I HI 2160 RC plus quick troubleshooting

HI 2160RC Plus
WAVERSAVER

Set Rate 1300 L/M

OP 0.0% ACT 0
Current Weight in
OFF Scale 00.00 LB
_
Start
STOP
Clear Exit Enter

Config Test Print Set Pt Display

1 2 3 4

Select
6 7 8 9 0

• First use the typical installation, grounding, shields, and troubleshooting aids for load cells and weight controllers
first. Insure there are not any mechanical connections that would cause poor weight readings. After you are certain
the scale is working correctly then work on feeder and configuration settings.
• The rate controller has been calibrated to the flow of the feeder. Any change in the feeders ability to move material
will change the ability to control the flow. Material consistency changes of up to 10% will be compensated for
automatically.
• There are three parts to the rate controller, a Weight controller, Feeder controller, and a Rate controller. Each part
receives and sends information to the next component. Any one component can cause poor rate control.
The two symptoms to watch for are erratic feed rates and stray characters on the screens. This can indicate a memory or
display corruption. Do not make configuration changes during the ON mode.
1. Press the Display button through the 3-6 different displays. This will clear temporary display corruptions. This is
an indication there is need for ground, shield, and power source checking.
2. Cycling power will reload the memory and clear many problems.
3. The system configuration is stored and retrieved in the configuration menus. Restoring a known good
configuration will clear memory. This is a good reminder to save the configuration when all is working correctly.
4. There are work sheets in the back of the manuals. Record the information in the event of a catastrophic system
failure.
5. If the above steps fail to correct a system problem. There are two methods of clearing the memory back to
factory defaults. If you have access to configuration menus use the software method. Without display or keypad
control, use the internal jumper method. After clearing memory, restore the configuration only if you know the
data saved is valid. These write-ups are available at; www.hardyinst.com, under support, technical notes and then
HI2160RC. They are also defined later in this article.

Hardy Instruments • 9440 Carroll Park Dr. • Suite 150 • San Diego, CA 92121-5201
Tel 858.278.2900 • Fax 858.278.6700 • www.hardyinstruments.com • hardyinfo@hardyinst.com
. What do you check first?
• Is the Display active and keypad functional?
• Does the weight change increase as weight is applied?
o Monitor the front display screen to verify:

Simply apply weight to the scale
• Does it return to the original weight reading or drift about and then
return to zero?
• Is the weight correct, is the weight stable to 1:10,000?
• Verify the load cell signal output is in range, 0.0 to 30 Mvdc. (The HI
2160RC series uses 10vdc excitation, so NO INTEGRATED
TECHNICIAN)
1. Is the wiring correct?
a. Load cell
b. Intermediate connection in the summing junction box.
c. Cable runs routed away from high voltage.
d. Shields terminated all the way back to a single ground drain.
i. Load cell shields do not contact the body of the load cell.
ii. Verify the shield is continuous to a single ground point.
2. Is the load cell installed correctly?
a. Upside down? Is the load cell mounting level?
b. Is the weight force applied only in the vertical plane?
3. Is the load cell is damaged?
a. Impact, Welding, Lightning,
b. Miss-handling the load cell or cable.
4. Monitor load cell for valid signal voltages.
a. Measure excitation for 10 volts DC
b. Measure the signal input for a positive 0-30 millivolts.
c. Insure the sense lines are attached or sense jumpers are installed.
5. Are the piping and flexures correctly installed?
a. Mechanical will show as slow weight response, incorrect weight, unstable weight, or no
weight response.
i. Verify all pipes and conduit attached to the scale are flexible and not applying or
dividing any force. If you can shake the pipe and conduit, it is flexible. Relocating
pipe supports away from the scale will allow a greater range of movement.
ii. Insure no objects are lodged under the scale system, limiting the scale’s movement.
A typical scale only deflects .020”.
iii. Apply a test weight to a load point and verify you are seeing the correct weight.
Move the test weight to the next load point and verify the correct weight.
Differences of more than 2.5% indicate a problem.

The performance of the controller is greatly affected by the setup configuration. If the system
configuration is in question, have the system engineer contact Hardy Instruments Technical Support for
additional assistance. 1-800-644-8550
If there are problems with the end user understanding the programming aspect, there are papers with
explanations at www.hardyinst.com under support, webtech, and tech-notes.

