hoist test weights. Zeroing the temporary
weight does not effect the calibration.
G
The difference between zero and span is less than 1000
counts
Using the IT Test or a millivolt meter:
Verify the Signal Millivolt reading is positive and within
the acceptable range of 0 to 15mV.
Verify when weight is applied there is a positive increase
in the signal millivolt readings.
Compression load cells can be installed upside down
refer to the load cell installation guide for proper
installation.
Check mechanical binding that restricts the vessel
movement under load.
Verify the load cell wiring is correct.
Check that each load cell signal changes under load. A
single load cell installed upside down or wired
backwards can algebraically reduce the total signal.
SPAN WEIGHT to Small
1000 counts out of 985,000 is very small.
(100,000 lb. Scale would require a minimum of 101 lbs.
yes
no
ERROR?
Contact
Hardy Instruments
Customer Service
800-321-5831
Ext. 1757
PROCEED
WITH
CALIBRATION
Troubleshooting
•
•
•177
•
•
•
H - Mechanical Inspection
H
(a) You weigh the output valve, not the input valve
(b) Does the weight scale see all the product to be
weighed?
(c) If the product applies a force to a valve or pipe, that
pipe or valve must be included in the weight vessel.
(d) Proper position of the flexures are key
(e) Your vessel must seem to float.
All pipes and conduits
flexible
H2
Mechanically isolated
from ladders and
connecting structures?
H3
Are the load cells
properly mounted?
1)
2)
3)
4)
H4
Are check rods
installed to dampen
vessel movement?
1) Protects the load cells from overload and impact forces
2) Limits the movement of the vessel
3) Rods must be loose and not interact with the vessel
H5
Are cables routed
properly?
Housekeeping
To
Verify Electrical
go to
J
Chapter 8
Keep flexures on the horizontal
Vertical flexures should be avoided
Do not use flexures to correct for misaligned piping
Do not use hose flexures to make right angle bends
Non-flexed piping should have an unsupported
horizontal run using a ratio of 36 times it’s diameter
6) Pipe flexure lengths should be a ratio of 6 times it’s diameter
7) Feed and discharge piping flexed
8) Are the flex joints on the correct side of the valve?
H1
H6
•
•
178 ••
•
•
1)
2)
3)
4)
5)
1) Floors or structure does not interact
2) Local traffic does not interact
3) Protected from forklifts and adjacent processing
equipment.
Level, solid mounting base
The load cell is mounted right side up
All load cell bolts installed using anti-seize compounds
Mechanically aligned to compensate for expansion and
contraction
1)
2)
3)
4)
5)
Separate conduit for low and high voltage cables
Do not bundle low voltage with high voltage cables
Maintain at least 3 inches of separation
Maintain 14” separation from magnetic fields and 440 VAC
Cables are in conduit or tied up and protected from damage
1)
2)
3)
4)
Product, tools and production aids are off the vessel.
No workers are physically on the scale
Must protect equipment from environmental damage
Insure openings are sealed to keep water and environmental
contaminates from damaging
(a) Instrument cabinet or enclosure
(b) Summing card
(c) Load Cells
(d) Conduit runs
(e) Covers properly installed
J - Electrical Inspection
J
J1
Verify the proper voltage
level has been supplied
J2
Apply power to the
controller only if supply
voltage is correct
J3
Does the scale reflect
a weight change?
J4
Cabling
To Verify Proper Load Cell
Operations Go to
K
DO NOT POWER UP THE CONTROLLER UNTIL
INPUT VOLTAGES CAN BE VERIFIED
1)
2)
3)
4)
5)
6)
7)
Verify the proper input power, AC or DC, is properly installed
Use a meter to verify neutral, ground and hot are correct
Computer grade power
Use Active filters for motor noises and spikes
Use isolation transformers to combat surges and sags
Isolated from SCR and motor control circuits
Use a Common earth ground.
(a) Keep ground cable runs as short as possible
(b) Excessive ground cable runs can act as an antenna
for AC noise
(c) Install grounding straps around load cells to direct
static away from the load cell and directly to ground
(d) Install ground straps on the input and discharge
piping and the vessel to a common earth ground
1) Verify the front display illuminates
2) Completes the initialization process
3) Displays a weight reading. This weight value will not be
correct if a calibration procedure was not performed
1) Press the MODE button to display NET weight
2) Press the TARE button to ZERO the NET weight
3) Apply weight to the vessel
(a) Does the weight increase and decrease in the
correct direction with the weight?
(b) Does the weight return to ZERO NET?
(c) The weight value will not be correct until a proper
calibration is complete
1) Use the load cell certificate, manuals or drawings to verify the
load cell color code. Input = Excitation, Output = Signal
2) Shielding
(a) Grounded only at the rate controller
(b) Continuous shield connection from the load cell cable
to the controller. Single point EMI/RFI drain
(c) Terminated but not grounded at the summing box
3) Sense lines installed?
(A) Jumpers or sense lines in the J1 connector?
(B) Sense lines must be installed for C2 or Softcal
calibration
4) Use IT TEST to verify readings
Troubleshooting
•
•
•179
•
•
•
K - Load Sharing and Load Sensor Checkout
K
K1
Load Cell wiring is
complete and
correct?
K2
Multiple load cells
MAP the mV reading.
Balance the load
1) Does the mV signal increase in a positive direction
2) If you receive a negative result, check if load cell is
mounted correctly.
