Hardy HI 4050 User Manual Download

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Configuration

•

Click the blue RIGHT arrow at the bottom of the screen.

NOTE:

If you are asked for a security code, enter the High security code. If you don’t know the
password and cannot access this screen, see your system administrator.

Normally, you will not need to manually adjust the gain or offset values.**

Summary of Contents for HI 4050

Page 1: ...Weight Controller HI 4050 User s Guide Hardy Process Solutions Document Number 0596 0303 01 REV W ...

Page 2: ...ts 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 9550 or Emergency Service after hours Standard Hours 6 30 AM to 5 30 PM Pacific Standard Time and weekends Ext 9550 Outside the U S Hardy Process Solutions has built a n...

Page 3: ... Mapped I O 4 WAVERSAVER 4 WAVERSAVER 4 C2 Calibration 4 Integrated Technician 5 Secure Memory Module SMM SD 5 Model Numbers 5 Model Number Option Symbols 5 Mounts 5 Power Supply 5 Internal Options 6 Network Options 6 Auxiliary Options 6 Rate of Change Option 6 Analog Output Option 6 Digital I O Option 6 RIO Option 7 ControlNet Option 7 Profibus Option 7 DeviceNet Option 7 Communication Options 7 ...

Page 4: ...ble Lithium batteries 10 Common Mode Rejection 11 Environmental Ranges and Limits 11 Operating Temperature Range 11 Storage Temperature Range 11 Temperature Coefficient 11 Humidity Range 11 Maximum Altitude for Installation 11 Approvals 11 Physical Characteristics 12 Panel Mount 12 Din Rail Mount 12 Wall Mount 12 Option Cards 12 Analog Option Card 12 Current Outputs 12 Voltage Output 12 Resolution...

Page 5: ...iring 25 AC Input Power Wiring AC 26 DC Power Input DC 27 Printer Scoreboard Wiring 27 External Inputs 1 3 28 Disassembly and Reassembly Notes and Cautions 28 Installing Printed Circuit Boards 29 Installing Option Cards 30 Installing a Card in the Option Slot applies to 4ANB and DIO 30 Installing Labels 32 Wiring the Analog Output Card 32 Analog Output Wiring 35 Wiring the Digital I O Option Card ...

Page 6: ... Configuring EtherNet IP from the Web page 53 Rate of Change ROC Option Configuration 55 ROC Time Base 55 Configuring Rate of Change From the Browser 55 ROC Configuration from the Front Panel 56 Configuring Rate of Change 57 Modbus TCP IP 59 Enabling Modbus TCP IP from the Front Panel 59 Configuring MODBUS TCP IP Over Ethernet 10 socket max 63 Error Messages 63 Analog Card Option Configuration 64 ...

Page 7: ...e Parameters Gross Weight 86 Tare Weight Parameter Net Weight 87 Capacity Parameter 87 RANGE 000001 999999 Default 999999 87 Certification Parameter 88 LCD Contrast Parameter 88 Printer and Time Setup Parameters 89 Printer Scoreboard Setup 89 Setup From the 4050 Interface 90 Configuring Date and Clock 90 Setup From the Web Interface 91 Setup From the 4050 Interface 91 Set Points 92 Parameters 93 D...

Page 8: ...tput 113 Data Types 115 Example 2 Mapping an Input 116 Simple Mapping Example from the Front Panel 117 Advanced Mapping 117 Boolean Mapping 117 Example 3 Mapping an Network Input to a Local Output 118 Example 4 Mapping a Switch 120 Command Word HSO2 and Status Word HSI1 121 Analog Mapping 122 Mixed Mapping 122 Special Command Mapping 123 Setting up the Command Interface Mapping 123 The Command Int...

Page 9: ...mV V are DC voltage signals between 0 3 0000 mv v 139 RTZ Return to Zero Test 139 IT Test 139 Sensor Number 139 Audit Trail 140 General Troubleshooting Flow Chart Index 141 A Guidelines for Instabilities on Formerly Operating Systems 142 A1 Guidelines for Instabilities on Formerly Operating System Cont d 143 B Guidelines for Instabilities on Formerly Operating Systems Cont d 144 B1 Guidelines for ...

Page 10: ...ity Test 161 Weight and Voltage Tests 162 Return to Zero test 165 Checking Inputs and Optional Outputs 165 Viewing System C2 Load Sensors 166 SMM SD Card Directory 167 Audit Trail and Event Log 168 Checking Network Connections and Configuration with the Ping Tool 168 Selecting the module by IP Address for Testing 168 General Policies and Information 169 Ordering Replacement Parts 169 Software Down...

Page 11: ...weighing web tension and vibration analysis applications You can also update the HI 4050 User Guide The latest revised manuals are available FREE in the product Documents Software tab on the HI 4050 page on our Web Site Other pages on the site provide answers to questions about load points process weighing vibration analysis tension control or other Hardy Process Solutions products Be sure to sign...

Page 12: ...ceNet interface allows multiple applications to be viewed and controlled from one display and enables 3rd party I O to be easily added to the system Mapped I O saves you wiring costs by distributing the I O where you need it at the process or in the control room The available communication protocols allow you to integrate the controller into your corporate network enabling data to be transferred t...

Page 13: ...browser or over a network You can read individual load sensor voltages and weights make comparisons and isolate individual system components for quick and easy troubleshooting Enclosure Options N4 used when no junction cards are specified IT1 Integrated Technician Summing with AUX connector IT2 Integrated Technician Summing with trim pots JB1 Standard summing card with AUX connector JB2 Standard s...

Page 14: ... WAVERSAVER technology that eliminates the effects of vibratory forces present in all industrial weight control and measurement applications By factoring out almost all of the ambient vibratory forces the controller can separate out the actual weight data WAVERSAVER can be configured from the front panel to ignore noise with frequencies as low as 0 25 Hz or as high as 7 0 Hz One of five higher add...

Page 15: ...libration and setup data thereby protecting this information from loss and or corruption The SD card dramatically increases the HI 4050 s non volatile storage capacity and flexibility Furthermore the SD card can be read by a PC with an SD card reader Each controller is equipped with one SD Card for additional SD cards and SD card readers writers and adapters contact your local Hardy Representative...

Page 16: ...can be set to units per second minute or hour A time base of discrete values is selectable from 1 to 1800 Analog Output Option Each of four independent analog outputs per option card is configured from the front panel or the embedded web server Two outputs are voltage and two are current This option allows the transmission of gross net available Rate of Change ROC or mapped weight Mapped weights c...

Page 17: ...rocess control systems communicate through a fast serial RS485 connection with distributed field devices e g PLCs 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 DeviceNet Option The DeviceNet Network is an open industry standard communication network protocol designed ...

Page 18: ...8 Chapter 1 ...

Page 19: ...attempting an installation or repair of the instrument General Channels and Display Number of Channels 1 Channel Update Rate 110 or 250 Updates per Second HI 4050 110 Updates per Second HI 4050 Resolution 1 10 000e HI 4050 1 30 000e HI 4050 Displayed 1 985 000 3 mV V 1 656 000 2 mV V Internal 1 1 048 576 Display 128 x 64 Backlit LCD Tricolor Graphic Display with Blue and Green display options and ...

