Hardy HI 6600 User Manual

HI 6600 Series Modular Sensor System User Guide

HI 6600 Series Modular Sensor System

User’s Guide

Hardy Process Solutions Document Number: 0596-0333-01 REV A

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HI 6600 Series Modular Sensor System User Guide

Local Field Service

Hardy has over 200 field technicians in the U.S., and more positioned throughout the world to assist you in your support needs. We also have factory engineers who will travel to your facility anywhere in the world to help you solve challenging applications. We're ready to support you with:

Installation and start-up

Routine maintenance and certification

Plant audits and performance measurement

Emergency troubleshooting and repair

To request Emergency Service and Troubleshooting, Start-up, Installation, Calibration, Verification or to discuss a Maintenance Agreement please call 800-821-5831 or Emergency Service after hours (Standard Hours 6:30 AM to 5:30 PM Pacific Standard Time) and weekends.

Outside the U.S

Hardy Process Solutions has built a network of support throughout the globe. For specific field service options available in your area please contact your local sales agent or our U.S. factory at

[phone].

HI 6600 Series Modular Sensor System User Guide

Contents

• • • • • •

Contents ..........................................................................................................................................	3
Chapter 1.........................................................................................................................................	8
HI 6600 Series Overview................................................................................................................	8
Introduction to the HI 6600 Modular Sensor System..............................................................	8
Typical Applications ............................................................................................................	9
HI 6600 Series Model Numbers ..........................................................................................	10
Chapter 2.........................................................................................................................................	11
SpecificationsandFeatures ................................................................................................................	11
Basic Specifications .................................................................................................................	11
HI 6610 Weight Processing Module (WPM) .................................................................	11
Hardy Gateway Module (HI 6600) .......................................................................................	12
Network Connectivity ......................................................................................................	12
OptionalHI6110FrontPanelDisplay ..................................................................................	13
Environmental Requirements..............................................................................................	13
Approvals .......................................................................................................................	13
Network Certifications .......................................................................................................	13
Features and Capabilities...........................................................................................................	13
Hardy Process Toolbox.......................................................................................................	13
C2® and eCal™ Calibration ...............................................................................................	13
INTEGRATED TECHNICIAN® ........................................................................................	14
WAVERSAVER® ...........................................................................................................	14
Chapter 3.........................................................................................................................................	15
HI 6600 Hardware Installation............................................................................................................	15
Safety .....................................................................................................................................	15
General Precautions ...........................................................................................................	15
Unpacking.............................................................................................................................	15
Tool List .........................................................................................................................	16
Installing the HI 6610 Modules ............................................................................................	16
Overview of the HI 6600 Hardware......................................................................................	17
Installation ......................................................................................................................	17
Cabling the Units Together..................................................................................................	19
DC Power Input ....................................................................................................................	19
Connecting Sensors ........................................................................................................	20
Installing the Optional Display ..................................................................................................	21
BlindUnit(Nodisplay) ......................................................................................................	21
Optional Remote Display Mount .........................................................................................	21
Mounting the Optional Front Panel Display....................................................................	22
Making Longer Display Interface Cables .............................................................................	24
Chapter 4.......................................................................................................................................	25
Instrument Configuration ..................................................................................................................	25
Using the Webserver.............................................................................................................	26

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HI 6600 Series Modular Sensor System User Guide
Using the HI 6110 Front Panel Display....................................................................................	27
Mode Button.....................................................................................................................	28
Channel Identification...............................................................................................................	29
System Discovery..............................................................................................................	29
Naming the Weight Processing Modules...............................................................................	30
Ordering the Weight Processing Modules..............................................................................	30
Deleting or Replacing Channels ..........................................................................................	30
Saving and Restoring Configuration Data Using the USB port ........................................	30
Suggested Minimum Steps When Setting Up the Instrument For the First Time...........	31
Capacity Parameter ..........................................................................................................	32
Decimal Point Parameter ................................................................................................	32
Graduation Size Parameter .............................................................................................	32
Instrument ID .................................................................................................................	33
Motion Tolerance Parameter ..........................................................................................	33
Operator ID Parameter .....................................................................................................	33
Unit (of Measure) Parameter ..........................................................................................	33
Filter Parameter Menu........................................................................................................	34
NumAverages Parameter ..................................................................................................	34
WAVERSAVER® Parameter...........................................................................................	34
Calibration ..............................................................................................................................	35
Pre-Calibration Procedures .................................................................................................	35
Electrical Check Procedures..................................................................................................	36
Load Cell/Point Input/Output Measurements .................................................................	36
Load Check.......................................................................................................................	37
C2 & eCAL Electronic Calibration.............................................................................................	37
C2andeCALCalibration Commands and Parameters .......................................................	37
Sensitivity Parameter........................................................................................................	37
Ref Weight Parameter.......................................................................................................	37
Cal Tolerance Parameter ...................................................................................................	38
Gravitation Correction....................................................................................................	38
C2andeCALCalibration Process ......................................................................................	40
Hard Calibration....................................................................................................................	41
Hard Cal Commands and Parameters .............................................................................	41
Cal Lo Weight Parameter .................................................................................................	41
Cal Tolerance Parameter ...................................................................................................	41
Do Cal Lo Command .......................................................................................................	41
Do Cal Hi Command........................................................................................................	41
Span Weight Parameter ....................................................................................................	42
Chapter 5 ........................................................................................................................................	43
Instrument Operation........................................................................................................................	43
Operations.............................................................................................................................	43
Tare Parameters and Commands ................................................................................................	43
Tare Amount ....................................................................................................................	43
Tare Offset .......................................................................................................................	44
Tare Command.................................................................................................................	44
Zero Parameters and Commands ................................................................................................	44
Zero Tolerance.................................................................................................................	44
Zero Amount....................................................................................................................	45
Zero Command ................................................................................................................	45
Auto Mode........................................................................................................................	45

