RDS Technology Athene 100 User manual

1
Athene 100
Belt Spreader Monitor/
Variable Rate Controller
Calibration
Software Reference WZ812-000 rev.2
Electro-Magnetic Compatibility (EMC)
This product complies with Council Directive 89/336/EEC
when installed and used in accordance with the relevant
instructions.
Service and Technical Support
PLEASE CONTACT YOUR NEAREST DISTRIBUTOR
If unknown then fax: [phone]
© Copyright RDS Technology Ltd 2003
Document number
S/DC/500-10-377 : Issue 2 : 10/7/03
\UK377-2.DOC
User Guide

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Contents
1Overview_________________________________________4
2Calibration on Installation _________________________5
2.1 Forward Speed Sensor Setup.......................................................................5
2.1.1 ‘Autocal’...........................................................................................5
2.1.2 Programme Cal Factor manually......................................................6
2.2 Belt/Gate Setup.............................................................................................7
2.2.1 Valve Autosetup Routine..................................................................7
2.2.2 Start up PWM...................................................................................7
2.2.3 Maximum Duty Cycle.......................................................................8
2.2.4 Minimum Duty Cycle........................................................................8
2.2.5 Response........................................................................................8
2.2.6 Deadband........................................................................................9
2.2.7 Millimetres of belt per pulse ..........................................................10
2.2.8 Setting "Monitor only" mode...........................................................10
2.2.9 Gate Width.....................................................................................11
2.2.10 Working Width...................................................................................11
3Product Calibration_____________________________ 13
3.1 Setting up for a given product/application rate ...........................................13
3.1.1 Set Density ....................................................................................13
3.1.2 Set Gate Height .............................................................................14
3.1.3 Set Application rate (Target rate)...................................................14
3.2 FAQ’s about Product Calibration.................................................................15
There is a small discrepancy in the amount applied....................................15
There is a big discrepancy in the amount applied. ......................................15
The instrument beeps continuously .............................................................15
3.3 Nudging the Product calibration..................................................................16
3.3.1 Under-application..........................................................................16
3.3.2 Over-application............................................................................16
3.3.3 Nudging the density ......................................................................17
3.3.4 Re-calculating a Density Factor.....................................................17

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4Other Calibration Settings _______________________ 18
4.1 Hopper Setup...............................................................................................18
4.1.1 Level Sensor Configuration............................................................18
4.1.2 Alarm On-Off ..................................................................................19
4.1.3 Set Hopper Current Volume ...........................................................19
4.1.4 Reset Hopper Current Volume to Maximum Volume.......................20
4.1.5 Set Hopper Alarm Volume..............................................................20
4.1.6 Set Maximum Tank Volume............................................................20
4.2 RPM Sensor Setup.......................................................................................21
4.2.1 PPR - Shaft.....................................................................................21
4.2.2 Under-speed Alarm........................................................................22
4.3 Total Area.....................................................................................................22
4.4 Simulated Forward Speed ...........................................................................23
4.5 Units.............................................................................................................24
4.6 Percentage Step ..........................................................................................24

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1Overview
There are two aspects of calibration :- Calibration procedures/system
settings made less frequently or only on installation, and the Product
calibration procedure as part of everyday operation. In addition to the normal
display / operating mode the instrument has 4 calibration modes.
On entering a Cal Mode the instrument defaults to the channel indicated by
the symbol. Table 1 shows the various Cal. modes and functions. Note
that the parameters required to ensure the correct application rate are
highlighted.
Cal Mode 1 Cal Mode 2 Cal Mode 3 Cal Mode 4
Press to
select channel,
then press and
hold
Press and
hold the
button, power on
and hold for 10
seconds
Press and
hold the
button and
power on
Press and
hold the
button and
power on.
Instrument must
be ‘out of work’
Channel
Selection As above Press Press Press
Channel 1 Speed Sensor
factor
(m/ 2 pulses)
[sect. 2.1]
Gate Width
(mm)
[sect. 2.2.9]
Simulated
forward speed
(km/h)
[sect. 4.4]
Response
(0.000 - 0255)
[sect. 2.2.5]
Channel 2
Working Width
(metres)
[sect. 2.2.10]
Total Area
(ha)
[sect. 4.3]
Units
(kg/ha or
tonnes/ha)
[sect. 4.5]
Start up PWM
(4.0 - 96.0%)
[sect. 2.2.2]
Channel 3 Hopper Alarm
Volume
[sect. 4.1.5]
Max Hopper
Volume
[sect. 4.1.6]
Percentage
Step (5, 10, 15,
20 or 25%)
[sect. 4.6]
Min Duty
Cycle
(4.0 - 96.0%)
[sect. 2.2.4]
Channel 4 Target
Application Rate
[sect. 3.1.3]
mm/Belt Pulse
[sect. 2.2.7]
Product
Density
(Kg/Litre)
[sect. 3.1.1]
Max Duty
Cycle
(4.0 - 96.0%)
[sect. 2.2.3]
Channel 5 Under-speed
alarm(rpm)
[sect. 4.2.2]
PPR Shaft
[sect. 4.2.1]
Gate Height
(mm)
[sect. 3.1.2]
Deadband
(0 - 100)
[sect. 2.2.6]
Channel 6 Tank
Contents/Alarm
on-off
[sect. 4.1.2]
Hopper Alarm
from
Volume/Sensor
[sect. 4.1.1]
NudgeDensity
[sect. 3.3.3]
Valve Auto
Setup Routine
[sect. 2.2.1]
Table 1