Page 20: ...ble Non Linearity 0 0015 of Full Scale Digital Voltmeter Accuracy 2 of full scale C2 Maximum Cable Length 1000 for C2 Non C2 load cells or JB Summing Card 250 for IT Summing Card WAVERSAVER 7 5 Hz 3 5 Hz 1 0 Hz Default 0 5 Hz 0 25 Hz OFF Power and Utility Ranges and Limits Voltage 12 27 VDC Class 2 AC 120 240 VAC Universal Optional Frequency 50 60 Hz Power 10 Watts maximum with options Battery Use...

Page 21: ...DC current Hazardous Locations 10 to 50º C 14º to 122º F using AC DC current Storage Temperature Range DR Type 40 to 85º C 40 to 185º F PM Type 30 to 70º C 22 to158º F Temperature Coefficient Less than 0 005 of full scale per degree C for zero and span Humidity Range 0 90 non condensing Maximum Altitude for Installation 2000 Meters 6 562 Feet Approvals UL CUL Hazardous Class I Division 2 Groups A ...

Page 22: ...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 2 99 H x 5 65 W x 3 125 D 75 9 mm H x 143 51 mm W x 79 37 mm D Wall Mount Stainless steel NEMA4 wall mount with or without display Dimensions 11 50 h x 8 28 w x 5 54 d 292 1 h x 210 3 w x 140 6 d mm Option Cards Analog Option Card Current Outp...

Page 23: ... 5V pull up min 3V at 5mA out Protected against input over voltage above 30V short term Inputs Three optically insulated inputs 24 VDC input 30 VDC Maximum 3V min input high 1V max input low Input load about 350 Network Option Cards Profibus Card Connector 9 pin serial connector female RIO Card Connector 5 pin connector DeviceNet Card Connector 5 pin connector ControlNet Connector BNC channels A B...

Page 24: ...14 Chapter 2 ...

Page 25: ... package matches the bill of lading Step 3 If items are missing or you have any questions contact Customer Service at Hardy Process Solutions 9440 Carroll Park Drive San Diego CA 92121 Phone 800 821 5831 FAX 858 278 6700 Web Site http www hardysolutions com E Mail hardysupport hardysolutions com WARNING EXPLOSION HAZARD SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR DIVISION 2 AVERTISSEMENT...

Page 26: ...ole pattern in the panel door or cover using the dimensions provided on the diagrams below Panel Hole Dimensions drawn from the back and not displayed to scale Printers and copy machines can distort or reduce the template measurements Verify the dimensional accuracy of any paper template before use WARNING YOU MUST INSTALL THE HI 4050 IN A NEMA 4X ENCLOSURE WHEN USING THIS INSTRUMENT IN A CLASS I ...

Page 27: ... you must drill the top center hole and install with the 6 32 x 1 2 inch screw Step 3 Using a Phillips head screwdriver install the five 6 32 x 1 2 inch screws that fasten the bezel to the panel Use a torque screw driver and torque each screw to 10 inch pounds DO NOT OVERTIGHTEN Step 4 Thread the four threaded rods through the appropriate holes in the panel and into the bezel Step 5 Hand tighten e...

Page 28: ... 32 thumb screws onto the threaded rods until tight Do not use pliers on the thumb screws NOTE The cable orientation is important to insure you do not pinch the ribbon cable when assembled Installing the Wall Mount HI 4050xxWS Weight Controller Wall mounting to dry wall backing The enclosure s four mounting holes are located two top and two lower sides With these top and bottom holes spaced 6 hori...

Page 29: ...ing into two adjacent wall studs Insure the four screws are flush and positioned to not interfere with the enclosure s four lag screws 3 8 x2 Drill 5 32 pilot holes to avoid splitting the wall studs With the plywood secured to the wall use a spirit level and install the enclosure to the plywood using four 14 1 wood screws Verify the door closes and seals properly You may need to use shims to insur...

Page 30: ...erfere with other electrical equipment or wiring ATTENTION Si vous n entendez pas un claquement cela signifie que les pieds de l appareil ne sont pas installés correctement et l instrument n est pas stable ce qui peut provoquer des interférences avec les autres équipements électriques ou câblage There are several horizontal and vertical mounting options It is required that at least two mounting fe...

Page 31: ...ion off the cable wires so that you can connect the wires to The Electronic Enclosure and Remote Display connector WARNING Always turn the instrument off before disconnecting the display connector Do not hot swap the display connector Doing so will cause property damage or personnel injury AVERTISSEMENT Toujours éteindre l appareil avant de débrancher le connecteur d écran Ne pas changer le connec...

Page 32: ...o the panel or wall Use a torque screw driver and torque each screw to 10 inch pounds DO NOT OVERTIGHTEN Installing a Remote Slave Display If you only want a remote display and do not want the functionality from the front panel keyboard you can install a remote display by doing the following Step 1 Use any 4 wire Shielded cable Max 20 AWG Min 22 AWG Maximum cable length 100 feet 30 48 meters Do no...

Page 33: ...rear panel connector per Remote Display instructions above Installing the SMM SD Memory Card Step 1 SlidetheSMM SD cardinto the SMM SD slot on the rear panel label side up Step 2 Push in the SMM SD card until a snap indicates that the card is seated NOTE The rear panel may have plugs mounted above the SMM SD slot When removing these plugs avoid accidently disconnecting the SMM SD card Step 3 To re...

Page 34: ...the use of C2 cable from the instrument to the junction box Note the color codes for C2 load points left to right facing the rear panel Match the load sensor s color coding to ease trouble shooting Load cell connector Rear panel 9 pin C2 cable TB9 7 pin JunctionBoxConnector Load cell color codes 3 pin connector Shield Ground Wire C2 Violet C2 Grey EXC Black SEN Brown SIG White SIG Green SEN BLUE E...

Page 35: ...0001 wires to the Weigh Scale Input terminal block according to the cable color chart or per manufacturers specification Step 3 Plug the terminal block into the channel connector on the rear panel Input Power Wiring NOTE When you use external over current protection devices mount the switch and or circuit breaker near the instrument Do not connect AC and DC power at the same time WARNING Do not pl...

Page 36: ...ine voltage can result in property damage and or personal injury AVERTISSEMENT Assurez vous que la source d alimentation ne dépasse pas 240 V L utilisation d un mauvaise voltage peut résulter en dégâts matériels et ou des risques de blessures 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 th...

Page 37: ... Connect the 12 27 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 Printer Scoreboard Wiring Serial Gnd to Scoreboard Gnd Serial Tx to Scoreboard RX Serial Rx No Connection Printer score board transmit data tx uses rs 232 serial interf...

Page 38: ...ee environment Always make sure that the assemblies and sub assemblies are well supported and insulated when working on the instrument Place small fasteners connectors and electrical parts in closed containers so as not to lose parts during reassembly Read the disassembly instructions before disassembly If you find the instructions for disassembly unclear contact Hardy Process Solutions Technical ...