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HI 6600 Series Modular Sensor System User Guide
Count Operations .....................................................................................................................	46
Determining Piece Count:.................................................................................................	46
Chapter 6.......................................................................................................................................	47
NetworkCommunications .................................................................................................................	47
Maximum Number of Channels Supported for PLC Communication Formats .............	48
LAN Connection ............................................................................................................	48
IP address. ......................................................................................................................	49
Enable DHCP ..................................................................................................................	49
Mask Address Parameter ................................................................................................	49
Gateway Address Parameter .............................................................................................	49
DNS Server Parameter .....................................................................................................	50
Fixed IP Configuration ...................................................................................................	50
Direct Connect Hardware ...............................................................................................	50
Windows PC Configuration: Windows 2000 ................................................................	51
Windows XP....................................................................................................................	51
Windows 7.......................................................................................................................	51
DirectConnectConfiguration-HI6600HGM ......................................................................	52
EtherNet/IP®...........................................................................................................................	52
EtherNet/IP Commands and Parameters ..................................................................................	53
TheEtherNet/IP Diagnostics Screen................................................................................	53
Ethernet UDP Parameters .........................................................................................................	55
Hardy Port ......................................................................................................................	55
Modbus TCP ...........................................................................................................................	55
Modbus TCP Commands and Parameters ......................................................................	55
Installing the Hardy Modbus-Link Test Package..............................................................	57
Configuring MODBUS TCP.............................................................................................	57
Modbus-RTU (over RS-485) .....................................................................................................	62
Modbus-RTU Commands and Parameters ............................................................................	62
Slave Address Parameter ..................................................................................................	62
Baud Rate Parameter.......................................................................................................	62
Parity Parameter..............................................................................................................	63
Modbus Setup ..................................................................................................................	64
Modbus Functions............................................................................................................	64
Profibus-DP ..........................................................................................................................	65
Profibus Configuration .......................................................................................................	66
Initialization Process ........................................................................................................	67
Profibus-DP .GSD File ....................................................................................................	68
Pre-Initialization Procedures.............................................................................................	68
USB Memory Stick ..................................................................................................................	73
Restore Command............................................................................................................	73
Chapter 7.......................................................................................................................................	74
Security.........................................................................................................................................	74
Optional HI 6110 Display Security Options ................................................................................	74
The Display Lock ..............................................................................................................	75
The Keypad Lock ..............................................................................................................	78
The Configuration Lock .....................................................................................................	79
The Read Only, Security & Calibration Locks...............................................................	81
Modifying the Calibration Parameters ..................................................................................	83
Modifying the Read Only Parameters ...................................................................................	83
Chapter 8.......................................................................................................................................	84

