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Chapter 7- Troubleshooting

Hardy H6800 Series Application Controllers User Guide

7.3 Troubleshooting Using Integrated Technician

Integrated Technician, along with an IT Summing Junction Box, provides built-in diagnostics that

allow you to troubleshoot and diagnose your weighing system. You can read individual load

sensor voltages and weights, make comparisons, and isolate individual system components for

quick and easy troubleshooting.
For more information, see section 5.9.

7.4 General Troubleshooting

The following sections describe general troubleshooting procedure. Refer to Table 7-2 for an

overview of the troubleshooting topics described in the following sections.

Table 7-2. General Troubleshooting

Problem

See

Drifting or unstable weight reading

Section 7.4.1

Electrical, mechanical, and configuration reviews

Section 7.4.2

Drifting or unstable weight reading

Section 7.4.3

Weight indication will not return to zero

Section 7.4.4

Verify individual load sensor operation

Section 7.4.5

Traditional calibration - A/D Failure Error

Section 7.4.6

Mechanical inspection

Section 7.4.7

Electrical inspection

Section 7.4.8

Load sensor installation

Section 7.4.9

Exceeds the Millivolt range. Out-of-range condition.

Section 7.4.10

Blank display

Section 7.4.11

SD card diagnostics and losing memory at power cycles

Section 7.4.12

Summary of Contents for HI6800 Series

Page 1: ...HI6800 Series Application Controller User Guide...

Page 2: ...infringement of rights of third parties which may result from its use THIS DOCUMENT IS PROVIDED AS IS AND ANY EXPRESS OR IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERC...

Page 3: ...1 Model HI6800 11 1 1 2 Model HI6850 11 1 2 Theory of Operation 12 1 3 Specifications 13 2 Hardware Overview 14 2 1 Model HI6800 Front and Rear Views 15 2 2 Model H6850 Front and Rear Views 17 3 Insta...

Page 4: ...itional Weigh Scale Input Cards 45 3 5 2 GPIO Card 46 3 5 3 Relay Card 49 3 5 4 PROFINET Card 51 4 Commissioning 52 4 1 Connections 53 4 2 Powering on the HI6800 Series Application Controller 54 4 2 1...

Page 5: ...rror Messages 87 7 3 Troubleshooting Using Integrated Technician 88 7 4 General Troubleshooting 88 7 4 1 A1 Troubleshooting Instabilities on a Formerly Operating System 89 7 4 2 B Troubleshooting Inst...

Page 6: ...of Change 109 B 4 Multi Channel Measurement 110 B 5 Feed Weight Control 110 B 5 1 Loss in Weight 110 B 5 2 Gain in Weight 110 B 6 Rate of Change Parameters 109 B 7 Set Point Controller Parameters 105...

Page 7: ...ng HI6800 Series Application Controllers Changes in This Revision This is the first version of this document Related Documents In addition to this guide the HI6800 Series Application Controller Quick...

Page 8: ...I6800 Series Application Controller problems APPENDIX A Shared Programming and Communications Options This appendix describes the programming and communication options common to all Hardy Process Solu...

Page 9: ...important points of the main text Tip Tips provide helpful information guidelines or suggestions for performing tasks more effectively Caution Indicates a potential hazard or unsafe practice which if...

Page 10: ...l application required in industrial manufacturing where fast stable weight data and low cost of ownership are critical components to successful design HI6800 Series Application Controllers can be use...

Page 11: ...nd process statistics Data from the instrument can be easily served up to the Intranet Extranet VPN and the Internet by utilizing the EtherNet IP Ethernet TCIP Modbus TCP IP or PROFINET communication...

Page 12: ...typically consists of a controller PLC PAC DCS IACS process instrumentation and sensors Figure 1 1 shows the primary components of a control system Figure 1 1 Example of a Basic Control System In a w...

Page 13: ...ion Controllers User Guide 13 Figure 1 2 Functions of a Weight Controller 1 3 Specifications Specifications for the HI6800 Series Application Controllers vary depending on configuration and applicatio...