Page 39: ... NOTE The Main Board and options are installed assembled We are showing the Main Board installation only for illustration purposes Step 2 The rear panel is normally installed before the printed board assembly is installed Step 3 Gently slide the circuit boards into the electrical enclosure until the rear panel is against the enclosure ...

Page 40: ...wing cards DIO options slot Analog Output option slot 4ANB or network slot 4ANA Profibus network slot DeviceNet network slot ControlNet network slot RIO network slot CAUTION Always protect printed circuit boards from electrostatic discharge ESD Always use approved ESD wrist straps and anti static pads ATTENTION Toujours protéger les circuits imprimés provenant de décharges électrostatiques ESD Tou...

Page 41: ...J2 on top of the card Align the card through holes with 20mm stacker pins Step 3 Gently push the card onto the 20mm board stacker pins making sure you align them through holes on the analog board with the two standoffs on the Main Controller board until the pins are seated Option Slot header J2 2mm Board Stacker Option Slot header J2 ...

Page 42: ... the Analog Output Card The Analog Output card is a plug in option using a 16 pin board stacker that you install in the controller board either using the option slot header as described above or network header slot as described in the section Installing Network Cards Four independent analog outputs can be configured to any of the instruments parameters over an adjustable 16 000 counts of resolutio...

Page 43: ...provoquer des blessures sur personnel 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 AVERTISSEMENT Les sorties de tension et de courant ne sont pas interchangeables Inter changer le courant et la tension peut provoquer des blessures sur personnel et ou des ...

Page 44: ...n Card Input Wiring To activate the DIO card s inputs apply 3 30 VDC between the input terminal pin 7 8 or 9 and the COM terminal pin 6 on the DIO card s 9 pin connector 6 Common Isolated 7 Input 1 8 Input 2 9 Input 3 Suggested Option Card Output Wiring You can use the four DIO card outputs to send a TTL weak 5vdc output signal worst case minimum 3 V at 5mA out to a relay driver circuit to actuate...

Page 45: ...s about 30 seconds or toggle the digital output in question to a high voltage state for 30 seconds 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 28mm board stacker into the header on the network option ca...

Page 46: ... 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 Step 6 Use the four pan head screws 6 32 x 1875 to fasten the rear plate to the chassis Wiring the PROFIBUS Card Profibus us...

Page 47: ...s the 40 pin board stacker Follow the procedure above under Installing Network Cards Left to Right facing the HI 4050 rear panel V Black CAN Blue Shield Uninsulated CAN White V 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 ControlNet Card ControlNet Connectors ...

Page 48: ... of bus controller Red Fatal event or faulty unit Led A or B Off Channel is disabled Alternating Red Green Invalid link configuration Flashing Green 1 Hz Temporary errors node will self correct or node Green Normal operation Flashing Red 1 Hz Media fault or no other nodes on the network is not configured to go on line State Indication Off No power Flashing Green 1 Hz The 4050 has not been configur...

Page 49: ...you would with any standard Ethernet connection Modbus TCP IP is a software option that comes pre installed in the HI4050 upon customer request A key is required to enable the software You can purchase the option with the Key by contacting your local Hardy Process Solutions Representative or Hardy Service Center Chapter 4 describes the activation procedure ...

Page 50: ...Set Point Configuration See Chapter 7 for a complete description of the front panel and how it works See Chapter 6 for a complete description of what set points are and how they are used See Chapter 7 for a description of how an operator can change a setpoint weight Ethernet Network Configuration NOTE Do not confuse the onboard Ethernet TCP IP communication with EtherNet IP EtherNet IP is an indus...

Page 51: ...ave a unique IP address or conflicts will result Contact your Network Administrator for the IP address to use for the instrument The IP address can be set manually fixed IP or it can be set automatically by a network service called DHCP If you are required to use Fixed IP addresses refer to the section Fixed IP Configuration Using the Front Panel below For automatic IP assignment DHCP use the foll...

Page 52: ...complete IP address NOTES You cannot change the values of the DHCP IP address Exit returns to the Ethernet Menu 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 4050 and you should use a Fixed IP configuration Fixed IP Configuration Using the Front Panel ...

Page 53: ...work 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 4050 and PC with compatible IP addresses Direct Connect Hardware Any standard Ethernet cable w...

Page 54: ...ep 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 Step 9 If the Use the Following IP Address box is already checked then write ...

Page 55: ...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 4050 IP address enter each digit using the up down arrows including the decimal points Pre...

Page 56: ... products from the front panel or your LAN Internet DeviceNet ControlNet and Wireless Servers that are connected to the Network Options Setup from the Web Page From the Home Page click Configuration to open the Configuration page and select Options to open the options menu What appears on this menu depends on the cards installed in your system The second Options menus shown here lists DeviceNet wh...

Page 57: ... From the Options Page select DeviceNet to display the DeviceNet Setup page Step 2 Select the Baud Rate from the pull down list See your Network Administrator if you don t know the correct Baud Rate Step 3 In the Node text field type the Node address of the instrument Our example shows a Node Address 3 Step 4 In the Bytes Input text field type the bytes input value you need for your application Ou...

Page 58: ...e Baud Rate if you don t know the correct Baud Rate RANGE 125K 250K 500K DEFAULT 125K Step 3 Use the Down arrow to select DNET Node then press Enter to display the DNET Mode edit screen RANGE 0 63 DEFAULT 63 Step 4 Use the left or right arrow to position the cursor and the up or down arrow to select the node address assigned to this instrument then press Enter to save the entry Step 5 Use the Down...

Page 59: ...ection reappears 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 4050 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 applicatio...

Page 60: ...nnot 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 hexidecimal values A...

Page 61: ... also see the output percentage of full scale displayed at the bottom of the display Viewing the Controller I O Card Option from the Front Panel Step 1 FromtheOptions 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...

Page 62: ...messaging message exchange EtherNet IP is an open network that takes advantage of commercial technology that already exists IP is the transport and network layer protocol of the Internet and is commonly linked with all Ethernet installations and the business world IP provides a set of services that any two devices can use to share data You will need a key number to enable EtherNet IP You can purch...

Page 63: ...4050 COMM FORMAT SINT INT DINT OR FLOAT Recommended as DATA INT INPUT INSTANCE 100 LENGTH 0 256 OUTPUT INSTANCE 112 LENGTH 0 256 CONFIGURATION INSTANCE 150 LENGTH 0 Step 4 From the Ethernet IP menu select EIP Bytes Input to open the edit form Step 5 Use the left or right arrow to position the cursor and the up or down arrow to select the values Step 6 Use the left arrow to move to the next digit a...

Page 64: ...low rates require a longer time base than high flow rates The HI 4050 measures weight to better than 1 part in 10 000 The formula below provides a general starting range TIME BASE SCALE CAPACITY 10000 LOW RATE units per second SCALE CAPACITY 10 000 determines a consistent and stable weight increment Example 440 10 000 0 044lb increments The lowest setpoint in units per second 1lb per minute is 1lb...

Page 65: ...hange evaluation type a value in the Timebase text field Step 7 Click on the Set Parameter button to set the entry Step 8 Click the back arrow to return to the HI 4050 Home Page ROC Configuration from the Front Panel See note above about the key requirement Step 1 Once you have a key number select ROC from the Options menu to display the ROC menu then press the down arrow to select ROC Key and pre...