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HI 6600 Series Modular Sensor System User Guide
Troubleshooting............................................................................................................................	84
Assembly Notes, Warnings & Cautions.......................................................................................	84
Updating Instrument Firmware ...........................................................................................	85
Information Page ...............................................................................................................	85
Indicator Lights Summary..............................................................................................	86
Common Error Messages..........................................................................................................	87
Diagnostics............................................................................................................................	87
Trouble Shooting Using Integrated Technician (IT®) .............................................................	87
Stability Test ALL .............................................................................................................	88
PASS/FAIL and Stability Test .............................................................................................	88
WAVERSAVER TEST....................................................................................................	88
Weight and Voltage ALL ...............................................................................................	88
RTZ(ReturntoZero)Test....................................................................................................	89
ITTest..............................................................................................................................	89
General Troubleshooting Flow Chart Index..................................................................................	91
A-ElectricalandMechanicalReview..........................................................................................	92
A1.CheckingforUnstableComponentsinaWeighingSystem.........................................................	93
B. Guidelines for Electrical, Mechanical or Configuration Issues ...................................................	94
B1-GuidelinestoVerifyElectricalInstallation.............................................................................	95
B2-GuidelinestoVerifyMechanicalInstallation..........................................................................	96
B3-VerifyConfiguration/FilterSettingstoImproveStability .........................................................	97
C-IntegratedTechnicianandStabilityTestOverview ....................................................................	98
ENon-ReturntoZero(SystemwithITSummingCard.).................................................................	99
F. Verify Individual Load Sensor Millivolt Output readings .........................................................	100
G- Calibration Errors During Calibration ..................................................................................	101
H. Mechanical Installation ......................................................................................................	102
J- Electrical Inspection ...........................................................................................................	103
K-InstallationCheckPoints ....................................................................................................	104
M. WeightProcessor’sOptionalFrontDisplayBlankorLocked ....................................................	105
Tests and Diagnostics..............................................................................................................	106
Diagnostictestingfromthe OptionalFrontPanel ................................................................	106
Parameters...........................................................................................................................	107
SystemandLoadCellTests ......................................................................................................	108
OverviewofTypicalLoadCellSystem...............................................................................	108
INTEGRATED TECHNICIAN................................................................................................	109
Stability Test ..................................................................................................................	109
Running the StabilityTestfromtheWebInterface ...........................................................	110
RunningtheStabilityTestfromtheOptionalFront Panel.................................................	110
WeightandVoltageTests................................................................................................	111
WeightandVoltageTestfromthe Webinterface ..............................................................	111
Running the IT test fromthe Optional Front Panel ..........................................................	111
Appendix A.................................................................................................................................	113
Communications I/O Table.........................................................................................................	113
I/OTablesforCommunicationstoPLCs.....................................................................................	113
OUTPUT Table Description ....................................................................................................	114
Portion of the OUTPUT table used for the Hardy Gateway Module (HGM)...............	114
Portion of the OUTPUT table used for Weigh Processing Modules (WPMs) .............	114
INPUT Table Description........................................................................................................	114
Portion of the INPUT table used for the Hardy Gateway Module (HGM)...................	114

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HI 6600 Series Modular Sensor System User Guide
Portion of the INPUT table used for Weigh Processing Modules (WPMs) .................	115
Hardy Command Numbers......................................................................................................	116
Appendix B.................................................................................................................................	118
Default Parameter IDs and Values .....................................................................................................	118
Default Parameters and Values Table ........................................................................................	118
Appendix C.................................................................................................................................	120
Drawings & Templates ....................................................................................................................	120
II Diagrams .........................................................................................................................	120
Image of HI 6600 Hardy Gateway Module II Diagram ......................................................	121
Image of HI 6610 Weight Processing Module II Diagram ...........................................................	122
OptionalHI6110DisplayPanelMountingTemplate...................................................................	123
Appendix D.................................................................................................................................	124
Spare Parts ..................................................................................................................................	124
Spare Parts ............................................................................................................................	124
Appendix E .................................................................................................................................	125
Wiring Junction Boxes or Summing Cards .........................................................................................	125
ConnectingtoHardyJunctionBoxesorSummingCards ..............................................................	125
HI6010SummingBoxDiagram ...........................................................................................	126

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HI 6600 Series Modular Sensor System User Guide

Chapter 1

HI 6600 Series Overview

• • • • • •

This Manual describes installation, setup and operating procedures for the HI 6600 Series Modular Sensor System. Be sure to read and understand all cautions, warnings, and safety procedures in this manual to ensure safe installation and operation of the instrument.

Hardy Process Solutions sincerely appreciates your business. We encourage input about the performance and operation of our products from our customers. Should you not understand any information in this manual or experience any problems with this product, please contact our Technical Support Department at:

Phone: [phone]

Toll Free: 1-800-821-5831

FAX: [phone]

E-Mail: [e-mail] or [e-mail] Website: www.hardysolutions.com

Please visit our website for the latest revision of the HI 6600 Series User Guide and sign up for the Hardy Newsletter to get the latest information on all Hardy products and services. For answers to technical issues and service problems, please visit the Hardy WebTech section of our website or contact a technician by phone during our normal operating hours (6:30 AM to 5:30 PM Pacific Time).

Introduction to the HI 6600 Modular Sensor System

The HI 6600 Modular Sensor System consists of at least one HI 6600 Hardy Gateway Module (HGM) and up to 30 HI 6610 Weight Processor Modules (WPM).

The system communicates with PLCs, PACs and DSCs over EtherNet/IP, Profibus-DP, Modbus-RTU and other popular communication protocols via a single communication link.

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HI 6600 Series Modular Sensor System User Guide

The system is used for front end signal processing of strain-gage type sensors and load cells for all types of industrial and machine weighing applications. Operating blind or with an optional display, the Modular Sensor System conditions, converts and communicates stable processed weight readings from connected load sensors or scales to a variety of control and monitoring systems.

The HardyNet Gateway Module (HGM or HI 6600) offers users many communication choices including Ethernet TCP/IP, Modbus RTU, Modbus TCP and either EtherNet/IP or Profibus-DP.

The HI 6600 series can be used with or without an optional Hardy HI 6110 display. The display is a bright 4.3” high-contrast LCD capable of high-resolution graphics and help text discrete messaging. The HI 6110 display can be panel mounted near the Gateway Module or remotely up to 100 feet away to provide a user interface for operating, calibrating or setting-up the system.