(a) The arrow goes with the direction of force
(b) If there isn’t an arrow, you must manually verify
the correct direction. A negative reading
indicates the load cell is upside down
(c) Load cells in tension will not reflect a negative
reading if installed upside down. If upside down,
only the force applied by the cable will be included
in the weight reading
(d) If you are still receiving a negative signal, verify
load cell wire color code
1) Verify a positive mV reading from each load sensor using
IT TEST, mV
2) Record the mV reading and compare each corner for
proper load sharing
(a) For proper load sharing you should see only a difference
of +/- .5mV
(b) Larger differences due to motors and piping
should not exceed +/- 2mV
(c) If there aren’t any motors, valves or piping to explain
the mV difference, adjust the corners and balance
the mV readings
(d) Use shims or if equipped adjusting bolts on the load
cell mounting hardware
(e) Drawing a load cell map helps determine the correct
leg to adjust and in which direction
Three load cells balance like a three legged chair
1) Using a spirit level, verify the vessel is vertically and
horizontally correct
2) Verify if any height change effects the attitude of adjacent
vessels or piping
3) Adjust each leg to dynamically match mV outputs
4) Verify the mV readings and physical level when complete
Four or more load cells present a challenge
Monitor system for proper
operation
Check out completely
•
•
180 ••
•
•
Chapter 8
1) Use the Weight and Voltage test to determine the sum of the
load cell signals to set your target mV reading for each load
cell
2) Read the output of individual load cells
3) Adjust the load cell with the lowest reading to dynamically
match the target mV readings obtained in Step 1
4) Read the mV readings from each load cell to verify a proper
correction
5) Repeat steps 3 and 4 to achieve a proper load sharing vessel
6) Verify the mV readings and vessel level when complete
M - (*******) or (- - - - - - -) ERROR
M
- - - - - - - or * * * * * *
The load sensor output signal has exceeded the
millivolt limits set in Configuration and/or the internal
factory setting.
1) Verify the signal wires are properly connected
(a) Verify load cell cable color code
(1) Load Cell Certificate
(2) Installation Manual
(3) Cable marking strips
(b) Broken signal wires act as antenna for EMI/RFI
(c) Load cell cable shields must be grounded only at the
Weight controller to dampen EMI/RFI signals
2) The load cell output signal voltage has exceeded 15mVDC or
is negative
(a) Use IT Test to verify mV levels
(1) Verify total millivolt signal level
(2) Verify individual load cell millivolt signals
a) An individual load cell may be over-ranged
and exhibit high millivolt readings
b) Possible physical damage to the load cell
c) Internal strain gauge bond broken
d) Moisture in the load cell cable or body
3) Weight in the hopper exceeds the configured Scale
Capacity setting
(a) Under configuration verify the Scale Capacity setting
(b) 9 divisions with division size based on the certification mode selected
NTEP MODE: 1 DIV Scale capacity/10,000
CANADIAN MODE: 1 DIV Scale capacity/3,000
(c) This is used only as a warning and does not effect
calibration
(d) Optional communication signals are unaffected by this
indication
4) Weight in the hopper exceeds the load cell capacity
(a) Mechanical forces or product acting on the scale
overloads the load cells
(b) Use IT TEST to verify Millivolt levels
5) Review Mechanical and Electrical Flow charts for additional
tips. B1
yes
Contact
Hardy Instruments
Customer Service
800-321-5831
HI
ERROR?
no
PROCEED WITH
WEIGHING
PROCESS
Troubleshooting
•
•
•181
•
•
•
N - Rate Controller’s Front Display is Blank
N
Measure AC or
DC Power, OK?
No
1) Check for proper power
and the source connection
2) Check the circuit breaker at
the source
Yes
Measure
excitation
voltage,
5 VDC?
No
Disconnect all the
connectors from the
back panel except
power
Yes
Contact
Hardy Instruments
Customer Service
800-821-5831
Yes
1) Reconnect the jacks one
at a time checking the 5VDC
excitation.
2) If reconnecting any jack
effects the 5VDC, check for
wiring errors.
Display OK
Monitor system for proper
operation
Check out completely
•
•
182 ••
•
•
Chapter 8
Measure
excitation
voltage,
5 VDC?
No
No
Contact
Hardy Instruments
Customer Service
800-821-5831
P - SD Card Diagnostics and Losing Memory at Power Cycles
P
Power Down then Power Up
Able to
Change Screen?
Yes
No
Remove all Connectors
Other than Power Connector
Able to
Change Screen?
Yes
No
Remove the SD card, cycle power.
Without the SD card, the instrument
should boot with factory default
configuration
Able to
Change Screen?
Yes
No
PROBLEM SOLVED
With SD Card installed Use the
EtherNet I/P port and a computer,
to enter the Operations Diagnostics,
SD CARD read Params selection
Parameters
intact?
Yes
Yes
Select: SAVE and
EXIT, then
cycle power
No
Contact Hardy Instruments
Customer Service for additional
instructions and possible return
for repair
Troubleshooting
•
•
•183
•
•
•
Erratic Weight or Rate Control
This section explains how to resolve problems relating to rate and Rate of Change (ROC)
calculation, Rate Exception Control (REC), motor speed control, and weight calibration.
1
Rate calculations
a
Rate calculations are no better than the scale’s calibration accuracy. Verify the
scale calibration using test weights.
b
Follow the weight troubleshooting flow charts and correct any equipment
binding, rubbing, and piping problems.
c
After an initial rate calibration on a new system, repeat the calibration several
times to ensure consistency, and verify that calibration using the posted
weight loss over time.
d
If the rate displayed does not match your test samples:
(1) Re-calibrate the weight and then the rate.
(2) Review the troubleshooting tips for mechanical influences relating to the
feeder mechanism
(3) Look for leaks in the delivery system or refill gate.
e
If the system is slow to change rate (or weight) readings.
(1) Adjust the number of averages setting.
(2)
Adjust the WAVERSAVER setting.
(3) See 4 below.
f
Look for a systematic and consistent weight loss. Determine what a stable rate
should be. If the weight displayed on the monitor continuously falls and rises
and you never get a stable rate or symmetrical weight loss pattern:
(1) The rate may be too slow for the load call capacity.
(2) The material may be bridging or liquefying and basically inconsistent.
(3) The feeder motor may be feeding too fast, mechanisms may be damaged, or
working conditions may not be right.
2
ROC calculation
The ROC reading does not necessarily indicate a smooth weight loss. The amount of ROC
control required depends on the material currently being fed.
•
•
184 ••
•
•
Chapter 8
a
Since ROC calculations are developed from the weight reading, the weight
reading must be correct.
b
The Loss In Weight (LIW) ratio is calculated from the total scale load cell
capacity. If an LIW rate error greatly exceeds the weighing error:
(1) Add decimal points up to 1 part in 50,000 to help determine the ROC.
(2) Balance the WAVERSAVER setting and averages.
3
Motor speed control output signal
a
If the motor speed control output signal indicates a problem, but the voltage
and current levels measured on the terminals is correct:
(1) Adjust the OP% out in manual mode.