Page 66: ... can be 1 1800 seconds default 1 Step 2 To set the Time Base use the left or right arrow to position the cursor and the up or down arrow to select the values Our example uses 20 Step 3 Press Enter to save the entry and return to the ROC screen Step 4 With the cursor is in front of ROC Time Units press the left or right arrows to select the Timebase value and use Enter to set the entry In our examp...

Page 67: ...P IP Key number then press Enter to save Note The key number shown is for illustration only Your ROC key number will differ Installing MODBUS from the Web Page 10 socket max NOTE MODBUS requires a Key to enable You can purchase the option with the Key by contacting your local Hardy Process Solutions Representative or Hardy Service Center If you have not received a key contact the Hardy Service Cen...

Page 68: ... install the software on your PC Upon completion a Hardy Modbus Link icon appears on your Desktop MODBUS is an application layer messaging protocol used to support client server communications between devices connected on different types of buses or networks Its services are specified by function codes that are elements of MODBUS request reply PDUs MODBUS is implemented for the HI 4050 using TCP I...

Page 69: ...P Address text box and click OK The red No Connection disappears and the values at the top of the page start to change Youarenowconnectedfrom your PC to the HI 4050 module Step 5 To verify that you have two way communication from the Mapping web page of the HI 4050 instrument you want to communicate with open the Destination Network pull down menu and select Modbus Float Out MFO Step 6 Using the d...

Page 70: ...mplete the mapping Float Variable O word 0 to Modbus Float Out Word 0 Step 10 Type a value in the Hardy Float Out HFO text field 0 Our example used 555 0000 Step 11 On the Hardy Modbus Link page Display pull down menu select Float Inverse The value we entered from the Mapping page appears to the right of the 00000 which is 555 0000 Step 12 Click button 23 to open the Write multiple registers displ...

Page 71: ... socket max Error Messages Function Not Supported Does not allow you to use the selected function Use a different function Address Error Wrong IP address of the register you want to send the data Get and enter the correct IP address which you can get from your Network Administrator Byte Count Error The Byte count is incorrect Enter the correct byte count Value Error The Value entered does not matc...

Page 72: ...sps The configuration objective is normally to set high and low weight values to match the high and low weight specifications in the PLC The analog card uses these high and low weight values to calculate its weight related outputs You can set these values from either the front panel or the Web interface NOTE Each analog out channel used needs to be connected to a weighing element Gross NET ROC usi...

Page 73: ...d High Weight Step 5 Click Set to save the parameters at any time However if you are configuring more than one channel you can wait until all the channels are configured Step 6 To Configure Channels 2 3 and 4 repeat the procedures above Remember that Channels 2 and 4 are current I outputs NOTE To refine a reading of say 10 02 where you want an output reading of 10 adjust the 0 10 values to get the...

Page 74: ...ping symbols for the output scaling results The Loopback Debug Values are estimates only and may not match the actual outputs HI 4050 Analog Output Adjustment If the output from the analog output card does not match the output levels required for your system there is now a method of recalibrating the output levels based on your system Starting in firmware Version 1 7 1 0 there is a page on the web...

Page 75: ...ottom of the screen NOTE If you are asked for a security code enter the High security code If you don t know the password and cannot access this screen see your system administrator Normally you will not need to manually adjust the gain or offset values ...

Page 76: ...or the first known input high for Desired Output High Step 4 Enter the actual output for this input for Actual Output High Step 5 Enter the desired output for the known low input for Desired Output Low Step 6 Enter the actual output for this input for Actual Output Low Step 7 Click Recalibrate The unit will recalibrate the outputs from the analog card to match the values expected for the input ran...

Page 77: ...select Low Weight and press Enter to display the Low Weight edit page Step 6 Use the left or right arrow to position the cursor and the up or down arrow to select the value When you finish press Enter Step 7 Repeat the steps above to set the High Weight value Analog Out Mapping Step 1 From the Options Menu select Map Step 2 Use the right arrow to scroll the Map options which are NONE Gross Net or ...

Page 78: ...process The pull down options allow you to place a relay in service or take it out of service for setup testing However if a relay has been mapped the mapped activity will override a manual Start or Stop activity set on this page NOTE Warning Turning relays ON or OFF during an active process can disrupt the process and result in serious problems Avertissement Mettre les relais en état Allumé ou en...

Page 79: ... 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 m...

Page 80: ...he 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 4050 See below This can be done before or after Initialization Step 3 Cyc...

Page 81: ...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 ...

Page 82: ... 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 Initializa...

Page 83: ...ameters are status indicators and are read only The status indicators indicate the state of communications between the Master and the HI 4050 DP State Read Only 00 Status Wait_ Prm HI 4050 waiting for communications from the Master Device 01 Status Wait_Cfg HI 4050 configuring for Data Exchange 10 Status DATA_EX HI 4050 Exchanging Data with Master WD State Read Only 00 Status Baud_Search HI 4050 s...

Page 84: ...words INT to send the PLC max 127 This must match the input table size in the PLC Step 3 For Words In enter the number of 16 bit words max 127 from the PLC This must match the output table size in the PLC which may be either INT or DINT Step 4 On the PLC use the following parameters Comm Format Data In PLC Input Assembly Instance 100 PLC Output Assembly Instance 150 PLC Config Instance 0 See the C...

Page 85: ...eter and command interface On the Web form from the Units pull down list select the weight units to use then click Change Unit to set the units value Our example shows pounds lb On the 4050 display Step 1 If the cursor is not already in front of Units press the down or up arrow to select Units Step 2 Use the Left or Right arrow to select the Unit of measure Step 3 Press Enter to save the selection...

Page 86: ...or of this instrument in Operator ID text field On the 4050 display Step 1 Press the Down arrow to select Operator ID Step 2 Press Enter to open theOperatorIDedit screen Step 3 Use the left or right arrow to position the cursor and the up or down arrows change the value Step 4 When you have selected all the values press Enter to save Decimal Point Parameter Step 5 Use the Decimal Point Parameter t...

Page 87: ... by 10 000 For example with two decimal points selected the graduation size 10 will display increments of 10 engineering units and the graduation size 50 will display increments of 50 engineering units For a scale with 10 000 capacity graduation size 1 RANGE 1 2 5 10 20 50 10 200 500 1000 default 1 NOTE Graduation is only for display resolution as full decimal point resolution is transmitted acros...

Page 88: ... weight samples that are available for communications and weight processing whether the weight has changed or not Note that this function is only available in the HI 4050 On the 4050 Display From the Setup Menu arrow down to select A D rate Toggle between 110 or 250 to make your selection and hit Arrow down to Enter to select the desired rate ...

Page 89: ...NumAverages Parameter The value you enter for Number of Averages NumAverages sets the number of weight readings used to compute a sliding average of displayed weight This setting is to aid in ignoring the effects of material impact and or vibration Applications requiring very quick weight readings should reduce this setting to its minimum If the weight is unstable increase the averages ...