The modular array, small enclosures and low power consumption enable high density cabinet design for systems that require up to 30 channels of processed weight.

Typical Applications

Ideally suited for applications that require multiple channels of weight, the HI 6600 series serves a variety of industrial weighing needs found in batching, blending, filling, dispensing, inventory management, level by weight and check by weight verification.

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		HI 6600 Series Modular Sensor System User Guide
HI 6600 Series Model Numbers
	Model Number	Description
	HI 6600-EIP	HardyGatewayModule-EtherNet/IP
	HI 6600-PB	HardyGatewayModule-Profibus-DP
	HI 6610-WP	WeightProcessingModule,nodisplay
	HI 6110	Optional Multi-Channel Display

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HI 6600 Series Modular Sensor System User Guide

Chapter 2

Specifications and Features

• • • • • •

Chapter 2 provides specifications for HI 6600 series instruments. The specifications listed are designed to assist in the installation, operation and troubleshooting of your instrument. All service personnel should be familiar with this section before installing or repairing the instrument.

Basic Specifications

HI 6610 Weight Processing Module (WPM)

Number of Channels

Each Weight Processing Module is a single channel of weight. HI 6600 Modular Sensor System can support up to 30 channels. The actual number of channels that can be transmitted by a single I/O table request depends on the PLC interface format.

	EtherNet/IP:	Up to 30Channels per request
	Modbus-TCP:	Up to 14 Channels per request

Modbus-RTU: Up to 14 Channels per request

Profibus-DP:

Up to 10 Channels per request

UpdateRateperWeightProcessingModule(WPM)

110 times per second per channel (processed weight, display, communications)

Weight ProcessingModule(WPM) Resolution

Displayed - 1:10,000

Internal - 1:8,388,608

WAVERSAVER®

User Selectable

OFF, 7.50 Hz, 3.50 Hz, 1.00 Hz (default), 0.50 Hz, 0.25 Hz

Averages

1 to 250

User-selectableinSingleIncrements

LoadSensorInputperWPM

Up to four 350-ohm full Wheatstone bridge, strain gauge load sensor/cells (5 volt excitation) can be connected to the weigh scale input on each WPM.

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HI 6600 Series Modular Sensor System User Guide

Note: Connecting 2 or more load cells requires a summing card or Junction Box.

Non-linearity

0.0015% of full scale

Common Mode Rejection

110 dB at or below 60 Hz

Common Mode Voltage Range

2.5 VDC maximum (with respect to earth ground)

Load Cell Excitation

5 VDC +/-1.15 VDCmaximum

Isolation from digital section 1000 VDC minimum

C2 Calibration Input

Isolationfromdigitalsection1000VDCminimum

Load Sensor Cable Lengths per Weight Processing Module

250 feet maximumof C2 authorized cable (Maximum of4 load sensors) with a Summing Card or IT Junction box

DCInputVoltageWeightProcessingModule(with4x350ohmloadcells)

1.72 Watts,12-27 VDC, 71-118 mA

Maximum System Span Distance

500 feet (150 meters) span from the first Weight Processor Module to the Hardy Gateway Module

Hardy Gateway Module (HI 6600)

Network Connectivity

Ethernet TCP/IP

Ethernet UDP

Modbus-RTU over RS485

Modbus TCP

EtherNet/IP (EIP models only)

Profibus-DP (PB models only)

USB Port: For Parameter Saving and Backup to PC

Display Port: For optional Front Panel Display

Scoreboard: Uses RS485 port to stream weight readings to a large display or data logger

DCInputVoltage HardyGatewayModule(HGM)

3.90 Watts, 12-24 VDC, 162-290 mA

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HI 6600 Series Modular Sensor System User Guide

OptionalHI6110FrontPanelDisplay

Monochrome 480 x 272 LCD display with back light

Five tactile keys for menu item selection

Displays in either white on black or black on white

IP66 rated when mounted on a smooth, rigid surface (minimum 16-gage) using the supplied gasket

2 watts maximum

Environmental Requirements

Operating Temperature Range

-10ºC to 60º C (14º to 140º F)

Temperature Coefficient

Less than 0.005% of full scale per degree C for Cal-LO and Cal-HI reference points

Storage Temperature Range

-40 to 85º C (-40º to 185º F)

Humidity Range

0-90% (non-condensing)

Environmental

Intended for Building-in, indoor use only at ambient temperatures between 10ºC to 60º C (14º to 140º F) with a pollution degree of 2.

Approvals

UL, CUL and CE

Hazardous Area Class I, Division 2, Groups A,B,C,D, T4A (pending)

Hazardous Area Class III, Division 2, Groups E, F, G, T4A (pending)

Network Certifications

EtherNet/IP ODVA Conformance Tested, Level 3)

Profibus-DP by Profibus.org (pending)

Features and Capabilities

Hardy Process Toolbox

The Hardy Process Toolbox is a set of productivity tools that support process weighing functions. Each tool in the Hardy Process Toolbox saves time, increases accuracy, improves efficiency or reduces risk in process weighing applications. The HI 6600 includes the Toolbox functions discussed below.