Page 14: ...WARE OVERVIEW Topics The HI6800 Series Application Controller is available in two models HI6800 and HI6850 This chapter describes the key items on the front and rear of both models Model HI6800 Front...

Page 15: ...ey items Figure 2 1 Model HI6800 Front View Table 2 1 Key Items on the Front of the Model HI6800 Item Description 1 Front panel display Shows the information associated with the items selected using t...

Page 16: ...with or without a junction box 2 Digital I O terminal block Two inputs isolated and two outputs 3 NTEP switch Two pin DIP switch for enabling or disabling NTEP 4 microSD card Accommodates a microSD mo...

Page 17: ...Figure 2 8 show the rear view of the Model H6850 with various option cards and Table 2 4 describes the key items Figure 2 3 Model H6850 Front View Note The layout of the display varies with the appli...

Page 18: ...as the tare weight ZERO press to reset the displayed weight to zero MODE press to change modes Gross Net App Specific CYCLE DISPLAY press to increase the font size of the displayed rate and reduce th...

Page 19: ...Chapter 2 Hardware Overview Hardy H6800 Series Application Controllers User Guide 19 Figure 2 5 Model H6850 Rear View with AC Option Card Figure 2 6 Model H6850 Rear View with AC and GPIO Option Cards...

Page 20: ...Hardware Overview Hardy H6800 Series Application Controllers User Guide 20 Figure 2 7 Model H6850 Rear View with AC and GPRC Option Cards Figure 2 8 Model H6850 Rear View with AC and Scale Input Opti...

Page 21: ...lse Four analog outputs 4 20 mA One analog input 4 20 mA 2 Primary scale input terminal block Connect to weighing device 3 Digital I O terminal block Four digital I O 2 inputs isolated and 2 outputs 4...

Page 22: ...22 3 INSTALLATION Topics This chapter describes how to install the HI6800 Series Application Controllers Planning Your Installation page 23 Unpacking and Climatization page 28 Mounting Instructions pa...

Page 23: ...Service Agent call 800 821 5831 option 4 between 6 30 AM and 5 30 PM PST For emergency downtime service after hours leave a message in our emergency mailbox and your call will be returned promptly or...

Page 24: ...the safety of the user s installation The user is responsible for procuring installing and maintaining adequate power to the equipment Allow only trained persons to use the HI6800 Series Application C...

Page 25: ...ty level and airflow rates Relative humidity above 40 reduces the resistance of items that can generate a charge making it more difficult to generate an ESD Store spare electric parts in antistatic ba...

Page 26: ...7 Pre installation Planning Successful installation of the HI6800 Series Application Controller requires careful pre installation planning Proper planning will help provide for a more efficient instal...

Page 27: ...d between 8 and 80 Is the installation location protected against vibration and acoustics Is all equipment not supplied by Hardy Process Solutions on site and ready for use Electrical Requirements Is...

Page 28: ...HI6800 Series Application Controller in any other container is not advised 4 Check the contents against the items referenced on the packing list If any item is missing or damaged notify a Hardy sales...

Page 29: ...HI6800 Series Application Controllers can be mounted in the following configurations Panel mount option using a 4 3 inch display or 7 inch display Model HI6850 series only Remote Panel mount when the...

Page 30: ...e The hole patterns for the 4 3 inch display and the 7 inch display are identical Figure 3 2 Panel Hole Dimensions Not to Scale A printable template is also available on the Hardy website Printers and...

Page 31: ...secure in place with tape 2 Using a center punch mark the locations of the 5 holes and drill as directed 3 Hand tighten the four screw rods into the front panel display 4 Align screw rods with the fou...

Page 32: ...venly compress the gasket to achieve an IP65 rating Note See I I diagram for torque specification 6 Install the display cable to the display as shown above 7 Position the instrument enclosure with the...

Page 33: ...the instrument enclosure onto the screw rods making sure the display cable remains flat until the instrument is flush with the panel 11 Install and tighten the four keeper nuts with the smooth side of...

