Athena Technologies 16C Weather Radio User Manual
Contents
1. Soak Menu If a ramp soak error condition occurs the upper display will toggle between and the numeric error code for three seconds before the recipe terminates Possible error codes are 02 Recipe Empty i e no non zero ramp times 05 Insufficient Setpoint Process Value Deviation Power Fail Resume Setting this parameter to On will cause the control to resume a recipe which was active when a power failure occurred The recipe will resume at the start of the last active ramp or soak segment Ramp Soak Events 1 8 If alarms are configured as ramp soak events Ramp Soak events occur at the beginning of their designated segment All events are terminated once the recipe has been completed or terminated This can be used as an alarm when a segment is reached Display Parameter Selection Recipe Option Single Setpoint Ramp Multi Step Ramp Disabled Single Setpoint 1 9999 mins Ramp Time NOTE Only available when single setpoint ramp is selected Holdback Band Off 100 degrees Termination State Last Setpoint Default Setpoint Recipe to Standby 23 Recipe Ramp Soak Menu Sa For Ramp Events and Soak Events to be employed Alarm 1 or Alarm 2 must be set for event usage in the Alarm Menu Supervisor Menu The Failsafe State is only enforced when a problem is detected with the process input It is not reli ably enforceable in instances of internal circuit2. 4 Hold for Press until Press Controller is three Once now autotuning seconds appears 27 Manual Tuning Sa While some processes other than heat or cool applications may respond successfully to autotuning procedures the controller may need to be manually tuned for non temperature processes 28 Manual Tuning Procedure Zeigler Nichols PID Method This tuning method may be used for non temperature control processes or if the spread between ambient temperature and process operating temperature is small For best results the use of a recording device is required when tuning with this method 1 2 3 4 5 6 7 8 9 For temperature control processes disable any cooling device used With the power off and the controller NOT in the Key Lockout security level apply power and immediately put the controller in Standby mode by pressing the Mode Enter key for three seconds the Raise AX key until appears and press the Mode Enter key again If you have a direct acting output it must be disabled before proceeding further ag Under the Control menu make sure that the derivative term the offset term MAA and the integral term are all set to zero and the proportional band or is set to the maximum setting Adjust setpoint to the desired value with the Raise Lower keys Press the Mode Enter key for four seconds the Raise ZA key twice and the Mode Enter key again to
3. SERIES 16C ATHENN comu 2 Instruction Manual Basic Operations Introduction REPRE Precautions E Features Congratulations on your purchase of an Athena Series 16C Temperature Process Controller It is designed for ease of use and reliability wherever accurate control is required After following the instructions for installation simply step through and set your operating parameters using the controller s easy menu system The instrument may then be automatically or manually tuned to your process for optimum setpoint control A Quick Setup Reference Card is on page 5 and also attached as a tear off card to the back of the instruction manual for experienced users of PID controllers As you look through this manual you will notice blue italicized text appearing in the margins and adjacent to operating information These notes impart important informa tion about the controller and may answer questions you may have about its setup or operation If you still have questions or require any assistance please contact your Athena repre sentative or call technical support at 1 800 782 6776 Outside the USA please call 610 828 2490 After unpacking inspect the instrument for any physical damage that may have occurred in shipping Save all packing materials and report any damage to the carrier immediately Field Selectable Thermocouple RTD Current or Voltage Input On Off Through Full PID Operation Autotun
