Service Menu
Introduction
Welcome to the weighing electronics world of the Multi-Function Model 6004 MF. Using the
latest ARM microprocessor technology we are now able to offer a powerful, compact, fieldmount unit that you can select for a variety of weighing functions at a cost-effective price.
The main advantage to the user, servicing organisation or marketing company is having one
electronics unit that can be used for almost any application in the weighing industry.
Applications
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Loadcell Transmitter
Beltweigher
Loss-in-weight Transmitter
Through-put Weigher
Bag-filler
Batchweigher
Dynamometer
Evolutions
Features
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Rugged, powder coated, cast Aluminum housing with splashproof keypad
Clear 20mm 6-digit LED main display & auxiliary information LCD display
Inputs from loadcell, incremental encoder & six digital
Powerful ARM microprocessor with integral clock & USB I/O port
Programming, keypad using LCD or PC via USB with supplied software
User-programmable function keys, digital inputs and relay outputs
Precalibration of sensitivity and range, zero trim and deadweight span trim
Lineariser 15-point, min/max hold, auto-zero maintenance, preset tare
PI control with auto-manual setpoints, bumpless transfer, anti-reset windup
Bootloader for remote internet firmware updates and program specials
Outputs for isolated analog 1-5/0-10Volts or 0/4 - 20mA
Power supply 90-260V switchmode or 10-30V isolated DC
Options
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Output relays or photomos 2, 4 or 6, plug&play, programmable functions
Serial outputs, RS232, RS485, Ethernet, plug&play
Formats in ASCII, Modbus or do-it-yourself Buildabus
SD memory card for storing commissioning setup or data logging
GPS, factory fit, for accurate position recording with on-board weighing
Page 1
Contents
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Introduction
Page 1
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Applications
Page 1
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Features
Page 1
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Options
Page 1
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Contents
Page 3
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Description of Units Available
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Loadcell Transmitter
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Beltweigher
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Loss-in-Weight Transmitter
Page 4
Page 4
Page 4
Page 4
Throughout Weigher
Dynamometer
Bagfiller
Batchweigher
Page 5
Page 5
Page 5
Page 5
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Safety
Page 6
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Cleaning
Page 6
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Guarantee
Page 6
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Installation
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Overall dimensions
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Mounting Holes
Page 7
Page 7
Page 7
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Wiring Links
Page 8
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Wiring Connections
Page 9
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Display and Controls
Page 10
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Getting Start
Page 11
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Application Menus
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Run Loadcell Transmitter
Page 12
Service Menu
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Setpoint Values
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Setpoint Configuration
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Analog Output
Page 14
Page 16
Page 18
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Communication
Max/Min
Net/Gross
Page 20
Page 22
Page 24
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Tare
Auto Zero
Preset Tare
Page 26
Page 28
Page 30
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Page 2
Contents
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Service Menu Continue
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Security Level
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Precalibrate
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Zero Trim
Page 32
Page 34
Page 36
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Span Trim
Lineariser
Simulate
Page 38
Page 40
Page 42
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Function Keys
Digital Inputs
Display
Page 44
Page 46
Page 48
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Transmitter Settings
Page 50
Page 3
Description of the units available
Loadcell transmitter
A loadcell transmitter is used to convert loadcell outputs into a standard instrumentation
analog signal such as 4-20mA or 0-10volts, it will also supply power to excite one or more
loadcells. The 6004MF has many additional features such as displays for mass and
programming, digital communications for direct connection to control computers and alarms.
Our weighing electronics has always incorporated a precalibrate, zero trim and span trim
feature. This is a simple way to set up a strain-gauge loadcell system. All the variables, such
as sensitivity and range, are inserted in the precalibrate section so that the system is
reasonably accurate before adding test weights. The weighing system is then zero trimmed
(backbalanced) to offset the dead weight of weighbin, weighframe or weighbridge deck. With
known test weights the system can be span trimmed to get higher accuracy. In some
instances, such as very large weightanks where it is not possible to use test weights,
precalibration using factory test certificates for loadcell sensitivity results in an acceptable
overall system accuracy.
The ARM processor used incorporates a USB port and a real time clock with day/date. We
have made full use of these facilities and added an optional, factory fitted, global positioning
system (GPS) to cater for such applications as on-board truck weighing, positioning and data
logging. In refuse removal some countries are introducing legistration for customers to pay
by weight for this service. Farmers are starting to monitor crop production and fertiliser
distribution by location to improve farming efficiency. Logging contractors need to load for
maximum profit without incurring overweight fines.
Beltweigher
The beltweigher measures the weight of material on a conveyor belt and it's speed, from this
a mass flow is calculated in kg/min or tonnes/hr. The 6004MF allows you to set or measure a
belt speed, and, if measure, to set the pulley diameter, encoder pulses/rev and also to enter
the weighsection length. With this information and the precalibrate feature described above
the material flow rate will be calculated and displayed. Zero trim time is selectable to allow
for one full conveyor belt cycle and, if some form of check weighing is available, a rate
correction factor can be inserted. All rates have a main totaliser as well as a resettable
totaliser. The totaliser can be set for remote display through one of the setpoint outputs using
an optional photomos solid state relay which is ideal for this purpose. The PI control
selection used with a variable speed drive can convert the beltweigher into a flow controller.
Loss-in-Weight Transmitter
Loss-in-weight is becoming a popular form of mass flow measurement or control as it
requires few moving or wearing parts. Measure a weighbin over time and you can can get a
material flow rate either emptying or filling. Although we sample the averaged weight every
second you can select the measurement comparison period from 10 to 480 seconds. A short
period is ideal for small bins and extended time for larger weighbins. The system can be
selected to run for one weighbin cycle then stop or can be set to hold the rate display and
output whilst it refills the weighbin. Totalisers and selectable PI control are also standard
features.
Page 4
Description of the units available
Throughput Weigher
A throughput weigher makes use of a small weighbin to weigh and dump batches in quick
succession typically used in bulk handling of cereals. The flexibility of the 6004MF allows you
to set high and low levels of the weighbin and various time delays in order to tune the
throughput weigher for maximum efficiency. The main display is normally the total but a flow
rate can also be displayed provided the timebase is long, say, kg/hr or tonnes/hr so that the
batches can be smoothed out.
Dynamometer
The dynamometer application measures power of engines, electric motors or hydraulic
motors in conjunction with some form of braking. It makes use of the loadcell input to
measure torque normally in conjunction with a lever arm and the encoder input to measure
revolutions per minute (RPM). The loadcell can be precalibrated and the lever arm length
entered. For various shaft encoders the impulses per revolution can also be set. The
6004MF will then display kW (or horsepower) , RPM and torque. Displays are selectable, eg,
kW on main and RPM and torque on the auxilliary LCD.
Bagfiller
This application provides the control for bagfilling machines as used for measuring precise
weights of cement or flour, etc. It has setpoints for fast and slow fill, inputs for interlock and
footswitch and outputs for filling, vibrating and bag clamps. The settle, vibrate and waiting
times are adjustable to optimise the filling. In-flight correction is standard which will correct
any weighing error over a preset number of bags. Total can be bags filled or totalised weight
or both
Batchweigher
Batchweighers are typically used for control of industrial concrete mixers but can also control
just about anything that requires a repetitive recipe mix. The freely programmable inputs,
function keys, displays and outputs results in a batchweighing system with tremendous
flexibility. The setup allows for a maximum of five ingredients. Each can be named (Sand,
Cement, etc), be a mass or count (say, from a water meter), have an interlock, time delay
and/or in-flight correction. In the setpoint values section up to four recipes (A,B,C or D) can
be set. With these selections just about any batching system can be customised, even on
site if need be.
Page 5
Safety
This equipment is supplied by a mains voltage which can cause an electric shock injury.
Before removing the cover from the housing, switch the instrument off, isolate it from the
mains power supply and make sure that it cannot be connected inadvertently by other
persons.
If the cover is removed from the housing, do not apply power to the instrument unless
specifically instructed to do so in these instructions. When working on live equipment,
exercise great care, use insulated tools and test equipment, and do not work alone.
When handling circuit boards, ensure that full anti-static precautions are observed.
Replace mains fuse with one of an equivalent type or rating.
Cleaning
Do not clean the instrument while the instrument is on. Harsh abrasives, solvents, scouring
cleaners and alkaline cleaning solutions, such as washing soda, should not be used
especially on the display window. The outside of the instrument may be wiped down with a
slightly damp clean cloth (lightly moistened with water only).