(2) In the ON condition, verify that the output signal matches the percentage
of full range. For example: 50% of a 0-10V signal should read 5 VDC at
the analog out terminal.
(3) Adjust the WAVERSAVER setting and averages.
b
NOTE
If the output is properly wired back to the motor speed controller, verify that
the Option parameters for that analog out are set correctly and that the HI
4060 analog signal is reaching the corrected controller terminals.
Hardy Instruments Inc. does not provide motor speed control converters. Consult
the motor speed controller manufacturer’s manual for troubleshooting and
settings.
4
REC +/- settings
a
The rate exception control display indicates whether the controller is running
within the requested range. If an out-of-range rate does not correct itself in the
REC time allowed, the RE+ is displayed to indicate the direction. While this may
indicate that the rate is too small for the scale’s accuracy or resolution, the reading
can be used to determine the effect of parameter and mechanical adjustments on
improving the material flow control.
b
The visual indicator does not activate corrective action, but during auto rate calibration the PI settings are adjusted to optimize the flow rate for your feeder settings
and material. The display shows the speed of oscillation and can be used to view
the effect of correction or adjustments to the PI settings.
(1) P = 0-100% correction factor. P determines the amount of action or
reaction that is made in response to an out-of-range rate indication
(2) I = the speed of that action/reaction. This value normally requires only a
small adjustment. (0.2 increments) If the rate is always high, reduce the
I. If it is always low, increase I.
5
The feeder fails to stop in HOLD, STOP or IDLE
a
Determine whether the motor speed control goes to the low setting.
(1) Verify with a multimeter.
Troubleshooting
•
•
•185
•
•
•
(2) Follow the speed control manufacturer’s troubleshooting guide(s) to
determine the malfunction.
(3) Verify that the Analog out is returning to the low parameter setting as set
in the Options menu for that analog out channel.
NOTE
Send a Stop or Hold signal when a stop condition occurs. Do not rely on the analog signal
to stop the feeder.
Tests and Diagnostics
The Test and Diagnostics menus provide an expanded view of how the rate controller and
scale are working. For example, for the last calibration, you can see the type of calibration
and when it was done. You can also check the graduation size, operator ID, and other
configuration information.
You can run several tests from either the test links on the Web Diagnostic page or the front
panel Test menu. Each test is described in its own subsection below. You can also learn the
serial number, model number, firmware revision number, and other information you may
want to record. A Hardy representative may ask for this information if you make a request
to Technical Support.
Diagnostic testing from the Web page
Select Operation on the
Home Page to open the
Operation - Choose One
menu.
Select Diagnostics to
open the OperationDiagnostics page.
While the page provides
serial number, model
number, firmware
revision number, etc. the
tests and related options
are listed as hypertext
links at the bottom of the
page.
•
•
186 ••
•
•
Chapter 8
Front panel test menu
From the Configuration
menu, use the down arrow
to select Test and press
Enter to open the Test
Menu.
The test menu not only lists the tests you can run, it also lists the same read-only options as
the Web-interface Operation-Diagnostics page, including serial, model, and firmware
revision numbers, etc.
Use the down arrow to read
the informtion. If an arrow
follows the options, press
Enter to see the display.
ProgPn# = Program Part
Number. This is the part
number of the firmware. To
see the entire part number,
select ProgPN and press
Enter.
NOTES
The values entered in the Test Menu are for illustration purposes only. Your values will vary.
To download the latest firmware version, see the HI 4060/Downloads site at:
http://www.hardyinst.com/4000_support/downloads/4000downloads.php.
Parameters
Parameters is the first listed hyperlink at the base of the OperationDiagnostics page. Click that link to
display the Parameters page. Note
the scroll bar on the right of the list.
The steps below explain how you can
duplicate the configuration of one HI
4060 either to use in configuring
another HI 4060 or for sending a
copy of your parameters to
[email protected]
To copy the parameters:
Step 1. Right click in the
parameter list.
Troubleshooting
•
•
•187
•
•
•
Step 2. Click Select All.
Step 3. Right click again.
Step 4. Click Copy.
To paste the parameter configuration into the instrument you want to configure:
Step 1. Enter the IP address of that instrument into a Web browser to display its Home
page.
Step 2. Select Operation, then Diagnostics, then Parameters, as described above.
Step 3. Right Click in the Parameter list.
Step 4. Click Select All.
Step 5. Right click again in the Parameter List.
Step 6. Click on Paste to replace the existing or default parameter settings with the
parameters settings of the instrument you copied.
Step 7. Click the Save button. You now have an exact duplicate of the pre configured
instrument.
If you need to make any modifications to the parameter settings go to Chapter 4 Configuration for more instructions.
Note the Other Parameter IDs hyperlink at the top of the parameters list. To view all the
other parameter settings, click that link.
•
•
188 ••
•
•
Chapter 8
System and Load Cell Tests
Overview of Typical Load Cell System
The typical load cell system consists of one or more load cells/points, a summing junction
box, and an HI 4060 Rate Controller.
Load Cell/Sensor/Point - is a strain gauge based force transducer that generates an
electrical signal proportional to the load applied to the scale. Tension or compression type
load cells/points can be used to measure pressure, load, or torque.
UNIVERSAL JOINT
OR
HOSE
USE SYMMETRIC BEAM LOADED
THROUGH SHEAR CENTER TO
AVOID TWIST WITH LOAD
JUNCTION
BOX
HI 4060
Rate Controller
INTERMEDIATE SUPPORT FRAME
FULLY CONSTRAINED
LATERALLY WITH STAY RODS
BIN ACTIVATOR
NON METALLIC EXPANSION
ASSEMBLY OR HOSE
The load cell/point takes as an input the 5 volts DC Excitation Voltage generated by the HI
4060. It generates a millivolt output proportional to the weight on the scale (0-10mv DC for
2mv/V load cells/points or 0-15mv DC for 3mv/V load cells/points).