Hardy Instruments • 9440 Carroll Park Dr. • Suite 150 • San Diego, CA 92121-5201
Tel 858.278.2900 • Fax 858.278.6700 • www.hardyinstruments.com • hardyinfo@hardyinst.com
 SOFTWARE METHOD: (If you have keypad access)
1. Enter the CONFIGURATION MENU
2. Use your high-level security code. (Factory default high Security Code is 1234)
3. Arrow to and Enter the SECURITY MENU.
4. Arrow to and Enter 7321 as the "LOW CODE" (If you only see asterisk, the password you
used is bad or keyed incorrectly.
5. "Wait for Automatic RESET" will appear on the display
6. The unit is now set to factory defaults.
7. If the data is current, restore the configuration data and calibration information.
Under Configuration Arrow down to the RESTORE data and select YES, enter. The system is now
operational. Verify the scale operation and Resume the process.

HARDWARE METHOD:
(When the screen is blank or software method failed.)
1. There is a jumper located in the center, or outside edge on the plus model, of the A/D board. (Top large
PC board)
2. Power down unit, remove rear panel screws, and slide electronics out.
3. Remove Option board to get to the jumpers, are labeled W5/W6 or W6/W7.
4. Move jumper from the current position to the forward set of pins for 20 seconds, and then back to the
original pins. This removes the battery from the RAM chip.
5. Assemble and power-up unit.
6. The unit is now set to factory defaults. If the saved data is current, you can restore the configuration and
calibration information.
7. Under configuration go to RESTORE data and select YES, and press enter.
8. Exit and re-enter the configuration menu selection. The information is restored.
9. The system is now operational.
10. Verify the scale and resume your process.

1. Measure the motor speed control output voltage of current to insure the signal is present and varying. Pins
1(+)-2 = 0-5 or 0-10 vdc, Pins 5-6(+) = 4-20ma or 0-20ma.

2. If the unit is stuck in Rate Exception (REC), press the ENTER button to restart REC calculations. This
indicates poor rate calibration, mechanical interference, continuous BWT59 communications, or the
product is not leaving the scale. (Blockage or motor failure)

3. Visually monitor the displayed weight in scale as the scale loses product. The digits should de-increment
smoothly and not jump.

4. The K number under tuning and control are established by pressing enter on any rate numbers in the rate
cal menu. They are not PID settings subject to common PID engineering calculations and adjustment
methods. There are papers covering that subject on the website www.hardyinst.com using the Web tech
knowledge base.

Hardy Instruments • 9440 Carroll Park Dr. • Suite 150 • San Diego, CA 92121-5201
Tel 858.278.2900 • Fax 858.278.6700 • www.hardyinstruments.com • hardyinfo@hardyinst.com
 Feeder Motor control out is an internal Solid-state Opto 22 relays require
jumper selectable for (0-5 or 0-10 vdc), or 110AC input voltage, and there are
(0-20ma or 4-20ma). Micro 5amp fuses located under
lid.

Shut On/
Off Off RE 4 5 6

RS-422
Port

Control
Out
V+

I+
V-

I-

Option
Port Secure
Memory
F Refill
Clear A
PLUS
RstTol

GND
Abor

Print
+Exc

Rem
Module
+C2

Stop
Paus
+Sen
+Sig

-Sen
-Exc
-Sig

Shield

1 8
-

1 6

Load Cells Remote Functions RS-232 Port

Serial No.

NO

NC

NC
C

NO
C

Relay 12345678
GND
Hot

Out
Ne

On Config Refill Alarm

u

Relays

Verify Neutral to GND is less

Load cell connector IMPORTANT: than 1vac. Verify Hot to
1. + EXC 10 vdc Remote functions wire Neutral and Hot to GND are
2. + SEN * connections are to be less equal. Unit requires computer
3. + SIG 0-30mv than 50”, twisted pair, clean power.
4. - SIG 0-30mv shielded cable, and routed
5. - SEN * away from high voltage.
6. - EXC 10 vdc
7. + C2 = Gray
8. - C2 = Violet
(*Must have Sense lines or These relays are “C” form contacts will handle up to 4A load and
jumpers) are dry contacts. (Require input voltage)

This controller does not support Integrated Technician

or the IT summing junction box.

Hardy Instruments • 9440 Carroll Park Dr. • Suite 150 • San Diego, CA 92121-5201
Tel 858.278.2900 • Fax 858.278.6700 • www.hardyinstruments.com • hardyinfo@hardyinst.com