Under no circumstances should you attempt to wipe the inside of the instrument.
Guarantee
This product is guaranteed against faulty workmanship or defective material, for a period of 3
(three) years from date of delivery.
The manufacturer undertakes to replace without charge all defective equipment which is
returned to it (transportation costs prepaid) during the period of guarantee, provided there is
no evidence that the equipment has been abused or mishandled in any way.
The manufacturer reserves the right to alter any specification without notice.
Page 6
Installation
Installation
Overall dimensions
- Not to scale.
- Height of 130mm excludes cable glands
- Depth is 70 mm
130 mm
220 mm
Mounting holes
- The housing side covers need to be removed to gain access to the mounting holes.
202 mm
80 mm
Hole diameter 6 mm
Cable gland hole dimensions: 8mm diameter
Page 7
Wiring and Links
LOADCELL WIRING
The straingauge loadcell is basically a four-wire device. For short distances or lower accuracy
requirements the remote sense leads are not essential. However the sense and excitation must
be linked (S+ to Ex+ and S- to Ex-) at some point or there will be no control of the excitation
voltage and it will go to maximum. You can use the links J1 & J2. For better accuracy on a
four-wire connection cut J1 & J2 then put in links on the field side of the plug-in terminals.
For long distances, higher accuracies or using Intrinsically safe (Is) barriers use a six-wire
connection with the sense leads to the loadcell/s. These sense leads measure the excitation
voltage at the loadcell (or field junction box) and compensate for any lead or barrier volt drops.
Cut J1 & J2. No links on terminals.
For multiple loadcell systems join all loadcells in parallel. Make sure that the loadcells are
impedance matched and have the same sensitivity (mV/V). Use a field junction box to save
wiring and facilitate terminal connections.
EXCITATION VOLTAGE
10 Volts for up to 4 x 350Ω loadcells (factory default)
10 Volts for up to 8 x 1000Ω loadcells
5 Volts for up to 8 x 350Ω loadcells
5 Volts for Is (barriered) applications up to 2 x 350Ω loadcell
3.5Volts for Is (barriered) applications up to 4 x 350Ω loadcells
LINKS
Power off, change links, power on.
Programmable excitation voltage links J7 & J10 then set in Precalibrate menu.
Fixed excitation voltages link J9 = 3.5 Volts, J8 = 5 Volts, J7+J8 = 10 Volts.
Link J27 connects ground plane to earth. Normally off.
Link J5 is for encoder NPN or PNP selection.
Link J2 on top circuit board is a hardlock for programming.
HARDWARE OPTIONS
Power off, fit option, check alignment with standoff pillor, power on, activate option in Transmitter
Settings, Hardware Fitted.
Plug-in relays or photomos. Use R6 (photomos) for totaliser output.
Plug-in coms options on top circuit board. RS232, RS485, USB, Ethernet, RF.
Factory fit options Global Positioning System (GPS) and SD data card.
POWER SUPPLY
Power supply is factory supplied 90-260V AC/DC or 10-30VDC. These modules are not easily
field replaceable as they have to be soldered in.
Note: For critical applications or electrically noisy environments (heavy switch gear or large
variables speed drives) ensure the power supply to the instruments is clean and stable, you may
need to fit an external uninterruptible power supply (UPS).
Page 8
Wiring Connections
Wiring connections, jumpers and fuse replacement
J3
J7
J9
J8
J10
+ SENSE
+ mV
- mV
- EXC
LOADCELL
+ EXC
- SENSE
NO
COM
DIGITAL INPUS
DI 1
DI 2
DI 3
DI 4
DI 5
DI 6
NC
NO
COM
NO
COM
IGND
I out
V out
+
RL
CURRENT
IGND
VOLTS
ANALOG OUT
+
ENCODER
ENCODER
RELAY
5
RELAY
3
J5
PNP
V+
PHOTOMOS
(NO Only)
NC
NC
NPN
RELAY
6
NO
COM
RELAY
4
NC
NO
COM
NC
NO
COM
RELAY
2
RELAY
1
NC
REPLACE FUSE WITH
THE SAME RATING
6004MAIN-A
GND
+
SIG
GND
J12
EARTH
GND
Digital
Inputs
J11
J27
Screen
J4
FUSE
Power Supply
AC
VDCEARTH
SUPPLY
AC
VDC+
AC SWITCHMODE
OR
DC SUPPLY
Page 9
Display and Controls
Keypad during run mode
Relay Status
Main Display
Auxilliary Display
(Max 4) as set in
Display Menu
1:
2:
3:
4:
Keypad for
Setpoint Values
Function Keys as
set in service Menu
Enter
Press 3” for operators menu
Clear or go back
Keypad during programming mode
AssizeLable
Main Display
Right Arrow
Units Lable
Up Arrow
- Program -
Left Arrow
Keypad
Down Arrow
Function Keys
(Programmable)
Enter
Logo Lable
LED Definitions
Clear or go back
Scroll through menus
A1 A2 A3 A4 A5 A6
Output relay status
Scroll through options
Net
Main display in net mode
Key
Net display value is zero
Display
Zero
Relay energised: Normal = LED on, Inverted = LED off
Page 10
Key in values (Alpha numeric)
Display options
Enter values or open function blocks
POWER ON
Getting Started
LOGO
3”
UNIT INFORMATION
Hold
3”
RUN
BAG
FILLER
RUN
BATCH
WEIGHER
RUN
LOSS-IN-WEIGHT
TRANSMITTER
5”
Application selection
Hold
3”
RUN
LOADCELL
TRANSMITTER
RUN
BELT-WEIGHER
RUN
THROUGHPUT
WEIGHER
RUN
DYNAMOMETER
5”
RUN
Hold 3”
SETPOINTS
Operator’s Menu
LOAD
SERVICE
PASSWORD
TAG ...
Service Menu Entry
ACTION ...
NEW TAG ...
Service
Menu
and their
Service Menu
Numbers
SETPOINT VALUES
01
PRECALIBRATE
11
BELTWEIGHER SETTINGS
21
SP CONFIGURATION
02
ZERO TRIM
12
CORRECTION FACTOR
22
ANALOG OUTPUT
03
SPAN TRIM
13
LOSS-IN-WEIGHT SETTINGS
23
COMMUNICATION
04
LINEARISER
14
THROUGHPUT SETTINGS
24
MAX/MIN
05
SIMULATE
15
DYNAMOMETER SETTINGS
25
NET/GROSS
06
FUNCTION KEYS
16
BAG FILLER SETTINGS
26
TARE
07
DIGITAL INPUTS
17
BATCH WEIGHER SETTINGS
27
AUTO ZERO
08
DISPLAYS
18
PRESET TARE
09
PI CONTROL
19
SECURITY LEVEL
10
TRANSMITTER SETTING
10
Service Menu
Numbers
Page 11
Applications Menu
Application Block Number 01
01. RUN LOADCELL TRANSMITTER
Select RUN LOADCELL TRANSMITTER if not already in this application. Press side
arrow after power up when RUN (application) is displayed, key in password, enter and
use side arrows to select, then enter again.
For quicker commissioning first select Security Level 1 and connect the Hardlock link.
Going in to the Service menu select Calibrate, not view, in order to change settings.
Change Security levels and passwords last. Note that you make changes to the whole
Service menu block then press Enter.
It is advisable to first set up the Displays, Digital inputs and Function keys, then go to
Precalibrate and set up loadcell values and scales. After this you can go through the
Service menu blocks to select and set other functions that you require. Descriptions of
these are listed in the Service menu pages.
Final calibration trim can be carried out on the system using Zero Trim and, if test weights
are available, Span trim.
The Loadcell Transmitter Service menu contains the following functions:descriptions are listed in the Service menu section of this manual)
(Detailed
01 Setpoint values
02 Setpoint configuration
03 Analog output
04 Communications
Set values for setpoints 1-6
Select functions for setpoints 1-6
Select output 1-5V, 0-10V, 0-20mA or 4-20mA
Select and set up serial output
05 Min/Max
06 Net/Gross
07 Tare
08 Auto zero
Select minimum and/or maximum hold
Select Gross only, Net only or Net/Gross
Select Tare to zero Net reading
Select and set up Auto Zero Maintenance (AZM)
09 Preset tare
10 Security level
11 Precalibrate
12 Zero trim
Select Preset tare function
Select access to Operator and/or Service menu
Set loadcell values, excitation and range details
Trim off empty weighbin/ weighbridge deck...