Rate Controller - is the part of the HI 4060 instrument that, among other functions:
•
•
•
Powers the load cell(s)/point(s)
Reads the millivolt signal output from the load cell(s)/point(s)
Digitizes, interprets, communicates and displays the results in terms of weight
Troubleshooting
•
•
•189
•
•
•
INTEGRATED TECHNICIAN (IT®)
INTEGRATED TECHNICIAN (IT®) is an optional diagnostics utility that enables the
operator to rapidly troubleshoot the individual load cells in a weighing system from either
the front panel or Web interface. The option requires an HI 215IT Summing junction box,
which provides separate inputs for each load cell.
If you have more than one load cell without the HI 215IT Summing junction box, there is
no way to isolate the load cell signals. The system can return either an average numerical
value or a PASS/ FAIL value for the test. If any load cell fails, the test will fail without
identifying the problem load cell
If you have more than one
load cell with the HI 215IT
Summing junction box, the
system can provide both the
average numerical values
and values specific to each
load cell, with PASS/ FAIL
values by load cell. The
number for a load sensor is
based on the connections in
the IT junction box.
Check the installation sequence in the box to determine which load sensor is number 1, 2
and so on.
If you do not have the optional IT junction box, some of the options described below will
not appear on either interface.
NOTE
Warning: Do not install your HI 215IT summing board in areas that are susceptible to high
vibrations since the relays on the summing board can “chatter” and affect your weight
readings.
Running the IT test from the Web interface
The IT Web page shows all the weight
and voltage values at once, so it is the
preferred way to view the test results.
If the IT option is installed on your
system, click “Do IT Test on the
Operation - Diagnostics page. If more
than one load sensor is connected, the
display will show them all, as shown
above.
Running the IT test from the front panel
Step 1. From the Test menu, select Weights and Voltages.
•
•
190 ••
•
•
Chapter 8
Step 2. Select IT Test
and press Enter
to list the
sensors, then
select the sensor
to test.
Step 3. Press Enter to
display that
sensor’s test
readings.
Step 4. To read the test
results press the
down arrow.
Step 5. Press Exit to return to the Sensor Menu. If you want to test other load sensors
select the sensor and repeat steps 1 through 5 above. Otherwise press Exit again
to return to the It Test Menu., and press Exit again to return to the Test Menu.
Understanding the Tests
To determine if an instrument or cabling problem exists, verify the basic operation of the
system by performing the following system checks.
Stability Test
The Stability test lets you check the A/D Raw count and average. With the IT option, it tests
and reports for each load cell. The Stability test switches a fixed signal into the analog-todigital convertor and calculates the mean squared variation from the average reading, using
100 samples. The test passes if the mean squared variation is less than 5.0.
If the weighing system passes the stability test, the results show OK and the variation and
mean results are posted.
FAIL indicates that the Mean Squared Variation is greater than 5.0, so the instrument is
considered unstable. In that case, see the Troubleshooting Flow Charts Section.
CAUTION
Do not perform the Stability Test during production. The test activities can cause
incorrect readings.
Running the Stability Test from the front panel
Step 1. From the Test menu, select Stability Test with use the down arrow and press Enter.
The HI 4060 runs the test and shows the results.
Troubleshooting
•
•
•191
•
•
•
Step 2. To see the AD/Raw Count and the A/D Average
select them from the menu.
Step 3. Press Exit to return to the Test Menu.
Running the Stability Test from the Web Interface
Select Stability Test at the bottom of the Operation-Diagnostics page. The instrument will
run the test and post the results after a few seconds.
Weight and Voltage Test
The Weight and Voltage tests are used to diagnose a weighing system and, if certain types
of problems are indicated, determine their source. It provides the total scale input to the
instrument such as mV, mV/V and Weight in the units selected (i.e. lbs, kg, oz, g).
Running the IT test will show the weight and voltage results for each load sensor, including
the following values:
Weight: Weight value recorded on the sensor
mV and mV/V: mV is a coarser reading than the mV/V or Weight readings. The mV
reading is sufficient to balance the corners of your scale or vessel. These readings allow you
to determine if the problem is in the instrument (internal) or in a load sensor(s) (external).
The normal specification range for the Rate Controller is 0-15 mV. Readings outside this
range (15.5 mV, 3.1 mV/V Maximum or any negative values), indicate an external problem.
(most likely improper wiring).
When you check the results, if all the load sensors read 0.00, something is probably wrong
between the HI 4060 and the HI 215IT junction box, e.g., the cable may be disconnected.
Something could also be causing the box to not transmit the readings to the HI 4060.
If you get no reading for one or possibly two or more load sensors (e.g., Sensor 3 reads 0.00
or the reading is larger or smaller than it should be) and you know that the sensors are
connected to the junction box, either the load sensor is malfunctioning or its cable to the
junction box is loose or miswired.
•
•
192 ••
•
•
Chapter 8
Running the Weight and Voltage Test from the Web interface
Click on Weight and Voltage to open the
Operation/Diagnostics - Weight & Voltage page, shown
below.
Running the Weight and Voltage Test from the front panel
Step 4. Select Weight
and Voltage and
press Enter to
run the test and
view results.
Step 5. To read the rest of the results, press the down
arrow. The weight and voltage/reading raw
counts and average are shown to the right.
Directory
The Directory contains the list of the ingredient files saved to non-volatile memory. The
filenames of ingredient files have .ing extensions. Files with other extensions may be listed,
but only the .ing files are ingredient files.
Step 1. From the Test
menu, select
Directory and
press Enter to
list the ingredient filenames.
Step 2. Press the right or left arrow to see the entire list.
Step 3. Press Exit to return to the Test Menu.
Troubleshooting
•
•
•193
•
•
•
Checking Inputs and (Optional) Outputs
The I/O test option, listed on the bottom
of the Operations - Diagnostics page,
allows you to see which inputs (user
switches) or outputs are operating by
clicking on I/O.
Click I/O to display the Input and
Output page.
If an input or output is in use, the I/O
reads 1.
If an Input or Output is not in use, the
I/O reads 0. In our example none of
the inputs are being used so they all
read 0. (To return to the Diagnostics
page click on the back arrow.)
Viewing System C2 Load Sensors
This test tells you how many C2 load cells are in use. You can also learn the version, serial
number, output resistance, output voltage, and capacity for a selected C2 load sensor. The
serial number is important if you need to contact Hardy Instruments Technical Support. You
do not need an IT summing box.