C2® and eCal™ Calibration

Traditional calibration uses certified test weights. C2® (or eCAL™ as it is called in China) Electronic Calibration allows a scale to be calibrated without the need for test weights. A C2 or eCAL weighing system consists of up to four load cell sensors per WPM, a junction box, interconnect cable, and an instrument with C2 capabilities (e.g., the HI 6600 series instrument).

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HI 6600 Series Modular Sensor System User Guide

Each Hardy Process Solutions C2-certified load sensor outputs digital information used for calculating the calibration. When the HI 6600 series instrument reads the signals from the load sensors, it calibrates the scale based on the load sensor’s output plus a user-supplied reference point value (from 0 to any known weight on the scale).

INTEGRATED TECHNICIAN®

In conjunction with an IT junction box, the HI 6600 series features INTEGRATED TECHNICIAN® (IT), a system diagnostics program that makes it possible to diagnose weighing system problems from Hardy’s Web Server or a connected optional display panel. IT reads individual load sensor voltages and weights and isolates individual system components for quick and easy troubleshooting

NOTE: If you do not have a Hardy IT Junction Box connected to the HI 6600, the weight reading is the total for all load cells on the system.

WAVERSAVER®

When measuring small weight changes, the effects of mechanical vibration and noise from feeders and other plant environmental conditions can introduce substantial interference. WAVERSAVER factors out vibration, noise, and other interference-related signals from the load cell so the weight processor can better decipher the actual weight data.

While WAVERSAVER can factor out noise with frequencies as low as 0.25 Hz, five cut-off frequencies can be selected, with higher frequencies providing a faster response time. The default factory setting is 1.00 Hz vibration frequency immunity.

C2, INTEGRATED TECHNICIAN and WAVERSAVER are registered trademarks of Hardy Process Solutions.

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HI 6600 Series Modular Sensor System User Guide

Chapter 3

HI 6600 Hardware Installation

• • • • • •

Chapter 3 covers physical installation of HI 6600 Modular Sensor System. User and service personnel should read this chapter before installing or operating the HI 6600 Modular Sensor System.

Safety

Before you begin installing your HI 6600 series equipment, please review the important safety precautions below.

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in this Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Hardy Process Solutions provides manuals in PDF format that are easily downloaded from our website, free of charge. Look under the Docs & Programs tab on the web page for each product.

General Precautions

Always disconnect the power cord before disassembling.

Always replace broken or damaged modules or hardware immediately.

Always check to be sure that no loose parts are sitting on printed circuit boards or electrical connectors or wires when disassembling or reassembling.

Always protect printed circuit boards from electrostatic discharge (ESD). Always use approved ESD wrist straps and anti-static pads.

Unpacking

WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY

IMPAIR SUITABILITY FOR DIVISION 2.

AVERTISSEMENT–Risqued’explosion–Lasubstitutiondecomposantspeut diminuerlaconformitépourlaDivision2

WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT

UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE

NON-HAZARDOUS

AVERTISSEMENT – Risque d’explosion – Ne pas débrancher l’équipement à moins que l’alimentation soit coupée ou que la zone ne présente pas de risques

1)Before signing the packing slip, inspect the packaging for damage, and report damage of any kind to the carrier company.

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HI 6600 Series Modular Sensor System User Guide

2)Check to see that everything in the package matches the bill of lading.

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: [phone]

International: [phone]

FAX: [phone]

Web Site: http//www.hardysolutions.com

E-Mail: [e-mail]

Record the model number and serial number of the HI 6600 series instrument. Store them in a convenient, secure location for reference when contacting Hardy Customer Service Department or to buy parts or firmware upgrades.

Tool List

To install the HI 6600 series the following tools will be required.

Jewelers screw driver (to make and modify cable assemblies)

10-50 mm Unibit (for optional display installation)

Drill with 5mm drill bit (for optional display installation)

8 mm nut wrench or socket (for Optional Display)

Installing the HI 6610 Modules

Before getting started, take the following precautions:

WARNING- Electrostatic discharge may damage semiconductor components in the module. DO NOT TOUCH THE CONNECTOR PINS.

AVERTISSEMENT – Les décharges électrostatiques peuvent endommager les composantssemi-conducteursdanslemodule.NETOUCHEZPASlesbrochesdu connecteur.

Wear an approved wrist-strap grounding device when handling the instrument.

Touch a grounded object or surface to rid yourself of any electrostatic discharged prior to handling the instrument.

Handle the instrument from the bezel in front away from the connector. Do not touch the connector pins.

Do not install the instrument right next to an AC power source or high voltage DC equipment

Route all the low voltage cables away from high voltage cables

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HI 6600 Series Modular Sensor System User Guide

Overview of the HI 6600 Hardware

Before installing the HI 6600 Series, familiarize yourself with the basic configuration as shown below.