13 Span trim
14 Lineariser
15 Simulate
16 Function keys
Trim range using test weights
Select up to 15 points of linearising
For testing, force analog and relay outputs
Set functions for keys F1-4
17 Digital inputs
18 Displays
19 PI Control
20 Transmitter settings
Set functions for inputs D1-6
Set main display and up to 4 auxilliary on LCD
Change transmitter into controller
Set password, calibration, hardware & time/date
Page 12
Applications Menu
Application Block Number 01
01. RUN LOADCELL TRANSMITTER POWER ON
LOGO
3”
UNIT INFORMATION
Hold
3”
5”
Hold
3”
RUN
LOADCELL
TRANSMITTER
RUN
LOSS-IN-WEIGHT
TRANSMITTER
RUN
BELT-WEIGHER
5”
RUN
Hold 3”
C
SETPOINTS VALUES
SP VALUES
C
RESET MAX/MIN
RESET
C
TOGGLE NET/GROSS
CHANGE OVER
C
TARE
TARE
C
LOAD SERVICE
C
PASSWORD
TIMEOUT
WRONG
TAG/LAST CAL/BY
VIEW/CALIBRATE
HARDLOCK ON
NEW CALIBRATION
TAG/DATE/BY
SETPOINT VALUES
01
AUTO ZERO
08
SIMULATE
15
SP CONFIGURATION
02
PRESET TARE
09
FUNCTION KEYS
16
ANALOG OUTPUT
03
SECURITY LEVEL
10
DIGITAL INPUTS
17
COMMUNICATION
04
PRECALIBRATE
11
DISPLAYS
18
MAX/MIN
05
ZERO TRIM
12
PI CONTROL
19
NET/GROSS
06
SPAN TRIM
13
TRANSMITTER SETTING
20
TARE
07
LINEARISER
14
TO SETPOINT VALUES
To Open
C
Return to
Load Service
Page 13
Service Menu
Function Block Number 01
01. - SETPOINT VALUES -
Setpoint Values can be viewed here in the Service Menu as well as in the Operators' Menu
and inserted or altered here (subject to password, calibrate and hardlock being
activated) and in the Operators' Menu (subject to the Security Level set)
To view or alter setpoint values press Enter +when the SETPOINT VALUES function block
is displayed. All values can be inserted or altered when highlighted. Do not press enter
until all required changes to the entire block (SP1-6) are completed.
When pairs of relays or photomos have been plugged in the option must be activated in
Options Fitted in the TRANSMITTER SETTINGS block or else the message 'Hardware not
fitted' will appear.
SP1 to SP6 are shown. If the SP has been set for High or Low you can key in a setpoint
value with the decimal point that corresponds to the tracked variable (gross, net or main
display in Setpoint Configuration, next function block). The value keyed in must be
within the scale range. If another configuration, such as None, Net, Zero, Total, etc has
been selected in the Setpoint Configuration this will be shown and no value can be
inserted.
If the Pretare function has been activated the Pretare Value: will be displayed on the first
line and the Gross offset value can be keyed in.
If the PI Controller has been activated in the Service Menu then the Setpoint Values block
will include Manual Output: (00-99)% which corresponds to a percentage of the selected
analog output and Auto SP: xxx,xxx which corresponds to a main display setpoint value
including the existing decimal point.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case SETPOINT CONFIGURATION.
Page 14
Service Menu
Function Block Number 01
01. - SETPOINT VALUES FROM
SERVICE
MENU
ENTRY
FROM
OPERATORS’
MENU
RUN
01
SETPOINT
VALUES
C
C
TRANSMITTER SETTINGS
SETPOINT CONFIGURATION
- SETPOINT VALUES -
If preset selected
PRESET :
If PI Control
Selected
MANUAL OUTPUT: 00.0%
Analog out % of mA or V range
AUTO SP
: 000.000
Main Display units and decimal
SP1
: 000.000
SP2
: 000.000
SP3
: 000.000
SP4
: NET
SP5
: ZERO
SP6
: TOT 1 OUT
Set here show on AUX1
: 000000
or
As set in SP Configuration
Vibrate, Bagclamp, None, Net, Zero, Total,
Beltspeed, Fault, Power,
Refill, Feed, ...
SERVICE
C
C
IF OK
IF OK SET VALUES
SETPOINT
CONFIGURATION
02
SETPOINT VALUES
SERVICE
C
ANALOG OUTPUT
- SP CONFIGURATION -
Note: Preset on Loadcell transmitter only
Preset and PI Control cannot be on together
Page 15
Service Menu
Function Block Number 02
02. - SETPOINT CONFIGURATION -
To view or alter the setpoint configurations press Enter + when the SETPOINT
CONFIGURATION function block is displayed. All values can be inserted or altered
when highlighted. Do not press enter until all required changes to the entire block
(SP1-6) are completed.
Select any Setpoint from 1-6 using the side arrows. Configure the chosen setpoint
number then select the next one.
Select the setpoint function using the side arrows list. Some examples:None= Not active,
High= Relay on above Setpoint value. Low= Relay on below Setpoint value
Total= Photomos pulse output to remote total counter. Use SP6 Photomos.
Net= Relay on if main display in net. Zero= Relay on if main display zero.
Power= Relay on when mains power on.
Fault= Relay on if fault (overrange, timeout, beltspeed low, RPM high,...)
Refill and Feed= Loss-in-weight outputs.
Note: The 6004MF treats relays and photomos (SSR) in the same way. Relays have
5A 250V AC change-over contacts and photomos is 0,5A 400V AC/DC.
Use relay outputs for higher current switching or for changeover contacts.
Use photomos for totaliser outputs and solenoids to prevent contact burnout.
Setpoint Tracks: allows you to select which variable the setpoint is compared to.
Side arrows to select Gross, Net, Main [display], Count or Total.
Setpoint Hysteresis: Use keypad to set 000-999 counts to reset setpoint relay below
High value or above Low value
Setpoint Delay: Use keypad to set 000-999 seconds delay before setpoint relay
energises
Setpoint LED: Use side arrows to select Normal (LED on when relay energised) or
Inverted (LED off when relay energised)
Setpoint Latch: Use side arrows, No or Yes. If Yes you must select a reset such as
D1-6 (Digital Inputs) or F1-4 (Function Keys) or power off.
Setpoint Reset: This displays the reset activator above
When all changes (SP1-6) are completed press Enter +. This will set the whole block
and move on to the next block, in this case ANALOG OUTPUT.
Service Menu
Page 16
Service Menu
Function Block Number 02
02. - SETPOINT CONFIGURATION -
SETPOINT
CONFIGURATION
02
SETPOINT VALUES
SERVICE
C
ANALOG OUTPUT
- SP CONFIGURATION SETPOINT
: SP1
Or 2-6
SP1 MODE
: HIGH
Or Low, None ........
SP1 TRACK
: GROSS
Or Net,Rate,Display,Total,None,Beltspeed,Max,Min
SP1 HYSTERESIS
: 000
Key
Counts 000-999, Hysteresis
SP1 DELAY
: 000
Key
Seconds 000-999, delay before activation
SP1 LED
: NORMAL
Or inverted (LED Off, Relay On)
SP1 LATCH
: OFF
Or On
SP1 LATCH RESET PB : NONE
Display
F1-4 (Function Keys), None
SP1 LATCH RESET DI : NONE
Display
D1-6 (Digital input), None
Set Values
ANALOG OUTPUT
03
SETPOINT CONFIGURATION
SERVICE
C
SERIAL INTERFACE
- ANALOG OUTPUT -
Off, High, Low, Power, Faulty, Net, Zero, Total 1 out, Liw feed, Liw Refill. Liw time Out, ...
None, Gross, Net, Max, Min, Display, Belt Rate, Belt Speed, Totaliser 1, Totaliser 2, LIW Rate....
Page 17
Service Menu
Function Block Number 03
03. - ANALOG OUTPUT -
To view or alter the analog output settings press Enter + when the ANALOG OUTPUT
function block is displayed. All values can be inserted or altered when highlighted. Do
not press enter until all required changes to the entire block are completed.
