Tuning the HI 2160 Rate Controller

The HI2160RC controller is now obsolete and the replacement controller is the HI 4060.  Contact your Hardy sales group 858-292-2710 selecting menu tree option 1

There are several methods used to tune the HI 2160RC to your particular feeder. You can run the RATE CALIBRATION using the auto rate calibration menu or manual mode where you can run in manual mode and make timed product catches. The recommended method is AUTOMATIC TUNING. AUTO RATE CAL, with set run percentages and selectable feed time. Both manual rate cal. and auto rate cal recalculate and update the K(p), K(I), and K(d) control constants.

Each procedure will be discussed:

AUTOMATIC TUNING/AUTO RATE CALIBRATION PROCEDURES

1. Initially, set AVERAGES = 1, and TIME BASE = 4.
(Increase AVERAGES if the weight varies >1% of full scale.)
(Increase TIME BASE if the expected rate is above 100 units/min
(Increase TIME BASE if the ACT <---> flashes on during automatic operation)

NOTE: Whenever changes are made to any rate calibration variables. Re-enter the rate calibration menu and press enter on the HI and LO rate cal %. This will recalculate the Kp, Ki, and Kd values.

2. Perform a good scale system installation and calibration prior to starting the rate cal. program. Most failures of the rate controller can be contributed to poor scale calibration, installation, and setup. Review shielding, cable routing, and grounding tips in the troubleshooting section.

3. This feature allows the HI 2160RC to tune it's self to the feed characteristics of the feeder and the material being feed. This process may need to be performed for every product you will be measuring. Where the controller can adjust about 10% for changing product conditions, your best results will be to use all 12 ingredients to insure you are getting the best possible feed control.

4. Rate Calibration is a sub-menu under the main menu accessible by pressing the "Config" key. Point to Rate Calibration and press the START/ENTER key.

5. Using the down arrow key point to "PAUSE LENGTH". This is the pause between the rate cal. cycles. PAUSE LENGTH allows time in between runs to press the HOLD/STOP button, check if there is enough material to complete the next section of the test. Noting how much was run out for the previous test session will give you a good idea if there is sufficient material for the next test section. Using the numeric key pads enter a value from 1 to 999 seconds and press the Start/ Enter key. The message "ENTRY ACCEPTED" appears for one second.

6. Using the down arrow key point to "PRIME LENGTH". The time it takes to fill the feeding mechanism with material for the first, 20%, run. This should be set long enough to insure a representative material flow. Using the numeric keypads enter a value from 1 to 999 seconds and press the ENTER key. The message "ENTRY ACCEPTED" appears for one second.

7. Using the down arrow key, point to "FEED LENGTH". Using the numeric keypad, press clear and enter a value from 30 to 999 seconds and press the ENTER key. This establishes the run time for each test segment. The message "ENTRY ACCEPTED" appears for one second. Ensure your feeder holds enough material, without refill, to feed at 80% for this length of time. Older systems are restricted to 30-second runs and 30 seconds is the minimum run time.

WARNING: Ensure the system is ready to be calibrated. As soon as the START/ENTER key is pressed in the following step the feeder will turn on and calibrate it-self.

8. Using the down arrow key, point to "AUTO RATE CAL NO". Press the select/0 key. The display changes to "AUTO RATE CAL YES". Press the Start/Enter key. The message "ENTRY ACCEPTED" appears for one second and the actual rate cal begins. The message "RUNNING RATE CAL" appears. Press exit twice, this will display the