DC Power, Shield, Ports for HardyNet and a Termination switch can be found on the bottom of both the Hardy Gateway Module and the Weight Processing Modules.

The RJ45 ports located on the bottom are used to connect the system using Cat5e cabling. Communications between modules (HardyNet) as well as power distributed from the Gateway Module to the Weight Processing Modules is carried on the Cat5e cabling.

Weight Processing Module

Hardy Gateway Module

The Weigh Scale Input is located on the front of the HI 6610 Weight Processing Module.

Located on the front of the HI 6600 Gateway module is a USB port (used to store system settings), a Display port (for connecting to an optional HI 6110 display), Serial Termination switch, Serial Port and an Ethernet Port.

Installation

The HI 6600 Series WPMs and HGMs are designed to be installed on a DIN rail as shown below.

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HI 6600 Series Modular Sensor System User Guide

The MAXIMUM span between the first and last module that comprise a system is 500 feet (150 meters).

Note: Use Heavy Gage DIN rail conforming to EN 60715 and EN 50022.

Use of thin or light gage DIN rail is not recommended.

Begin by installing the WPMs or HGMs onto the DIN rail as shown below.

1)Hook DIN rail bracket onto the DIN rail using the groove at the top of the bracket

2)Push the module down on the top of the DIN rail and then rotate the bottom of the module onto the bottom bracket of the DIN rail until it clicks into place.

3)While holding the HI 6600 series instrument, gently pull the bottom of the HI 6600 away from the DIN rail to verify that it is mounted correctly.

To remove, pull up on the bottom of the front corner of the module to disengage the bottom DIN rail catch first, and then lift up on the module to remove the top DIN rail catch.

Note: Between 8 – 12 pounds of upward force is required to remove a Hardy HI Series Instrument from most DIN rail.

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HI 6600 Series Modular Sensor System User Guide

Cabling the Units Together

Once the units are all placed on a DIN rail, connect them together in a series using the RJ45 ports on the bottom of the units and Cat5e cable.

The Cat5e cabling carries communications between the modules and distributes power from the Hardy Gateway Module to the Weigh Processing Modules.

Redundant DC power may also be supplied individually to each Weight Processing Module via the DC power input terminal located on the bottom of the module. DC power supplied to individual Weight Processing Modules is isolated and not distributed to other modules on the system.

At minimum, DC power must be supplied to the Gateway Module.

The maximum distance between the first and last module on a system is 500 feet (150 meters).

DC Power Input

WARNING - Do not operate with incorrect line voltage. To do so will result in property damage and/or personal injury. Make sure that the power source does not exceed 24 VDC.

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.

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HI 6600 Series Modular Sensor System User Guide

WARNING - Be careful not to reverse the ground and hot wires, which can result in damage to the equipment.

AVERTISSEMENT – Attention à ne pas inverser le sol et fils chauds, ce qui peut entraîner des dommages à l'équipement.

A power-limited 12-24 VDC power supply (Class 2) must be used on the DC input wiring.

DC power should be supplied by a clean primary line, directly from the DC power source.

1)Make sure the VDC power is shut off before installing the wires to the connector.

2)Connect the 24 VDC voltage wire, ground wire and shield wire to the connector that plugs into the DC voltage header at the rear panel. The jumper connects the Earth ground and the internal ground making them common, and should remain in place.

3)Plug the connector into the bottom panel.

4)Apply VDC power to the unit.

WARNING - If the HI 6600 series equipment is used in a manner that is not specified by the manufacturer, the protection provided by the equipment may be impaired.

AVERTISSEMENT – Si l'équipement de série HI 6600 est utilisé d'une façon qui n'est pas spécifiée par le fabricant, la protection fournie par l'équipement peut être altérée.

Connecting Sensors

The diagrams below show Hardy Load Sensors with C2 and non-Hardy Load Cells (4 wire and 6 wire are similar except 6 wire adds sense wiring) that do not have C2. Wire the terminal connector that plugs into the front of the Weight Processor Modules by carefully following the Weigh Scale Input termination label.

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HI 6600 Series Modular Sensor System User Guide

Non-C2 load cell wiring

Hardy load sensor with C2

Note: when connecting the HI 6600 series instrument to a junction box, the sense lines would be connected between the +Sen and –Sen connections for the junction box and the instrument. See the I/I Diagram for further detail. You can find the I/I Diagram in the Hardy website under Products>

WARNING - Instrument power should be routed away from all other signal cables to avoid electrical interference.

AVERTISSEMENT – Tension de l'appareil doivent être acheminés à l'écart de tous les autres câbles de signaux pour éviter toute interférence électrique.

Installing the Optional Display

The following section provides details on how to mount the Optional Front Panel Display and connect to the HI 6600 HGM.