The Analog Output is isolated from the input and power supply for safety. You can select
a standard analog output from 0-20mA, 4-20mA, 1-5V or 0-10V. This output can then be
ranged to suit your tracked value or less. Tracks: allows you to select the measurement
that the analog output will follow and Fault Value: is the analog output under fault
conditions. When Fault Value is set to off then the analog value continues to track the
selected measurement.
Analog Output: Use side arrows to select from 0-20mA, 4-20mA,1-5V or 0-10V
Tracks: Use side arrows to select analog output tracking of Gross, Net, Rate, (main)
Display, kW, RPM, Torque, minimum, maximum, none, Total....
4mA value: (or 0mA, 0V or 1V value) Use keypad to insert lower scale value.
20mA value: (or 5V or 10V value) Use keypad to insert a full scale value.
Fault output: What occurs to the output when a fault condition (overrange, underrange,
timeout, etc) occurs. Use side arrows to select high, low, off or value. If higher then output
goes to 21mA (or 5.5V or 10.5V). If low then output goes to 0mA (or 0V or 0V). If off then not
active, if value then use keypad to select output value.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case COMMUNICATIONS.
Page 18
Service Menu
Function Block Number 03
03. - ANALOG OUTPUT -
ANALOG
OUTPUT
03
SETPOINT CONFIGURATION
SERVICE
C
COMMUNICATION
- ANALOG OUTPUT TRACK
: GROSS
Or Net, Display, Min, Max, Total, Rate, Belt speed,none
ANALOG OUT
: 4-20 mA
Or 0-20mA or 0-10V, 1-5V
Or (0) or (1)
4 VALUE
: 000.000
Key
Low Scale Value
Or (10) or (5)
20 VALUE
: 020.000
Key
High Scale Value
FAULT MODE
: LOW
FAULT VALUE
: 024.000
If Value
Or high or Value, or off
Key
In Value
Set Values
SERIAL
INTERFACE
04
ANALOG OUTPUT
SERVICE
C
MIN/MAX HOLD
- SERIAL INTERFACE -
Track: None, Gross, Net, Max, Min, Display, Belt rate, Belt speed, Totaliser 1, Totaliser 2, .....
Page 19
Service Menu
Function Block Number 04
04. - COMMUNICATION -
To view or alter the serial interface settings press Enter + when the SERIAL INTERFACE
function block is displayed. All values can be inserted or altered when highlighted. Do
not press enter until all required changes to the entire block are completed.
Unit Address: is needed when using RS485. Use the keypad to select.
Protocol: is currently ASCIIBUS. Future selections will be MODBUS and a propriety
flexable protocol format compiler, BUILDABUS.
Line Settings: can be off (NO) or on (YES) in which case you can select Baud Rate, Data
Bits, Stop Bits and Parity.
Press Enter to set and return to the Communications menu.
ASCIIBUS setup: can be off (NO) or on (YES) in which case you can select:- Track: None,
Gross, Net, Max, Min, Display, Belt rate, Beltspeed, Totaliser 1, Totaliser 2, .....
Time&Date: Off or On
Mode: Continuous or On demand
If On demand the Print pushbutton and digital input will be shown if selected.
Press enter to set and return to the Communications menu
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case MIN/MAX .
Page 20
Service Menu
Function Block Number 04
04. - COMMUNICATION -
COMMUNICATIONS
04
ANALOG OUTPUT
SERVICE
C
MAX/MIN
- COMMUNICATIONS Key
UNIT ADDRESS : 00
PROTOCOL
: ASCIIBUS
LINE SETTING
: NO
If Yes
00 - 99
Or yes
- LINE SETTING BAUD RATE
: 1200
Or 2400, 4800, 9600, 14 400.
19 200, 28 800, 38 400, 57 600 or 115 200
DATA BITS
: 7
Or 8
STOP BITS
: 1
Or 2
PARITY
: NONE
Or Odd or Even
ASCIIBUS SETUP: NO
- ASCII SETUP TRACK
: NONE
Gross, Net, Max, Min, Display, Belt Rate,
Belt Speed, Totaliser 1, Totaliser 2, ...
TIME & DATE
: OFF
Or On
MODE
: CONTINUOUS
Or on Demand
PRINT PB
: NONE
Display F1-4 (Function Keys), None
PRINT DI
: NONE
Display D1-6 (Digital Inputs), None
MAX/MIN
05
COMMUNICATION
SERVICE
C
NET/GROSS ( OR SECURITY LEVEL)
- MAX/MIN -
Page 21
Service Menu
Function Block Number 05
05. - MAX/MIN -
To view or alter the min/max settings press Enter + when the MIN/MAX function block is
displayed. All values can be inserted or altered when highlighted. Do not press enter until
all required changes to the entire block are completed.
Tracks: use side arrows to select Gross, Net, Rate, Display...
Min Reset PB: display only, select in Service menu Function Keys (F1-4)
Min Reset Dig Input: display only, select in Service menu Digital Inputs (D1-6)
Max Reset PB: display only, select in Service menu Function Keys (F1-4)
Max Reset Dig Input: display only, select in Service menu Digital Inputs (D1-6)
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case NET/GROSS for Loadcell Transmitter and Batchweigher or
SECURITY LEVEL for Beltweigher, Loss-in-weight transmitter, Throughput Weigher,
Bag-filler and Dynamometer.
Page 22
Service Menu
Function Block Number 05
05. - MAX/MIN -
MAX/MIN
05
COMMUNICATIONS
SERVICE
C
NET/GROSS ( OR SECURITY LEVEL )
- MAX/MIN Or Net, Belt, Rate, Display,...
TRACKS
: GROSS
MIN RESET PB
: F3
Display
F1-4 ( Function Keys ),None
MIN RESET DI
: D3
Display
D1-6 ( Digital Inputs ), None
MAX RESET PB
: NONE
Display
F1-4 ( Function Keys ),None
MAX RESET DI
: NONE
Display
D1-6 ( Digital Inputs ), None
GROSS PB
: F3
Display
F1-4 ( Function Keys ),None
GROSS D1
: D2
Display
D1-6 ( Digital Inputs ), None
NET/GROSS
06
MAX/MIN
SERVICE
C
TARE
- NET GROSS -
Gross, Net, Belt rate, LIW rate
Page 23
Service Menu
Function Block Number 06
06. - NET/GROSS -
To view or alter the net/gross settings press Enter + when the NET/GROSS function
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
Gross is defined here as the total material mass without the dead weight of the bin itself.
(On weighbridges the gross is the measured mass without the mass of the deck)
Net is defined here as the change in material mass (positive or negative) displayed after
the bin has been tared.
Mode: Use side arrows to select Gross (main display locked in Gross only), Net (main
display locked in Net only) or Net/Gross (display can toggle between Gross and Net,
normally used for batching in or out a specific mass). We suggest that when Net/Gross is
selected that the Main display is set to Gross and the first auxiliary display is set to Net in
Service menu Displays. When Function key (F1-4) or Digital input D1-6 is set to Net/Gross
then these two displays will swop over.
The Net/Gross changeover can be activated through the Operator's menu.
Net/Gross Pushbutton: Display of None or F1-4 if selected in Function Keys.
Net/Gross Digital input: Display of None or D1-6 if selected in Digital Inputs.
Net Output: Display of None or SP1-6 if selected in Setpoint Configuration. The Net
output relay is used to signal that the LCT is in Net mode to some external device such as
a PLC.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case TARE.
Page 24
Service Menu
Function Block Number 06 (LTC)
06. - NET/GROSS -
NET/GROSS
06
MAX/MIN
SERVICE
C
TARE
- NET/GROSS Gross, Net, Net/Gross
MODE
: NET/GROSS
NET PB
: F3
Display
F1-4 ( Function Keys), None
NET DIGIN
: D2
Display
D1-6 ( Digital Inputs ), None
Display
SP 1-6 ( SP Configuration ), None
NET OUTPUT : NONE
TARE
07
NET/GROSS
SERVICE
C
AUTO ZERO
- TARE -
Page 25
Service Menu
Function Block Number 07
07. - TARE -
To view or alter the tare settings press Enter + when the TARE function block is
displayed. All values can be inserted or altered when highlighted. Do not press enter until
all required changes to the entire block are completed.
For this block to be active (On), Net or Net/Gross must be selected in the NET/GROSS
block above
Tare is defined as an instruction to zero the net value
Tare:
Use side arrows to select for Off or On.
If ON then:
The Tare can be activated through the Operator's menu.