4. Normal Standby FOP or Tune From Menu System From Security Level Menu 2 To enter Standby operating mode From Normal operating mode From FOP Manual operating mode From Menu System From Security Level Menu 3 To escape from Standby operating mode 4 To initiate Autotuning 34 Action Press and hold for 3 sec Press Action Press and hold for 3 sec Press ZX Press Press and hold gt for 3 sec Press Press Press and hold gt for 3 sec Press and hold z for 3 sec Press A Press Press Press and hold EX for 3 sec Press ZX Press Action Press and hold for 3 sec Press A Press Action Enter Standby operating mode See Quick Help 2 Press Press NV Press Display m gt mI Dd 58 un Tr uc PV SV PV SV m un mieu D alt o d js tc md und mn Q 3 Uni m 5 Ro PV SV m m Pa mu a jmd 14 54 fs 79 m E um lt m m i Dd RJ i RE 5 4 md in E PV SV om oa xa 28 5 m MS gR hich PV SV Display o mm rc bal es x ps d rir I PV SV Quick Helps Es 5 To abort Autotuning and return to normal operation 6 To enter FOP Manual operating mode 7 To escape from FOP Manual operati
5. Obs Value at any time press and hold Menu Access key for three seconds Figure 10 Series C Functional Diagram Security Levels for 10 seconds once lt EJ for 3 seconds Process gt Mod f ode Variable System gt Display Selection lt EJ for 3 seconds once Menu System Overview Figure 11 Chart of Series 16C Menu System and Security Levels Continued on Next Page Notes 1 It is recommended you start with the input menu Menu 2 Parameter labels displayed will vary depending Access upon the controller s configuration Key Mode Enter Key O1 AG Figure 11 Chart of Series 16 Menu System and Security Levels Continued from Previous Page HB Mode Raise Enter Key Lower Key three seconds Functional When Option Card Installed p Win ES LM em gm See options manual for parameter selections Security Levels Key Lockout No Access D P Setpoint Setpoint Value or Output Percentage Manual Mode Setpoint plus Mode Plus a E 5 User Plus ea 8 Configuration H Plus Ei FS rg FACE Du Factory Plus Menus and Parameter D escriptions Input Display Output Control Alarm Tune Recipe Supervisor Calibration Option Communications Contact Digital Input Remote Analog Setpoint Auxiliary Output Menus a
6. setting a slower recovery but with minimum or no overshoot Single Setpoint Ramp Time This selection will cause the controller to ramp the process from the starting point current process value to the setpoint in the time specified This ramp will take place at startup when selected from the Ramp Soak menu The setpoint must be at least 0 2 of sensor span for the ramp to be employed Multi Step Ramp This selection will enable the programming of a recipe make all ramp soak recipe variables visible Recipes can be resumed on startup if interrupted by a power failure or initiated held and terminated from the front panel via the Mode Menu or with the logic input option initiate and held resumed only Holdback Band Specifies the maximum number of degrees above or below setpoint that the process can be for the segment timer to keep going The timer will hold while the process settles back into the band and then continue If this feature is not desired this param eter should be set to which will disable it Termination State This parameter determines what the control will do at the completion of a recipe Last Setpoint refers to the last temperature specified in the ramp soak recipe Default Setpoint refers to the standard setpoint which was in effect prior to recipe initiation Recycle Number Specifies the number of times after the first time that the recipe is run before the program terminates Recipe Ramp
7. AND MERCHANTABILITY IT IS UNDERSTOOD AND AGREED THE SELLER S LIABILITY WHETHER IN CONTRACT IN TORT UNDER ANY WARRANTY IN NEGLIGENCE OR OTHERWISE SHALL NOT EXCEED THE RETURN OF THE AMOUNT OF THE PURCHASE PRICE PAID BY THE PURCHASER AND UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES THE PRICE STATED FOR THE EQUIPMENT IS A CONSIDERATION IN LIMITING SELLER S LIABILITY NO ACTION REGARDLESS OF FORM ARISING OUT OF THE TRANSACTIONS OF THIS AGREEMENT MAY BE BROUGHT BY PURCHASER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED SELLER S MAXIMUM LIABILITY SHALL NOT EXCEED AND BUYER S REMEDY IS LIMITED TO EITHER i REPAIR OR REPLACEMENT OF THE DEFECTIVE PART OR PRODUCT OR AT SELLER S OPTION ii RETURN OF THE PRODUCT AND REFUND OF THE PURCHASE PRICE AND SUCH REMEDY SHALL BE BUYER S ENTIRE AND EXCLUSIVE REMEDY THE SPECIFICATIONS PUT FORTH IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE Warranty Repairs p Unit Repairs It is recommended that units requiring service be returned to an authorized service center Before a controller is returned for service please consult the service center nearest you In many cases the problem can be cleared up over the telephone When the unit needs to be returned the service center will ask for a detailed explanation of problems encountered and a Purchase Order to cover any charge This information should also be put in the box