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2Calibration on Installation
After installation, first proceed to calibrate the forward speed sensor and the
belt drive.
2.1 Forward Speed Sensor Setup
Cal Mode 1 – channel 1 Default = 1.000m (39.38 inches)
The instrument must be programmed with the correct Speed Sensor Factor
(S.S.F.). This is the distance travelled per two pulses received from the
sensor.
If a cal factor has previously been established for the vehicle, that factor can
be manually programmed. If the factor is not known then it can be calculated
automatically via the “Autocal” function as follows.
2.1.1 ‘Autocal’
1. Set two markers at 100 metres apart (328
feet). Choose a convenient reference point
on the vehicle and position this point
opposite the first marker.
2. Press and hold the button until the
cal factor is displayed
(Default = 1.000 m /2 pulses).
3. Continue holding the button,
and press the button until the display
shows "Auto’ ready for the Autocal.
4. Drive the vehicle until the chosen reference point is opposite the second
marker. The instrument counts and displays the sensor pulses received over
the distance traveled.
NOTE: If the count exceeds 9999 (as may occur if the forward speed signal comes
from a radar sensor), then the instrument displays the first 4 digits i.e "1001"
indicates between 10,010 and 10,019 pulses.
Figure 10: Start ‘Autocal’
2
3

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5. Press the button again to complete the Autocal routine.
The calibration factor is automatically calculated and stored in memory.
2.1.2 Programme Cal Factor manually
Calculate as follows;
(i) If a conventional wheel sensor with two magnets is installed, the Speed
Sensor Factor is half the effective rolling circumference of the wheel. Drive
the vehicle forward in field conditions with the implement attached, for
exactly 5 revolutions of the sensed wheel. Measure the distance travelled
(metres) and divide by ten to find the Speed Sensor Factor.
(ii) If a prop shaft sensor with a single magnet is installed, the distance
traveled for two turns of the prop shaft must be determined. To determine
this distance, drive the vehicle forwards for exactly 10 revolutions of the prop
shaft. Measure this distance (metres) and divide by five, to find the Speed
Sensor Factor.
(iii)If an RDS Radar sensor is installed, set the factor to 0.0016 (m / 2 pulses).
1. Press and hold the button until the cal factor is displayed. Continue
holding this button and...
2. QUICKLY PRESS and RELEASE the button to select the digit or decimal
point to change, or...
3. HOLD the button to change the digit, or if selected move the decimal
point.
4. Release the button to return to the normal operating mode.

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2.2 Belt/Gate Setup
2.2.1 Valve Autosetup Routine
Cal mode 4 - Channel 6 (ref. Table 1)
The valve auto-calibration routine establishes the startup PWM and maximum
duty cycle for controlling the belt speed.
1. Ensure the instrument is switched ‘out of work’ (is flashing) at the
bottom of the display and then turn the instrument off.
2. Press and hold the button and switch the instrument on to enter Cal
mode 4.
3. Press the button to select channel 6. The display shows "AUtO".
4. Press the button to select the auto-calibration routine and then switch
the system into work.
The display then alternates between "X" and "run" (Xbeing the PWM value
being sent to the valve) as it then establishes the Start up PWM and Max.
Duty Cycle PWM values as follows.
5. Once the routine is complete the PWM output will be turned off, the
instrument can be switch ‘out of work’ again and the Start Up PWM and Max
Duty Cycle PWM will be saved accordingly.
2.2.2 Start up PWM
Cal mode 4 - Channel 2 (ref. Table 1)
Default: 4% (Display shows 0004)
Auto-calibration first establishes the Start up PWM value. This is the PWM
output that enables a speed feedback signal to be received and from which
point closed loop control can continue.
The PWM output is slowly ramped up from 0% until the system registers a
slow but steady belt speed. The PWM value (typically around 20%) is then
stored to channel 2.