Tare Pushbutton: Display of None or F1-4 if selected in function Keys
Tare Digital input: Display of None or D1-6 if selected in Digital Inputs
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case AUTO ZERO.
Page 26
Service Menu
Function Block Number 07 (LTC)
07. - TARE -
TARE
07
NET/GROSS
SERVICE
C
AUTO-ZERO
- TARE -
If On
Or Off
TARE
: ON
TARE PB
: F4
Display
F1-4 ( Function Keys ), None
TARE DIGIN: D4
Display
D1-6 ( Digital Inputs ), None
AUTO-ZERO
8
TARE
SERVICE
C
PRESET TARE
- AUTO ZERO -
Page 27
Service Menu
Function Block Number 08
08.- AUTO ZERO -
To view or alter the auto zero settings press Enter + when the AUTO ZERO function
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
Auto zero or Auto Zero Maintenance (AZM) can be used to automatically compensate for
zero drift which is usually caused by temperature changes or load cell creep (bonding
movement) or slight physical imperfections in the system. AZM can only be used for very
small amounts of zero drift or it will result in system errors (such as pulling a real reading
back to zero in a slowly filling weighbin). In Assized Systems the deviation and time is
defined.
AZM:
Use side arrows to switch Auto Zero Maintenance Off or On
If On then:Band: Use keypad to select the number of counts (000-127)
Time: Use keypad to select the time (000-999 seconds)
Example:- Band is 10 counts and Time is 30 seconds. If the average deviation (positive
or negative) is more than 10 counts over 30 seconds it is ignored. If it is less than 10
counts in 30 seconds the reading is brought to zero.
Max: Use keypad to select the maximum counts to be accumulated. Fault output is
activated and warning displayed on auxiliary LCD if maximum exceeded.
The accumulated value in the AZM register is cleared to zero if mains power is turned off,
if the AZM : is switched to Off or if Zero Trim (Backbalance) is activated.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case PRESET TARE.
Page 28
Service Menu
Function Block Number 08 (LTC or (06) Beltweigher or (06) Loss-in-Weight)
08.- AUTO ZERO -
AUTO ZERO
08
TARE
SERVICE
C
PRESET TARE
- AUTO ZERO Or On
AZM : OFF
If On
BAND : 010
Key
000-127 Counts
TIME : 030
Key
000-999 Seconds
MAX : 100
Key
000-999 Counts
PRESET TARE
09
AUTO ZERO
SERVICE
C
SECURITY LEVEL
- PRESET TARE -
Page 29
Service Menu
Function Block Number 09
09. - PRESET TARE -
To view or alter the preset tare settings press Enter + when the PRESET TARE function
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
Pretare can be used to manually offset a known tare weight. Imagine a quarrying
operation with many road trucks. As each truck comes on to the weighbridge the
Operator keys in the tare weight of the truck which is displayed on it's door. The gross
(contents) weight is then shown on the weigh indicator. This saves preweighing every
truck every time it comes to the quarry. The same procedure can be used for railcars or
containers to determine the gross (contents) weight.
Pretare: Use side arrows to select Off or On
If On:PRETARE: xxx.xxx will be displayed on first line of the LCD auxiliary display in the same
units and with same decimal place as Gross on the main scale. Press the down key for
three seconds to go to Setpoint Values, key in Pretare value and Enter + to offset the
Gross value on the main LED scale.
For this application we suggest that a function key (F1-4) is selected for Set Setpoints to
provide a short cut to the settings.
Before using Pretare the Precalibration, Zero Trim (backbalance) and Span Trim menus
should all be completed to ensure calibration and taring off the scale or weighbridge
deck.
When Pretare is switched ON then the PI Control is automatically turned off.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case SECURITY LEVEL.
Page 30
Service Menu
Function Block Number 09 (LTC)
09. - PRESET TARE -
PRESET TARE
09
AUTO-ZERO
SERVICE
C
SECURITY
- PRESET TARE PRETARE
Or On
: OFF
PRETARE PB : F1
Display
F1-4 (Function Keys), None
PRETARE DI : D1
Display
D1-6 (Digital Inputs), None
SECURITY LEVEL
10
PRETARE ( Or MIN/MAX Hold )
SERVICE
C
PRECALIBRATE
- SECURITY LEVEL -
Page 31
Service Menu
Function Block Number 10
10. - SECURITY LEVEL -
To view or alter the security level press Enter + when the SECURITY LEVEL function
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
The Security Levels set access to the various menus. The Operator's menu can always
be viewed in Security Level 0 but not altered. In Security Level 1 the Operator's menu
can be viewed/activated, with password can enter service menu, with link can alter. In
Security Level 2 the Operator's and Service Menu can be viewed or calibrated without a
password but will still require the hardlock to be in place on the back of the display PCB
for activation.
Level 1: View and activate Operators' Menu. Service Menu can be viewed WITHOUT
PASSWORD and activated (calibrated) with hardlock link .
Level 2: View and activate Operators' Menu. Service menu can be viewed WITH
PASSWORD and activated (calibrated) with hardlock link.
Level 3: View Operators' Menu only. Service menu can be viewed WITH PASSWORD
and activated (calibrated) with hardlock link.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case PRECALIBRATE.
Page 32
Service Menu
Function Block Number 10 (LCT or (07) Beltweigher or (07) Loss-in-Weight)
10. - SECURITY LEVEL -
SECURITY LEVEL
10
PRETARE ( 0R MAX/MIN)
SERVICE
C
PRECALIBATE
- SECURITY LEVEL Or 2
Activate Operator’s Menu only. Activate service
menu with password and hardlock on
LEVEL: 3
VIEW OPERATOR’S MENU
Or 1
Activate Operator’s and service menu without
password and with hardlock on
PRECALIBRATE
11
SECURITY LEVEL
SERVICE
C
ZERO TRIM
- PRECALIBRATE -
Page 33
Service Menu
Function Block Number 11
11. - PRECALIBRATE -
To view or alter the precalibrate menu press Enter + when the PRECALIBRATE function
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
Precalibrate is a simple way to set up a strain-gauge loadcell system. All the loadcell
variables are inserted here so that the system is reasonably accurate before adding test
weights. In some instances, such as very large weightanks where it is not possible to use
test weights, precalibration using factory test certificates for loadcell sensitivity results
in an acceptable overall system accuracy.
Excitation Voltage: Measure or Set.
In Measure you select an excitation voltage which the transmitter will generate. The
transmitter then measures the excitation voltage on it's own sense terminals and uses
this value in the display calculation.
In Set you can key in a theoretical excitation value. This is normally only used if the
system excitation is external, coming from a stable source other than the 6004MF.
Loadcell mV/V: This is the loadcell sensitivity and is nominally the mV/V on the lable or
specification sheet. For higher accuracy use the mV/V off the calibration certificate
supplied with the loadcell. For higher accuracies on multiple loadcell systems add all the
mV/V together and divide by the number of loadcells. All sensitivities should be
approximately the same on a multiple system. (Do not mix 2mV/V with 3mV/V) Good
quality loadcells have matched internal impedances.
Decimal: Select a decimal place in the six digit display to give the best reading in the
range and units required.(eg, 150.00 tonne or 1000.0 kg)
Zero: Key in low-end range, usually 000.000 with decimal point as selected above. (Can
also be 1.000 for example in Specific Gravity (SG) measurement)
Full Scale: Key in the full scale range of the system (For example, 3 x 10 tonne loadcells
equals 30.000 tonnes)
Units: Select (Metric) mg, g, kg, tonne, N or (Imperial) oz, lb, ton
Increment: Key in (001-100) 1 is 1,2,3. 2 is 2,4,6. 10 is 10,20,30 for last digit
Overrange: Key in. Typically fullscale + 20% or 80% bin capacity
Filter Band: Key in filter band (000-999)
Filter Value: Select filter time in seconds. 5, 10 or 20 seconds.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case ZERO TRIM.
Page 34
Service Menu
Function Block Number 11 (LCT or (08) Beltweigher or (08) Loss-in-Weight)
11. - PRECALIBRATE -
PRECALIBRATE
11
SECURITY LEVEL
SERVICE
C
ZERO TRIM
- PRECALIBRATE Or Set(from external excitation)
EX VOLTAGE : MEASURE
EX VALUE
: 10,0 VOLTS
Key
Key in excitation required
LC mV/V
: 2.000
Key
Loadcell sensitivity
DECIMAL
: xxx.xxx
ZERO
: 000.000
Key
Low Range
FS
: 020.000
Key
Full Scale Range
UNITS
: kg
Select Decimal Place
or Tonne, Newton, lb...