BlindUnit(Nodisplay)

The front display is not necessary for the HI 6600 series instrument to operate as a weight processor. Blind units can be fully configured using the Web browser communication.

Optional Remote Display Mount

The HI 6600 Modular Sensor System is compatible with HI 6110 displays.

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The optional display for the HI 6600 series instrument can be mounted in a remote location up to 250 feet (75 meters) from the Hardy Gateway Module by modifying the supplied cable.

Mounting the Optional Front Panel Display

(1)Make sure that all Electrostatic Discharge (ESD) precautions are taken before and during installation.

(2)A thin plastic template comes with the product. Make the hole pattern in the panel door or cover using the dimensions provided on the diagrams below.

WARNING - We recommend installing the HI 6600 series modules in a

NEMA 4, 4X or IP 55 rated enclosure or better.

AVERTISSEMENT – Nous vous recommandons d'installer le HI 6600 dans un boîtier NEMA 4, 4X ou IP 55 ou mieux.

PanelHoleDimensions(notdisplayedtoscale)

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i)Connect and hand-tighten the four screw rods into the Optional Front Panel display.

ii)Place the gasket over the screw rods then slide the screw rods through the panel until flush with the surface.

iii)Place washer and nut onto the screw rods sticking through the panel. Tighten nuts so that the gasket is fully compressed and that the metal bezel of the display is in contact with the panel. Nuts should be torqued to 20 inch-lbs to ensure the seal required for an IP-66 rating.

iv)Remove the terminal connectors from the cable assembly provided and replace the original cable with the desired cable length. See instructions above for Making Longer Display Interface Cables below.

v)Connect the display cable to the back of the display and to the Display Port located on the front of the Hardy Gateway Module

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Making Longer Display Interface Cables

The terminal block uses a spring cage type contact. There is a slot provided to use an insert/release tool. The tool is a 2.0 mm x 0.4 mm wide flat blade screw driver. Inserting the end of the small screwdriver tool opens the cage contact and allows one wire to be inserted. Removing the insertion tool with bare conductor wire inserted will lock the connection.

Wiring Specifications

Wire size: 20 AVG maximum / 26 AVG minimum

Maximum cable length: 100 ft. (30.48 meters)

Use three twisted pairs with a drain wires

Pair wires +12 and GND, D1 and D2, D3, and D4

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HI 6600 Series Modular Sensor System User Guide

Chapter 4

Instrument Configuration

• • • • • •

Menu Structure

The menu tree below shows the location of commands and parameters used to configure and use the system.

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The system can be set-up, calibrated and operated either through the built-in Webserver or through an optional front panel display. The menu structure above may be followed using either interface.

Using the Webserver

To use the Webserver, a connection must first be established between the Hardy Gateway Module and a connect PC. The following steps will assist in establishing a connection:

1)Connect an Ethernet cable between the RJ45 port located on the front of the HI 6600 Gateway Module’s RJ45 and a PC then power up the instrument. A cross-over cable is not required, but can be used.

2)The instrument will auto-negotiate settings suitable for a variety of operating systems and network configurations. Wait approximately 15 seconds and check to see if the green light of the Ethernet port is on and blinking – if so, skip to step 8 – you are connected.

3)If the green light on the Ethernet port does not light up, use the Optional Display to check that the unit’s Enable DHCP is turned off and follow steps 4 through 8 If an optional display is not available, please call Hardy Tech Support for further assistance.

4)Using the unit’s Fixed IP address (the default is 192.168.000.100), the PC must now be assigned a unique IP address (for example, 192.168.000.101)

There are two simple rules for the IP Address:

•It must have the same network identifier as the computer.

•It must have a different node identifier than the computer.

5)On a PC running windows, open Internet Properties (TCP/IP).

Click in the ‘Use the Following IP Address’ checkbox; then enter the following into the TCP/IP Properties dialog.

•IP Address = 192.168.0.101

•Subnet Mask = 255.255.255.000

6)Select OK on the TCP/IP Properties dialog box. The computer is now configured.

7)Enter the HI 6600 HGM’s IP address into the Windows PC Web browser to access the embedded web browser. For example: http://192.168.000.100

NOTE Additional information for setting up communications between the Gateway Module and the PLC, DCS, or PC is under Network Communications (Chapter 6).

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HI 6600 Series Modular Sensor System User Guide

Once connected, browse the webpages by following the menu tree presented in the beginning of this chapter. Changes are made by clicking the item and either selecting an option or inputting a value using your PCs keyboard.

NOTE: Selections and inputs are ONLY saved to memory by clicking SAVE PARAMETERS in the webpage.

Using the HI 6110 Front Panel Display

1)Toggle between showing multiple channels and a single-channel by pressing the ENTER button

2)Move the quadrant outline to the desired channel by using the arrows keys. Press ENTER to select the channel, once a channel is selected it will show in full-display mode and change function of the buttons from navigation (up, down, left, right) to instrument function (mode, config, zero, tare).