Step 1. Click C2 at the bottom of the
Operation - Diagnostics page
to open the Operation - Diagnostics
C2 Data page. This page shows the
number of C2 load sensors that are
found in the weighing system. The
default sensor information is for the
first load sensor to respond.
NOTE
The information on this page is C2 load sensor data only. It does not refer to any position
on the IT Junction box, nor does it tell you the operating condition of the load sensor. To
determine the load sensor’s condition and position, use the Weight and Voltage/IT Test.
Step 2. On the Read Data from pull-down list, select the C2 load sensor to view; then
click Read Sensor to display for that sensor. Our example shows only one C2
sensor found. If no C2 load sensors are installed, “C2 Sensors Found” will read 0.
•
•
194 ••
•
•
Chapter 8
Step 3. Click on the back arrow to return to the Diagnostics page.
Viewing the SMM-SD Card
If your computer has an SD card reader you
can read and modify the contents of the base
(PARAMS.TXT) files on the SD Card page.
Click the SD Card link to open the page
It shows the Write Protect status and lists the
base directory with the files where the nonvolatile memory is located for the HI 4060.
The Read Param File button invokes a
reading of the parameters file, which
updates the system based on the current content of that file.
If you type in a filename, including the suffix, and click the Delete File? button, the file will
be deleted.
NOTE
Warning: Random file deletion from the SD Card Directory can result in lost audit logs or
damage to your system configuration. Do not use the Delete function unless you know that
the file you want to delete currently has no vital system function. There is storage for more
than 100 ingredient files.
Event Log
The event log lists the time and
date of power-up events.
Click the Event Log link at the
bottom of the Operation Diagnostics page to display the
read-only log.
Troubleshooting
•
•
•195
•
•
•
Using the Ping Tool to Test the Network Connections and Configuration
The Ping Tool is used from the Start > Run of the PC.
Selecting the module by number for ping testing
NOTE
You can only ping from the PC you cannot ping from an instrument.
Step 1. Type PING <space>IP address of the instrument you want to test. For Example:
PING 192.168.110.99
Step 2. In our example we used the default address for all HI4060 Series Instruments. The
IP address you are testing will be different.
Step 3. Press the Enter key on the PC.
Step 4. The PING utility starts sending out a packet to a specified address and gets a reply
if the unit is functioning correctly. If the instrument or network are configured
incorrectly and cables are loose or not connected correctly, nothing prints out after
the first line, check the Network cables and connectors to be sure they are tightly
fastened and the correct cables for this application. Also, check the configuration
to be sure that the instrument is configured correctly. (See Configuration IP
Address in Chapter 4)
If the unit is configured correctly and Ethernet functioning correctly and the
cables are the correct ones for this application and are securely fastened, 64
signals should be returned and the print out will reflect this fact.
General Policies and Information
Hardy Instruments provides world-wide support for its products. The following paragraphs
describe Hardy's customer support services and equipment warranty. When returning a
product, call the Technical Service Department listed below for a Return Authorization
Number. You will need to provide your company name, address, telephone number,
equipment model number, S/N, and a brief description of the problem.
NOTE
•
•
196 ••
•
•
Chapter 8
For all non-warranty repairs a purchase order or credit card information is required. You
can also go to the Hardy web site and request a Return Authorization number. An RA# will
be e-mailed to you. http://www.hardyinst.com/service/repair.php
Warranty
A warranty problem may be handled by returning the product to the factory for repair or
replacement under warranty. In the event you experience a problem with this instrument
contact your local Hardy Representative or the Hardy Instruments Service Center to
determine if the problem is covered under warranty.
Web Address:http://www.hardyinst.com/Service/term.php
Ordering Replacement Parts
Contact the Hardy Instruments Sales Department to order replacement parts and option
boards. Have your equipment model number and serial number ready.
System Support (Requires Purchase Order or Credit Card)
Technical Service is provided as follows:
•
New system start-up: Ensure that the installation is checked and correct;
instruments are calibrated, and operators trained.
•
Service: Engineers are trained and qualified to provide on-site installation,
calibration, and maintenance.
•
On-site training: A Hardy Support Representative can be scheduled to train your
operations and maintenance personnel. This can be as simple as basic load cell
theory or as complete as troubleshooting techniques which allow you to service
your equipment.
Software Downloads for Your HI 4060
To access the software that Hardy Instruments has made available for downloads:
Step 1. In a web browser, go to www.hardyinst.com/4000_support/index.html to open the
HI 4000 Series On-line Support Site, and click HI 4000 Download Section.
Troubleshooting
•
•
•197
•
•
•
Step 2. This will display the screen shown below which can be used to download
software for HI-4000 Series instruments.
Downloading and Installing Firmware Updates (S-19 Files)
In the procedure below, you will download both the Hardy Auto Update program and the
latest HI-4060 rate controller firmware to a common directory on the same network as the
rate controller.
Step 1. On the Hardy Auto Update line of the HI 4000 Series Downloads page (shown
above), right click on the Update link and use the Save Target As menu option to
save the file.
Step 2. Under HI-4060 Rate Controller Firmware, right click on the Latest Firmware link
and use the Save Target As menu option to save this file to the same directory. You
can rename the firmaware, but the name must always include _APP.s19 for the
AutoUpdate program to recognize it.
Step 3. Find and start the
Auto Update.exe
program.
Step 4. Click Find to search
for and list the units
that are online on this
network.
•
•
198 ••
•
•
Chapter 8
Step 5. Select the IP address
of the unit you want to
upgrade.
Step 6. Click Browse to find
and select the
firmware file you
downloaded.
Step 7. Once you have the IP
address and the file
selected, click on the
Update button.
Step 8. You should now be asked for a User Name and Password. Username is hardy and
password is updatepass (all one word in lowercase letters). If Update does not
give you the Password screen, the path to your program file may be too long. Try
moving your files up to your root directory and run again.
Step 9. After you log on, a percent complete bar will show the progress of the upgrade.
Once it completes the download, it should show the screen indicating the
programming is complete without error.
Step 10. Cycle power on the HI 4060 unit.
FOR FURTHER INFORMATION CONTACT:
Technical Service Manager
Hardy Instruments, Inc.