INCREMENT : 001
Key
001-100
OVERRANGE : 024.000
Key
Value
FILTERBAND : 0000
Key
00-99 Counts
5, 10 or 20 seconds
FILTER VALUE: 10 secs
ZERO TRIM
12
PRECALIBRATE
SERVICE
C
SPAN TRIM
- PRECALIBRATE -
Page 35
Service Menu
Function Block Number 12
12. - ZERO TRIM -
To alter the zero trim press Enter + when the ZERO TRIM function block is displayed. Do
not press enter until you are ready to zero trim
Zero Trim (or Backbalance) is the way the 6004MF automatically deducts the empty bin
weight (or weighbridge deck weight or beltweigher dead-weight) from the total loadcell
measurement to leave a pure gross weight. In most systems Zero Trim is carried out
during initial commissioning and at annual or bi-annual routine service intervals, but, in
some cases where the bin weight can change due to regular, permanent material buildup,
such as paint weighbins, Zero Trim may have to be carried out more often.
The standard averaging time for the Zero Trim to take place is 20 seconds but, in the case
of the Beltweigher application, this averaging time can be lengthened to exceed one belt
revolution by only pressing Enter when you want the zero averaging to end.
(Pressing Enter +early during trimming sets the zero value at that moment and may not
give a good average.)
When enter+is pressed for zero trim the auxilliary LCD display shows a time bar. Do not
move the system or add on extra weight whilst this zero trimming is taking place. At
completion of the time bar the main display should show 000000, the Zero Trim menu will
close and move on to the next block, in this case SPAN TRIM.
Page 36
Service Menu
Function Block Number 12 (LCT or (09) Beltweigher or (09) Loss-in-Weight)
12. - ZERO TRIM -
12
ZERO TRIM
PRECALIBRATE
SPAN TRIM
12
PRESS ENTER
TO START
SERVICE
C
- ZERO TRIM -
Busy with zero trim
Normally 20 second except in
Beltweigher settings
When Complete
13
SPAN TRIM
ZERO TRIM
SERVICE
C
LINEARISER
(OR ......SETTINGS)
- SPAN TRIM -
Page 37
Service Menu
Function Block Number 13
13. - SPAN TRIM -
To alter the span trim press Enter + when the SPAN TRIM function block is displayed. Do
not press enter until you have applied test weights and keyed in the test weight mass.
Span Trim is a way to set the range to a better accuracy than using the precalibration
values only. If possible use test weights to the full scale mass. If this is not possible due
to weighbin size or shortage of test weights then a partial load can be applied, preferably
as high as possible but should exceed 25% of the full scale value.
After applying test weights and keying in the test weight value press Enter+.
The auxilliary LCD display shows a time bar for 20 seconds. Do not move the system or
add on extra weight whilst this span trimming is taking place. At completion of the time
bar the main display should show the test weight value, Span Trim menu will close and
move on to the next block, in this case LINEARISER.
Page 38
Service Menu
Function Block Number 13 (LCT or (10) Beltweigher or (10) Loss-in-Weight)
13. - SPAN TRIM -
13
SPAN TRIM
ZERO TRIM
SERVICE
C
LINEARISE ( OR SETTING )
- SPAN TRIM LOAD TEST WEIGHT & ENTER
LOAD TEST VALUE
SPAN : + 000.000kg
Key in Test Weights Value
Press Enter
C
- SPAN TRIM Busy With Span Trim
SPAN : 000.000
Normally 20 seconds
When Complete
14
LINEARISER
SPAN TRIM
SERVICE
C
SIMULATE
- LINEARISER -
Page 39
Service Menu
Function Block Number 14
14. - LINEARISER -
To view or alter the lineariser settings press Enter + when the LINEARISER function
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
The Lineariser is used to correct any repeatable linearity errors due to poor quality
loadcells or mountings or weightank distortions. Be careful that errors are not caused by
fouling or friction as these will not be repeatable. The lineariser can also be used for other
applications such as converting mass to level in non-symetrical weightanks or for
inverting the output signal. The linearising is relative to the Gross display and decimal
point is as Gross.
If the Lineariser is selected On then up to 15 values in ascending order of actual input
values can be keyed in with corresponding desired output values.
For example, if a mid-range only correction of +10 counts is required on a full scale range
of 160,000 select 3 points, 1: 000,000 actual/desired, 2: 080,000 actual / 080,010 desired
and 3: 160,000 actual / 160,000 desired.
In run mode the linearisor will extrapolate output values between the inserted points, for
example 040,000 in above would be 040,005 out.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case SIMULATE for Loadcell Transmitter or SETTINGS for the
other applications.
Page 40
Service Menu
Function Block Number 14 (LCT or (13) Beltweigher or (12) Loss-in-Weight)
14. - LINEARISER -
LINEARISER
14
SPAN TRIM
SERVICE
C
SIMULATE ( OR SETTINGS )
- LINEARISER LINEARISER : OFF
Or On
If On
NUM OF POINTS : 02
02-15
Inputs must be
in ascending
order
ACTUAL 1
: 000.000
Key
Lowest Input Actual Value
DESIRED 1
: 000.000
Key
Desired Value
ACTUAL 2
: 000.000
Key
Next Actual Value
DESIRED 2
: 000.000
Key
Desired Value
15
SIMULATE
LINEARISER
SERVICE
C
FUNCTION KEYS
- SIMULATE -
Page 41
Service Menu
Function Block Number 15
15. - SIMULATE -
To view or alter the simulate settings press Enter + when the SIMULATE function block
is displayed. All values can be inserted or altered when highlighted. Do not press enter
until you no longer need the Simulate function.
Simulate is useful during commisioning to test analog and relay/photomos outputs
whether the system is running or not. All Simulate outputs default to inactive when not in
the Simulate function block.
Select the Analog output: to On and you can key in a value for the mA or Volt output
(which was selected in Analog Outputs). Select any Setpoint output (SP 1-6) and you can
use the side arrows to select On, Off or On/Off (which will cycle 1 second On and 1 second
Off).
When you no longer need the simulate function press Enter +. This will de-activate the
whole block and move on to the next block, in this case FUNCTION KEYS.
Page 42
Service Menu
Function Block Number 15 (LCT or (14) Beltweigher or (13) Loss-in-Weight)
15. - SIMULATE -
15
SIMULATE
LINEARISER
SERVICE
C
FUNCTION KEYS
- SIMULATE Or On
ANALOG OUT: OFF
If On
Value ( mA or V )
VALUE
: 00.000mA
SP1
: OFF
Or On or On/Off
SP2
: OFF
Or On or On/Off
SP3
: OFF
Or On or On/Off
SP4
: OFF
Or On or On/Off
SP5
: OFF
Or On or On/Off
SP6
: OFF
Or On or On/Off
Key
ALL SETTINGS DEFAULT TO OFF
16
FUNCTION KEYS
SIMULATE
SERVICE
C
DIGITAL INPUTS
- FUNCTION KEYS -
Page 43
Service Menu
Function Block Number 16
16. - FUNCTION KEYS -
To view or alter the Function Keys settings press Enter + when the FUNCTION KEYS
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
The Function keys (F1-4) on the front keypad of the 6004MF can be individually selected
for a number of functions such as None, Tare, Display Gross, Display Net, Display Power,
Display RPM, Display Torque, Set Setpoints, Display Setpoints, Print, Reset Min/Max,
Reset Latch, Start, Stop, Man/Auto, Service menu, .......
Note that in run mode pressing any Function key first displays the function chosen. Press
it again to activate the function.
Default functions
F1
F2
F3
F4
Loadcell Transmitter
Set SPs
Print
Reset peak Tare
Suggested Functions for other applications
Loadcell + PI Control
Loadcell Tx + Pretare
Set SPs
Set Sps
Start PI
Print
Man/auto
None
Stop
None
Beltweigher
Beltweigher + PI
Set Sps
Set Sps
Print
Start PI
Show Rate Show Total
Man/Auto Stop PI
Loss-in-Weight Tx
L-in-W + PI Control
Set Sps
Set Sps
Start LiW
Start PI
Print
Man/Auto
Stop LiW
Stop LiW
Throughput Weigher
Set Sps
Start TPut
Residual
Stop TPut
Dynamometer
Set Sps
Show kW
Show RPM Show Torque
Bag Filler
Set Sps
Start BFill
Print
Batch Weigher
Set SPS
Start Batch Add Water
Stop BFill
Stop Batch
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case DIGITAL INPUTS.