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It should not normally be necessary to program this value as it will be
determined with an ‘Autocal’ (see section 2.2.1).
2.2.3 Maximum Duty Cycle
Cal mode 4 - Channel 4 (ref. Table 1) Range: 4 - 96%
Default: 96% (Display shows 0096)
After establishing the Start up PWM value, auto-calibration then establishes
the Maximum Duty Cycle PWM value. This is the PWM output at which the
belt is at maximum speed.
The PWM output continues ramping up until the belt speed no longer
increases. The PWM value is then stored to channel 4. When this is
completed the PWM output is switched off and the display shows "donE".
It should not normally be necessary to program this value as it will be
determined with an ‘Autocal’ (see section 2.2.1).
2.2.4 Minimum Duty Cycle
Cal mode 4 - Channel 3 (ref. Table 1) Range: 4 - 96%
Default: 4% (Display shows 0004)
This the percentage duty cycle at which the valve does not enable oil to
pass, and the hydraulic motor to rotate.
2.2.5 Response
Cal mode 4 - Channel 1 (ref. Table 1) Range: 0.000 - 0255
Default: 250 (Display shows 0250)
This factor affects how quickly the system will respond to a change in
application rate.
If it is set too high then the system will respond quickly but may overshoot
the target. This may result in the rate remaining unsettled and fluctuating
about the target rate.

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If it is set too low, then the system will not respond quickly enough and the
system will take longer to reach the target rate.
1. Ensure the instrument is switched ‘out of work’ (is flashing) at the
bottom of the display and then turn the instrument off.
2. Press and hold the button and switch the instrument on to enter Cal
mode 4. On entry the instrument will automatically default to channel 1
showing the response factor programmed (default 0250).
3. QUICKLY PRESS and RELEASE the button to select the digit or
decimal point to change, or...
4. HOLD the button to change the digit and release when the required
number is shown.
NOTE: It is possible to program a number greater than 0255 but when the instrument
is turned OFF it will not be saved. Therefore ensure the number set does not
exceed the maximum of 0255.
2.2.6 Deadband
Cal mode 4 - Channel 5 (ref. Table 1) Range: 0 - 100
Default: 10 (Display shows 0010)
This setting sets a 'tolerance band' about the target rate. The control system
will only adjust when the calculated application rate is outside of this band.
The lower the factor, the more accurate the system will be in trying to achieve
the target. If you find that the system is constantly 'hunting' to meet the
target then you should increase the factor.

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2.2.7 Millimetres of belt per pulse
Cal mode 2 - Channel 4 (ref. Table 1) Range: 0.000 - 99.99
Default: 30.00 mm (Display shows 30.00)
This is the length the belt moves for every pulse from the belt drive encoder.
It will need to be calculated mathematically for each different type of
machine, and must take account of the overall gear reduction ratio between
the encoder shaft and the belt drive roller.
1. To enter cal mode 2, press and hold the button, power on and then
hold for 10 seconds.
2. Press the button to select channel 4.
3. Quickly PRESS and RELEASE the button to select the digit or decimal
point to change, or...
4. HOLD the button to change the digit and release when the required
digit is shown.
NOTE: It is possible to program a number greater than 99.99 (by moving the decimal
point) but if the factor required is greater than this suggested maximum we
would advise that the device used to provide the speed signal (encoder or
sensor) is relocated to provide a greater number of pulses. Having an
installation requiring a factor greater than 99.99 will not enable the control
system to work correctly.
2.2.8 Setting "Monitor only" mode
Cal mode 2 - Channel 4 (ref. Table 1) Range: 0 - 99.99
Default: 30.00 mm (Display shows 30.00)
1. To enter cal mode 2, press and hold the button, power on and then
hold for 10 seconds.
2. Press the button to select channel 4.
3. QUICKLY PRESS and RELEASE the button to select the digit or decimal
point to change, and...

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4. HOLD the button to cycle each digit to zero.
NOTE: When setting a value of 00.00 the instrument will revert to ‘monitor only’
mode. In the operating mode the instrument will not carry out proportional
PWM control and the side indicator will not be seen. Programming mode 4
will not be selectable, and only channel 2 will be available in mode 3.
2.2.9 Gate Width
Cal mode 2 - Channel 1 (ref. Table 1)
Default: 300 mm (Display shows 0300)
This is the width of the gate (in milli--metres) at the rear of the machine. It is
used along with other parameters in the software to calculate the theoretical
volumetric discharge.
1. To enter cal mode 2, press and hold the button, power on and then
hold for 10 seconds. On entry the instrument will automatically default to
channel 1 showing the current width programmed (default 0300).
2. QUICKLY PRESS and RELEASE the button to select the digit or
decimal point to change, or...
3. HOLD the button to change the digit and release when the required
number is shown.
2.2.10 Working Width
Cal mode 1 - Channel 2 (ref. Table 1)
Default: 4.000 m (Display shows 4.000)
As with the gate width setting the spread width setting is required along with
other parameters in the software to calculate the theoretical volumetric
discharge.
1. Select the channel.
2. Press and hold for 5 seconds to enter programming mode 1.