9440 Carroll Park Drive Suite 150
San Diego, CA 92121Phone: (800) 821-5831
Telephone: +1 (858) 278-2900
FAX: +1 (858) 278-6700
Web Site: http://www.hardyinstruments.com
E-Mail: [email protected]
Troubleshooting
•
•
•199
•
•
•
•
•
200 ••
•
•
Chapter 8
Appendix A
About Time Zones
••••••
Greenwich Mean Time
There are 25 integer World Time Zones from -12 through 0 (GMT) to +12. Each one is 15°
of longitude as measured East and West from the Prime Meridian of the World which is at
Greenwich, England. Some countries have adopted non-standard time zones, usually a 30
minute offset.
Each Time Zone is measured relative to Greenwich, England. Civilian designations are
typically three letter abbreviations (e.g. EST) for most time zones. Below is a list of the
abbreviated time zones with the GMT time adjustment.
GMT
GMT
Civilian Time Zones
GMT: Greenwich Mean
UT: Universal
UTC: Universal Co-ordinated
WET: Western Europe
Cities
London, England
Dublin, Ireland
Edinburgh, Scotland
Reykjavik, Iceland
Casablanca, Morocco
EAST OF GREENWICH
+1
CET: Central Europe
Paris, France
Berlin, Germany
Amsterdam, Holland
Brussels, Belgium
Vienna, Austria
Madrid, Spain
Rome, Italy
Bern, Switzerland
Oslo, Norway
+2
EET: Eastern Europe
Athens, Greece
Helsinki, Finland
Istanbul, Turkey
Jerusalem, Israel
Harare, Zimbabwe
+3
BT: Baghdad
Kuwait
Nairobi, Kenya
Riyadh, Saudi Arabia
Moscow, Russia
GREENWICH TIME ZONES (GMT)
About Time Zones
•
•
•201
•
•
•
GMT
Civilian Time Zones
+3:30
Cities
Tehran, Iran
+4
Abu Dhabi, UAE
Muscat
Tblisi
Volgograd
Kabul
+4:30
Afghanistan
+5
+5:30
India
+6
+6:30
Cocos Islands
+7
+8
CCT: China Coast
Shanghai, China
Hong Kong, China
Beijing, China
+9
JST: Japan Standard
Tokyo, Japan
Osaka, Japan
Taipei, Taiwan
Australian Central Standard
Darwin, Australia
Adelaide, Australia
+9:30
+10
GST: Guam Standard
+10:30
Lord Howe Island
+11
+11:30
+12
Norfolk Island
IDLE: International Date Line East
NZST: New Zealand Standard
Wellington, NZ
Fiji
Marshall Islands
+13
Rawaki Islands
+14
Line Islands
WEST OF GREENWICH
-1
WAT: West Africa
-2
AT: Azores
Azores
Cape Verde Islands
GREENWICH TIME ZONES (GMT)
•
•
202 ••
•
•
Appendix A
GMT
Civilian Time Zones
-3
Cities
Brasilia, Brazil
Buenos Aires, Argentina
Georgetown, Guyana
-3:30
Newfoundland
-4
AST: Atlantic Standard
Caracas, Venezuela
La Paz
-5
EST: Eastern Standard
Bogota, Colombia
Lima, Peru
New York, NY, USA
-6
CST: Central Standard
Chicago, Illinois, USA
Mexico City, Mexico
Saskatchewan, Canada
-7
MST: Mountain Standard
Phoenix, Arizona
Denver, Colorado
-8
PST: Pacific Standard
Seattle, Washington
Portland, Oregon
San Francisco, CA
-9
AHST: Alaska-Hawaii Standard
CAT: Central Alaska
HST: Hawaii Standard
Anchorage, Alaska
Honolulu, Hawaii
-11
NT: Nome
Nome, Alaska
-12
IDLW: International Date Line West
GREENWICH TIME ZONES (GMT)
Step 11. Check the Greenwich Time Zones Table for the time zone you are in.
Step 12. Press the right or left arrow until the correct time zone appears. For example Pacific
Standard Time is -8.
Step 13. Press the Enter button to save the entry.
Step 14. Press the Down arrow until the cursor is in front of Time-Year.
About Time Zones
•
•
•203
•
•
•
•
•
204 ••
•
•
Appendix A
INDEX
Symbols
!C2 Caps Unequal! 164
!Function Error! 164
!Not Allowed! 164
!Security Violation! 165
“clean” primary line 22, 27
*.gsd file 66
Numerics
0-10 VDC 54
10/100 base T Ethernet connection 28
14 AWG power line 22
25 integer World Time Zones 201
4-20 mA 54
5 VDC excitation 124
A
A - Guidelines for Instabilities on Formerly
Operating Systems 169
A/D Average 192
A/D Convert Error 164
A/D Failure Error 164
A1 - Guidelines for Instabilities on
Formerly Operating System (Cont’d)
170
About Chapter 9 197
About Hardy Manuals 1
About The Gravitation Correction Factor
128
AC Input Power Wiring (-AC) 22
AC Power Input 22
actual rate of flow 1
AD/Raw Count 192
Additional Field Devices Folder 67
address allocation list 65
Address Error 64
ALARMS 3
Allen-Bradley Company Inc. 6
Analog Card 56
Analog Mapping 143
Analog Out Sub-Menu 56
analog parameters 54
Analog Wiring 30
AND 142
ANYBUS-S PDP 67
Applications 3
Approvals 11
appurtenances 125
Audit Trail 168
Automatic Control Mode 4
Automatic Refill 4
Automatic Tuning (Auto Rate Calibration)
4
average reading
Averages 9
191
B
B - Guidelines for Instabilities on Formerly
Operating Systems (Cont’d) 171
basic load cell theory 197
Baud Pull Down List 45
Baud Rate 69
board stacker pins 31
Boolean Mapping 142
boolean operations 142
Boolean tables 142
Boolean variable 143
Byte Count Error 64
Bytes Input field 48
Bytes Input text field 46
Bytes Output field 48
Bytes Output text field 46
C
C - Guidelines for Instabilities on Formerly
Operating Systems 174
C2 Cal Error 164
C2 Calibration Procedures From the Front
Panel 126
C2 Data page 194
C2 Load Cell count 127
C2 Sensors Found” reads 0 194
C2® Load Point Connection 20
Cable color Code for Non-C2 Load Points
21
Index 105
•
•
•
•
•
•
Cal Completed OK 129
Cal completed OK 127
CAL Failed 164
Cal Failed 129
A to D Converter Error 127
No C2 sensors found 127