Page 44
Service Menu
Function Block Number 16 (LCT or (15) Beltweigher or (14) Loss-in-Weight)
16. - FUNCTION KEYS -
16
FUNCTION KEYS
SIMULATE
SERVICE
C
DIGITAL INPUTS
- FUNCTION KEYS F1: SET SETPOINTS
Or
F2: PRINT
Or
F3: RESET PEAK
F4: TARE
Or
Or
17
DIGITAL INPUTS
FUNCTION KEYS
SERVICE
C
DISPLAYS
- DIGITAL INPUTS -
No Function, Tare, Toggle Net/Gross, Print, Reset Sp Latch, Reset, Max Value,
Reset Min Value, Reset MIN/MAX, Reset Totaliser 1, Set Setpoints, Pretare,
PI man/auto, PI Start, PI Stop LIW Start, LIW Stop ......
Page 45
Service Menu
Function Block Number 17
17. - DIGITAL INPUTS -
To view or alter the digital inputs press Enter + when the DIGITAL INPUTS function block is
displayed. All values can be inserted or altered when highlighted. Do not press enter until all
required changes to the entire block are completed.
Digital Inputs (D1-6) are inputs from remote potential free contacts. Contact closure activates the
input. Each input can be individually selected for a number of functions such as None, Tare,
Toggle Net/Gross, Show Gross, Show Net, Show Power, Show RPM, Show Torque, Print, Set
Setpoints, Min/Max Reset, Reset Latch, Start.., Stop.., Man/Auto, Residual, Interlock 1-5, Add
Water, .......
Default inputs
Loadcell Tx
D1
D2
D3
D4
D5
D6
None
Net/Gross
M/M reset
Tare
None
None
Suggested Digital Inputs for other applications
LCT + Pretare
LCT + PI
None
Stop LCT
Set Sps
None
M/M reset
M/M reset
Print
Print
None
Start PI
None
Man/auto
Beltweigher
Belt W + PI
None
Stop BW
Tot reset
Tot reset
M/M reset
M/M reset
Print
Print
None
StartPI
None
Man/Auto
Loss-in-Wght
Loss in W+PI
Stop LiW
Stop LiW
Tot reset
Tot reset
M/M reset
M/M reset
Print
Print
Start LiW
Start LiW
Non
Start PI
Throughput
StopTP Tot reset Discharge
Print
Start TP
Residule
Dynamometer
None
Print
M/M reset
Show kW
Show Nm
Show RPM
Bag Filler
Stop BW
Tot reset
RemoteTare
Bagclamp
Psensor
FootSwitch
Batch Weigh
Stop BW
Intlok1
Intlok2
Intlok3
Intlok4
Start Batch
When the entire block is ready press Enter
next block, in this case DISPLAYS.
Page 46
. This will set the whole block and move on to the
Service Menu
Function Block Number 17 (LCT or (16) Beltweigher or (15) Loss-in-Weight)
17. - DIGITAL INPUTS -
17
DIGITAL INPUTS
FUNCTION KEYS
SERVICE
C
DISPLAYS
- DIGITAL INPUTS D1
: NONE
Or
D2
: NET/GROSS
Or
D3
: RESET MAX/MIN
Or
D4
: TARE
Or
D5
: NONE
Or
D6
: NONE
18
DISPLAYS
DIGITAL INPUTS
SERVICE
C
PI CONTROL
- DISPLAYS -
No Function, Tare, Toggle Net/Gross, Print, Reset SP Latch, Reset Max Value,
Reset Min Value, Reset min/max, Reset Totaliser 1, Set Setpoints, Show setpoints,
Pretare, PI man/auto, PI Start, PI Stop, LIW Start, LIW Stop ......
Page 47
Service Menu
Function Block Number 18
18. - DISPLAYS -
To view or alter the displays selection press Enter + when the DISPLAYS function block is
displayed. All values can be inserted or altered when highlighted. Do not press enter until
all required changes to the entire block are completed.
The Displays function block allows you to select what you want the Main LED display to be
as well as up to four selections for the LCD graphics display. In most common uses for the
Loadcell transmitter and Bagfiller the Main display would be Gross, with a Beltweigher and
Loss-in-weight transmitter it would be Rate, a Throughput weigher Total and the
Dynamometer would be kW or HP.
The auxilliary LCD display can be used for a group of other useful values such as (for LCT)
net, analog output, mV, excitation voltage,... (Beltweigher) belt speed, (Loss-in-weight)
gross [bin contents], (Throughput) non-resettable total, (Bagweigher) bag total,
(Dynamometer) RPM & torque and (Batchweigher) aggregate and water values.
Note that if PI Control (Service menu function block 19) is selected then the first line of the
auxilliary LCD automatically becomes Manual Output (00.0-99.9)% and the next line
becomes Auto Setpoint 000,000 . These values can be changed in the Setpoint Values
menu, hold down arrow 3 seconds (or set F1-4 for setpoint values) and you go into
Operator's menu (observe Security Level). Values can be keyed in and entered when in run
mode.
If Preset Tare (Service menu, function block 9) is selected then the Pretare Value will be
displayed on the first line. The value can be keyed in and entered in Setpoint Values when
in run mode. Select F1-4 for Setpoint Values.
Default displays
Main
Aux1
Aux2
Aux3
Aux4
Loadcell Transmitter
Gross
Net
Ex Volts
mV
A Out
Auto SP
None
Reset Total
Auto SP
Total
Auto SP
Gross
RPM
Gross
Total
None
None
Beltspeed
Total
Reset Total
Gross
None
Max
None
Reset Total
A Out
A Out
A Out
A Out
A Out
A Out
None
None
None
None
Suggested displays for other applications
Loadcell + PI Control
Gross
Man %
Loadcell Tx + Pretare
Gross
Pretare
Beltweigher
Rate
Total
Beltweigher + PI
Rate
Man %
Loss-in-Weight Tx
Rate
Gross
L-in-W + PI Control
Rate
Man %
Throughput Weigher
Total
Reset Total
Dynamometer
kW
Nm
Bag Filler
Total
Reset Total
Batch Weigher
Gross
Net
When the entire block is ready press Enter +. This will set the whole block and move on
to the next block, in this case PI CONTROL.
Page 48
Service Menu
Function Block Number 18 (LCT or (17) Beltweigher or (16) Loss-in-Weight)
18. - DISPLAYS -
18
DISPLAYS
DIGITAL INPUTS
SERVICE
C
PI CONTROLS
- DISPLAYS MAIN: GROSS
Or
AUX1: NET
Or
AUX2: EXCITATION
Or
AUX3: mV
Or
AUX4: ANALOG OUTPUT
Or
19
PI CONTROL
DISPLAYS
SERVICE
C
TRANSMITTER SETTINGS
- PI CONTROL -
Gross, Net, Max, Min, Totaliser 1, Totaliser 2, Belt Rate, LIW Rate
None, Gross, Net, Max, Min, Totaliser 1, Totaliser 2, Belt Rate, Beltspeed, Beltfreq, Analog out, mV,
Ex Voltage, Date and Time, PI Man output, PI Auto SP, Setpoint 1, 2, 3, 4, 5, 6, Tare Value,
Model Number, Preset Tare, Tag Number, Message, F1, 2, 3, 4, e=0000, RPM, Torque Nm, Torque,
ft/lb, Power kW, Power HP
If Preset on Then AUX1: Preset ( 000,000 )
If PI Control on then AUX1: Manual Output 00.0%,
and AUX2; Auto Setpoint 000.000
Page 49
Service Menu
Function Block Number 19
19. - PI CONTROL To view or alter the PI control selection press Enter + when the PI CONTROL function
block is displayed. All values can be inserted or altered when highlighted. Do not press
enter until all required changes to the entire block are completed.
When the PI Control function is switched On the 6004MF becomes a PI
(proportional+integral) controller. This function can only be used where the application
is controllable such as load, rate or specific gravity (SG). For example where a loadcell
weighing system is controlling the level in a surge tank, controlling SG in an overflow
tank or where a Beltweigher or Loss-in-Weight can measure a flow rate which can be
varied by a control actuator or variable drive.