Page 34: ...800 Series Application Controllers User Guide 34 Figure 3 1 Zoomed in View of Keep Nut Note The HI6800 Series Application Controller front panel display is NEMA 4 4X rated when installed correctly in...

Page 35: ...play the display is not necessary to monitor and operate the controller Blind units can be fully configured using a web browser see Chapter 5 1 To install pull down the DIN rail clip to expose both of...

Page 36: ...n is possible with the supplied cable make a display cable between the panel and the instrument using the following wiring specifications Wire size 20 AVG maximum 26 AWG minimum Maximum cable length 1...

Page 37: ...zed motor requirements a minimum wire gauge for supply wiring is 14 Ga stranded conductor provided with an Earth Ground Do not use solid conductors To maintain the environmental rating of the control...

Page 38: ...Controller AC Input Power Terminal Block Optional AC Input Power Terminal Block Table 3 2 Pin Numbering on the Optional AC Input 100 240VAC Power Terminal Block Pin Signal Name Properties 1 Line AC L...

Page 39: ...the wires to the connector 2 Connect the 24 VDC voltage wire and shield wire to the connector that plugs into the DC power terminal block at the rear panel 3 Apply VDC power to the unit Figure 3 3 DC...

Page 40: ...near the instrument Do not connect AC and DC power at the same time 3 4 2 Ethernet Communications The rear panel of HI6800 Application Controllers have dual port Ethernet interfaces that connect to lo...

Page 41: ...Chapter 3 Installation Hardy H6800 Series Application Controllers User Guide 41 Table 3 4 Pin Numbering on the Ethernet Ports Pin Signal Name 1 TX 2 TX 3 V 4 GND 5 GND 6 V 7 RX 8 RX...

Page 42: ...lot to serve as external memory for the instrument The memory can be used to transfer parameters from one instrument to another cloning or used as back up memory to restore an instrument in the event...

Page 43: ...such as buttons and switches commonly used to initiate a print or tare command or to drive peripherals such as status lights or motor starters Figure 3 6 Digital I O Terminal Block Table 3 5 Pin Numbe...

Page 44: ...scale input connection is capable of 250 updates second It also features Hardy s exclusive C2 and WAVERSAVER technology This input can be used with almost all industrial load cells sensors and scales...

Page 45: ...t each of these three optional connections support up to 100 updates second They can also be used with almost all industrial load cells sensors and scales These optional weigh scale input connections...

Page 46: ...ch card provides the following Six digital I O pins 4 input and 2 output with one high speed pulse counter Four independent 4 20mA analog outputs featuring 16 000 counts of resolution One analog input...

Page 47: ...Application Controllers User Guide 47 Figure 3 10 HI6850 with Two Optional I O Card Terminal Blocks Table 3 7 Pin Numbering on the Optional I O Card Terminal Block Digital I O 8 IN 2 OUT Two high spe...

Page 48: ...LOG OUT 4 DC 4 20 mA Load resistance 350 Ohm 8 ANALOG OUT 4 COMMON Common 4 Table 3 9 Pin Numbering on the Digital Input Output Port Pin Signal Name Properties 1 DIGITAL OUT 1 Sourcing 0 32VDC 300mA 2...

Page 49: ...on Controllers User Guide 49 3 5 3 Relay Card The Model H6850 supports up to two optional relay cards Each block provides 8 pins for four DC relay connections eight total per option card Figure 3 11 H...

Page 50: ...mes Figure 3 12 Pin Numbering on the Relay Card Terminal Block Table 3 11 Pin Numbering on the Relay Card Terminal Block DC Relay Port Pin Signal Name Properties 1 Line 1 NO 5 30 VDC 1A 2 Common 1 Lin...

Page 51: ...rollers User Guide 51 3 5 4 PROFINET Card Model H6850 Application Controller supports up to one PROFINET interface card This card must reside in the top option slot See section A 5 for information abo...