Page 90: ...tion the cursor and the up or down arrows change the value Step 3 When you have selected all the values press Enter to save The WAVERSAVER Parameter Mechanical noise from other machinery in a plant environment can be present in forces larger than the weight forces being measured The HI 4050 is fitted with WAVERSAVER technology that eliminates the effects of vibratory forces present in all dynamic ...

Page 91: ... change on the scale the total time to finalize a new weight reading is the WAVERSAVER plus the NumAverages Calculate the amount of time your product will be fully on the scale Then adjust the WAVERSAVER and NumAverages setting to add up to less than that time period Section 1 describes the benefits of using the WAVERSAVER feature On the Web page from the pull down list select the value for WAVERS...

Page 92: ...the 4050 display Step 1 Use the Down arrow to select the Setup Menu Press the Right or Left Arrow buttons to select the variation_thd or Motion_thd Enter the setting for your instrument and press Enter to save the selection On the Web page Select the options from the Configuration Setup menu Low Pass Filter Parameter NOTE Low Pass Filter has been replaced in Firmware Version 1 14 0 0 or greater wi...

Page 93: ...ay Step 1 After selecting Motion Tolerance with the down arrow on the Setup menu press Enter to display the Motion Tolerance edit form Step 2 Use the left or right arrow to position the cursor and the up or down arrows change the value Step 3 When you have selected all the values press Enter to save Step 4 Use the left or right arrow to position the cursor and the up or down arrows change the valu...

Page 94: ...ro Tolerance parameter is used by the auto zero tracking feature and any zero command sent over communication or mapping path AutoZero sets the gross weight units to zero using the current gross zero as reference Set the AutoZero Tolerance parameter smaller than the ZERO Tolerance parameter If the AutoZero Tolerance is exceeded for some reason you may press the ZERO button on the instrument and ut...

Page 95: ...e Our example shows 3 50 which is for illustration only Capacity Parameter Scale Capacity is the scale s nominal operating capacity the total weight capacity of the scale system If this value is exceeded by eight graduations when configured using one of the certified modes DASHES will appear on the front display This signifies that you have exceeded the certified scale limit When a certified mode ...

Page 96: ...the instrument RANGE NTEP MC None Default None On the Web page for Certification select the certification type from the pull down list Click Save Parameters when you have finished this screen On the 4050 display Step 1 Use the Down arrow to select Certification and click Enter to open the Certification edit page Step 2 Use the Left or Right arrows to scroll the options and press Enter to save LCD ...

Page 97: ...ll Gross Net Tare ROC Rate of Change Scoreboard Outputs to a device that displays weight data in large print NOTE See your Network Administrator if you don t know the correct values for Baud Rate Parity and Data Bits Baud Rate RANGE 300 1200 2400 4800 9600 default 19200 Parity RANGE NONE default ODD EVEN Data Bits RANGE 7 OR 8 default Setup From the Web Interface Step 1 Click the right green arrow...

Page 98: ...Baud Rate then press Enter to save the entry Step 9 Select Parity Step 10 Press the left or right arrows to set the Parity then press Enter to save the entry Step 11 Select Data Bits Step 12 To change the Data Bits value press the left or right arrow to toggle between 8 and 7 then press Enter to save your selection Step 13 Press Exit to return to the Setup Menu Configuring Date and Clock You can s...

Page 99: ...enu with the cursor in front of Time Zone Step 2 Press the Left or Right arrows to select the time zone in your location RANGE 24 zones Default PST 8H Step 3 Press Enter to save the zone and display the time screen with the cursor in front of Time Year showing the currently set value Step 4 Press Enter to display the Time Year edit screen Step 5 Use the left or right arrow to position the cursor a...

Page 100: ...ay the Time Minutes edit form Step 13 Use the same procedure described for setting the month to set the current minutes RANGE MM 1 60 with no default Set Points A set point value is a threshold weight or level based on the Unit of Measure you select during system configuration It may be set in either Net Gross or available ROC weight units Up to four setpoints are available for optional use This s...

Page 101: ...e is no compensation You need to select the Type Gain in Weight is used if a setpoint is a high trip limit Loss in Weight and deadband is used for a low trip limit as shown in the pictures below Mode Specifies which weight source to use as the setpoint input GROSS NET or ROC Target Weight Setpoint target weight A setpoint ON OFF status change is based on this value combined with the effect of impl...

Page 102: ...set high until 350 then the output goes low and stays low until LIW is below 5 HI 4050 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 that Web page secu...

Page 103: ...to save the security settings Setting Parameter Security Now that you have created a High and Medium Security Code you can now use a dollar sign notation to set security on any of the parameters you want If you want to require a password for changing units you can enter one dollar sign for Medium Security Code or two dollar signs for High Security Code This can be done by editing the Parameter Dum...

Page 104: ...ter must know the High Security Code password NOTE If you have not set a Medium or High Security Code and enter dollar signs for a parameter s the instrument disregards the security code You must enter a High or Medium security code before entering the dollar signs Configuring Security from the Front Panel Step 1 From the Configuration Menu press the down arrow to select Security Verify Password 0...

Page 105: ...he instrument Verify Password appears Step 8 Press Enter to display the Verify Password edit screen Use the up or down arrows to enter the assigned password for either High or Medium Passwords and press Enter The Zero process can then proceed and you are returned to the Security Menu Since we assigned a Medium Password of 456 we would enter 456 Step 9 Use the password procedure described above for...

Page 106: ...98 Chapter 4 When you run the the IP Setup program from a network computer it will find the HI 4050 and allow you to set its IP address ...

Page 107: ...per installation instructions On some load cells an arrow indicates the direction of 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 Check for Binding on the Load Cell or other parts of the system CAUTION Binding on a Scale Vessel or Load Cell does not allow the load cell free vertical movement ...

Page 108: ...cell point depends on the mV V rating of the load cell point and weight Typical Load Cell Point Input Output Measurements EXC SIG outputs A 2 mV V load cell point will respond with a maximum of 10 mVDC at full weight capacity where the system 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 po...

Page 109: ... running C2 calibration run all of the pre calibration procedures Make sure you have configured the HI 4050 This includes setting the units decimal point scale capacity averages etc For instructions please see Chapter 4 Configuration Reference Weight Reference Weight is the total live load that is currently on the scale The calibration process uses a reference weight which is normally zero no weig...

Page 110: ...84 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 Cit...

Page 111: ... Correction Factor see the table above then enter the Correction Factor number you selected from the table in the Gravity Correction field Step 3 Click the Do C2 Calibration button Step 4 Wait a few seconds and the results will appear If the Calibration was successful a Cal completed OK appears and the Load Sensor Number will read 0 Step 5 This message appears if no incorrectly wired or over range...

Page 112: ...isplayed number matches the actual number installed If not check to ensure that each load cell point cable connection is securely fastened and that each load cell point cable is not broken On the HI 4050 web page select Operations Diagnostics C2 and Weight and Voltage to determine which load cell point is malfunctioning Step 3 Press the down arrow to select Ref Weight Reference Weight and press En...