In order to take a control action you need a Process Variable (PV) (load, rate, SG) which
must be on the Main display and is compared to the Setpoint (SP).
PI Control Action: is normally set for Reverse Action ( Increasing PV results in decreasing
output) but some systems may need Direct Action (increasing PV results in increasing
output).
Start: selection allows you to set the controller to start in Manual with the output value set
in Setpoint Values and displayed on the auxiliary LCD to a percentage (00-99,9%) of the
chosen analog output. Only when Man/Auto F3 (or F1-4 or D1-6) is activated does the
output follow the PI Control action. If Auto is selected then the output goes to Manual %
for one second to set the start value then automatically begins controlling from the Auto
Setpoint value. If Power on is selected the PI action will automatically begin in Auto mode
20 seconds after the power is applied to the 6004MF.
The Start Pushbutton: displays the Start activator, suggest F2 (F1-4 or/and D1-6) select in
Function keys or Digital Inputs.
The Manual/Automatic: displays the Man/Auto activator, suggest F3 (F1-4 or/and D1-6)
select in Function Keys or Digital Inputs.
With PI Control the analog output is now no longer proportional to the measured variable
(load, rate or SG) as in a transmitter but is proportional to the deviation of the measured
Process Variable from the Auto Setpoint which is set in Setpoint Values and displayed on
the auxiliary LCD. The proportional action can be varied using the P-Gain setting (0,5 to
50,0). A low proportional gain setting results in weak corrections whilst a high gain value
can overreact causing wild oscillations. To correct for any offset due to system load
variations the Integral Time can be set from 001-999 seconds. (000 is treated as off). A low
time value results in a fast offset correction and a long time a very slow offset correction.
When the entire block is ready press Enter +. This will set the whole block and move on to
the next block, in this case TRANSMITTER SETTINGS.
Ziegler-Nichols Closed Loop Tuning
When optimising start the loop in automatic with a gain low enough to prevent oscillation.
Increase the gain in steps one half the previous gain, If no oscillation occurs change the
Setpoint slightly in order to trigger an oscillation. Adjust the gain until the oscillation is
sustained. If the oscillation is increasing decrease the gain slightly. If it is decreasing,
increase the gain slightly. Note the gain which causes the sustained oscillation and
measure the period of oscillation (high peak to high peak). Set the P-Gain to 45% of this
value. To optimise the integral time take the period of oscillation and set the I-Time to 1,2
x oscillation period in seconds.
Page 54
Service Menu
Function Block Number 19 (LCT or (18) Beltweigher or (17) Loss-in-Weight)
19. - PI CONTROL -
PI CONTROL
19
SERVICE
DISPLAYS
C
TRANSMITTER SETTINGS
- PI CONTROL -
If On
PI CONTROL
: OFF
Or On
ACTION
: REVERSE
Direct
START
: MANUAL
Auto ( Start MAN, 2”, go to Auto ),Power on
P-GAIN
: 01.0
Key
Proportional Gain ( 00.5 - 50.0 )
I-TIME
: 000 SECS
Key
Integrating Time 001-999 secs,000 = Off
START PB
: F2
Display
F1-4 ( Function Keys ), None
START DIGIN
: NONE
Display
D1-6 ( Digital Inputs ), None
MAN/AUTO PB
: F3
Display
F1-4 ( Function Keys ), None
MAN/AUTO DIGIN : NONE
Display
D1-6 ( Digital Inputs ), None
STOP PB
: NONE
Display
F1-4 ( Function Keys ), None
STOP DI
: D1
Display
D1-6 ( Digital Inputs ), None
20
TRANSMITTER SETTINGS
PI CONTROL OR DISPLAYS
SERVICE
C
SETPOINT VALUES
- TRANSMITTER SETTINGS -
PI Control Formula used in the 6004MF
REVERSE ACTING : Ao = Mo + Pg.E + Pg.E.Ts/Ti + Ic
DIRECT ACTING : Ao = Mo - Pg.E - Pg.E.Ts/Ti - Ic
Where
Ao = Analog output % (Volt or mA as selected in Analog out)
E = Deviation error ± % = ( SP % - PV % )
Pg = Proportional Gain ( P-Gain: 0,01 - 50)
Ts = Sample period seconds (fixed to 1 second)
Ti = Integration Time seconds ( I-Time: 001 to 999)
Mo = Manual analog output % (00-99,9%)
Ic = Start at 0, each 1 sec cycle add previous Pg.E.Ts/Ti value
PV = Process Variable % (PV value in % , 00-99,9%)
SP = Auto Setpoint % ( Auto SP in % , 00-99,9%)
Page 55
Service Menu
Function Block Number 20
20. - TRANSMITTER SETTINGS -
To view or alter the Transmitter Settings selection press Enter + when the
TRANSMITTER SETTINGS function block is displayed. In this function block use
Enter to set each sub-menu and return to the Tx Settings menu.
The Transmitter Settings are used to set functions related to the transmitter itself.
These include Cold Start, LCD Contrast, Unit Information, Change Password, Access
code for calibration, Hardware fitted Menu timeout, Date & Time and Reset Totaliser 2.
Cold Start: No (or Yes) is used to reset the 6004MF to default factory settings. This may
be used due to requiring a new starting point for programming or if an old unit is being
used on a new system and you want to clear all old programming data. Please note
that all your existing programming will be lost and you will have to re-enter all values
and re-commission the system.
Contrast: use side arrow for LCD screen contrast bar display.
Unit Information: use side arrow to display Model, Version and Serial number.
Change Password: use side arrow to display Change Password menu.
Access Code: use side arrow to display Access Code. Key in the Password to enter the
calibration menu and follow instructions for calibrating internal mV, Excitation
Voltage, mA outputs and Voltage outputs.
Hardware Options: use side arrow to List Hardware options fitted. These are Setpoints:
1-6, SD card: No (or yes), GPS: No (or Yes).
Menu Timeout: No (or Yes) (Use No during commissioning)
Date & Time: use side arrow to display Date/Time menu. Date is YYYY:MM:DD, Time is
displayed as a 24 hour clock HH:MM:SS. Move highlight down and key in the values.
Press Enter to set and return to Tx Settings menu.
Reset Totaliser 2: No (or Yes) Caution! This is the 'non-resettable' totaliser. Press
Enter to reset and return to the Tx Settings menu.
When you have completed all changes to the block press Enter+. This will move on to
the next block, in this case SETPOINT VALUES at the beginning of the service menu.
Pressing Clear will then take you to the Service Menu block and Clear again to RUN.
Page 50
Service Menu
Function Block Number 20 (LCT or (19) Beltweigher or (18) Loss-in-Weight)
20. - TRANSMITTER SETTINGS 20
TRANSMITTER
SETTINGS
SERVICE
PI CONTROL
C
SETPOINT VALUES
- TRANSMITTER SETTINGS COLD START
- COLD START -
: NO
C
RESET ALL SETTING
TO FACTORY DEFAULTS?
NO
YES
RESET
CONTRAST
: NO
C
SET
UNIT INFORMATION : NO
- UNIT INFORMATION -
C
MODEL : 6004MF
VERSION: V3
SERIAL :
- NEW PASSWORD -
CHANGE PASSWORD: NO
C
NOW: 0000
NEW: _ _ _ _
SET
ACCESS CODE
: NO
- ACCESS CODE -
C
ENTER ACCESS CODE
____
WRONG / TIMEOUT
- CALIBRATION MENU -
C
HARDWARE OPTIONS : NO
- HARDWARE FITTED -
C
MENU TIME OUT
: OFF
SET DATE & TIME
: NO
SP1+2 :
SP3+4 :
SP5+6 :
SD CARD:
GPS
:
NO
NO
NO
NO
NO
Yes
Yes
Yes
Yes
Yes
OR ON
- SET DATE/TIME -
C
RESET TOTALISER 2: NO
mV INPUT: NO
EXCITE VOLTAGE: NO
mA OUTPUT: NO
VOLTS OUTPUT: NO
SET YEAR
:____
SET MONTH : _ _
SET DAY
:__
DATE YYYY:MM:DD
SET HOUR
:__
SET MINUTE : _ _
SET SECONDS: _ _
TIME HH:MM:SS
Key in
Key in
Key in
Display
Key in
Key in
Key in
Display
OR YES
GO TO SETPOINT VALUES
Page 51
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