Page 52: ...Application Controllers User Guide 52 4 COMMISSIONING Connections page 53 Powering on the HI6800 Series Application Controller page 54 This chapter describes how to commission the HI6800 Series Appli...

Page 53: ...en a display is used pay close attention to the interface between the display bezel and the panel to which it is mounted NO GAP should be visible and gasket should be completely compressed Make all co...

Page 54: ...l damage the equipment and or cause personal injury Make sure the power source does not exceed 24 VDC Do not reverse the ground and hot wires because it can damage the equipment 5 Make sure the VDC po...

Page 55: ...s It also describes the parameters that can be set Accessing Configuration Parameters page 56 Understanding the Home Screen page 61 Understanding the Operation Menu page 63 Initial Configuration page...

Page 56: ...screen The touchscreen interface provides quick and simple operation by directly touching the menu items and parameter with a finger Touch the screen with a finger or blunt object only Using sharp obj...

Page 57: ...through an Ethernet network via a router or switch The rear panel of the application controller has two 10 100 BASE T Ethernet ports for linking to any Windows personal computer Once connected Hardy...

Page 58: ...the application controller is 192 168 0 100 enter 192 168 0 101 in the IP address field g In the Subnet mask field type 255 255 255 0 h Back out by clicking OK or HOME all the way back 4 Open a browse...

Page 59: ...u icon at the top right of the Home screen 2 With the Operation Menu displayed touch Communication under Setup 3 Under Manual IP assignment enter the fixed IP address netmask and gateway in the approp...

Page 60: ...to connect to the application controller Double click the connection d In the next window click the Properties button e Select IP version 4 TCP IPv4 and click Properties In the Protocol Properties wi...

Page 61: ...screen appears when the HI6800 Series Application Controller receives power Figure 5 3 shows Home screen and Table 5 1 describes the key areas Note Most parameters are the same for Models HI6800 and H...

Page 62: ...green No connection detected red Mode Gross Net Count Set up Input Status Digital Input state High green low red Output Status Digital Output state Latched green unlatched red Condition Msg In motion...

Page 63: ...onfigures the network IP address for the application controller connected to the network 5 5 4 Security enables passwords to protect unauthorized access to certain screens 5 5 5 Display configures the...

Page 64: ...ries Application Controllers User Guide 64 5 4 Initial Configuration When the HI6800 Series Application Controller is received for the first time we recommend performing the following initial configur...

Page 65: ...tal weight capacity of the scale system If this value is exceeded by eight graduations when configured using one of the certified modes dashes appear on the front display to show that the certified sc...

Page 66: ...l points selected the graduation size 10 displays increments of 10 engineering units and the graduation size 50 shows increments of 50 engineering units For a scale with 10 000 capacity graduation siz...

Page 67: ...ted to provide a faster instrument response time The default factory setting is 1Hz vibration frequency immunity To determine which WAVERSAVER setting is right for your application use the rough guide...

Page 68: ...t Frequency is set to Custom enter the desired value The value you enter sets the number of weight readings used to compute a sliding average of displayed weight This setting is to aid in ignoring the...

Page 69: ...on of the weight value Then set Variation Threshold to 1 5 times larger than the observed weight variation Set the Motion Threshold to 1 3 of the observed peak to peak weight variation For example if...

Page 70: ...alue is within the Auto Zero tolerance value the application controller is automatically zeroed every few seconds until you turn off Auto Zero This does not override the Zero button You can still pres...

Page 71: ...HCP ON or OFF at the application controller Range ON OFF Default OFF Dyn IP Read only field that shows the application controller s IP addresses obtained from the DHCP server DNS IP address of the DNS...

Page 72: ...ity Setup screen Parameter Description Level 1 Enables or disables security for the Tare Zero and Mode buttons on the Home screen by pressing the corresponding icon Lock icon security is enabled for t...

Page 73: ...then select which home screens you want to cycle through Parameter Description Startup Home Screen Sets Home screens you want to add to the Home screen list so you can cycle through the Home screens...