8. ANT On initial startup there is a possibility that outputs may be activated We recommend placing the unit in Standby mode until you have configured the controller according to your application requirements To place the controller in Standby follow this procedure 1 Press and hold Mode Enter key until a menu label appears in upper display approximately three seconds 2 Press Raise A or Lower N7 key until appears in the lower display 3 Press Mode Enter key The upper display will alternate between and process value Operations Overview The user interface of the Series C allows you to use menus to set up the instrument set the desired security level change the setpoint and conveniently change operating modes Figure 9 on page 15 provides a functional representation of the user interface and the key presses necessary to perform the basic functions Security Levels rera The controller 5 initial security level set at the factory is Configuration iiis When you have completed configuring the instrument we recommend the security level be set to the most restrictive level suitable for your application The security level feature allows you to limit access to the menus setpoint and operating mode selection according to the needs of your application The security levels provided are Key Lockout Setpoint Setpoint plus Mode User Configuration and Factory To view or change security level from the Proces
9. ON OFF ALARM OR OFF 6 Press the key to display the next output parameter and select the desired value using the AX keys 7 Press to select other Output Type following steps 4 to 6 8 Press the lt repeatedly until is displayed then press and make sure autotune damping parameter is set to the proper setting for your application See page 37 for more information 9 Press and hold gt key for approximately 3 seconds until upper display flashes and Process Value 10 Press the AX or NY keys adjust setpoint to desired value 11 Press and hold key for seconds Lower display will indicate Press ZZ key until is displayed Press to initiate autotuning Display will flash After autotune is complete the display stops flashing and the controller will revert to Process Value display and begin controlling the process 12 If unacceptable overshoot occurs change damping setting to high or if response is sluggish change damping setting to low MEI y ATHENA Please keep this information handy in case your controller should lose its configured initial parameter Keep This Information in a Safe Place Configured Parameters Reference Data Series C Temperature Controllers Model Number Zone Location Firmware Version No Displayed when the controller is powered up after all the segments on both lines of the display have been tested Dear Customer values
10. Type Display Parameter Bias Display offset Low Scale High Scale Lower Setpoint Limit Upper Setpoint Limit Filtering T 3 A E Ge ms Me Bm jm Ru m Hm m e et x Selection 100 to 100 Span of Sensor Span of Sensor 0 1 10 0 sec Selection 100 to 100 1999 to 9999 1999 to 9999 Span of Sensor Span of Sensor 0 1 10 0 sec Display Menu 21 Output Menu Ea Q m ma rc z c Display Parameter Selection Decimal Position 0 3 Linear Inputs 0 1 TC RTD Filter 0 1 10 0 sec Units Fahrenheit Celsius Kelvin NOTE Does not appear for linear inputs Blanking Wilda 0 9999 sec Time selected before setpoint diplay turns off The first parameter that needs to be set in the Output Menu is the Output Type There are three possible Output Type configurations PID On Off Alarm or Off If you are not sure which Output Type is best for your particular application refer to the Glossary for an explanation of Output Types The remaining menu parameters in the Output Menu will change depending on the Output Type selected The Control Menu will also change depending on the Output Type selected If you ordered two outputs you can select two different Output Types After setting your Output Type refer to the correspond ing sections below for the remaining Output Menu parameters For simplification purposes the
11. Vdc 53 5 Vdc Auxiliary Output 60 410 20 61 1to5V 62 0 to 20 mA 63 0to5V EP Engel Arburg Communications Protocol Recalibration Procedures ger The Series C controller is precalibrated at the factory Under normal circumstances the factory calibration should be valid for the life of the instrument If recalibration should be required allow the controller to warm up Jor 15 minutes and follow these steps carefully a E gt im P o LES 1 Remove power from the controller and disconnect all output devices Disconnect input Attach an appropriate calibrator to the input terminals 2 Apply power to the calibrator making sure that the dis played value is not outside the range of the controller Then apply power to the controller 3 Index to the Calibration Low menu item in the Calibration Menu You must have Security Level set to Factory to access this menu 4 Dial Calibrator to prompted value on the controller s dis play See chart below for RTD resistance vs temperature values 5 Allow the controller to settle for at least one minute 6 Press Raise ZX Key 7 Repeat Steps 4 5 and 6 for the Calibration High setting 8 Press the Menu Access key for three seconds to return to the Process Value display RTD Calibration Values 33 Quick Helps 5 1 To return the unit to last operating mode
12. alibration operation is triggered by pressing the up arrow key Display Parameter Selection E installed Card Serial Communications Serial Communications with Switch Input Remote Analog Setpoint Auxiliary Output Alarm PIRJA Switch Input with Alarm Note See options manual for parameter selections 25 Autotuning a In order for the controller to autotune properly the setpoint value must be at least 1 of span above or below the initial process value Make sure that the Setpoint Target Time parameter is set to OFF Tuning accuracy increas es as the spread between ambient and setpoint value increases Tuning should be performed with system in equilibrium no latent energy remaining 26 To place the controller in Autotune mode 1 2 3 4 3 Configure the controller by following the directions for Initial Setup Sequence through Step 3 on page 7 Set damping parameter See page 22 If the controller is not already in Standby mode place it in Standby now as follows Press and hold the Mode Enter key for three seconds Display will indicate your current operating mode Press the Raise A key Lower N7 key to select Standby Press Mode key again and the display will alternate between and the pro cess value This will deactivate all outputs If Setpoint Value has not been entered adjust setpoint now by using the Raise or Lower key to set the desired setpoint Wait for pr
13. an of sensor Notes Alarms Deviation Inverse Band and Normal Band Alarms track with setpoint When a latching alarm has been activated and the alarm condition has been removed the Mode Enter key must be pressed to unlatch the alarm 20 Outputs can be set up as an alarm similar to the standard alarm format Four types of alarms are available Process Deviation Inverse Band and Normal Band All alarms may be configured to be inhibited on power up for a configurable time duration Process Alarm Deviation Alarm Inverse Band Alarm Normal Band Alarm Activates at preset value independent of setpoint High process alarm activates at and above alarm setting Low process alarm activates at and below alarm setting Activates at a preset deviation value from setpoint High or Low deviation alarm activates above or below setpoint according to the preset deviation value Activates when the process is within a specified band centered around the setpoint Activates when the process exceeds a specified band centered around the setpoint Latching Alarms The Series C s alarms may also be configured as latching alarms by the Alarm Action parameter selection Output Menu m t E mn XT 01 OFF 01 80 Note The Control Menu does not apply to an Alarm Output Type therefore the Control Menu does not appea
14. d on the side of the controller matches what was ordered Figure 1 Recommended Panel Layout for Multiple Controllers I 2 850 72 4 mm EN n 2 150 54 6 mm Dimensions c Mounting ay When properly installed through a NEMA enclosure the integrity of the enclosure will be maintained and will remain Watertight Figure 2 Case Dimensions 4 654 118 21mm 3 937 2 100 gt 53 3mm 0 gt 8 21 mm 100 mm gi pv B Hi L SS UE 53 3mm 420 sv 445 mm F2 ry B V bi Prior to mounting the Series C in your panel make sure that the cutout opening is of the right size 1 771 x 1 771 45 mm x 45 mm and deburred to enable a smooth fit A mini mum of 4 100 mm of depth behind the panel is required Figure 3 Series C Mechanical Components Insert the Series C through the front panel cutout and slide the mounting collar back onto the unit from behind the panel Push the mounting collar up tight to the back of the mounting panel Bezel Case Clip D CCo PRI aaa ip Grips ip p 0 Gasket Customer Panel Wiring IMPORTANT All electrical wiring connections should be made only by trained personnel and in strict accorda