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3. QUICKLY PRESS and RELEASE the button to select the digit or
decimal point to change, and...
4. HOLD the button to cycle each digit to zero.
5. RELEASE both buttons and the instrument will then return to the normal
display mode.

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3Product Calibration
Ensuring that the system applies the correct quantity of product is a simple
matter of programming both the product density (kg/litre) and the
appropriate gate height (mm) for the desired application rate (referring to the
manufacturer’s calibration chart).
3.1 Setting up for a given product/application rate
Simply perform the following steps,
3.1.1 Set Density
Cal mode 3 - Channel 4 (ref. Table 1) Default: 1.000 kg /m3
1. Select Cal Mode 3 by pressing the
button and switching the instrument on
again (fig.6).
2. The instrument defaults to the UNITS
channel. Press to select the
channel.
3.Use the or button to adjust the
density figure.
NOTE: You can programme either
(i) a “corrected” density (section 3.3.4)
established previously or,
(II) the specified density for the product and a
separate nudge factor (section 3.3)
established previously.
Figure 6: Select CAL Mode 3
ON

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3.1.2 Set Gate Height
Cal mode 3 - Channel 5 (ref. Table 1)
Default: 100 mm (Display shows 100)
4. Press to select the channel.
5. Use the or button to adjust the gate height (10mm to 750mm
max.) for the desired application rate according to the manufacturer’s
calibration chart.
NOTE: In the case of (ii) above, press to select the channel and
programme the appropriate “Nudge Factor” (section 3.3), otherwise continue
to section 3.1.3.
3.1.3 Set Application rate (Target rate)
Cal mode 1 - Channel 4 (ref. Table 1)
Default: 100 kg/ha (Display shows 100.0)
6. Switch the instrument off then back on again. The instrument then defaults to
the target rate channel.
7. Use the or button to adjust the application rate.
8. Press and hold the button for 3 seconds to return to the normal
application rate display.
NOTE: The Target rate can subsequently be changed or nudged from the normal
operating mode (see sections 6.3 and 6.4 in the Operation manual).

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3.2 FAQ’s about Product Calibration
There is a small discrepancy in the amount applied.
Possible Cause: Variable factors such as field conditions, nature of
product etc.
Remedy: You can “nudge” the density figure (3.3).
There is a big discrepancy in the amount applied.
Possible Cause: The gate opening is altered.
The product is changed.
(Certain machines) The speed ratio between the shaft
onto which the encoder is fitted and the belt drive shaft
(e.g. according to the application rate you require) is
changed.
Programmed density or gate height is incorrect.
Remedy: Set correct gate height and/or density.
The instrument beeps continuously
The beeping indicates that the PWM control parameters have been
exceeded, and so the application rate set cannot be met. As a result the
actual quantity dispensed will be less than it should be.
Possible Cause: Gate opening incorrect.
Forward speed too high.
Remedy: Check the gate opening is correct according to the
manufacturer’s chart*.
Reduce forward speed.
*In the event custom gate settings need to be established, they can be noted
in the back of this manual for future reference.

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3.3 Nudging the Product calibration
If you find a consistent discrepancy between the instrument weight reading
and the actual weight dispensed, then either,
(i) leave the existing user-programmed density figure as it is and adjust the
calibration by setting a “Nudge Factor” (a % change to the programmed
density).
(ii) Calculate a “corrected” density factor using a simple formula (3.3.4) and re-
programme it.
The user-programmed density factor can be nudged up to ±50% in 1%
steps.
3.3.1 Under-application
If the weight displayed on the instrument is more than the actual weight
dispensed, the density factor must be decreased.
E.g. If the weight reading is 10% high, then set the nudge figure to “90”
(indicating the system is only applying 90% of what it should be). This value
will then nudge the current density factor to ensure that 10% more product
will be dispensed, which will then ensure the application rate is correct.
3.3.2 Over-application
If the weight displayed on the instrument is less than the actual weight
dispensed, the density factor must be increased.
E.g. If the weight reading is 15% low, then set the nudge figure to “115”
(indicating the system is applying 15% more than it should be). This value
will then nudge the current density factor to ensure that 15% less product will
be dispensed.