Page 74: ...cable and an instrument with C2 capabilities such as the HI6800 Series Application Controller Digital information within an HI C2 certified load sensor details its unique performance characteristics T...

Page 75: ...With nothing on the scale the Reference Weight is 0 00 With 5 lbs on the scale the Reference Weight is 5 00 lbs C2 Cal Press Do C2 Cal to perform the calibration Wait a few seconds and the results app...

Page 76: ...efault 0 0 Zero Weight unit limit from zero that the application controller accepts as gross zero during the zeroing function when you push the Zero button Range 000001 999999 Default 10 0 Mode Weight...

Page 77: ...the set point input Range Net Gross Default Gross Calibration Date Date when the calibration is performed Num of Points Number of Cal Points necessary to accommodate for non linearity that cannot be...

Page 78: ...1 and or 2 circles to toggle the output between 1 green and 0 red for digital output Press the disk icon to send the state s to the application controller 5 8 Metrology Path Home screen Operation Menu...

Page 79: ...HNICIAN IT is an optional diagnostics utility that allows you to troubleshoot individual load cells rapidly The option requires an HI 6020IT or HI 6010IT Summing Junction Box see Figure 5 5 that provi...

Page 80: ...le 5 4 Operation Diagnostic Integrated Technician Sensor Number Weight mV V mV RTZ Variation Stability Test Sensor 1 1 449430 0 1201 0 6 PASS 3 59 PASS Sensor 2 0 993904 0 0336 0 2 PASS 3 88 PASS Sens...

Page 81: ...s User Guide 81 5 10 Option Card Setup Path Home screen Operation Menu Option Option Card Setup The Option Card Setup category configures specific option cards available to the system For more informa...

Page 82: ...d down time Optimal performance will be achieved by regular cleaning of system components Only qualified personnel should perform maintenance procedures in accordance with the instructions in this cha...

Page 83: ...eat buildup resistance or binding of movement As needed Calibrate the system whenever mechanical changes have been made to any part of the scale system Daily Check for alarms and warnings in the touch...

Page 84: ...Clean the HI6800 Series Application Controller with dry or light moisturized cloth only Avoid aggressive cleaning Do not use high pressure air lines high pressure water jets or high pressure steam cle...

Page 85: ...h is updated frequently and available 365 days a year 24 7 It contains frequently asked questions to assist you in troubleshooting and provides a form for requesting additional information and answers...

Page 86: ...y Process Solutions Technical Services Department for additional information and assistance Do not disconnect any electrical plug connector or terminal unless an identification tag is present or one i...

Page 87: ...on tolerance settings and retry 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 No C2 Sensor...

Page 88: ...rocedure Refer to Table 7 2 for an overview of the troubleshooting topics described in the following sections Table 7 2 General Troubleshooting Problem See Drifting or unstable weight reading Section...

Page 89: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 89 7 4 1 A1 Troubleshooting Instabilities on a Formerly Operating System...

Page 90: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 90 7 4 2 B Troubleshooting Instabilities on a Formerly Operating System...

Page 91: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 91 7 4 2 1 B1 Troubleshooting Instabilities on a Formerly Operating System...

Page 92: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 92 7 4 2 2 B1 continued Troubleshooting Instabilities on a Formerly Operating System...

Page 93: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 93 7 4 3 C Troubleshooting Instabilities on a Formerly Operating System...

Page 94: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 94 7 4 4 E Troubleshooting Non Return to Zero Must be Connected to an IT Summing Box...

Page 95: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 95 7 4 5 F Troubleshooting Individual Load Cell Millivolt Readings...

Page 96: ...er 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 96 7 4 6 G Calibration Failed Not Enough Counts Between Zero Weight and Span Weight This error occurs at the Span Weight para...

Page 97: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 97 7 4 7 H Mechanical Inspection...

Page 98: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 98 7 4 8 J Electrical Inspection...

Page 99: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 99 7 4 9 K Load Sharing and Load Sensor Checkout...