Cal High 131
Calibration 36
Calibration menu 127
Calibration page 126
Calibration Procedures From the Front
Panel 125
Channel 1 -Dribble 30
Channel 2 - Cutoff 30
Channel 3 - Bag Clamp 30
Channel 4 - Unused 30
Channel connector 20
Channel terminal block 20
Chapter Five 1
Chapter Four 1
Chapter One 1
Chapter Seven 1
Chapter Six 1
Chapter Three 1
Chapter Two 1
Checking Inputs and Output s 194
Client 60
closed containers 14, 163
Common Mode Rejection 10
Common Mode Voltage Range 10
Configuring Profibus from the Front Panel
68
Configuring the Analog Output Card from
the Front Panel 54
configuring the Hardy Instruments 33
Configuring the Instrument from the Web
Page 36
Connection pull down menu 61
connector 14, 163
Continuous or Batch Modes 4
controlled static environment 14, 163
Cycle power 66
cyclic 65
•
•
•
•
•
•
106
Index
D
data transmission baud rate(s) required. 66
DC power 27
DC Power Input (-DC) 27
DC power source 27
DC voltage header 27
default word 62
Description 1
Description of a Ratio Controlled System
156
desired rate of flow 2
Destination and Source 62
Destination Network pull down menu 62
deterministic 65
DeviceNet 28, 43
Devicenet 1, 33
DeviceNet cable 47, 50
DeviceNet Setup page 44
DI is the DeviceNet input image table 142
Diagnostics 186
Digital Voltmeter 10
Din Rail Mount 11
disassembly 14, 163
Disassembly and Reassembly Notes and
Cautions 14, 163
Display 9
Display Increments (Graduations) 9
DNET Connection. LED On 47
DNS 50
Do C2 Calibration” button 126
Do Cal High button 130
Do Cal Low button 130
DO is the DeviceNet output image table
142
Do IT Test 190
DP State (Read Only)
drives 44
69
E
E - Non-Return to Zero 175, 183
EIP Bytes In” menu 49
Electrical Check Procedures 124
electrical parts 14, 163
electrical plug 14, 163
electrostatic discharge 14, 163
embedded controllers 44
Enabling MODBUS 60
Enabling Mod-Bus in the HI 3000 Module
59
Enabling Modbus TCP/IP from the Front
Panel 60
Enter Value display 64
Entry Accepted 57
Environmental Requirements 11
Error Messages 164
ESD 14, 163
EST 201
Ethernet Adapter 29
Ethernet Network 28, 43
Ethernet/IP 1, 33
Ethernet/IP page 48
Ethernet/IP™ Parameters 47
Excitation Monitor 10
Excitation Voltage 9
Extranet 28
F
F - Verify Individual Load Cell Millivolt
Readings 175
factory installed jumpers 20
feeding device 1
Firmware Updates 198
Float Inverse 63
Float Variable O (HFO) 62
follow proper safety procedures 164
FOR
FURTHER
INFORMATION
CONTACT 199
Frequency 10
Front Panel 4
Front Panel Calibration Security” pull
down list 75
Front Panel TARE/ZERO Security” pull
down list. 74
Function Not Supported 64
G
G - Calibration Failed
Not Enough Counts Between ZERO
and SPAN 177
Gate 50
General Folder 67
General Policies and Information 196
General Troubleshooting Flow Chart Index
168
Getting Started 43
global industry-standard communication
network 44
GMT 201
GMT time adjustment 201
gravity 128
Gravity Correction Menu 129
Greenwich Mean Time 201
Greenwich, England 201
Ground wire 27
GSD file 65
guard band tolerance 3
H
H - Mechanical Inspection 178
Hardware Catalog 67
Hardy Auto Update program 198
Hardy Modbus-Link .exe file 61
Hardy Modbus-Link Display 63
Hardy Modbus-Link display 61
Hardy Modbus-Link icon 61
Hardy Modbus-Link Software 61
HI 215IT Junction Box 190
HI 3000 Series Network 28, 43
HI 3000 Series Network configurations
28, 43
HI 4050 Resources Web page 61
HI 4050 Series (ANYBUS) module 68
HI 4050 web page 127
HI is the Hardy input image table 142
High Security Code text field. 74
High Voltage value 57
High Weight Menu 58
higher-level controllers 44
highest order bit set 144
HO is the Hardy output image table 142
Host Controller 156
Humidity Range 11
HW Config dialog box 68
Index 107
•
•
•
•
•
•
I
individual Boolean variable 142
Initializaiton Process 65
Initialization Procedures 67
Input 9
Input and Output page 194
Input Power Wiring 22
Installing Hardy Modbus-Link 60
Installing Optional Boards 29
Installing the Analog Output Card 30
Installing the Analog Output Card (4ANB) in the Option Slot 29
Installing the DeviceNet Card 32
Installing the PROFIBUS Card 32
INTEGRATED TECHNICIAN 186
Integrated Technician 163
INTEGRATED TECHNICIAN (IT®)
190
Internet 28, 43
Interpreting the Model Code Number 5
Intranet 28
IP Menu 50
IP Setup program 122
IT Test 167
IT Web page 190
J
J - Electrical Inspection
179
K
K - Load Sharing and Load Sensor
Checkout 180
Key Pad 9
Key text field 48
Key to enable 60
L
LAN 28, 43
lattitude 128
least significant byte 144
load (Vessel + Contents) 123
load (weight) 125
load cell I&M manual 123
Load Check 125
•
•
•
•
•
•
108
Index
Lock Washers 14, 163
Low Output voltage value 57
Low Weight 57
Low Weight Menu 57
M
M - (*******) or (- - - - - - -) ERROR 181
Main Control board Network header 30
Manual Control Mode 4
Manual Refill 4
Map
text field 62
Map button 62
Mapping web page 62
Mask 50
master device 64
Materials Required 28
Maximum Zero Tolerance 10
mean squared variation 191
Mechanical Check Procedures 123
MFO0= 62
Mixed Mapping 143
MODBUS - TCP/IP Over Ethernet 59
Modbus Float Out 62