Instrument 1	Instrument 2
Instrument 3	Instrument 4

Instrument 3	Instrument 4
Instrument 5	Instrument 6

Scroll through available instruments by pressing the UP and DOWN arrows.

1)Enter Set-Up for the selected channel by pressing the CONFIG button.

Pressing the CONFIG button minimizes the displayed weight value and shows a list of submenus to the left that follow the menu tree presented in the beginning of this chapter.

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HI 6600 Series Modular Sensor System User Guide

2)Navigate UP and DOWN the submenus using the arrow keys, then select a menu by pressing the ENTER button.

3)Fixed options within a submenu are selected by using the UP & DOWN buttons to navigate to the choice, then by pressing ENTER key to select. Once an option is selected, back out of the submenu by pressing the LEFT arrow key.

4)Entering Numeric and Alphanumeric values are done pressing the UP & DOWN buttons to change a value and RIGHT & LEFT buttons to move the position of the cursor. Once a value is keyed in, press the ENTER key to save then the LEFT arrow key to return to main menus.

5) Values are saved to memory only by backing out to the top level.

Mode Button

Press the Mode Button to switch between differentweighing modes of:

•GROSS: Displays the GROSS weight of the system.

NET: Displays the NET weight of the system. The NET weight displayed is the GROSS weight minus the TARE value.

COUNT: Counts the number of objects once the weight for one object is set.

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The displayed mode on the instrument can also be changed by selecting DISPLAY MODE on the Operations webpage and choosing Gross, Net or Count from the drop-down menu or by sending the DISPLAY MODE command over communications.

Channel Identification

System Discovery

Once the HI 6600 Series Modular Sensor System is installed, connected and powered, a discovery process is required to allow the Hardy Gateway Module to identify all Weight Processing Modules present on the HardyNet. This discovery process can be initiated in a number of ways and should be used each time the HardyNet system is changed. Examples of changes are removing a module from the system or adding a new module to the system.

The system initiates a discovery process that enables the Gateway Module to identify and track changes to the Weight Processor Modules connected on the HardyNet. The discovery process can also be initiated manually by selecting Start Discovery under the HardyNet sub-menu of the HI 6600 Gateway Module.

Discovered Weight Processing Modules are added to a list that is saved in non-volatile memory of the Gateway Module. The discovery process is designed to only add units that are not already saved in memory. If a Weight Processing Module has been physically removed or disconnected from the system, it must be manually deleted from the list of available modules by selecting Delete Channel. A module that is accidentally deleted can be discovered again by power cycling the Gateway Module or again by manually selecting Start Discovery

The number of Weight Processor Modules discovered (ie: channels of weight) connected to the system will be displayed as Discovered units: XX on the Web Browser as shown below or listed in the Discovery section of the optional front panel display once the process is complete.

Using the Webserver (shown below) is recommend for initial system set-up and changes to a system with a large number of channels.

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Naming the Weight Processing Modules

To ease identification of a particular Weight Processor Module, a meaningful name (ie: Ingredient C or BIN 8) may be assigned to the module by using Select Channel, Confirm Selection, then identifying the physical location of the module by pressing Identify On/Identify Off which will cause the LED on the selected module to blink. Once the particular module is identified, rename the module and press Save Parameters in the Web Server or ENTER on the front panel display to save the module name into memory.

Each Weight Processor Module is assigned a channel number during the discovery process. Weight Processor Modules are listed in the order they are discovered, not by physical position or location on the HardyNet.

Ordering the Weight Processing Modules

The order in which the channels appear in the drop down menus or on the optional display may be changed by using Swap Channel in the web server or by selecting the channel using the front panel of the optional display, pressing enter to ‘capture’ the channel, moving it by using the UP/DOWN arrows, then pressing enter again to ‘release’ the channel to its new position.

NOTE: The channel will retain its Channel Name but be reassigned a new channel number and position on the list.

Deleting or Replacing Channels

Deleting an unwanted channel from the system is completed by selecting Delete Channel (for example when a spare channel is connected to the system).

Parametersassociatedwithchannelsremaininnon-volatilememoryoftheGateway Module and can therefore be transferred to a replacement WeightProcessing Module by following these steps:

1)Delete Channel of the WeightProcessor Module to be removed.

2)RemovethedeletedWeightProcessorModule.bydisconnectingtheRJ45connectors on the bottom and lifting gently up the unit to lift it off the DIN rail

3)Place the new Weight Processor Module on the DIN Rail and connect the RJ45 connectors to reconnect the new module to HardyNet

4)StartDiscovery to find the new module. Parameters from the removed module will now be applied to the new module.

NOTE: The new module will appear at the end of the channel list. If need be, reassign the channel number and change its order in the list by using the Swap Channel process described above.

Saving and Restoring Configuration Data Using the USB port

The HI6600 Gateway Module provides a USB port to save parameters to a memory stick. Parameters can be saved, restored, copied and modified from one instrument or channel to another instrument or channel using this feature. Details of use can be found in the USB Memory Stick section of the Network Communications section of this manual.

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