15. e thermocouple and extension wire Connect the negative lead generally colored red in ISA type thermocouples to contact 9 connect the positive lead to contact 10 Extension wires must be the same polarity as the thermo couple Figure 6 RTD Wiring The Series C accepts input from 2 or 3 wire 100 ohm platinum ESH BIDS C 7 d S Connect 2 wire S 0 RTD to contacts 9 and 10 with a jumper across contacts 8 and hd ES TE 10 Keep leads short and use heavy gauge copper extension wire if necessary to minimize lead resistance For long runs 3 wire RTDs should be used Note For 2 Wire RTD Jumper 8 amp 10 Figure 7 Process and Linear Input Wiring Voltage Inputs Connect the positive voltage input to contact 10 the negative input to contact 9 Current Inputs Connect the positive current input to contact 10 the negative input to contact 9 e CURRENT and VOLTAGE The Series C power supply accepts 100 to 250 Vac and 100 to 250 Vdc line power without any switch settings or polarity considerations All connections should be made in accordance with the National Electrical Code and local regulations using only NEC Class 1 wiring for all power terminals It is advisable but not necessary to fuse one leg of the incoming power line contact 11 with a 2AG 0 5 amp rated fuse f is recommended that instru
16. ely prior to reapplying power Glossary Alarm Delay the time delay between the detection of the alarm condi tion and the initiation and indication of the output action Alarm Inhibit prevents low setpoint alarm activation during cold startup applications Bias allows the operator to compensate for any difference between sensor temperature and the point to be measured The process display and set point will be offset by the value entered in the Bias parameter in the input menu Ex Desired temperature is 150 degrees Sensor is adjacent to heater and reads 50 degrees higher than the actual process temperature Enter bias of 50 Enter setpoint of 150 Process will display 150 even though sensor will be measuring 200 degrees Blanking controls the time the setpoint value display remains on After the set time the setpoint value display turns off Pressing any button causes the setpoint value display to reappear for the selected time interval Cycle Time The period of time in which the controller s output completes an on off cycle Proportional Output Type only Example Output type Mechanical relay Cycle time 10 seconds Output power 50 Controller output 5 seconds closed 5 seconds open Deadband In On Off temperature control it is the band above or below the setpoint where there is no output action It has the effect of moving the apparent setpoint Derivative rate Adjusts the controller gain quickly in response
17. f both outputs are set oido TH the Series C will func tion as a non control ling indicator Control outputs will be disabled and the Operating Modes will not be displayed Operating Modes TT Manual operating mode overrides auto matic control allowing you to control the outputs using a fixed percentage of output power regardless of the process variable or setpoint If current automatic control is PID transfer to Manual mode is bumpless The Series C s operating modes are Manual Standby Normal Autotune Ramp Soak Recipe Run and Hold To select a different operating mode press th The operating mode that played To index through Raise AX or Lower NV e Mode Enter key for three seconds the controller is currently in will be dis the available operating modes press the keys When the desired mode is displayed press the Mode Enter key once to select the mode p Manual Standby Normal Autotune Only available when unit is placed in Standby mode and one output is PID Start Ramp Soak Recipe Only when programmed Run Only available when recipe is active Hold Only available when recipe is active Manual Standby Normal Autotune Ramp Soak Recipe Run Hold Used to set control output percentage Fixed Output Percentage independent of Process Value To set percentage use the Menu Access gt key to select and the Raise or Lower key
18. following sections assume the same Output Type for both outputs If you selected different Output Types refer to both of those sections Output Type Display Parameter Output 1 Type Q m RI c rA BE E i EN e 3 Output 2 Type Q RJ c3 m m Output Menu P Output Type m Control Menu a EJ EZE Vv Setting Derivative Rate or Integral Reset o disables that aspect of PID control If BOTH outputs are set to direct acting or BOTH outputs are set to reverse acting then only one proportional band selection will be displayed 18 Output 1 Action Reverse acting Heating Direct acting Cooling Output 1 Cycle Time 0 2 1 to 120 seconds DINNER Output 1 Low Limit 1 100 Output 1 High Limit 1 100 Output 2 Action Reverse acting Heating Direct acting Cooling Output 2 Cycle Time 0 2 1 to 120 seconds Output 2 Low Limit 1 100 Output 2 High Limit 1 100 Recommended Cycle Time Settings Output Type Recommended Setting seconds B 5 15 to 120 E 0 20 mA 0 2 F 4 20 mA MUST be set to 0 2 G 4 20 mA MUST be set 0 2 S pulsed 20 Vdc 0 2 S S relay 15 to 120 Y 5A 3A 15 to 120 Output 2 only T outputs directly driving non inductive loads small heaters can have cycle times as low as 0 2 seconds PID Output Type As with the Out