Modbus Key 60
Modbus Key text field 60
Model Code Breakdown 6
Motion Error 164
motor starters 44
Mv/V and MV
166
mV/V rating 124
N
N - Weight Controller’s Front Display is
Blank 182
Netburner IP Service Program 122
Network pull down list 62
No C2 Sensor 164
No Connection” message 47, 50
Node address 45, 66
Node Address at #7 69
Node text field. 45
Non-C2 Load Point Connection 21
NONE/MEDIUM/HIGH 73
Non-Linearity 10
NOT 142
Num C2 127
Num C2 is read only
127
O
Operating Temperature Range 11
Operation 186
Operation Choose One page 186
Operation Displays 4
Operation/Diagnostics - Weight & Voltage
page 193
Operational Displays 153
Operation-Diagnostics Page 186, 187,
192
Operations/Diagnostics/C2 127
Option port 30
Option Slot Header 29
Options Configuration 91
Options Menu 44
Options Page 43, 44
Options. 44
OR 142
Ordering Replacement Parts 197
original point of remova 163
original point of removal 14
OSI model 59
out of tolerance flow rate 3
Output Resistance 194
Output Voltage 194
Overview of Typical Load Cell System
189
P
P - SD Card Diagnostics and Losing
Memory at Power Cycles 183
Pacific Standard Time 203
pan cone head screws 31
Panel Mount 11
parameterization 65
PARAMTER ID 144
PASS/FAIL and Variance Test 166
passive nodes 65
password to the Calibration Section 73
PCs 28, 43
Performing a Parameter List (Dump)
periodic 65
Physical Characteristics 11
Ping Tool 196
PING utility 196
PLC 68
PLCs 28, 43
Poll Connection entry 47
polling mechanism 65
polls 64
Power 10
Power and Utility Requirements 10
PP# = Program Part Number 187
Pre-Calibration Procedures 123
Pre-Initialization Procedures 66
Prime Meridian 201
printed circuit boards 14, 163
ProfiBus DP 64
Profibus DP network 66
PROFIBUS Interface Card 157
PROFIBUS label 31
Profibus Node Menu 69
ProfiBus system 65
PROFIBUS® Configuration 64
Profibus-DP .GSD File 66
Profibus-DP cable specifications 66
Profibus-DP Network 67
Profibus-DP PLC 65
Program Part Number 187
push buttons 44
145
R
rate control algorithm 1
Rate Exception Control (REC) Alarm 3
Rate Tolerance Alarm 3
Ratio Control (Master/Slave) 156
Ratio Process Control System (See Fig. 822) 156
Raw A/D Average Counts 166
Raw A/D Count 166
Read Data from
” pull down list 194
Read/Write Multiple Registers 63
reassembly 14, 163
REC Alarm 3
Index 109
•
•
•
•
•
•
Ref Weight 127
Ref Weight Menu 127
Ref Weight text field 130
Ref Weight” text field 126
Reference Weight 128
Remote I/O Interface 6
Remote Set Point Analog Input Option
card 156
Remote Set Points Option for Ratio
Control Applications 157
repairs 14, 163
Reports 4
Request Error 64
request/reply PDUs 59
request/reply protocol 59
reserved system port 502 59
Resolution 9
Response OK pop 64
Response pop up 64
RS NetWorx® 142
RTZ (Return to Zero) Tests
167
S
S-19 Files 198
Save Parameters button 48
Screws 14, 163
SD Card 195
SD Card page 195
Secure Memory Module 3
Security 73
security for the Tare/Zero functions 73
Security page 74
Security Violation” message 129
Select Destination Module dialog box 68
Selecting Operational Displays 153
Selecting the module by number for
Testing 196
Sensor Number
167
sensors 44
Server 60
Set LCD Contrast Parameter 87
Setting the Set Point Amount Batch Mode
156
•
•
•
•
•
•
110
Index
Setting up the Command Interface
Mapping 144
Shield wir 27
Siemens PLC 66
Siemens Step 7™, Simatic Manager 65,
67
Simatic Manager 66
Simple Ethernet Network 28
simple operator interfaces 44
slave 64
Slave Controller 156
small fasteners 14, 163
Spacers 14, 163
Span Weight 131
Span Weight text field 130
Special (Command) Mapping 144
Stability Test 190, 191, 192, 193
Stability Test ALL 165
Starting the HI 4050 31
Station Address Dialog box 68
Storage Temperature Range 11
system diagnostics utility 190
System Support 197
T
TCP/IP Connection display 61
TCP/IP over Ethernet. 59
TCP/IP stack 59
Test 187
Test Menu 187
The Command Interface 144
The Network Number 49
There are three Continuous Rate Displays
153
Time - Hours 93
Time - Hours Menu 93
Time - Minutes 37, 50, 93
Time - Minutes Menu 93
Time - Month 92
Time - Month Menu 92
Time-Year 203
Time-Year Menu 92
Too Hi Error 164
Too Lo Error 164
Trad Cal Error 164
Traditional Calibration from the Front
Panel 129, 130
troubleshooting techniques 197
Troubleshooting
The
Network
Connections and Configuration with the
"Ping" Tool 195
Trunk Line 66
U
universal power supply 22
Update Rate 9
UR dialog box 67
Using IT From the Front Panel
190
V
V/I Out High 57
V/I Out Low Menu 57
Value Error 64
vertically passing 123
vibration based feeders 2
Viewing System C2 Load Sensors
Viewing the SMM-SD Card 195
Voltage 10
VPN (Virtual Private Network)
28
W
Warranty 199
Washers 14, 163
WAVERSAVER 10
WAVERSAVER® 3
WD State (Read Only) 69
Web Page Security” pull down list
Weight 166
Weight and Voltage ALL 166
Wireless IR 28, 43
Wireless Servers 28, 43
wiring harness 14, 163
Write Multiple Registers 64
Write Protect status 195
75
Z
194
zero point 130
Zero Value menu
130
Index 111
•
•
•
•
•
•
•
•
•
•
•
•
112
Index
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement