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Hardy Process Solutions HI 2160RC PLUS, Operation And Installation Manual

The Hardy Process Solutions HI 2160RC PLUS comes with a comprehensive Operation and Installation Manual, which you can easily download for free from our website. This manual provides step-by-step instructions and guidelines for seamless installation and efficient operation of the product.

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HI 2160RC

PLUS

 MANUAL

iv

Chapter 6

Setup  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-1

About Chapter 6  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-1

Display Menu Trees   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-1

Display Menu Flow Chart with Standard Serial Port -  -  -  -  -  -  -  -  -  - 6-1
Display Menu Flow Chart with Allen Bradley Remote I/O Option -  -  -  - 6-2
Display Menu Flow Chart with PROFIBUS Interface Option  -  -  -  -  -  - 6-2

Front Panel Display   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-2
Function/Numeric Buttons   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-3

Config/1 Button   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-3

Security Sub-Menu -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-3

Security Access Levels -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-3
Setting the Security Access Levels  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-5
Setting the Security Code Numbers-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-6
What to do if You Lose the HI Security Code Number -  -  -  -  -  -  - 6-7
When to Use the Select Button -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-7
When to Use the Clear Button   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-7

How to Exit a Sub-Menu Without Changing the Values  -  -  -  -  -  -  -  - 6-8
Tuning and Control Sub-Menu  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-8

Tuning/Control (Sec) Parameter Definitions -  -  -  -  -  -  -  -  -  -  -  - 6-9
Manual (Calculating Parameters) Tuning Control Process -  -  -  -  - 6-12
Setting Up the Controller for Manual Tuning   -  -  -  -  -  -  -  -  -  -  - 6-13
Set the OP% to 99.9%  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-15
Gathering Data-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-15
Calculate the K(pu) value (initial K(p) -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-16
Calculate the Ultimate Oscillation Cycle Time (Tc)   -  -  -  -  -  -  -  - 6-16
Calculate the Time of Repeat (Tr)   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-16
Calculate the Three (3) Control Constants: K(p), K(i) and K(d) -  -  - 6-16
Enter the new Control Constants  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-16
Manual Tuning Control Process (Cont’d)  -  -  -  -  -  -  -  -  -  -  -  -  - 6-17

Rate Tolerance Sub-Menu  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-19

Setting the LO ALARM Tolerance   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-19
Setting the HI ALARM Tolerance -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-20
Setting the ALARM TIME (Sec.)   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-20
Setting the HI and LO Shutoff   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-21
Setting the Shutoff Out Percentage -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-22
Process Example using Rate Tolerances -  -  -  -  -  -  -  -  -  -  -  -  - 6-23

Auto Refill Sub-Menu-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-24

About the Auto Refill Sub-Menu   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-24
Selecting the Auto Refill Function -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-25
Setting the START (LO) and STOP (HI) Parameters   -  -  -  -  -  -  - 6-26
Setting the LO SHUTOFF and HI SHUTOFF Alarm Weight

Parameters   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-26

Selecting the Initial Fill Function   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-28
About the Refill Correction Factor-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-28
Force Refill-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-29

Time and Date Sub-Menu   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-30

Setting the Time  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-30
Setting the Date  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-31

Serial Communications/Serial Port #1 Sub-Menu (For RS-232C 

Specifications See Chapter 2)   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-31

Disabling the Front Panel Print Button   -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-34
Printing Batch Reports  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-35
Bi-Directional Port Setup -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-36

Saving to the Secure Memory Module (SMM) -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-37

When to Save  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-37
Saving to the Secure Memory Module (SMM) -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-37
Data Saved in the Secure Memory Module  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 6-39

Summary of Contents for HI 2160RC PLUS

Page 1: ...HI 2160RCPLUS Rate Controller Operation and Installation Manual ...

Page 2: ...eration Calibration 1 4 Remote Operation 1 4 Multiple Configuration Storage 1 4 Two Sigma 1 4 Interpreting the Model Code Number 1 4 Model Code Breakdown 1 4 Chapter 2 Specifications 2 1 About Chapter 2 2 1 HI 2160RCPLUS Specifications 2 1 Input 2 1 Output 2 1 Storage 2 1 Instrument Resolution 2 1 Remote Control Options 2 1 Alarms Relays 2 1 Analog to Digital Specifications 2 1 Output Display Spec...

Page 3: ...d Cell Wiring Diagram 3 20 Remote I O Interface for the Allen Bradley Network 3 22 PROFIBUS Interface Option 3 22 Interconnect Wiring Diagram 3 23 Computer Clean Power Requirement 3 24 Installing the Secure Memory Module 3 24 Chapter 4 Configuration 4 1 About Chapter 4 4 1 Output Relay Configuration 4 1 Refill and Alarm Relays 4 1 Solid State Relays 4 1 Dip Switch Configuration 4 1 Speed Control O...

Page 4: ...Rate Decimal Points 5 4 Setting the Batch Decimal Point 5 4 Setting the Total Decimal Point 5 5 Setting the Graduations 5 5 C2 Calibration Process 5 6 Hard Calibration Process With Calibrated Test Weights 5 7 ZERO Calibration Procedures 5 7 SPAN Calibration Procedures 5 7 Setting the Sticker Value 5 8 Rate Calibration Process 5 9 Feeder System Verification Procedures 5 9 Automatic Rate Calibration...

Page 5: ...16 Calculate the Time of Repeat Tr 6 16 Calculate the Three 3 Control Constants K p K i and K d 6 16 Enter the new Control Constants 6 16 Manual Tuning Control Process Cont d 6 17 Rate Tolerance Sub Menu 6 19 Setting the LO ALARM Tolerance 6 19 Setting the HI ALARM Tolerance 6 20 Setting the ALARM TIME Sec 6 20 Setting the HI and LO Shutoff 6 21 Setting the Shutoff Out Percentage 6 22 Process Exam...

Page 6: ... are three Continuous Rate Displays 8 1 The Rate Section 8 3 The Weight Section 8 3 Current Weight Total Display 8 4 Batch Displays 8 5 Selecting Batch Displays 8 5 Display Parameters 8 8 Rate Current Weight Display Parameters 8 8 Current Total Weight Display Parameters 8 9 Clearing the Total Register Totalizer from the Front Panel 8 9 Clearing the Total Register from the Rear Panel 8 10 Setting t...

Page 7: ...ting 9 3 Drift 9 3 Checking if Drift Problem is Internal or External 9 3 System Lock Ups 9 4 Weights Displayed are Incorrect 9 7 After Calibration Display Weight Reading is Incorrect 9 7 Feeder Motor Won t Start 9 9 Erratic Actual Rate Readings 9 12 Rate Exception Control REC Alarm Appears too Often 9 12 Readings on the Display are Not Correct 9 13 Remote Setpoint Input Card 9 14 Allen Bradley RIO...

Page 8: ...MENSIONS DIAGRAM FOR REMOTE MOUNT 3 12 FIG 3 18 PIN CABLE ASSEMBLY HI 2160PLUS REMOTE PANEL 3 13 FIG 3 19 QUAD EXPANDER INSTALLED 3 14 FIG 3 20 REAR PANEL 3 15 FIG 3 21 OUTPUT RELAY CONNECTION 3 15 FIG 3 22 MOTOR CONTROL OUTPUT 3 16 FIG 3 23 REFILL AND ALARM RELAYS 3 16 FIG 3 24 RS 232 WIRING DIAGRAM 3 16 FIG 3 25 REMOTE FUNCTIONS WIRING DIAGRAM 3 17 FIG 3 26 POWER CONNECTION WIRING DIAGRAM 3 18 F...

Page 9: ...Y CODE ENTRY DISPLAY 6 4 FIG 6 3 SELECTING SECURITY SUB MENU 6 5 FIG 6 4 SECURITY MENU SELECTING ACCESS LEVELS 6 5 FIG 6 5 SECURITY MENU ENTERING LEVEL VALUES 6 7 FIG 6 6 ACT BLANK TIMEBASE ERROR 6 9 FIG 6 7 DERIVED LOSS OF WEIGHT SLOPE INTERPRETED AS GAIN IN FIGWEIGHT 6 10 FIG 6 8 DERIVED LOSS OF WEIGHT SLOPE INTERPRETED AS NO CHANGE IN WEIGHT 6 10 FIG 6 9 DERIVED LOSS OF WEIGHT SLOPE INTERPRETED...

Page 10: ...TAL WEIGHT DISPLAY 8 2 FIG 8 4 RATE DISPLAY 8 3 FIG 8 5 TOTAL ACCUMULATED WEIGHT 8 4 FIG 8 6 CURRENT AND ACCUMULATED TOTAL WEIGHT DISPLAY 8 5 FIG 8 7 SET POINT MENU SELECTING BATCH MODE 8 5 FIG 8 8 BATCH AMOUNT AND RATE DISPLAY 8 6 FIG 8 9 BATCH AMOUNT CURRENT WEIGHT DISPLAY 8 7 FIG 8 10 BATCH AMOUNT AND TOTAL WEIGHT DISPLAY 8 8 FIG 8 11 SET RATE CURRENT WEIGHT DISPLAY PARAMETERS 8 8 FIG 8 12 CURR...

Page 11: ... DISPLAY 8 34 FIG 8 35 SELECTING 2 SIGMA DATA 8 35 FIG 8 36 2 SIGMA DATA DISPLAYED 8 35 CHAPTER 9 TROUBLESHOOTING AND REPAIR 9 1 FIG 9 1 RESISTOR SHUNT BRIDGE DIAGRAM 9 3 FIG 9 2 SURGE SUPPRESSION RESISTIVE CAPACITIVE CIRCUIT PRT 4802 0002 9 6 FIG 9 3 TEST SUB MENU CHECKING CURRENT COUNT 9 8 FIG 9 4 USING A VOLTMETER TO CHECK LOAD CELL VOLTAGE 9 9 FIG 9 5 CONNECTOR WIRING DIAGRAM FOR CONTROL OUTPU...

Page 12: ...sily referenced chapters that are almost always the same Chapter One Provides an introduction to the instrument and an Overview of the equipment and its capabilities Chapter Two Provides a complete list of Specifications Chapter Three Contains information needed to Install the HI 2160RCPLUS both standard equipment and optional equipment and the HI 215IT series Junction Box Chapter Four Provides co...

Page 13: ...in all material flow applications WAVERSAVER enables the rate controller to decipher actual weight data from mechanical noise and blocks the mechanical noise transmitted from the load cell ALARMS The HI 2160RC LUS is fitted with two alarms to detect exceptions to the desired flow rate The Rate Tolerance Alarm is configured to monitor a tight guard band around the desired flow rate The guard band i...

Page 14: ...ontinuous or batch processing Automatic Refill User selectable refill points to start and stop the refill process HI and LO alarms to detect a refill failure Manual Refill Allows for manual refill at anytime Automatic Tuning Auto Rate Calibration Provides the user with automatically calculated parameters or the user can manually enter their own derived values Operation Displays Single button selec...

Page 15: ...ration The HI 2160RCPLUS is fitted with a bi directional serial port an optional Allen Bradley I O card or PROFIBUS Interface which allow for remote operation of the controller Multiple Configuration Storage Stores up to twelve different complete system configurations allowing fast and easy transition to a new material auger or entire feeder Two Sigma The 2 Sigma Test feature is used to measure th...

Page 16: ...ower 240 VAC 10 Refill and Alarm relays 240 VAC 3 Amps Solid State Outputs 240 VAC 4 Amps B4 PROFIBUS INTERFACE CARD C1 CURRENT INPUT 4 20 MILLIAMPS REMOTE SETPOINT INPUT CARDS C2 CURRENT INPUT 0 20 MILLIAMPS C3 VOLTAGE INPUT 0 10 VOLTS C4 VOLTAGE INPUT 0 5 VOLTS D1 ANALOG OUTPUT OF 4 20 MILLIAMPS OPTIONAL ANALOG OUTPUTS D2 ANALOG OUTPUT OF 0 20 MILLIAMPS D3 ANALOG OUTPUT OF 0 5 VOLTS D4 ANALOG OU...

Page 17: ... Fig 1 3 The dash number for the expander box is HI216EX If the expander box is configured for 240 VAC Opera tion the dash number is B2 NOTE Requires the E1 option expander card to be installed in the main rate controller FIG 1 3 OPTIONAL EXPANDER BOX NON FM ...

Page 18: ...Isolated Outputs user selectable 4 20 Milliamp 0 20 Milliamp 0 5 Volt DC 0 10 Volt DC Storage Battery Backed RAM Secure Memory Module Calibration Data Instrument Resolution Display 1 985 000 for 3 mv v Internal 1 1 048 576 Remote Control Options Allen Bradley Programmable Logic Controller PLC Profibus Various PLCs Serial Port RS 232C Standard Serial Port RS 422 485 Remote Set Point Analog Alarms R...

Page 19: ...acteristics Overall Size 7 W x 4 88 H x 10 04 L Weight 6 pounds 2 72 Kilograms Enclosure Rating NEMA 4 4x Seal when placed in a NEMA 4 4X Enclosure Approvals UL Certification CSA Certification Factory Mutual FM Approval Connectors Relays Phoenix 12 pin connector RS 232 Phoenix 6 pin connector Standard Alarm Relays Phoenix 6 pin connectors Load Sensors Phoenix 8 pin connectors Options Remote Set Po...

Page 20: ...0RC PLUS 2 Interfaces to the HI 2160RC PLUS rate controller Enables communications on the Profibus network utilizing comprehen sive block and operator selectable output Quad Option Expander Box Basic Function See Fig 1 3 1 Expands the capability of the HI 2160RC PLUS 2 Houses up to four option cards in its own enclosure 3 Interfaces to the 2160 Rate Controller TTL interfacing between the HI 2160RC...

Page 21: ...seconds 20 times second RS 232 to RS 422 Converter Board Option The RS 232 to RS 422 Converter Board Option converts RS 232C standard signals to RS 422 4 wire format signals RS 232 Connector Required Input Signals PIN SIGNAL Control Lines 1 CTS 2 RTS Data Lines 3 Rxd 4 Txd 6 Signal GND Board Power not isolated 5 5v RS 422 Connector Output Signals PIN SIGNAL Data Lines 2 Txd 3 Txd 4 Rxd 5 Rxd ...

Page 22: ...Chapter 2 Specifications 2 5 NOTE We recommend that the RS 422 cable shield connection be terminated to frame ground on the HI 2160RC PLUS rear panel ...

Page 23: ...HI 2160RCPLUS MANUAL 2 6 ...

Page 24: ...ou should normally have 1 HI 2160RCPLUS instrument with mating connectors installed 1 Mounting Rail Kit Prt 0551 0287 01 4 mounting Rails 4 6 32 UNC phillips panhead machine screws 1 Installation and Operation Manual NOTE The HI 2160RC PLUS comes in two configurations Panel Mount and Remote Mount Depending on the configuration purchased some additional hardware such as rack mounts may be included ...

Page 25: ... 1 2 CLEARANCE REQUIREMENT Dimensions of the enclosure cutout See Fig 3 3 6 35 06 161 3mm 1 50 Wide 4 09 06 103 9mm 1 50 High All cutout surfaces must be deburred before installation of the con troller WARNING DO NOT MOUNT THE HI 2160RCPLUS RATE CONTROLLER NEAR A HIGH MAGNETIC FIELD OR HIGH VAC POWER SOURCE TO DO SO WILL EFFECT THE PERFORMANCE OF THE CONTROLLER AND MAY RESULT IN PROPERTY DAMAGE In...

Page 26: ...ler into the cutout in the enclosure See Fig 3 4 Be sure to secure the controller with both hands when installing 1 0 1 0 Bezel 1 Clearance Requirement around bezel FIG 3 2 1 CLEARANCE REQUIRE AROUND BEZEL 4 09 6 35 PANEL CUTOUT FIG 3 3 PANEL CUTOUT DIMENSIONS ...

Page 27: ...NG CONTROLLER IN PANEL Step 4 Slide the controller into the panel cutout until the NEMA 4 gasket is flush against the front panel of the enclosure See Figs 3 5 6 7 Front Panel Rear Panel Compression Gasket FIG 3 5 NEMA 4 GASKET FLUSH AGAINST THE FRONT PANEL ...

Page 28: ... Step 5 Install the four 4 mounting bars See Fig 3 8 Slide each of the mounting bars into the slots at the rear of the controller One end of the mounting bar is recessed Make sure you install the bars from this end See Fig 3 8 Check to be sure the mounting bars are flush against the inside surface of the front panel See Fig 3 9 ...

Page 29: ...0RCPLUS MANUAL 3 6 FIG 3 8 INSTALLING MOUNTING BARS Install the four 4 6 32 pan head machine screws into the threaded slots at each corner of the controller See Fig 3 9 FIG 3 9 INSTALLING 6 32 MACHINE SCREWS ...

Page 30: ...ially tighten each screw until the NEMA 4 bezel gasket is completely compressed and the bezel is flush against the front panel of the enclosure See Fig 3 10 3 11 Do not tighten one screw down completely and then go on to the next screw Each screw must be tightened a little before going on to the next to maintain the alignment between the controller and the front panel of the enclosure CAUTION DO N...

Page 31: ...with a NEMA 4 rated compression gas ket Make sure the gasket is properly seated in the bezel before installation Step 3 The front panel comes with two 2 mounting brackets mounted on the bezel See Fig 3 12 Step 4 Remove the nuts that fasten the brackets to the bezel See Fig 3 13 Step 5 Remove the brackets Step 6 Gently slide the front panel into the enclosure cutout until the gasket is seated again...

Page 32: ...Chapter 3 Installation 3 9 FIG 3 12 FRONT PANEL WITH BRACKETS FROM FACTORY FIG 3 13 BEZEL INSTALLATION DIAGRAM ...

Page 33: ...er and hex nut on the four 4 bezel studs See Fig 3 13 Step 8 Make sure that the bezel is centered in the cutout Step 9 Tighten the 6 hex nuts finger tight Step 10 Use a nut driver or box end wrench and tighten the nuts in turn so that the bezel is flush against the front surface of the enclosure front panel See Fig 3 15 ...

Page 34: ...HTEN ING CAN DEFLECT THE BEZEL SO THAT IT WILL NOT BE WATER TIGHT AND OR BREAK OFF THE CORNERS OF THE BEZEL Step 11 To mount the electronics to the back plate in the enclosure you will need to drill a 156 inch tapped or thru hole and use a 6 32 pan head machine screw to fasten the electronics to the panel See Fig 3 16 ...

Page 35: ...UNTED TO ENCLOSURE REAR PANEL FIG 3 17 DIMENSIONS DIAGRAM FOR REMOTE MOUNT Step 12 Connect the 60 inch 40 pin ribbon cable See Fig 3 18 to the 40 pin connection J5 on the electronics and the 40 pin con nection J4 at the rear of the front panel display ...

Page 36: ... AC Power Cord Prt 6006 0008 a 60 inch 40 pin controller interface ribbon cable Prt 0509 0451 and four 4 mounting brackets Prt 0505 0264 Step 3 Drill and tap four 4 holes in the rear panel of the enclosure for four 4 6 32 pan head machine screws 6 lock washers 6 flat washers See Fig 3 19 Step 4 Place the expander box over the holes and install the four fas teners and washers See Fig 3 19 Step 5 Co...

Page 37: ...N INSTRUMENT POWER AND RELAY WIRES SHOULD BE ROUTED AWAY FROM ALL OTHER SIGNAL CABLES TO AVOID ELECTRICAL INTER FERENCE All cabling should be neatly bundled tied and dressed Use a 6 inch service bend to relieve stress on the connectors and to ease servicing the unit Make sure that all plugs are firmly in place Be sure to secure the power cord with the two 2 captive screw on clips All connections a...

Page 38: ...elay Contact Rating 120 240 VAC 4 AMPS Fuse Rating 5 AMPS Wire Size 14 AWG Relay 4 used for Optional Batch Complete Signaling Relays 5 6 are not used Shut Off ON Off REC 4 5 6 Relays FIG 3 21 OUTPUT RELAY CONNECTION Speed Control Output Wiring Diagram See Fig 3 22 Wire Size Maximum 12 AWG Minimum 22 AWG ...

Page 39: ...m See Fig 3 23 Wire Size 14 AWG No Normally Open C Coil Nc Normally Closed No Refill C Nc No Alarm C Nc FIG 3 23 REFILL AND ALARM RELAYS RS 232 Port Wiring Diagram See Fig 3 24 Wire Size Maximum 12 AWG Minimum 22 AWG Cts BUSY Rts Rxd Txd 5V Gnd RS 232 Port RXD GND TYPICAL PRINTER FIG 3 24 RS 232 WIRING DIAGRAM ...

Page 40: ...DIFICATIONS TO THE POWER RELAY CIRCUIT BOARD AND RELAY OUTPUT BOARD THIS PROCEDURE SHOULD ONLY BE DONE BY AUTHORIZED PERSONNEL FOR FURTHER ASSISTANCE CONTACT HARDY PROCESS SOLUTIONS CUSTOMER SUPPORT Remote functions wires carry very low voltage signals They operate on TTL ground levels The Remote Functions wires should be shielded and routed away from the relay output wires and all other AC voltag...

Page 41: ...block connector See Fig 3 26 Wire Size Maximum 14 AWG Minimum 20 AWG Fuse 5 AMP Slow Blow Neu Hot POWER FIG 3 26 POWER CONNECTION WIRING DIAGRAM Remote Setpoint Option Wiring Diagram See Fig 3 27 Wire Size Maximum 12 AWG Minimum 22 AWG RS 422 Converter Option Wiring Diagram See Fig 3 28 Wire Size Maximum 12 AWG Minimum 22 AWG Analog Output Option Wiring Diagram See Fig 3 28 Wire Size Maximum 12 AW...

Page 42: ...apter 3 Installation 3 19 FIG 3 27 REMOTE SETPOINT OPTION WIRING DIAGRAM RS 422 Converter Option Gnd Txd Txd Rxd N C Rxd RS 422 Port FIG 3 28 RS 422 CONVERTER OPTION WIRING DIAGRAM Option Port Analog Output Option V V I I FIG 3 29 ANALOG OUTPUT OPTION WIRING DIAGRAM ...

Page 43: ...y If load cables are too short select an appropriate summing junction box The HI 2160RCPLUS is capable of powering up to four 350 ohm load cells When using more than four load cells an external power supply is required Contact Hardy Customer Support for details NOTE Load cell wires carry very low voltage signals 10VDC Excitation voltage and 0 30mvdc Signal voltage The load cell wires should be rou...

Page 44: ...AD CELLS OR 5TH LOAD CELL SHIELD Chapter 3 Installation 3 21 FIG 3 30 C2 LOAD CELL WIRING DIAGRAM N C N C C2 RATE CONTROLLER EXC SEN SIG SIG SEN EXC LOAD CELL CONNECTOR LOAD CELL 1 LOAD CELL 2 LOAD CELL 3 LOAD CELL 4 TO AUXILLARY JUNCTION BOX FOR 5 OR MORE LOAD CELLS OR 5TH LOAD CELL SHIELD FIG 3 31 4 CONDUCTOR LOAD CELL WIRING DIAGRAM NON C2 LOAD CELLS ...

Page 45: ... WIRING DIAGRAM NON C2 LOAD CELLS Remote I O Interface for the Allen Bradley Network For installation instructions for the Allen Bradley Remote I O please refer to Manual Part Number 0596 0175 PROFIBUS Interface Option For installation instructions for the PROFIBUS Interface Option Card please refer to Manual Part Number 0596 0199 NOTE If an RIO or Profibus option is added to a previously configur...

Page 46: ...Chapter 3 Installation 3 23 Interconnect Wiring Diagram See Fig 3 33 FIG 3 33 INTERCONNECT WIRING DIAGRAM ...

Page 47: ...C 440 VAC CONTROLLERS FIG 3 34 COMPUTER CLEAN POWER DIAGRAM Installing the Secure Memory Module Step 1 When replacing an HI 2160RCPLUS controller or adding a con troller with the same operating parameters transferring the Secure Memory Module SMM from the existing controller is a fast way to calibrate and setup a new instrument The user should make a back up SMM when setting the operating paramete...

Page 48: ...Chapter 3 Installation 3 25 FIG 3 35 SECURE MEMORY MODULE FIG 3 36 INSTALLING REMOVING SECURE MEMORY MODULE ...

Page 49: ...HI 2160RCPLUS MANUAL 3 26 ...

Page 50: ...arm relays can be wired as Normally Open or Nor mally Closed contacts See Chapter 3 for instructions Solid State Relays The Factory default setting for the solid state relays is normally open For configuration purposes the solid state relays can be configured as normally open or normally closed To set the relays as normally open or normally closed change the dip switch position See Fig 4 1 S1 SP8 ...

Page 51: ...rol and must be configured to match the inputs of the motor control Jumper Settings See Fig 4 1 TABLE 4 1 CONTROL OUTPUT JUMPER SETTINGS JUMPER CONFIGURATION CHART Current Selection Voltage Selection Configuration 0 24 mA 4 24 mA Jumper W1 W2 Configuration 0 5 VDC 0 10 VDC Jumper W3 W4 Potentiometers Voltage Zero R4 Voltage Span R16 Current Span R5 Current Zero R19 The potentiometers are calibrate...

Page 52: ...nt panel you can reverse the voltage and current ranges 5 0V 10 0V 20mA 0mA or 20mA 4mA See the Setup Chap ter for procedures The receiving device must be capable of accepting one of the analog signals When configuring the Analog Output Card both the receiver and the HI 2160RCPLUS must be in the same mode e g Gross Batch Rate of Change ROC Peak or Total Weight The analog card can also span the vol...

Page 53: ...r and remove the two 2 pan head machine screws that fasten the rear panel to the extrusion See Fig 4 3 Step 3 Gently pull out the rear panel with the top and bottom panel and printed circuit boards attached Step 4 Remove the two 2 pan head machine screws that attach the top panel to the rear panel See Fig 4 4 Step 5 On the Analog Output Card set the jumper that matches the system s feedback voltag...

Page 54: ...ear panel to the extrusion See Fig 4 5 Step 3 Gently pull out the rear panel with the printed circuit boards attached Step 4 On the Analog Output Card set the jumper that matches the system s feedback voltage or current configuration See Table 4 2 Step 5 Gently slide the rear panel back into the extrusion Step 6 Replace the pan head machine screws that attach the rear panel to the extrusion Step 7...

Page 55: ...CPLUS and the receiving device in the same mode for example HI 2160RCPLUS Gross Mode when configuring the PLC it should also be labeled Gross Mode 0535 0406 REV ANALOG OUT PWA S N 1 2 25 26 P1 C1 U1 RN1 U2 C2 C6 U5 C5 S G D Q1 C5 U4 C4 C3 U3 RN2 U6 U7 R2 R1 R3 C7 C8 CR1 VR1 C11 C12 C9 U8 R4 R5 G O C13 C14 C15 C19 C17 C18 C16 TP1 U9 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 C10 C20 0 1 VR2 C21 C22 VR3 R1...

Page 56: ... Remote pin is grounded again If the Remote pin is kept shorted to the ground pin it tracks the analog input signal and con stantly updates the Rate Set point value 1 2 3 4 5 6 7 8 9 10 Start Pause Abort Rst Tot Print A Refill Remote Grnd Grnd Momentary Switch Maintained Switch J2 P2 FIG 4 7 REMOTE FUNCTION OPTION Remote Set Point Input Option Card Configuration Prt 0535 0410 About Remote Set Poin...

Page 57: ...t configuration Select one only See Fig 4 8 See Tables 4 3 4 4 4 5 Step 7 Attach the top panel to the rear panel by replacing the two 2 pan head screws Step 8 Gently slide the rear panel back into the extrusion Step 9 Replace the pan head machine screws that attach the rear panel to the extrusion TABLE 4 3 INPUT SELECTION FUNTION DESCRIPTION JUMPER INPUT TYPE SELECT 0 5 VDC W1 0 10 VDC W2 CURRENT ...

Page 58: ...l to the extrusion Connector Pins for Input Voltage and Current Input The connector pins number from 1 6 left to right when facing the rear panel of the HI 2160RCPLUS See fig 3 5 The connector pins number 1 6 right to left if installed in Option slots 3 or 4 when fac ing the rear panel of the Quad Expander Box See Fig 4 5 Pins 1 2 are used for Voltage input See Fig 4 9 Pins 5 6 are used for Curren...

Page 59: ...ler must put a contact or switch between the ground and remote positions on the remote functions connector J2 The switch must momentarily close when you want to read the input level grounding the remote pin This automatically sets the Rate Set Point Continuous Reading of the Analog Input Signal In the Remote Functions connector Install a jumper wire between the ground and the remote See Fig 4 10 ...

Page 60: ...efer to Manual Part Number 0596 0199 Changing the RS 422 Converter Port Option B1 Setting the Dip Switches See Fig 4 11 TABLE 4 6 JUMPER SETTINGS FOR RS 422 CONVERTER S1 S3 ON Enable 1 K ohm RS 422 Txd pullup pulldown resistors OFF Disconnect Txd Txd pullup pulldown resistors from circuit S2 ON Enable RS 232 RTS control of RS 422 output Txd Txd signal tri stating RTS hi enable Txd Txd OFF RTS not ...

Page 61: ...p position The Configuration Dip Switches enable disable certain functions as indicated below Assigned functions Enable Multi Drop Disable Screen Print from the front panel Print button or remote Print input Disable Batch Report Print at end of batch Enable Continuous Scale Weight Output to the Serial Port Ignore Incoming Checksums OFF 1 second ON 1 20 second transmission OFF Gross Weight ON Count...

Page 62: ... particular feeder current or voltage control Step 4 Relay Output Wires Check to see if devices controlled by these outputs are operational Exercise valves indicators etc Step 5 Analog and Serial Communications Cable Check to see that the proper cable connections are being used and proper configuration Step 6 Remote Functions Wiring Check to be sure all wires are tight and routed away from high vo...

Page 63: ...o the controller The result is inexact weight readings WAVERSAVER is a combination of hardware and firmware which effectively eliminates the effects of vibration voltage WAVER SAVER rejects the effects of vibration 025 Hz and above and extracts the true weight signal WAVERSAVER performs these functions at high speed and can be adjusted to reject signals above 7 5 with virtually instantaneous respo...

Page 64: ...screws that attach the top panel to the rear panel See Fig 4 15 Phillips Pan Head Screws FIG 4 14 REMOVAL OF REAR PANEL Phillips Pan Head Screws FIG 4 15 REMOVAL OF TOP PANEL Step 7 Secure the printed circuit card with one hand and gently pull the jumper off See Fig 4 16 ...

Page 65: ...he power cord Step 13 Run the system Check to see if the weight readings are stable Step 14 If the weight readings are not stable and or the response time is not what you want repeat steps 2 13 this time putting the jumper in another position Step 15 W1 provides the fastest response time but eliminates less vibration W5 provides the slowest response time but elimi nates the most vibration Step 16 ...

Page 66: ... changing jumpers for the setting best suited for your application requirements TABLE 4 7 JUMPER SETTINGS AND RESPONSE TIME JUMPER MINIMUM FREQUENCY APPROXIMATE RESPONSE TIME W1 7 5 Hz Least vibration immunity Fastest time to reach the final weight reading approximately 20mS W2 3 5 Hz 100 mS to reach the final weight reading W3 1 0 Hz 500 mS to reach the final weight reading W4 0 5 Hz Default sett...

Page 67: ...HI 2160RCPLUS MANUAL 4 18 ...

Page 68: ...ore operating the system Pre Calibration Procedures Mechanical Check Procedures Checking the Load Cell Installation Step 1 Check to determine if the load cells have been installed prop erly Step 2 Refer to your load cell O M manual for proper installation instructions Step 3 On some single and double ended shear beam load cells there is an arrow that indicates the direction of the applied load If ...

Page 69: ...1 PROPERLY INSTALLED LOAD CELL W NO BINDING Electrical Check Procedures Step 1 Check to see that there is power to the controller If there is power to the controller The front panel display should be lit Step 2 Allow the controller to warm up for about 15 minutes before performing the calibration procedures Load Check Step 1 Place a load weight on the scale or feeder Step 2 Check to see if the wei...

Page 70: ...ommend using the High Code number Step 4 Press the Enter button The Main Menu appears Step 5 Press the down arrow button until the cursor is next to the Calibration sub menu Step 6 Press the Enter button The Mass Units sub menu appears Setting the Mass Units Step 1 Press the Select button to scroll through all the Engineering weight and volume Mass Unit selections which are LBS pounds Default OZS ...

Page 71: ...lace the decimal point three 3 places to the left e g 999 999 If the rate range is 1000 9999 use two 2 deci mal places to the left 1000 00 Step 1 Press the Select button to select the decimal point placing The choices are 0 1 2 3 4 Step 2 When you have scrolled to the selection you want press the Enter button The Rate Decimal Point selection is accepted Step 3 Press the down arrow button until the...

Page 72: ... Rate Decimal Point value Press the Enter button Step 4 If the decimal point placing is the Rate Decimal Point the Batch Decimal Point selection is accepted Setting the Graduations Step 1 Press the down arrow until the cursor is next to the Gradua tion sub menu Step 2 Press the Select button to select the graduation level The graduations levels are 1 Default 2 5 10 20 50 100 200 500 Step 3 The rec...

Page 73: ... The Main Menu appears Step 6 Press the down arrow button until the cursor is next to the Calibration sub menu Step 7 Press the Enter button The Mass Units sub menu appears Step 8 Press the down arrow button until the cursor is next to REFPT C2 Reference Point C2 NOTE The reference point is any known live weight found on the scale This value can be zero or any known weight up to the scale capacity...

Page 74: ...IS STABLE TO YOUR SATISFAC TION BEFORE PRESSING THE ENTER BUTTON OR THE SYSTEM WILL NOT BE CALIBRATED CORRECTLY Step 4 Press the Enter button Step 5 The instrument has entered the gross weight the millivolt sig nal of the system to this point of the calibration process SPAN Calibration Procedures Step 1 Place a span test weight equal to 80 to 100 of the scale capacity on the scale NOTE If you do n...

Page 75: ...RANSFERRED THE SECURE MEMORY MODULE SMM TO A NEW SYSTEM DO THE FOLLOWING PROCEDURES NOTE The C2 Calibration uses the sticker value If the SMM is replaced or the sticker value is lost and you are using C2 calibration you will need to use this process to enter the new sticker value Step 4 Check the sticker number of the A D PCB Prt 0535 0445 Step 5 Disconnect the Power Cable from the unit Step 6 Rem...

Page 76: ...ss the Select button to scroll through all the rate selections which are Manual Mass Units Time Units e g 5 00 LB M Remote Remote Input Option Only Select Manual Press the Enter button Press the down arrow to select the Amount sub menu Step 4 Setting the Amount Press the Select button to scroll through all the rate selections which are Continuous 000 000 Mass Unit LB KG GL etc Select Continuous Pr...

Page 77: ...urity code number has been assigned to the con troller use the numeric keys to enter the security code Press the Enter button If a security code number has not been assigned press the Enter button Step 11 The unit is operational and at the lower left corner of the screen you will see that the status is ON See Fig 5 3 Step 12 Adjusting the OP Operating Percentage output signal per centage Initially...

Page 78: ...L M O P 0 0 1 A c t 0 0 0 C u r r e n t W e i g h t i n O N S c a l e 1 2 3 4 5 L B FIG 5 4 OUTPUT SIGNAL IN 00 1 INCREMENTS Increasing Decreasing the OP output signal by increments of 1 Press the up arrow to increase the output signal percent age driver RPM in increments of 00 1 and down arrow to decrease the output signal percentage driver RPM in increments of 00 1 ...

Page 79: ... point begins flashing Press the up arrow to increase the output signal percentage driver RPM in increments of 10 0 and down arrow to decrease the output signal percentage driver RPM in increments of 10 0 S e t R a t e M A N U A L L M O P 1 0 0 A c t 0 0 0 C u r r e n t W e i g h t i n O N S c a l e 1 2 3 4 5 L B FIG 5 5 OUTPUT SIGNAL IN 10 INCREMENTS Step 13 Set the Operating Percentage for 10 in...

Page 80: ...p button again and the status changes to OFF See Fig 5 7 Step 18 If the feeder system is not responding correctly check the sys tem to see if there are problems with the installation Step 19 If the feeder system is responding correctly go on to the Rate Calibration procedures Set Rate MANUA L L M OP 00 0 A ct 0 00 Current We ight in OFF Scale 123 45 lb FIG 5 7 OPERATIONAL DISPLAY OFF ...

Page 81: ...row button until the cursor is next to the REC LEVEL Step 8 Press the Clear button The REC level should display 0 Step 9 Press the Enter button Entry accepted flashes momentarily on the display Step 10 Press the exit button to exit the Tuning Control sub menu Enter the PAUSE TIME Value Step 1 Press the down arrow until the cursor is next to the Rate Calibration sub menu Step 2 Press the Enter butt...

Page 82: ...keys to enter the new Feed time value Step 7 Press the Enter button to accept the new value NOTE Make sure there is enough material for the feeder to dispense during this time period AUTO RATE CALIBRATION From the Front Panel Step 1 Press the down arrow until the cursor is next to the AUTO RATE CAL sub menu Step 2 The Default setting is NO which appears on the display Step 3 Press the Select butto...

Page 83: ...Time Pauses for the pre set Pause Time Runs at OP 50 for the pre set Feed Time Pauses for the pre set Pause Time Runs at OP 80 for the pre set Feed Time The unit stops An OFF should appear in the lower left corner of Operational Display 1 Current Weight Automatically calculates the Rate values If the auto rate calibration fails the low reads 20 and high reads 80 and can be viewed in the Configurat...

Page 84: ...ee Chapter 6 for instructions Double the Time Base value and repeat the Auto Rate Calibration process If any one of the points reads zero 0 again the rate cali bration fails Contact your local dealer or Hardy Process Solutions Customer Support for further instructions To view a percent of deviation from the calibrated norm at each of the five calibrated percentages Press the Test but ton scroll to...

Page 85: ... LEVEL is not 0 0 Press the Clear button Enter 0 0 Press the Enter button If the REC LEVEL reads 0 0 Press the Exit button to return to the Main Menu Press the Exit button to return to the Operational Dis play Step 3 Setting the Totalizer to Zero if you do not have a scale avail able to weigh the samples In the Operational Display 1 See Fig 5 10 press the Clear button Enter the security code numbe...

Page 86: ... 19 FIG 5 10 OPERATIONAL DISPLAY 1 CURRENT WEIGHT Current Weight in Scale 87 566lb Total Wt 287 987lb ON From 08 15 23 15 FIG 5 11 SCALE DISPLAY Step 4 If you have a scale Check the scale with a known weight to see if it is accu rate Weigh the container s that will catch the sample from the feeder ...

Page 87: ...ted operational range For Example 30 40 anticipated operating range OP Set the OP for the low rate samples at 20 which is your LOW RATE CAL on the form See Feeder Verification Pro cedures Paragraph 5 3 1 sub paragraph 12 e for instruc tions Simultaneously press the start and the timer at the same time This procedure can be done with one person but is best done with two people one operating the con...

Page 88: ...e run the samples at 30 and 40 or any of the rates between the antici pated low and high feed rates Step 6 If the results are consistent between samples enter the rate data into the Rate Calibration sub menu See Automatic Rate Calibration Procedures above Gathering Rate Calibration Data Method 2 Materials Required Rate Calibration Data Gathering Form Appendix A Timer or stop watch Two 2 Containers...

Page 89: ...e material flow back to the first container Step 6 Weigh the material in the second container Step 7 Divide the weight by the sample time in minutes to get your calibration weight Step 8 Write the OP Weight and date in HIGH RATE CAL Reading 1 Step 9 Repeat this procedure for Readings 2 and 3 This will insure a higher degree of accuracy Entering the Calibration Values Entering the rate data into th...

Page 90: ...g the High Rate Calibration Data Step 1 Press the Clear button Step 2 Enter the High Rate OP value used in the high rate sampling runs In our example 50 0 The Default is 80 0 Step 3 Press the Enter button to accept the value Step 4 Press the down arrow until the cursor is next to the HIGH L M Step 5 Press the Clear button Step 6 Enter the weight value taken during the timed one minute high rate sa...

Page 91: ...HI 2160RCPLUS MANUAL 5 24 ...

Page 92: ...g K Prop K Derv CTL Out LO CTL Out HI Avrg 1 200 REC Level REC Time Sec REC Shutoff Pre Act Corr Save Data Restore Data LO Alarm HI Alarm Alarm Time LO Shutoff Hi Shutoff Shutoff Out Analog Out Selectable Output Zero Span Time Date Time Date Serial Port Standard Auto Refill Calibration Remote Set Points Config Baud Rate Parity Stop Bits Data Length Address Auto Refill Start LO Stop HI LO Shutoff H...

Page 93: ... HI Averages SPL SPH Tuning Control Rate Tolerance Analog Output Time and Date Auto Refill Calibration Serial Port 1 Remote Setpoint Clear Alarms Start Set Points Clear Total Rte Calib Low Code Med Code HI Code Clear Press Clear Button Security Code Clear Alarm Clear Total Set Point Press SETPT 1 Button Security Code Rate Manual Remote Amount Continuous Information data stored in the SMM during a ...

Page 94: ...Allen Bradley I O and PROFIBUS Interface options can setup parameters remotely and the HI 2160PLUS security system will not interfere or prevent this trans fer of data Security Access Levels Access Levels Factory default settings All parameters are set for Low Access 0000 code number is the same as pressing the Enter Button Low 0000 Functions used by an operator such as Clear Alarms Start Batch Se...

Page 95: ...NUAL 6 4 FIG 6 1 PRESS CONFIG 1 BUTTON TO GET TO THE MAIN MENU Step 2 Enter the HI access security code number 1234 See Fig 6 2 ENTER SECURITY CODE to make changes or press ENTER to view data FIG 6 2 SECURITY CODE ENTRY DISPLAY Step 3 Press the Enter button The Main Menu appears See Fig 6 3 ...

Page 96: ...ty Sub Menu Step 5 Press the Enter button The Security Menu appears See Fig 6 4 SECURITY MENU HI TUNING CONTROL MED RATE TOLERANCE MED ANALOG OUTPUT FIG 6 4 SECURITY MENU SELECTING ACCESS LEVELS Setting the Security Access Levels You must enter the HI access security code number that is currently in the controller in order to change the access levels ...

Page 97: ...ept the level selection Here is a recommended access level selection HI Tuning Control MED Rate Tolerance MED Analog Output MED Time and Date MED Auto Refill HI Calibration MED Serial Port 1 MED Remote Setpt LOW Clear Alarms LOW Start LOW Setpoints MED Clear Total HI Rate Calibration LOW CODE XXXX MED CODE XXXX HI CODE XXXX Setting the Security Code Numbers You must know the HI access security cod...

Page 98: ...rivers license numbers which can be easily deciphered What to do if You Lose the HI Security Code Number When to Use the Select Button When to Use the Clear Button Contact your local Hardy Representative or Hardy Process Solutions Service Center When the Sub Menu text is in upper and lower case for example Time Base Sec use the Select button to move through the selec tions When the Sub Menu text i...

Page 99: ...his Sub Menu allows the user to view the factory default parame ters and constant values used by the HI 2160RCPLUS for optimal control flow rates The Sub Menu also allows the user to change the default settings and calculate new constants if the user believes the settings do not create optimal flow rates for their particular process The Default Settings are Time Base Sec 4 K INTG K PROP K DERV CTL...

Page 100: ... See Fig 6 7 This graph shows the worst case slope derived from weight readings taken at the beginning and end of the Timebase Period The first reading was taken at a low spike while the second reading was taken on a high spike As a result the HI 2160RCPLUS interprets this information as GAIN IN WEIGHT data instead of LOSS IN WEIGHT data On the Action display an graphic appears See Fig 6 6 The arr...

Page 101: ...e Seconds o Reduced Window of Weight Variations FIG 6 8 DERIVED LOSS OF WEIGHT SLOPE INTERPRETED AS NO CHANGE IN WEIGHT By INCREASING the AVERAGES in the Tuning Control Menu you effectively reduce the Window of Weight Variations which effects the Derived Slope of the weight readings taken at the beginning and end of the TIME BASE period This may improve the performance of the controller but in som...

Page 102: ... maintain the required feed rate These values are determined either by performing a Rate Calibration or by the use of mathematical formulas CTL OUT LO control output Low sets the lower limit of the analog output to the feeder s speed control circuits for minimum feeder speed CTL OUT HI Control output High sets the upper limit or the analog output to the feeder speed control circuits for maximum fe...

Page 103: ...e are any number of variations from one application to the next there are a few applications when the HI 2160RCPLUS will not provide optimum values to control your process Be sure that new control constants are needed before Man ual tuning process Once you determine the new constants write them down in a secure location because they will be replaced auto matically the next time a rate calibration ...

Page 104: ... cursor to the left of Timebase sec See Fig 6 10 T U N I N G C O N T R O L M E N U Ti m e b a s e S e c 4 K I N T G 2 6 K P R O P 2 1 0 FIG 6 10 ENTERING TIMEBASE PARAMETER Step 4 The default setting for Timebase is 4 seconds Press the Select button until a new value appears 1 min 120 max Step 5 Press the Enter button to accept the new value setting Step 6 Press the down arrow until the cursor is ...

Page 105: ...VEL value Step 11 Use the numeric keys to enter 0 0 Entering 0 0 prevents alarms during the data gathering procedures Step 12 Press the Enter button to accept the 0 0 value Step 13 Press Exit twice to get to the Operations Display Step 14 Press the Set Pt button The security message displays Step 15 Enter the HI security code number Step 16 Press the Enter button The Set Point Sub Menu appears Ste...

Page 106: ...Step 2 Run the feeder until the Act Rate stabilizes and the material flows consistently as determined by the user Step 3 Push the Stop button to stop the feeder Step 4 Press the Display button until the Operating Display Total Weight appears See Fig 6 12 S e t R a t e M A N U A L L M O P 1 0 0 a C T 0 0 0 To t a l W e i g h t i n O F F S c a l e 1 2 3 4 5 l b FIG 6 12 OPERATING DISPLAY TOTAL WEIGH...

Page 107: ...ate lbs hr Calculate the Ultimate Oscillation Cycle Time Tc Formula Tc Timebase Averages 20 08 Calculate the Time of Repeat Tr Formula Tr Tc x 20 Tiimebase Calculate the Three 3 Control Constants K p K i and K d Formulas K p K pu 1 67 K i 2 x K p Tr K d 4 x K i Enter the new Control Constants Step 1 Press the Config button The security message displays Step 2 Enter the HI Security Code number Step...

Page 108: ...f the REC LEVEL Sub Menu Step 15 Initially change the REC LEVEl to 2 0 Step 16 Press the Enter button to accept the REC setting Step 17 Press the Exit button twice to get to the operational display Manual Tuning Control Process Cont d Step 1 Make sure the feeder is on Step 2 Press the Set Pt button Step 3 Enter the Security code number Step 4 Press the Enter button The Set Point Menu appears with ...

Page 109: ... appears again If REC appears more than once in 30 seconds without external disturbances stop the feeder and increase the REC LEVEL Step 13 Continue this process until the REC displays only once in 30 seconds or doesn t display at all Step 14 Monitor the OP values for excessive drifts 10 Step 15 If the feeder appears to drift excessively try reducing all con stant values by half until adequate con...

Page 110: ...ons from the setpoint flow rate This allows you to simply change the desired setpoint rate and the alarm tolerance bands follow the new setpoint automatically The Alarm levels notify you of unac ceptable rates of flow Setting the LO ALARM Tolerance NOTE The LO Alarm value must be the Lowest Set Point Value Step 1 Press the down arrow button until the cursor is to the left of the LO ALARM Sub Menu ...

Page 111: ...nd short enough to provide a responsive alarm When an Alarm condition exists for longer then the allowed period the Alarm relay energizes and the top line of the operations dis play reads LO RATE ALARM or HI RATE ALARM and if an audio or visual alarm has been connected to the controller that alarm is energized alerting the operator that an alarm condition exists For Remote I O systems a bit is set...

Page 112: ...ort RstTot Print A Refill Rem Gnd Momentary Switch FIG 6 15 GROUNDING THE A PIN TO CLEAR ALARM Setting the HI and LO Shutoff HI and LO shutoff values are entered as absolute rates of flow so that critical limitations of the process remain firm and fixed Shutoff levels are utilized to stop a potentially dangerous or expen sive error Step 1 Press the down arrow button until the cursor is to the left...

Page 113: ...cess must continue to operate at a some percentage at all times set the Shutoff Out percentage to that value The HI 2160RCPLUS automatically goes into the manual mode and the con trol output goes to the output percent OP value entered If a process does not have to operate at a certain percentage at all times use the default percentage of 0 When a shutoff condition exists The Shutoff relay is energ...

Page 114: ... Step 3 Press the Clear button to clear the entry Step 4 Use the numeric keys to enter the Shutoff Out percentage Step 5 Press the Enter button to accept the new value Process Example using Rate Tolerances See Fig 6 17 1 2 1 8 1 3 1 4 1 5 1 6 1 7 A1 A2 A B C1 C TIME SECONDS RATE TOLERANCES RATE FALLS TO 10 RATE LBS MIN FIG 6 17 PROCESS GRAPH USING RATE TOLERANCES Set Point Rate 1 5 Rate Tolerance ...

Page 115: ... feeder will not run out of material during the dispensing process When the relay is energized it can turn on an audio or visual alarm indicating a refill condition exists and the operator needs to replenish the feeder The energized relay can also actuate a solenoid which in turn can open a valve or start a driver to automati cally load more material into the feeder The refill relay remains ener g...

Page 116: ... button The AUTO REFILL Menu appears See Fig 6 19 A U T O R E F I L L M E N U A u t o R e f i l l N O S TA R T L O 2 0 0 0 S T O P H I 4 0 0 0 0 FIG 6 19 AUTO REFILL MENU START AND STOP SETTINGS Step 4 Press the down arrow button until the cursor is to the left of the AUTO REFILL Sub Menu Step 5 Press the Select button to select YES Step 6 Press the Enter button to accept the selection NOTE When s...

Page 117: ... the new value Step 4 Press the Enter button to accept the new value Setting the LO SHUTOFF and HI SHUTOFF Alarm Weight Parameters HI and LO SHUTOFF values are entered as absolute weights so that critical limitations of the process remain firm and fixed Shutoff levels are utilized to stop a potentially dangerous or expen sive error The setting for LO must be below the START value The setting for H...

Page 118: ...eric keys to enter a new weight value Step 4 Press the Enter button to accept the new value Step 5 If the values are not accepted a message appears NOT APPROVED The value entered is above the START LO value Clear the entry and enter a value that is lower Press the Enter button to accept the corrected value Setting the HI SHUTOFF Weight Step 1 Press the down arrow button until the cursor is to the ...

Page 119: ...OP HI weight whenever the user pushed the Start Enter button on the front panel of the HI 2160RCPLUS The function makes sure that the feeder has enough material at the beginning of a process and can prevent refills in the middle of a dispensing pro cess See Fig 6 21 Step 1 Press the down arrow button until the cursor is to the left of the INITIAL FILL Sub Menu Step 2 Press the Select button to sel...

Page 120: ...lue Press the Clear but ton two times for a positive sign to appear before the per centage value Step 3 Use the numeric keys to enter the percentage value NOTE Disregard the decimal point An entry of 1 is 1 1 0 IS 10 AND SO ON Step 4 Press the Enter button to accept the value AUTO REFILL MENU HI SHUTOFF 2 000 INITIAL FILL YES RFL CORR 0 0 FIG 6 22 AUTO REFILL MENU SETTING THE REFILL CORRECTION FAC...

Page 121: ...me and Date Sub Menu Setting the Time Set the time according to the 24 hour clock format 1 00 AM is 01 00 2 00 AM is 02 00 etc 1 00 PM is 13 00 2 00 is 14 00 etc Step 1 Press the down arrow button until the cursor is to the left of the Time and Date Sub Menu See Fig 6 24 MAIN M ENU ANALOG OUTPUT TIME AND DATE AUTO REFILL FIG 6 24 MAIN MENU SETTING TIME AND DATE ...

Page 122: ...he Date Setting Step 2 Press the Clear button to clear the date entry Step 3 The Date setting is mm dd yy Step 4 Use the numeric keys to enter the date Step 5 Press the Enter button to accept the date setting Serial Communications Serial Port 1 Sub Menu For RS 232C Specifications See Chapter 2 This Sub Menu allows the user to setup the serial port as a Printer Port or a Bi Directional Port The Ser...

Page 123: ...E C U R I T Y FIG 6 26 MAIN MENU SELECTING SERIAL PORT 1 Step 2 Press the Enter button The Serial Port 1 Sub Menu appears with the cursor to the left of the Config See 6 27 S E R I A L P O R T 1 M E N U C o n f i g P R I N T E R B a u d R a t e 1 2 0 0 P a r i t y N O N E FIG 6 27 SERIAL PORT 1 CONFIGURATION Step 3 Press the Select button to toggle between Printer and Bi Directional BI DIR communi...

Page 124: ...e Print but ton to print any of the operational displays The controller prints only operational displays See Fig 6 28 S E R I A L P O R T 1 M E N U C o n f i g R I N T E R B a u d R a t e 1 2 0 0 P a r i t y N O N E FIG 6 28 SERIAL PORT 1 CONFIGURATION SetRate MANUAL L M OP 00 0 Act 0 00 Current Weight in OFF Scale 123 45lb FIG 6 29 OPERATIONAL MENU ...

Page 125: ...e new Parity setting Press the down arrow until the cursor is to the left of the Stop Bits Sub Menu Press the Select button to select one of the following Stop Bit settings ONE TWO Press the Enter button to accept the new Stop Bit setting Press the down arrow button until the cursor is to the left of the Data Length Sub Menu Press the Select button to select one of the following Data Length settin...

Page 126: ...atically print out a Batch Report if the controller is in the Batch Mode of operation See Chapter 8 for detailed information The Batch Report is triggered when the actual amount dispensed reaches the batch amount requested An example of a batch report BATCH REPORT START 08 22 04 10 32 12 STOP 08 22 04 10 33 11 BATCH TIME 00 00 59 BATCH AMOUNT REQ 5 000LB ACT 5 003LB RATE DATA SET POINT 5 000 L M A...

Page 127: ...ess the Enter button to accept the BI DIR port setting Step 5 To setup the Bi Directional Port Press the down arrow button until the cursor is to the left of the Baud Rate Sub Menu Press the Select button to select one of the following Baud Rate settings 600 1200 Default 2400 4800 9600 19200 Press the Enter button to accept the new Baud Rate set ting Press the down arrow button until the cursor is...

Page 128: ...ters are automatically saved to the battery backed up internal memory of the HI 2160RCPLUS when the Enter button is pressed to accept the parameters When to Save 1 Upon completion of a Configuration Calibration or Setup Proce dures 2 Anytime you change any of the Configurations Calibrations or Setup Information Saving to the Secure Memory Module SMM Step 1 Press the Stop button two times to stop t...

Page 129: ...Menu See Fig 6 33 M A I N M E N U S a v e R e c a l l D a t a T u n i n g C o n t r o l R a t e T o l e r a n c e s FIG 6 32 SAVING TO SECURE MEMORY MODULE Save Recall Menu Save Data 1 Recall Data 1 FIG 6 33 SAVE RECALL MENU Step 7 Press the 0 Select button to select the number for the current data set Default is 1 ...

Page 130: ...WAIT then the message changes to SUC CESSFUL then ENTRY ACCEPTED for 1 second when the display returns to SAVE DATA 1 Step 11 Press the Exit button to return to the Main Menu Step 12 Press the Exit button to return to the Operating Display Data Saved in the Secure Memory Module All data in the Tuning Control Menu All data in the Rate Tolerances Menu All data in the Auto Refill Menu All data in the...

Page 131: ...RECALL menu reappears Step 8 Press the Exit button to return to the Main Menu Step 9 Press the Exit button to return to the Operating Display Parameters Restored are All data in the Tuning Control Menu All data in the Rate Tolerances Menu All data in the Auto Refill Menu All data in the Calibration Menu All data in the Rate Calibration Menu All data in the Set Point Menu All data in the Test Menu ...

Page 132: ...st be prepared This graph shows the operating characteris tics of a particular application Step 2 Click on the Set Pt Button Step 3 Enter the Security Code Number Step 4 Press the Enter button The Set Point Menu appears Step 5 Press the Select button to set the Rate to Manual Step 6 Press the Select button to set the Amount to Continuous Step 7 Press the Exit button to return to the Operating Disp...

Page 133: ...uning Control Menu Step 17 Press the Enter button The Tuning Control Menu appears Step 18 Press the down arrow button until the cursor is to the left of the Control Out LO Sub Menu See Fig 6 36 TUNING CONTROL MENU CTL OUT LO CTL OUT HI AVRG 1 200 0 100 200 FIG 6 36 TUNING CONTROL MENU SETTING CONTROL OUT LO PERCENTAGE Step 19 Press the clear button to clear the value Step 20 Use the numeric keys t...

Page 134: ...t every application there is no requirement to change the default setting However in cases where flow levels off when the output signal reaches a certain percentage of the operating span or when equipment damage might occur e g cavitation in pumps when rates are set above the Control Out HI it is recommended the Control Out HI be set The Control Out HI is a high operat ing limit where higher setti...

Page 135: ... occurs and not down the OP In Fig 6 35 the graph above the flow starts to level off at about 74 of output span and the rate is about 11 6 lbs m Step 12 Stop the feeder Step 13 Press on the Config button The security prompt appears Step 14 Enter the Security Code Number and press the Enter button The Main Menu appears Step 15 Press the down arrow button until the cursor is to the left of the Tunin...

Page 136: ...s entered higher than 11 6 lbs m an error statement appears SETTING TOO HIGH Step 22 Press the Exit button to return to the Main Menu Step 23 Press the Exit button to return to the Operating Display Setting Up the Analog Output Option The Analog Output Option contains user scaled calibration data used to transmit information to a PLC recorder remote display or similar devices accepting analog inpu...

Page 137: ...ton The Analog Output Menu appears with the cursor to the left of Analog Output Main See Fig 6 41 ANALOG OUTPUT MENU ANALOG OUTPUT MAIN RATE OF CHANGE ZERO L M 1 000 FIG 6 41 ANALOG OUTPUT MENU Analog Output Main Step 1 The Main indicates where the analog output option card is located In our example it is located on the Main Board in the ...

Page 138: ...erence voltage See Fig 6 42 ZERO Output Reference Voltage and Current The ZERO output reference parameter sets the zero output refer ence voltage and current Range 0000 to 9999 lbs min or LBS Units are automatically defaulted depending on the selected output Actual values depend on the decimal place Default Setting 1 000 lb min or LBS NOTE Set to the lowest expected value for the selected output N...

Page 139: ... clear the entry Step 8 Use the numeric keys to enter the new value Step 9 Press the Enter button to accept the new value Step 10 If the SPAN value is equal to the ZERO value an error prompt appears Change the SPAN value so that ZERO and SPAN are not equal Step 11 Press the Enter button to accept the new setting Step 12 Press the Exit button until you reach the Operational Display ...

Page 140: ... before trying to communicate with the controllers from the host System Configuration Host Functions 1 A host can be a Programmable Logic Controller or a Computer or both 2 The host provides a single operator interface to an entire process blending or batching system 3 The host saves recipes calculates a variety of parameters adjusts formulation based on other process parameters and prints compre ...

Page 141: ... command The instrument accepts command strings up to 40 characters the 40th character will internally default to a carriage return Serial Command Lists 1 Set Commands S COMMAND SUB CMD DATA FORMAT DESCRIPTION OF COMMAND S AH XXXXXX Set Auto Refill HI Shutoff up to 6 digits include decimal point if used S AI Y OR N Set Initial Fill Y for ON N for OFF S AL XXXXXX Set Auto Refill LO Shutoff up to 6 ...

Page 142: ...ros required S KT XXX Set Timebase selections 1 6 8 10 12 15 20 30 40 50 60 120 leading zeros required S MD MMDDYY Set Date in Month Day Year Format leading zeros required S MO X Set Setpoint Mode Selection 1 6 See Data Transmission format for X M command S RAH XXXXXX Set Rate Tolerance HI ALARM up to 6 digits include decimal point if used S RAL XXXXXX Set Rate Tolerance LO ALARM up to 6 digits in...

Page 143: ...r X Q command X RAH XXXXXX Xmit Rate Tolerance HI Alarm X RAL XXXXXX Xmit Rate Tolerance LO Alarm X RAT XXXX Xmit Rate Tolerance Alarm Time in Seconds X RCHP Transmit Rate Calibration High Percentage X RCHR Transmit Rate Calibration High Rate X RCLP Transmit Rate Calibration Low Percentage X RCLR Transmit Rate Calibration Low Rate X REL XX Xmit Relay Status See Data Transmission format for X REL c...

Page 144: ...X G CR CHK 1 CHK 2 EOT NOTE The example uses decimal and mnemonic abbreviation format for clarity however the actual data would be in ASCII format b There is one space 20 hex required between each type of data following the INSTRUMENT ADDRESS The outgoing com mand represented in hex format would be 3E313020582047200D364404 This Represents 3E 31 30 20 58 20 47 20 0D 36 44 04 For 1 0 X G CR 6 D EOT ...

Page 145: ...the form they were received from the host with the return data and units added to the message and a LF added to the CR 3 Continuing the example the return data would be START CHAR INSTRUMENT ADDRESS CMD SUB CMD 6 BYTE DATA D6 D1 MODE CR 2 BYTE CHECKSUM EOT CHK 1 CHK 2 10 X G D6 d1 LB KG CRLF CHK 1 CHK 2 EOT NOTE LB or KG follow data a Data Formats 1 Weight Rate Data Format a Weights are transmitte...

Page 146: ...l Communications 7 7 3 When return data is not valid for the command an A is returned by the instrument For example START CHAR INSTRUMENT ADDRESS CMD SUB CMD 6 BYTE DATA D6 D1 MODE CR 2 BYTE CHECKSUM EOT CHK 1 CHK 2 10 A CRLF CHK 1 CHK 2 EOT Command Sets X Xmit Command Xmit is issued with a sub command Only one sub command per command is allowed Transmit data specified in SUB CMD as follows SUB CM...

Page 147: ...RT 80 2 PAUSE SUB CMD MEANING DI DIP Switch Status Data is returned in the format X_DI_XX_YY where XX are the External DIP switches and YY are the Internal DIP switches XX RETURNED DATA INTERNAL DIP NUMBER DIP SWITCH FUNCTION 01 2 DISABLE PRINT 02 4 ENABLE DATA LOGGING 04 5 IGNORE INCOMING CHECKSUM 08 7 OFF GROSS WEIGHT ON COUNTS 10 8 RESERVED 20 6 OFF 1 SEC ON 1 20 SEC 40 3 DISABLE BATCH REPORT 8...

Page 148: ...Set point menu display currently selected RETURNED DATA MEANING 1 RATE SET POINT AND BATCH AMOUNT 2 MANUAL SET POINT AND BATCH AMOUNT 3 RATE SET POINT AND CONTINUOUS AMOUNT 4 MANUAL SET POINT AND CONTINUOUS AMOUNT 5 REMOTE SET POINT AND BATCH AMOUNT 6 REMOTE SET POINT AND CONTINUOUS AMOUNT SUB CMD MEANING Q The query command obtains a block of information For example Description Bytes Var ASCII By...

Page 149: ...are decimal codes returned in response to receiving a command from the Host General Communication Return Codes Response Code A Acknowledge good data received Response Code N Negative Acknowledge error code will follow Response 23 Illegal command while in Hold Mode Response 24 Negative value not allowed Response 25 Invalid interrupt status Response 26 Framing error Response 27 Parity error Response...

Page 150: ...esponse Code 40 Rate alarm low set point out of range Response Code 41 Rate alarm high set point out of range Response Code 42 Shutoff low set point out of range Response Code 43 Shutoff high set point out of range Response Code 44 Alarm time out of range 4 Status Force Functions Weight and Rate Parameters Response Code 80 Invalid ROC set point Response Code 81 Invalid set point mode Response Code...

Page 151: ...HI 2160RCPLUS MANUAL 7 12 ...

Page 152: ... completed before operating the controller Alternatives to the instructions either explicit or implied contained in this chapter are not recommended Operational Displays Selecting Operational Displays Any display can be selected at any time Selecting displays will not effect the currently running process To select a display press on the Display Button until you reach the desired display There are ...

Page 153: ...CPLUS MANUAL 8 2 FIG 8 2 RATE TOTAL WEIGHT DISPLAY Current Total Weight Display See Fig 8 3 Current Weight in scale 87 566 LB Total WT 1267 987LB ON From 08 15 23 15 FIG 8 3 CURRENT TOTAL WEIGHT DISPLAY The displays are divided into two sections See Fig 8 4 Rate Section Weight Section ...

Page 154: ...e out put signal driving the feeder Act Rate shows the actual flow rate of 1 521 pounds per minute The Weight Section Current Weight Display See Fig 8 5 The current weight display shows that the actual weight of the ingredient currently in the feeder or scale is 87 566 lbs Total Weight Display See Fig 8 6 Displays the accumulated weight total that has passed through the feeder from a start date an...

Page 155: ...WEIGHT NOTE This display is extremely useful in continuous operations Current Weight Total Display See Fig 8 6 Displays the Current weight in the feeder or on the scale Displays the Total Accumulated weight that has passed through the feeder since 11 15 PM August 15th NOTE The continuous displays appear in continuous mode or in batch mode However the Batch displays do not appear when the controlle...

Page 156: ...EIGHT DISPLAY Batch Displays Selecting Batch Displays Step 1 From the Operating Displays press the Set Point button Step 2 Enter the security code number Step 3 Press the Enter button The Set Point Menu appears See Fig 8 7 S E T P O I N T M E N U R A T E 0 0 0 0 L B M A M O U N T 1 5 0 0 0 L B FIG 8 7 SET POINT MENU SELECTING BATCH MODE ...

Page 157: ...ay Step 7 To select a display press on the display button until you reach the desired display Step 8 There are three Batch Rate Displays Batch Amount and Rate Display See Fig 8 8 S e t R a t e 1 5 2 0 L M O P 6 5 3 A c t 1 5 2 1 A m o u n t R e q 1 2 0 5 0 O N A c t 1 1 8 3 L B FIG 8 8 BATCH AMOUNT AND RATE DISPLAY The Batch Amount Display shows the amount of ingredient requested the set point amo...

Page 158: ...in the feeder Our example display shows 120 50 pounds requested 118 3 pounds actually delivered 87 566 pounds of ingredient currently in the feeder Batch Amount and Total Weight Display See Fig 8 10 This display shows the amount of ingredient requested the set point amount and the current weight of the ingredient in the feeder Our example display shows 120 50 pounds requested 118 3 pounds actually...

Page 159: ...int Menus L M pounds per minute Mass Unit Time Unit and can be changed in the Calibration Sub Menu See Chapter 5 2 Actual Rate an ingredient is being dispensed 3 Output Percentage of the total available motor control output applied to the feeder motor controller S e t R a t e 1 5 2 0 L M O P 6 5 3 A c t 1 5 2 1 C u r r e n t W e i g h t i n O N S c a l e 8 7 5 6 6 L B 1 2 3 4 5 FIG 8 11 SET RATE C...

Page 160: ... Mode ONr Controller is configured to be controlling to a remotely entered set point 5 Scale displays the weight of the material currently in the feeder Current Total Weight Display Parameters See Fig 8 12 1 From displays the date and time the Total Register Totalizer was cleared month day hour minute C u r r e n t W e i g h t i n S c a l e 8 7 5 6 6 l b T o t a l W t 1 2 6 7 9 8 7 L B O N F r o m...

Page 161: ...r button to clear the total register The display automatically returns to the Operational Display Clearing the Total Register from the Rear Panel See Fig 8 14 Remote Functions Start Pause Abort RstTot Print A Refill Remote Gnd Gnd Momentary Switch FIG 8 14 CLEARING TOTAL REGISTER FROM THE REAR PANEL Step 6 Momentarily ground the Reset Total RstToT on the Remote functions Connector located on the r...

Page 162: ...Mode NOTE The OP can be adjusted with the unit ON or OFF Step 1 Press the Set Pt 4 button The security message appears Step 2 Enter the security code number or press the Enter button The Set Point Menu appears with the cursor next to the Rate sub menu Step 3 Setting the Rate Press the Select button to scroll through all the rate selections which are Manual Remote Optional Mass Units Time Units e g...

Page 163: ...al per centage Initially the OP reads 00 0 with the digit to the right of the decimal point the least significant digit flashing The flashing means that the value can be changed See Fig 8 15 Press the up arrow The flashing number changes from 0 to 1 See Fig 8 16 Set Rate MANUA L L M OP 00 0 A ct 0 00 Current We ight in ON S cale 123 45 lb FIG 8 15 OPERATIONAL DISPLAY RUNNING ...

Page 164: ...increments of 1 Press the Select 0 button The number to the left of the decimal point begins flashing Press the up arrow to increase the output signal percent age increased driver RPM in increments of 01 0 and down arrow to decrease the output signal percentage driver RPM in increments of 01 0 Step 3 Increase Decrease the OP output signal by increments of 10 See Fig 8 17 Press the Select 0 button ...

Page 165: ...s the STOP button twice Setting the Remote Set Point Input Mode The Remote Set Point Input Mode requires the Remote Set Point Input Option Board Prt 0535 0410 The Remote Set Point Input Mode of operation is used if the opera tor wants to control the rate of flow remotely via Analog Input from a Host Controller Flow Meter or other device The rate is governed by the analog inputs supplied by the hos...

Page 166: ...utomatic Rate Control Mode Gravimetric Mode The Automatic Rate Control Mode is used if the operator wants to set a rate of flow to a pre determined rate The rate is set in mass units time units For example LBS M pounds per minute LBS H pounds per hour etc Step 1 Press on the Set Pt button Step 2 Enter the security code number Step 3 Press on the Enter button The Set Point Menu appears with the cur...

Page 167: ...e feeder The amount is set in Mass Units Time Units The Mass Units are express as LB pounds OZS ounces etc See Chapter 5 for instructions on how to set the Mass Units The Time Units are expressed as HR hours MIN minutes SEC seconds See Chapter 5 for instructions on how to set the Time Units The controller automatically stops the feeder when the target weight batch is reached Step 1 f Press on the ...

Page 168: ...lear button to clear the entry Step 7 Use the numerical keys and enter the new amount In our example display 15 000LB pounds SETPOINT MENU RATE 1 500 LB M AMOUNT 15 000LB FIG 8 21 SETPOINT MENU SET POINT AMOUNT BATCHING Step 8 Press the Enter button to accept the new amount Step 9 Press the Exit button to return to the operating display ...

Page 169: ... rate of ingredient 1 For example if ingredient 1 s flow rate is 10 gallons minute and the process requires that ingredient 2 be fed at 10 of the flow rate of ingredient 1 ingredient 2 must be fed at a flow rate of 1 gallon minute a 10 1 ratio However ingredient 1 s flow rate is not constant The rate controller for ingredient 2 must maintain the 10 proportional feed rate no matter what the flow ra...

Page 170: ...al can come from a variety of Host Controllers including a flow meter B and C are the Slave ingredients which track the flow of A The remote set point to B and C from A is setting the desired rate set point Remote Set Points Option for Ratio Control Applications The Remote Set Point Input Option enables the user to set a range which is used to receive rate set point values from another unit s anal...

Page 171: ...equirements When using a value other than 0 000 the value must be below less than the HI value setting Press the Config button The Main Menu appears d Press the down arrow until the cursor is to the left of the Remote Set Point sub menu Press the Enter button The Set Point Menu appears with the cursor next to the Percentage parameter More will be said later about setting percentages See Fig 8 24 P...

Page 172: ...corresponds to 20 milliamp or 5 or 10 volts output The Default setting is 3 000 mass units time units The value must be higher than the LO value setting Press the down arrow until the cursor is to the left of the HI setting sub menu Press the Clear button to clear the old value NOTE If the old value is Zero enter a new number If the old value is not Zero press the Clear button two times then enter...

Page 173: ...n is a running average where the input signals are totaled and the total is divided by the number of set averages 1 20 The Default setting is 20 The instrument reads one new signal plus the last 19 sig nals and repeats the averaging process again c For example An averaging setting of 20 The instrument reads 20 of the most current input signals amps or voltages totals the signals divides by 20 drop...

Page 174: ...f the process requires 5 7 LBS MIN set the percentage for 57 6 3 LBS MIN set the percentage for 63 etc Press the Config button The Main Menu appears Press the down arrow until the cursor is to the left of the Remote Set Point sub menu Press the Enter button The Set Point Menu appears with the cursor next to the Percentage sub menu See Fig 8 25 Press the Clear button to clear the value A setting of...

Page 175: ...metric mode and begins again to control the flow rate Press the Clear button to clear any values Use the numeric keys to enter the new value Enter any value as long as it is lower than the SPH Set Point High value Press the Enter button to accept the new value Press the down arrow until the cursor is to the left of the Set Point High SPH sub menu Step 8 Setting the Set Point High SPH Parameter See...

Page 176: ...al C Controlled by an HI 2610RC Rate Controller Blended into Material A at a rate of 10 of the full flow rate of Material A i e 200 lbs hr NOTE Note that the settings for Material B and Material C are the same as the full flow rate of Material A This is necessary so that the feed rates for B and C are propor tional for the entire output span of Material A Setup Material B Step 1 Set the LO Output ...

Page 177: ...a Analog Signal for PLC s that are not Equipped with PROFIBUS or Allen Bradley Remote I O Equipment Required for the PLC Analog Output Module Relay Module Equipment Required for the HI 2160RCPLUS Remote Set Point Option Card that matches the Analog Output Signal of the PLC 0 20 Milliamps 4 20 Milliamps 0 5 Volts 0 10 Volts Step 1 Set the jumpers for the amperage or voltage range that matches the a...

Page 178: ...FIGURATION DIAGRAM Step 9 The remote set point is set for 4 20 mA and a single analog output from the PLC controls all three HI 2160RCPLUS s Step 10 Downloading Set Points See Fig 8 27 8 28 Download the set point information to the 4 20 milliamp output line Close the Relay for the selected controller in this case HI 2160RCPLUS 1 Open the Relay for the selected controller in this case HI 2160RCPLUS...

Page 179: ...ELAY WIRING CONFIGURATION Rate Exception Control Definition Rate Exception Control is a method of quickly detecting a distur bance and changing operation from gravimetric to volumetric until the disturbance has been eliminated Formula for determining when the HI 2160RCPLUS detects an REC condition ROCSP x REC x 0 1 DEV ROCSP Rate of Change Set Point Desired Flow Rate REC Rate Exception Control Lev...

Page 180: ...n in REC mode with the alarm relay energized Setting the Rate Exception Control REC LEVEL Step 1 Press the Config button Step 2 Enter the security code number Step 3 Press the Enter button Step 4 Press the down arrow until the cursor is to the left of the Tuning Control sub menu Step 5 Press the Enter button Step 6 Press the down arrow until the cursor is to the left of the REC LEVEL sub menu Step...

Page 181: ...way system malfunction operator pause REC mode or refill mode an invalid test alarm is displayed and the test is aborted Once the test is complete the results are kept in the 2 Sigma Data memory and can be displayed by selecting the 2 Sigma Data sub menu in the Test Menu The 2 Sigma accuracy test of a feeder is the repeatability of the feed rate expressed as a percentage of the Mean feed rate You ...

Page 182: ...ion of the cursor is next to 2 Sigma Test If you are in the menu you need to press the down arrow or up arrow until the cursor is next to 2 Sigma Test Step 3 4 Press the Enter button The 2 Sigma Test Menu appears See Fig 8 31 2 SIGMA MENU Sample Period 2 Qty of Samples 5 TEST TIME 10 Sec FIG 8 31 2 SIGMA TEST MENU ...

Page 183: ... Even though the samples number from 1 20 Hardy Process Solutions recommends 5 samples Step 9 The TEST TIME is automatically calculated for you You will notice that the Test Time is the product of the Sample Period and Qty of Samples For example if we selected 20 seconds for the Sample Period and set the Qty of Samples for 20 sam ples the Total Test Time is 400 seconds NOTE The examples are provid...

Page 184: ...message NOT ENOUGH MATERIAL appears For continuous feed processes wait until you think there is enough material in the feeder hopper then start the test Keep in mind a valid test requires that there be no interruptions during the test cycle so plan accordingly For batch processes make sure that the test parameters are selected so that the test fin ishes before the batch ends If the Feeder is not r...

Page 185: ...5 The 2 Sigma Data Display appears See Fig 8 36 Step 3 The 2 Sigma Test value indicates the repeatability accuracy of the feeder system under test Step 4 The number of Samples for the test and the Period is the time in seconds between samples Step 5 The Mean is the sum of all the selected sample values divided by the number of samples This is displayed with the number of digits to the right of the...

Page 186: ... Smpls 20 Perd 01 Mean 0 498 LBS 11 00 00 12 12 04 FIG 8 36 2 SIGMA DATA DISPLAYED Step 7 To exit these displays press the Exit button Step 8 The last Test Data is automatically stored in the Secure Mem ory Module and can be displayed on the front panel at any time Step 9 To print the Test Data press the Print button ...

Page 187: ...HI 2160RCPLUS MANUAL 8 36 ...

Page 188: ...lutions Service Center for additional information and assis tance Make sure that the proper tools are used when disassembling reas sembling or installing the HI 2160RCPLUS or options Check all external connectors first to be sure they are securely fas tened before disassembling the controllers Do not disconnect any electrical plug connector or terminal unless an identification tag is present or on...

Page 189: ...r mation is not correct or the display itself appears not to be cor rect The Key Pad still responds Memory Failure Perform the Auto Clear Ram Memory Procedures in Chapter 8 Auto Clear Ram Memory Procedures Step 1 Press on the Config button Step 2 Enter the High security code number Step 3 Press the Enter button The Main Menu appears Step 4 Press on the down arrow until the cursor is to the left of...

Page 190: ...he power cord from the power source Step 2 Disconnect the load cell connector at the rear panel Step 3 Install a Resistor Shunt Bridge See Fig 9 1 EXC SEN SIG SIG SEN EXC DATA GND NC Half Watt Qtr Watt Qtr Watt Half Watt FIG 9 1 RESISTOR SHUNT BRIDGE DIAGRAM NOTE Use four resistors of the same value Resistance between 120 and 350 ohms Step 4 Connect the power cord to the power source Step 5 Wait 5...

Page 191: ...shields are grounded at the summing box 1 Use an ohm meter and check to seed if the shield is grounded only at the controller 2 Disconnect the shield at the controller and check for an open cir cuit toward the load cells 1 Check to see that the shield is not con nected to ground at the summing box See Chapter 2 for wiring diagrams 2 Load cell cable shields only pass through the summing boxes and a...