Page 100: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 100 7 4 10 M or Error...

Page 101: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 101 7 4 11 N Application Controller Front Panel Display is Blank...

Page 102: ...Chapter 7 Troubleshooting Hardy H6800 Series Application Controllers User Guide 102 7 4 12 P SD Card Diagnostics...

Page 103: ...n the Option Card screen s of the instrument or via the embedded webserver Alternatively navigate to the Optional I O screen of the instrument or to Setup Options of the browser and select the Option...

Page 104: ...setpoint is a high trip limit Loss in Weight and deadband are used for a low trip limit as shown in the pictures below Name Provides the option to assign a nickname to the setpoint Mode Specifies whic...

Page 105: ...ow 5 With a setpoint setting using reverse relay logic Settings NET LIW Target 5 Pre 0 Deadband 345 The Output is set high until 350 then the output goes low and stays low until LIW is below 5 Status...

Page 106: ...I O Configuration Main board I O configuration is separated into two sections Digital Inputs and Digital Outputs Inputs are used to assign an action to a state change while outputs are used to create...

Page 107: ...0Quck Reference Hardy H6800 Series Application Controllers User Guide 107 A 4 Main Board I O See the diagram below for the appropriate settings...

Page 108: ...ry 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 s...

Page 109: ...easurement B 2 Piece Count B 3 Rate of Change Parameters Path Home screen Operation Menu App Rate Of Change If your HI6800 Series Application Controller has access to the rate of change application re...

Page 110: ...nger time base than high flow rates The application controller measures weight to better than 1 part in 10 000 Generally Time Base should be greater than scale capacity 10000 low rate units per second...

Page 111: ...eight controller ON or OFF Range ON OFF Default OFF Check Mode Range Weight PhotoEye Auto Default Weight Check zones Number of zones through which the object will pass Range 5 Zones 3 Zones Weight Uni...

Page 112: ...as a percentage Statistics total count Quck Reference This appendix provides quick reference information as well as I I diagrams and drawings B 8 Sequential Batch Control All HI6800 Series Applicatio...

Page 113: ...orrect timing and filtering for a correct check weight Check Off Weight A check weight Auto Zero located on the diagnostics screen When filters and settings are correct this weight will be your refere...

Page 114: ...losure Remove the four Phillips screws one at each corner of the backplate Figure 7 1 Removing the Backplate Screws 4 Lift the backplate from the enclosure and set it aside 5 Install the option cards...

Page 115: ...rollers IIoT Industrial Internet of Things An extension and use of the Internet of Things IoT designed for industrial sectors and applications Modbus TCP IP Modbus RTU protocol with a TCP interface th...

Page 116: ...maintenance 85 unit 87 Climatization 28 Commissioning 51 Configuration 56 calibration 76 calibration parameters 75 digital I O states 80 Home screen 62 initial 65 IT tests 82 metrology 81 Operation M...

Page 117: ...nd maintenance 85 commissioning 51 configuration 56 connections 52 disassembly 89 electrical inspection 101 error messages 90 general troubleshooting 91 installation 22 mechanical inspection 100 Model...

Page 118: ...and rear views 18 installing option cards 122 Models 12 Mounting controller 29 DIN rail 35 panel mount option 31 remote display mount 36 using a front panel display 30 Multi channel measurement 114 Mu...

Page 119: ...s 23 Responsibilities user 24 S Safety labels 24 Schedule of preventive maintenance 86 SD card diagnostics 105 using 106 Seismic considerations 27 Set point controller parameters 117 Setting up option...

Page 120: ...hing dynamic 115 static 115 Weight gain in 114 loss in 114 monitoring 115 Weight measurement parameters 116 Wiring instructions 37 digital I O 42 Ethernet communications 39 GPIO card 45 Micro USB devi...

Page 121: ...Application Controllers User Guide 121 Hardy Process Solutions 10075 Mesa Rim Road San Diego CA 92121 hardyinfo hardysolutions com http www hardysolutions com Hardy Process Solutions Document Number...

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