19. iation or Band Alarms 1 to Span of Sensor 0 to 9600 Seconds 0 to 2400 Seconds 200 ms 1 to 120 sec 1 to Span of Sensor Operator Initiated from Front Panel Operator Initiated from Front Panel Dual 4 digit 0 36 9 2 mm LED display Process Value Orange Setpoint Value Menu Green 1999 to 9999 1 771 x 1 771 45 mm x 45 mm 3 937 100 mm NEMA 4X 32 to 140 F 0 to 60 C 90 R H max non condensing Solid state non volatile memory Input and output via barrier strip with locking terminals Twin bifurcated Technical Specifications CE Input Type Thermocouple RTD Linear Output Device B Alarm Type B C E J K N NIC NNM R S T Platinel 11 Maximum lead resistance 100 ohms for rated accuracy Platinum 2 and 3 wire 100 ohms at 0 C DIN curve standard 0 00385 1000 ohms available 0 50 mV 10 50 mV 0 5 V 1 5 V 0 20 mA 4 20 mA 0 100 mV 0 10 V 5 A 120 240 Vac relay normally open used for switching resistive loads 11 relays or solenoids are to be driven select the T output If a B output is selected order snubber network 23527005001 0 20 mA 4 20 mA full output to load with 500 ohm impedance max High impedance F 800 ohms max 20 Vdc pulsed output for solid state relays 1 A 120 240 Vac solid state relay zero voltage switched and optically isolated from drive signal Only resistive loads to 1A may be controlled directly Larger l
20. ing Heat or Cool Eight Segment Ramp Soak On Off Output with Adjustable Hysteresis and Deadband Dual Output Capability Field Configurable Process or Deviation Alarms Bumpless Auto Manual Transfer NEMA 4X Front Panel Watertight Dual 4 Digit 0 36 7 Segment Alphanumeric Display Selectable Ramp to Setpoint Alarm Inhibit Loop Break Alarm Capability Available Options Include Serial Communications Contact Digital Input Remote Analog Setpoint Transducer Excitation aliar Output Dual Alarms or Electromechanical Relay arm Approvals UL cUL CE Copyright 2004 Athena Controls Inc Safety Warning ae ZN zx In addition to presenting a potential fire hazard high voltage and high temperature can damage equipment and cause severe injury or death When installing or using this instrument follow all instructions carefully and use a safety controls Electrical connections and wiring snould be performed only by suitably trained personnel Do not locate this instrument where it is subject to excessive shock vibration dirt moisture oil or other iquids The safe operating temperature range for this unit is 32 F to 140 F 0 to 60 C This unit has been tested and found to be compliant with NEMA Type 4X Enclosure For Indoor Use Only When propery etalon this controller will maintain the integrity of a NEMA enclosure and remain Watertight This rating is only applicable when the controller i
21. ls of operation and most importantly for safety precautions If you have any questions or experience problems with setting up your controller consult the full instruction manual first and if you still need assistance contact your Athena representative or call 1 800 782 6776 A Lower Mode Enter 1 Apply power After self check display stops place controller in Standby mode by pressing and holding the Mode Enter key for 3 seconds the A or 5 key until appears and then the key again will flash alternating with the Process Value 2 Press and hold the Menu Access lt key for 3 seconds until is displayed Press key once until appears then use v or N keys to select sensor input type 3 Press lt to display Then press once to display MEEI Use A Y to select 4 Press the key until Output 1 Action is displayed Select the desired output action using the or Y keys Reverse Heating 5 Press again to display the Output 1 Cycle Time parameter Select the desired cycle time according to the output device used If unsure refer to the ordering code on page 52 of the instruction manual and compare it to the number on the label Recommended cycle times are For Control Output Device Select Cycle Time in seconds B 15 to 120 0 2 0 2 0 2 5 0 2 T 15 to 120 15 to 120 IMPORTANT IF ONLY ONE OUTPUT IS P D SET THE OTHER OUTPUT TO EITHER