Page 113: ... the display reads100 pounds and a 20 pound load is placed on the vessel or scale the display should read 120 or some value over100 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 show...

Page 114: ...appears briefly if the calibration was successful Step 8 An Error message appears if the calibration was not successful See the error list in Chapter 8 for help in correcting errors Step 9 The scale is now calibrated Traditional Calibration from the Front Panel Step 1 From the Configuration menu use the down arrow to select Calibration then press Enter to display the Calibration menu Select Trad C...

Page 115: ... Weight edit page showing the last Span Weight Step 6 To set the Span Weight place a certified test weight on the scale Step 7 Use the left or right arrow to position the cursor and the up or down arrow to select the value If a 10 lb weight is used enter10 00 Press Enter to save Step 8 Use the Down Arrow button to select Cal High then press Enter to do the Cal High A Cal Completed OK message appea...

Page 116: ...108 Chapter 5 ...

Page 117: ...he destination memory address to which data will be moved left side of the equation See also Source I O Interface The section of the instrument that communicates with the external input Input Contact Inputs interface selector and limit switches push buttons and sensors to the HI 4050 An address assigned to each input identifies the location of the input device Input table Defined in the section In...

Page 118: ...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 th...

Page 119: ...utput 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 Inputs interface with selector switches push buttons limit switches and other sensors connected to the HI 4050 for an ON OFF connection When the firmware is initiated...

Page 120: ... Inputs User Switches Volatile and Non Volatile Memory The HI 4050 output tables and input tables use volatile memory This means when you power off the HI 4050 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 Destinat...

Page 121: ... Source setup options Example 1 Mapping to a Network Output Step 1 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 ...

Page 122: ...he following EFO EtherNet Float Out 2 Word 2 Step 3 An address appears in the text box below You must scroll down to see it Since we selected EtherNet IP Float Out the destination address is EFO0 followed by Step 4 As our source we select Gross Weight from the Process Data pull down list Step 5 A Select button then appears to the right Click Select to use Gross Weight as the Source Step 6 This com...

Page 123: ...or yes no value If you map as a Short Int you will use one word If you map as an Int or float you will use two word locations The selection of Int or Float will specify the format of the data within the two words HI 4050 The setup size of the communications registers in the HI 4050 differ by network type Packet size determines how much data can be transferred in each send or receive activity Devic...

Page 124: ...we must map User Switch 1 1 of 3 inputs to the HI 4050 to Tare The assignment statement is Destination Source Tare HO2 0 User Switch 1 HI0 4 Step 1 Select Tare on the Control pull down menu A Select button appears Step 2 When you click Select the Control text box displays the destination address Step 3 FromtheControlpull down list in the Source Section select User Switch 1 A Select button will app...

Page 125: ...nt display to enter Configuration Arrow to MAP and press enter Starting says no equations defined if the mapping is empty Arrow to Map Dest press enter Using the arrows change the existing or create the mapping HO0 0 and press enter Down arrow to Map Src press enter Using the arrows change the existing or create the mapping HSI2 and press enter Arrow down to Add Map Pressing enter adds the two equ...

Page 126: ...Rockwell Software s RS NetWorx 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 Example 3 Mapping an Network Input to a Local Output If you have the Digital I O card and you want a PLC to send yes no instructions to an HI 4050 you wi...

Page 127: ... on the Select button to assign the source to the right side of the assignment statement Click the Map button The new mapping will appears below the Map text field This sets the digital output 1 to high low from the input selected NOTE HI 4050 network input is the source for the data from PLC output The PLC can send instructions to the network input source on the HI 4050 and in turn to the HI 4050...

Page 128: ...lect Tare HO2 0 Step 3 Click Select Tare HO2 0 appears in the mapping field You will need to send a transition signal from low to high each time you want to Tare Zero or any other function Step 4 To Map the inputs on the Main Board select User Switch 1 2 or 3 as the Source A Select button will appear next to the Control field Step 5 Click Select to display the full mapping in the Map field Step 6 ...

Page 129: ...1 bit 6 HI1 6 Motion 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 When you send a command by setting a bit in HSO2 the command word the HI 4050 will run that command and send a copy of the command bit sent back to the user in HSO2 being read At that time the unit will also send a command status in HSO1 to give an indica...

Page 130: ...teger 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 is an offset in words in the case of the network tables The offsets in Hardy tables have various predefined meanings When an analog equation is evaluated all terms are converted to float The final result is ...

Page 131: ...1 and 2 above Instead you would write the 0000 and 0001 into JSO15and JSO1 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 The Command Interface The HI 4050 may receive commands over any of its network interfaces A command consists of four bytes which it receives through its net...

Page 132: ...pper bit set to set the upper bytes All write commands are 1 shots The first two bytes of the response to a write command are an echo of 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 ZERO or TARE a status code indicating whether the command succeeded or failed If the PARAMETER ID is no...

Page 133: ...0000000E AutoZero Tolerance 0 0000002A Baud Rate 4 9600 0001002A Data bits 1 8 0002002A Parity 0 NONE 0003002A Printer Mode 2 TARE 000002F2 scratchpad 3 000000 000102F2 scratchpad 1 000000 000202F2 scratchpad 1 000000 000302F2 scratchpad 3 000000 000402F2 scratchpad 3107 000000 000502F2 scratchpad 3110 000000 000602F2 scratchpad 0 000000 000702F2 scratchpad 0 000000 00000036 DNET Baud 2 500k 00010...

Page 134: ...e new text to save the parameters to the new HI 4050 instrument NOTE In some instances the calibration data cannot be transferred between 4050 controllers using the SD card or the parameter dump method The problem occurs when a controller containing the old analog weigh scale card s data tries to copy to a controller with the new version of the Analog weigh scale card used in the HI 4050 The diffe...

Page 135: ...Taring and or zeroing the instrument and creating setpoints We highly recommend reading the procedures before operating the Weight Controller Being familiar with the operating procedures insures that the Controller will provide trouble free service Getting Started Before operating the Hardy HI 4050 Weight Controller check to make sure the following procedures have been performed Power and Load Poi...

Page 136: ...reen above each button These functions vary depending on the screen selected For example to Zero the instrument press the button directly below the ZERO function Up Down Left Right Buttons The Up or Down arrow s move the cursor vertically allowing the user to scroll through a list or menu Use them to move from one sub menu to another or to increase decrease displayed values The Left Right arrow bu...

Page 137: ...on Tares the selected scale The Tare button sets the Net Weight equal to 0 In Net Mode i e a channel displays Net in the Summary display the weight changes to 0 00 In Gross mode the Gross Weight does not change however the Net weight is changed to 0 00 Print Button The Print button prints the Gross Net and Tare weights to an attached printer If the Rate of Change option is activated the print butt...

Page 138: ...e Check the Zero and AutoZero Tolerances parameters Instructions for Zero Tolerance and AutoZero Tolerance Parameter Setup is in Chapter 4 WARNING After configuring your system and turning the instrument off make sure that the SMM SD is installed correctly before powering up If the SMM SD is not installed the instrument returns to a default condition which probably does not meet your process requi...