Page 192: ...rol or relay bank 1 Relocate the low volt age and or high volt age cable so that there is a minimum of 3 inches separation between the low volt age cable and the high voltage cable 2 Increase the separa tion between the low voltage cable and a high electro magnetic field Move the cable until the problem goes away 3 Relocate the cable so that the cable is a mini mum of 14 inches from SCRs Motor Con...

Page 193: ... Power Surge Noise produced by relays Install surge suppression The solenoids operated by the internal relays of the con troller must be fitted with surge suppression A resis tor and a capacitor across the coil of the solenoid pre vents a sudden surge of cur rent when the relay energizes See Fig 9 2 CONTROL VOLTAGE SURGE SUPPRESSOR SNUBBER HI 2160RC SET POINT RELAY EXTERNAL RELAY EXTERNAL DEVICE N...

Page 194: ...il you reach stable weight readings See Chap ter 3 for instructions Weights Displayed are Incorrect After Calibration Display Weight Reading is Incorrect TROUBLE PROBABLE CAUSE REMEDY The Weight Display indi cates zero with a weight on the scale The Weight Indication does not change Input from the Load Cell is negative Load cell correct input should always be between 0 and 30 mV DC Check the curre...

Page 195: ...ng is not correct for the application make the correction If there is a loose connection make sure the connector is plugged in correctly or replace the connector Step 4 Use a volt meter and check the voltage between SIG and SIG on the load cell connector See Fig 8 4 Result 1 If the volt meter reads between 0 and 30mVDC the load cell voltage is in range go onto Step Six Result 2 If the volt meter d...

Page 196: ...CAUSE REMEDY When pushing the Start button it does not acti vate the motor controller Analog Control on the feeder 1 Wiring to Analog Control Connector is incorrect 2 Output configuration jumpers are not set cor rectly for the feed back signal 3 Feeder motor malfunc tion 1 Check the wiring to the Control Output con nector See Fig 9 5 For Jumper Settings See Chapter 4 Pin 1 Voltage Pin 2 Voltage Pi...

Page 197: ...1 2 3 4 5 6 V V I I VOLTAGE CURRENT HI 2160RCPLUS MANUAL 9 10 FIG 9 5 CONNECTOR WIRING DIAGRAM FOR CONTROL OUTPUT CARD ...

Page 198: ... set too low 5 Control Out HI is set too low NOT ALLOWED statement appears preventing the feeder motor from start ing 4 Raise the Batch Set Point Amount Setting If the batch set point is too low the instrument does not have time to see it and thinks it has already met or exceeded the condi tion See Chapter 7 for instructions 5 Raise the Control Out HI the CTL Out HI setting is located in the Tunin...

Page 199: ...ll to a capacity closer to the weight of a fully loaded feeder or use a counter balance scale to increase the live load counts 4 Re Accept Rate CAL parameters or Rerun the Rate Calibration Rate Exception Control REC Alarm Appears too Often TROUBLE PROBABLE CAUSE REMEDY Rate Exception Alarm appears too often 1 Rate Calibration Error 2 REC level too small or too large 3 Averages or Time Base setting...

Page 200: ...display the following data 1 Firmware 2 Revision 3 Check Sum 4 Zero Count 5 Span Count 6 Span Weight 7 Current Count 8 Count Grad 9 Time 10 Date 11 Rear Dip Switch 12 Internal Dip Switch 13 Relay Status 14 WAVERSAVER Status Review the data and correct the incorrect setting s If several of the param eters are incorrect re calibrate the instru ment and go through the Setup procedures again ...

Page 201: ...so reduces control during refill and rate expectation Finding the balance is a matter of trial and error a If the typical range is 25 to 30 min and that cor relates to an output percentage of 35 to 50 This would be a variation of 15 b The REC level should be set to 1 5 This allows an OP change allowance of the 15 within the acceptable gravimetric feed range c Changes that require more than 15 moto...

Page 202: ...ility for the material to move at a given rate If it requires more energy to move the material at a low motor speed than at a high motor speed The zero point will not pass through zero and have a positive feed rate at zero feed rate If the mate rial tuns easier at the low rate the controller will have a negative feed rate at zero and will not feed material at the low signal level 1 Since the feed ...

Page 203: ...n motion while entering the Zero or Span Value 2 Zero or Span value is trying to be entered before the controller has accumulated and averaged 200 readings When calibrating the scale feeder and agitator motors must be off and you must wait at least 12 seconds before entering Zero and Span 3 Remove the source of the scale motion and then re calibrate Zero and Span 4 Too many decimal points selected...

Page 204: ...L first depending on which parameter is incorrect 1 A minus value has been entered as the LO or HI value Press the Clear button to indicate a positive value 2 LO value is greater than the HI value Enter a LO value that is less than the HI value 3 Value entered for Averages was less than one 1 or more than twenty 20 Enter a value between 1 and 20 RATE TOO LOW RATE SET POINT Value entered for RATE t...

Page 205: ... flow dropped above the LO SHUT OFF setting in the RATE TOL menu causing the analog control output to be forced to the SHUTOFF OUTPUT setting See Possible Cause for LO RATE ALARM HI SHUTOFF ALARM RATE TOLERANCE The rate of flow dropped below the HI SHUT OFF setting in the RATE TOL menu causing the analog control output to be forced to the SHUTOFF OUTPUT setting See Possible Cause for HI RATE ALARM...

Page 206: ...OFF A refill did not stop when the AUTO REFILL STOP set point was reached Refill will continue in that instance Possible Causes 1 Faulty refill gates and solenoid 2 Faulty AUTO REFILL STOP relay 3 Faulty output relay connections or wires MESSAGE DESCRIPTION ...

Page 207: ...HI 2160RCPLUS MANUAL 9 20 ...

Page 208: ...Analog Output Card Option Configuration Prt 0535 0406 4 3 Analog Output Main 6 46 Analog Output Option Card 2 3 Analog Output Option Wiring Diagram See Fig 3 28 3 18 Analog Signal Information 4 8 Analog to Digital Specifications 2 1 Analog Transmitter Outputs 4 3 Application 8 25 Approvals 2 2 Appurtenances 5 2 Arrow 5 1 ASCII Command Protocol 7 1 ASCII Format 7 2 Auto Clear Ram Memory Procedures ...

Page 209: ...sembly Notes Cautions 9 1 Display Menu Flow Chart with Allen Bradley Remote I O Option 6 2 Display Menu Flow Chart with PROFIBUS Interface Op tion 6 2 Display Menu Flow Chart with Standard Serial Port 6 1 Display Menu Trees 6 1 Display Parameters 8 8 Down Loading Rate Set Points Via Analog Signal for PLC s that are not Equipped with PROFIBUS or Allen Bradley Remote I O 8 26 Drift 9 3 E Effects of ...

Page 210: ... LocTite 290 9 1 Loss in Weight 6 9 Low Access 6 3 M Manual Calculating Parameters Tuning Control Pro cess 6 12 Manual Control Mode 1 3 Manual Rate Calibration Procedures 5 18 Manual Refill 1 3 Manual Tuning Control 6 12 Manual Tuning Control Process Cont d 6 17 Mass Units Actual Weight 6 26 Mass Units Sub Menu 5 3 Material A 8 25 Material B 8 25 Material C 8 25 Materials Required 5 20 5 21 Mechan...

Page 211: ... Process Control System 8 18 Readings on the Display are Not Correct 9 13 Rear Panel Config Option Dip Switch Settings 4 12 REC Alarm 1 2 REC Level 5 18 6 11 8 29 REC Shutoff 6 12 REC Time 6 12 Recommended Graduation Level 5 5 Recommended Installation Procedures 3 14 Refill and Alarm Relays 4 1 Refill and Alarm Relays Diagram See Fig 3 23 3 16 Refill Condition 6 24 Relay Output Wire 4 13 Remote Co...

Page 212: ...the Rate Exception Control Parameters 8 29 Setting the Remote Set Point Input Mode 8 14 Setting the Security Code Numbers 6 6 Setting the Set Point Amount Batch Mode 8 16 Setting the Set Point High SPH Parameter 8 24 Setting the Shutoff Out Percentage 6 22 Setting the START LO and STOP HI Parameters 6 26 Setting the Sticker Value 5 8 Setting the Time 6 30 Setting the Time Units Rate of Flow 5 4 Se...

Page 213: ...Weight Calibration Process 5 3 Weight Section 8 2 Weights Displayed are Incorrect 9 7 What to do if You Lose the HI Security Code Number 6 7 When to Save 6 37 When to Use the Clear Button 6 7 When to Use the Select Button 6 7 X X Xmit Command 7 7 Z ZERO Calibration Procedures 5 7 ZERO Output Reference Voltage and Current 6 47 ...

Page 214: ...ient in the event that replacement of the controller with a spare is necessary or when you require assistance by our local representative or Hardy Process Solutions Customer Support Department Date of Installation ____________ Model _________________ S N __________________ SELF TEST PROGRAM RESULTS Perform Self Test by Press the Test Button Parameter Example 1 2 3 Firmware 0650 0045 Revision B Che...

Page 215: ... Menu Parameter Default Values 1 2 3 TIMEBASE SEC 4 K INTEGRAL 26 K PROPORTIONAL 210 K DERIVATIVE 52 CTL OUT LO 0 CTL OUT HI 52 AVRG 1 200 1 REC LEVEL 0 0 REC TIME Sec 30 REC Shutoff 00 00 00 REAR SW No Pre Act Corr 32 Rate Tolerances Menu Parameter Default Values 1 2 3 LO ALARM 0 020 Lbs Min HI ALARM 0 020 Lbs Min ALARM TIME Sec 60 LO SHUTOFF 0 100 Lbs Min HI SHUTOFF 25 00 Lbs Min SHUTOFF OUT 0 ...

Page 216: ...s HI SHUTOFF 50 000 Lbs INITIAL FILL YES RFL CORR 0 0 Calibration Menu Parameter Default Values 1 2 3 Mass Units LBS Time Units MIN Rate Decimal Pt 3 Batch Decimal Pt 3 Total Decimal Pt 1 ZERO No Value SPAN 10 000 Lbs Graduation 0 001 Rate Calibration Menu Parameter Default Values 1 2 3 LO RATE CAL 20 0 LOW L M 0 300 HI RATE CAL 80 0 HIGH L M 1 700 ...

Page 217: ...Values 1 2 3 Configuration PRINTER Baud Rate 1200 Parity NONE Stop Bits One Data Length Eight ADDRESS 0 Remote Set Point Menu Parameter Default Values 1 2 3 PERCENTAGE 0 0 LO 0 000 Lbs Min HI 3 000 Lbs Min AVERAGES 1 20 20 SPL 1 000 Lbs Min SPH 2 000 Lbs Min ...

Page 218: ... Values 1 2 3 Tuning Control LOW Rate Tolerance LOW Analog Output LOW Time and Date LOW Auto Refill LOW Calibration LOW Serial Port 1 LOW Remote Setpoint LOW Clear Alarms LOW Start LOW Setpoints LOW Clear Total LOW Rate Calibration LOW LOW CODE MED CODE HI CODE ...

Page 219: ...Data Worksheets WKSHT 6 ...

Page 220: ...CA 9211 Telephone 1 800 821 5831 FAX 858 278 6700 Web Address https www hardysolutions com HARDY PROCESS SOLUTIONS NUMBER 0596 0244 01 REV B Copyright July 1997 2022 Hardy Process Solutions All Rights Reserved Printed in the U S A ...

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