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3.3.3 Nudging the density
Cal mode 3 - Channel 6 (ref. Table 1)
Default: 100 (Display shows 100)
1. Switch the instrument off.
2. Select Cal Mode 3 by pressing the button and switching the
instrument on again. The instrument defaults to the channel.
3. Press the button to select the channel.
4. Press the or button to set the nudge factor.
5. Switch the instrument off then back on again to resume the normal operating
mode.
3.3.4 Re-calculating a Density Factor
A “corrected” density factor can also be determined by a simple calculation
using the actual weight and the displayed weight as follows :
Corrected density = Programmed density x Actual weight
Displayed weight
For example: The existing density set is 1.500. The displayed weight was
780 kg but the actual weight dispensed was 1000kg.
The density needs to be set as 1.500 x (1000/780) = 1.923
Refer to section 3.1.1 to re-programme the density.
NOTE: Each time the density is re-programmed, any existing “Nudge Factor” is
cancelled i.e. it returns to 100.

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4Other Calibration Settings
4.1 Hopper Setup
4.1.1 Level Sensor Configuration
Cal mode 2 - Channel 6 (ref. Table 1)
Default: "Sensor" (Display shows ‘SenS’)
Depending on the installation, level measurement is by one of two methods -
(i) A capacitive sensor is fitted in the side of the hopper to give a low level
signal. The setting should be set to "Sens". When this setting is made,
channel 2 in cal modes 1 and 2 ("Tank Alarm Volume" and "Max Tank
Volume") have no function.
(ii) There is no level sensor. The setting should be set to "tHEO". Volumetric
information will then be displayed on channel 6 in the normal operating
mode. This information and the level alarm is based on the application rate
and the area covered.
1. Select the channel.
2. Hold the button to enter programme mode 1. Continue holding the
button and…
3. PRESS to change the selection on the display between “SenS”
(sensor) and “tHEO” (theoretical).
4. Release both buttons when the desired option is shown. The instrument will
then return to the normal display mode.

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4.1.2 Alarm On-Off
Cal mode 1 - Channel 6 (ref. Table 1)
Default: "on” (Display shows “1”)
If in "SenS" mode (see above) the alarm function can be enabled/disabled.
Set to "0" to disable.
1. Select the channel.
2. Hold to enter programme mode 1. Continue holding the button
and…
3. PRESS to select 0(Off) / 1(On).
The display will stay blank on this channel when the alarm is disabled.
4. Release both buttons when the desired option is shown. The instrument will
then return to the normal display mode.
NOTE: If the "Hopper Max. Volume" setting (see next section) is zero, the alarm
function no longer applies as the Hopper Volume display will then count up in
the normal operating mode
4.1.3 Set Hopper Current Volume
Cal mode 1 - Channel 6 (ref. Table 1)
NOTE: This is also in the Operation manual section 8.3.3)
If the instrument is set in volumetric mode ("tHEO" - see under "Level Sensor
Configuration" ), then this channel is used to alter the current hopper volume.
(e.g. if starting a job with a part loaded hopper).
1. After selecting channel 6, press and hold the button for 5 seconds.
The calculated current volume will then flash on the display.
2. Release the button.
3. Adjust the volume using the or buttons.
4. Press the button again for 3 seconds to revert to the normal operating
display.

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4.1.4 Reset Hopper Current Volume to Maximum Volume
Cal mode 1 - Channel 6 (ref. Table 1)
1. Select the channel.
2. Press and hold the to reset the current figure to the maximum hopper
volume. The display will flash and the instrument will beep.
3. When the maximum is shown the button can be released.
4.1.5 Set Hopper Alarm Volume
Cal mode 1 - Channel 3 (ref. Table 1)
NOTE: This is also in the Operation manual section 8.3.3)
1. Select the channel, then press and hold the button for 5 seconds
The current alarm quantity appears (fig 8a). The factory default setting is
500kg (0500).
2. Continue holding the button.
3. PRESS and RELEASE the button to select the digit or decimal point to
change, or...
4. HOLD the button to change the digit or move the decimal point.
Remember, setting a decimal point sets the units as tonnes. If no decimal
point is set, the units are in kgs.
5. Release the button to return to the normal operating mode.
4.1.6 Set Maximum Tank Volume
Cal mode 2 - Channel 3 (ref. Table 1)
Default = 0000kg (Display shows 0000)
1. Switch the instrument off.
2. Select Cal Mode 2 by pressing the button and switching the
instrument on again. Hold for 10 seconds to access Mode 2.