Page 139: ...h the new firmware You can use the up and down arrow to scroll through the line options These are in order 1 BLANK 2 BLANK 3 GROSS 4 NET 5 CUSTOM 6 ROC Rate of Change if enabled in the controller As you press the up or down arrow you can scroll through and stop at any two consecutive lines showing from list This shows the selection of Net and CUSTOM CUSTOM display is a mapped value Below the displ...

Page 140: ...et point target weight For example if a packaging operation switches from 10 pound bags to five pound bags you would change a set point target weight from ten to five Target weight is one of several values on the set point web page but in most cases operators will not be asked to change the other values Instructions for Configuring the instrument can be found in Chapter 4 Target This is the target...

Page 141: ...own list In our example we selected Gross Step 3 From the Type pull down list select the Type of control you want for your application In our example we selected Loss in Weight Step 4 Enter the Target weight for your application in the Target field Our example shows 180 0 lbs Step 5 In the Preact text field enter the Preact value for your application Our example uses 5 00 lbs Step 6 In the Deadban...

Page 142: ...er to open the Setpoint menu then use the left or right arrow to select the Setpoint Our example shows Setpoint 2 Step 2 Mode then use the Right or Left arrow to toggle between Gross Net or available Rate of Change modes Our example shows Gross Step 3 Use the Down arrow to select Target then press Enter to display the Target edit form Step 4 Use CLR to clear the existing value and position the cur...

Page 143: ...l 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 Process Solutions Technical Support Department for additional information and assistance WARNING EXPLOSION HAZARD DO NOT REPLACE COMPONENTS UNLESS POWER HAS BEE...

Page 144: ...alances 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 Process Solutions Web tech at http www hardysolutions com Web tech is updated often and is available 365 days a year 24 7 It contains several frequently asked question...

Page 145: ...ed 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 Over range 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 Shoot...

Page 146: ...hese numbers also reflect weight change at the smallest measurement the internal analog to 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 read...

Page 147: ...sensitivity to enable you to troubleshoot the condition of the load cell in question under certain conditions Load Cells are rated in Millivolts Volts RTZ Return to Zero Test This check is to see if the scale returns to a zero reading condition when it is empty 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 ...

Page 148: ...ist 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 ...

Page 149: ... Mechanical Inspection Electrical Inspection Load Sensor Installation Exceeds the Millivolt range Out of range condition Blank Display A Drifting or unstable weight readings E Weight indication will not return to zero P SD Card Diagnostics and losing memory at power cycles Verify individual load sensor operation C Drifting or unstable weight readings ...

Page 150: ... press ENTER Monitor the Test results PASS EXIT to the Summary Display STABLE Monitor the display for stability STABLE Replace IT summing card STABLE A1 Verify wiring and connectors are solid and clean Cont C B1 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 Yes No No No No Yes Yes Yes ...

Page 151: ...l cables and shields except AC Power Monitor the Display for stability STABLE Reconnect signal cables one at a time A1 If installing any cable causes unstable readings REVIEW TROUBLESHOOTING SECTION B B1 1 B1 7 Go to B Yes No Monitor the display for stability Problem could be in the instrument Contact Hardy Customer Support PH 800 821 5831 ...

Page 152: ...ines for Instabilities on Formerly Operating Systems Cont d Check for Electrical Stability OK Check for Mechanical Stability B Yes No B1 OK Check Configuration settings for stability Yes No B2 OK Yes No B3 Go To A Stability ...

Page 153: ...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 Cable Shielding Ground low voltage cable shields only at the controller end Grounding both cable ends produce ground cur...

Page 154: ...not applying pressure to the vessel when energized 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 Incorrect WAVERSAVER settings can cause unstable weight readings Adjust to the lowest WS setting that gives you a stable r...

Page 155: ... Box Remove and Replace the load sensor s determined to be faulty STABLE No Yes TEST COMPLETE STABLE Yes Replace summing card Re install all load sensors 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 Yes No ...

Page 156: ...ut of each individual load point only when connected to an IT Summing Box This program level reads and compares the millivolt output of each individual load point to the values recorded at calibration Out of tolerance readings flag an error LS1 ERROR Check load sensor 1 Yes LS2 ERROR Check load sensor 2 Yes LS3 ERROR Check load sensor 3 Yes LS4 ERROR Check load sensor 4 Yes TEST COMPLETE F No No N...

Page 157: ...TEST menu and run ITECH TEST Program Select IT TEST MV IT TEST Checks individual load sensor output mV readings Press ENTER to check load sensor Record load sensor mV output level for comparison Repeat for all load sensors mV readings acceptable Zero mV reading 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 po...

Page 158: ...ngs 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...

Page 159: ...om forklifts and adjacent processing equipment H3 Are the load cells properly mounted 1 Level solid mounting base 2 The load cell is mounted right side up 3 All load cell bolts installed using anti seize compounds 4 Mechanically aligned to compensate for expansion and contraction H4 Are check rods installed to dampen vessel movement 1 Protects the load cells from overload and impact forces 2 Limit...

Page 160: ... 3 Displays a weight reading This weight value will not be correct if a calibration procedure was not performed J3 Does the scale reflect a weight change 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 DO NOT POWER UP THE CONTROLLER UNTIL INPUT VOLTAGES CAN BE VERIFIED a Does the weight increase and decrease in the correct d...

Page 161: ...ceed 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 Monitor system for proper operation Check out completely 1 Using a spirit level verify the vessel is...

Page 162: ... cable or body 3 Weight in the hopper exceeds the configured Scale Capacity setting a Under configuration verify the Scale Capacity setting b 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 ce...

Page 163: ... Contact Hardy Instruments Customer Service 800 821 5831 Yes Disconnect all the connectors from the back panel except power Measure excitation voltage 5 VDC Contact Hardy Instruments Customer Service 800 821 5831 1 Reconnect the jacks one at a time checking the 5VDC excitation 2 If reconnecting any jack effects the 5VDC check for wiring errors Monitor system for proper operation Check out complete...

Page 164: ...the SD card the instrument should oot with factory default configuration b Able to Change Screen 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 Contact Hardy Instruments Customer Service for additional instructions and possible return for repair PROBLEM SOLVED Select SAVE and EXIT then cycle power ...

Page 165: ...r ID and other configuration information and you can learn the serial number model number firmware revision number Diagnostic testing from the Web page Step 1 From the Home Page click on Operation The Operation Choose One page appears Step 2 Click Diagnostics to view the Operation Diagnostics Page The page lists the Instrument ID Model Number Program Part Number Firmware Revision Serial Number Las...

Page 166: ...ograms and instructions are listed along with other drawings and the latest manual For more extensive information about the Weight Controller and scale operation see Operation Diagnostics in the System Integrity Check and Fault Determination from the Web Page section below Parameters Parameters is the first listed hyper link at the base of the Operation Diagnostics page Click that link to display ...

Page 167: ...erlink or similar serial program To view all the other parameter settings click that link System and Load Cell Tests Overview of Typical Load Cell System The typical system consists of one or more load cells points a summing junction box and an HI 4050 Weight Controller Load cell sensor point Used to measure pressure weight or torque the sensor point is a strain gauge based force transducer that g...

Page 168: ...onse without identifying the problem load cell For numerical values the system will return an average of all the load cell responses and in some cases will return values that cannot be used With the HI 215IT Summing junction box and IT firmware the HI 4050 can provide both average numerical values and values specific to each load cell including PASS FAIL values for each load cell as shown below JU...

Page 169: ...s and reports for each load cell The test sends the load cell data to the analog to digital 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 Square...

Page 170: ...will display an average reading and PASS FAIL for the system as a whole 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 4050 runs the test and shows the results 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 Weight and Voltage Tes...

Page 171: ...V so a reading between 0 15 mV is within the normal range A reading outside this range 15 5 mV 3 1 mV V Maximum or any negative values would normally indicate that the problem is external to the Instrument most likely improper wiring If all the load sensor readings are 0 00 something is wrong between the HI 4050 and the HI 215IT junction box or with the junction box itself Either the cable is disc...

Page 172: ...formation can be obtained from the front panel From the Test menu select Weight and Voltage and press Enter to show the menu Then select IT Test to run the test To read the rest of the results press the down arrow The weight and voltage reading raw counts and average are shown below ...

Page 173: ...etermines whether the instrument returns to a starting zero point PASS indicates that you are within the sum of the preset Motion and Zero Tolerance settings FAIL indicates that you are outside the sum of the preset Motion and Zero Tolerance settings If this results from too much build up on the scale you need to clean the scale or you have scale problems Run this test whenever you cannot zero the...

Page 174: ... button allows you to read this information for all C2 load sensors in the system When you press the Read Sensor button it receives the information from the first load sensor The serial number is important if you need to contact Hardy Process Solutions Technical Support You do not need an IT summing box Step 1 Click on C2 at the bottom of the page to display the C2 Data page listing the number of ...

Page 175: ...File button the file will be deleted 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 E G PARAMETERS OR WORKING INGREDIENT FILES AVERTISSEMENT LA SUPPRESSION ALEATOIRE DE FICHIERS DEPUIS LE REPERTOIRE DE L...

Page 176: ...Trail display showing the event time and date Step 5 To view the rest of the Audit Trail log press the up or down button Step 6 To return to the summary display press Exit until the summary display appears Checking Network Connections and Configuration with the Ping Tool The Ping Tool is used from the computer s start run utility Click Start and then Run Selecting the module by IP Address for Test...

Page 177: ... fastened 64 signals should be returned and the print out will reflect this fact General Policies and Information With over 70 years of industrial weighing experience and products in the field Hardy Process Solutions continues to design manufacture install and support Hardy products worldwide The following paragraphs describe Hardy s customer support services and equipment warranty NOTE For all no...

Page 178: ...ww hardysolutions com 4000_support index html to open the HI 4000 Series On line Support Site and click HI 4000 Download Section Step 2 This will display the screen shown below which can be used to download software for HI 4000 Series instruments ...

Page 179: ... menu option to save this file to the same folder You can rename the firmware 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 Step 5 Select the IP address of the unit you want to upgrade Step 6 Click Browse to find and select the ...

Page 180: ...rvice term php 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 1 Service Engineers are trained and qualified to provide on site installation calibration and maintenance 2 On site training A Hardy Support Representative can be schedu...

Page 181: ...t time zones Below is a list of the abbreviated time zones with the GMT time adjustment GMT Civilian Time Zones Cities GMT GMT Greenwich Mean UT Universal UTC Universal Co ordinated WET Western Europe 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 Aust...

Page 182: ...pan Taipei Taiwan 9 30 Australian Central Standard Darwin Australia Adelaide Australia 10 GST Guam Standard 10 30 Lord Howe Island 11 11 30 Norfolk Island 12 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 Azores Cape Verde Islands 2 AT Azores GMT Civilian Time Zones Cities GREENWI...

Page 183: ...na 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 HS...

Page 184: ...4 Appendix A ...

Page 185: ...lay 1 basic load cell theory 172 Baud Rate 48 75 89 Binding on the Load Cell 99 board stacker pins 36 Boolean Mapping 117 Boolean tables 118 Boolean variable 118 Byte Count Error 63 Bytes 48 C C Guidelines for Instabilities 147 C2 Cal 104 C2 Cal Error 136 C2 Calibration Menu 104 C2 Calibration Procedures From the Front Panel 104 C2 Data page 166 C2 Sensor page 166 C2 Sensors Found reads 0 166 C2 v...

Page 186: ...9 54 DNET Mode Menu 49 DNET Node 49 Do C2 Calibration button 103 Do Cal High button 106 Do Cal Low button 106 DO is the DeviceNet output image table 118 Do IT Test 163 Do Trad Cal Zero 107 DP State Read Only 75 Drives 48 E E Non Return to Zero 148 E Option 5 EIP Ke 54 Electrical Check Procedures 100 electrical parts 28 135 electrical plug 28 136 electrostatic discharge 28 136 embedded controllers ...

Page 187: ...ual Boolean variable 118 Initializaiton Process 71 Initialization Procedures 73 Input 10 Input and Output page 165 Input Power Wiring 25 Installing Network Cards 36 Installing Optional Boards 30 Installing the Analog Output Card 32 36 Installing the Analog Card 4ANB 30 Installing the DeviceNet Card 38 Installing the PROFIBUS Card 37 INTEGRATED TECHNICIAN 135 157 Internet 47 IP Setup program 97 IT ...

Page 188: ...Option Slot Header 30 Options Configuration 48 Options Menu 49 Options 49 OR 117 Ordering Replacement Parts 166 172 original point of remova 136 original point of removal 28 Output Resistance 166 Output Voltage 166 Overview of Typical Load Cell 159 168 P P SD Card Diagnostics Memory 156 Pacific Standard Time 3 Pan cone head screws 37 Panel Mount 12 parameterization 71 PARAMTER ID 124 Parity 90 PAS...

Page 189: ...coreboard 89 Screws 28 136 SD Card page 167 Security 96 security for the Tare Zero functions 97 Security Menu 68 96 Security page 94 Security Violation message 105 Select Destination Module dialog box 74 Selecting the module Testing 168 Sensor Number 139 sensors 48 Set Parameter button 56 Set Points Configuration 134 Setpoint 70 Setting Command Interface Mapping 123 Shield wir 27 Siemens PLC 73 Si...

Page 190: ...echniques 172 Troubleshoot Network Connections 168 Trunk Line 72 U Unit of Measure 77 Units 77 Universal power supply 26 Update Rate 9 UR dialog box 73 V Value Error 63 vertically passing 99 vibration analysis 1 Viewing System C2 Load Sensors 166 Viewing the SMM SD Card 167 Voltage 10 W Warranty 172 Washers 28 136 WAVERSAVER 10 WD State Read Only 75 Web Page Security pull down list 95 Weight 139 W...

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Page 192: ... CA 92121 Telephone 1 800 821 5831 FAX 858 278 6700 Web Address http www hardysolutions com Hardy Process Solutions Document Number 0596 0303 01 REV W Copyright 2008 2013 Hardy Process Solutions All Rights Reserved Printed in the U S A ...

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