22. ment power and load power be fused independently Figure 8 Power Wiring Connection 100 250 V 50 60 Hz 100 250 Auto Polarity L1 L2 Output Types e J The Type B output is a mechanical device and subject to wear To extend the life of the relay set the Cycle Time for the relay output to the longest duration that still affords good control When you ordered your Series C controller specific output types were specified designated as E G S or Y You also had the option of configuring your con troller with either one or two output actions The numbers below are suggested for most typical applications For Control Output Type Select Cycle Time in seconds gt 15 0 2 0 2 0 2 0 2 15 gt 15 lt mr T outputs directly driving non inductive loads small heaters have cycle times as low as 0 2 seconds Output Type B Description 5 A 120 240 Vac relay normally open used for switching resistive loads If relays or sole noids are to be driven select the T output If a B output is selected order snubber network 2352005001 0 20 4 20 output to load with 500 ohm impedance max suppressed High impedance F 800 ohms 20 Vdc pulsed output for solid state relays 1A 120 240 Vac solid state relay zero volt age switched and optically isolated from dri
23. nce with the National Electrical Code and local regulations The Series C controller has built in circuitry to reduce the effects of electrical noise RFI from various sources However power and signal wires should always be kept separate We recommend separating connecting wires into bundles power signal alarms and outputs These bundles should then be routed through individual conduits Shielded sensor cables should always be terminated at one end only If additional attenuation is required noise suppression devices such as an R C snubber at the external noise source may be used If you wish you may order this suppressor directly from Athena part number 235Z005U01 gt gt Figure 4 Contact Identification ALARM amp COMM NO COM 1 RCV XMT RS 232 B A RS 485 T OUTPUT 1 13 14 N C EJ 12 OUTPUT 2 C T 1 L1 L2 100 250 V 50 60 Hz 100 250 Vdc Auto Polarity 24 Auto Polarity END COM iL ALARM A amp COMM RTD SENSOR INPUT Wiring pomum GE Thermocouple circuit resistance should not exceed 100 ohms for rated accuracy errors will occur at higher resistance values If shielded thermo couple wire is used terminate the shield only at one end Wiring ZN Figure 5 Thermocouple Input Wiring Make sure that you are using the appropriat
24. nd Parameters Used to select sensor related parameters such as input type limits and scaling Used to set or change decimal position and display units Used to specify output usage control methods and alarms Used to select parameters associated with the control methods Used to select alarm parameters Note This menu is also functional for controllers not eguipped with alarm hardware however alarm indication will be only visual via the A1 and A2 LEDs on the front panel Used to set the autotune damping parameter Used to set ramp and soak parameters Used to set fail safe and supervisory parameters Used to recalibrate input Used to select installed option Option Used to set serial communications parameters Option Used to select switch input functions Option Used to enter remote analog setpoint parameters Option Used to set auxiliary output parameters Input Menu NOTE FOR A MORE DETAILED DESCRIPTION OF MENU PARAMETERS REFER TO THE GLOSSARY RAO WHICH BEGINS ON PAGE 64 ve The first parameter that needs to be set is Input Type The remaining YPE Input Menu parameters will change depending upon whether a linear input type or a temperature input type is selected Other menu param eters related to the sensor range may also change After selecting your Input Type refer to the corresponding section on page 16 for the remainder of the Input Menu parameters Input Me
25. ng mode Action Display Press and hold stars for 3 sec Press NV feck Press PV SV Action Display Press and hold 8 for 3 sec Press ETE PV of Power Value Press A Y to set new of Power Value Press 4 to PV set of Power of Power for Output 2 Value if desired Action Display Press and hold for 3 sec Press ZX Press PV SV 35 Warranty Repairs egy 36 Two Year Limited Warranty THIS EQUIPMENT IS WARRANTED TO BE FREE FROM DEFECTS OF MATERIAL AND WORKMANSHIP IT IS SOLD SUBJECT TO OUR MUTUAL AGREEMENT THAT THE LIABILITY OF ATHENA CONTROLS INCORPORATED IS TO REPLACE OR REPAIR THIS EQUIPMENT AT ITS FACTORY PROVIDED THAT IS RETURNED WITH TRANSPORTATION PREPAID WITHIN TWO 2 YEARS OF ITS PURCHASE THE PURCHASER AGREES THAT ATHENA CONTROLS INCORPORATED ASSUMES NO LIABILITY UNDER ANY CIRCUMSTANCES FOR CONSEQUENTIAL DAMAGES RESULTING FROM ITS USE OR FROM IMPROPER HANDLING OR PACKAGING OF SHIPMENTS RETURNED TO THE FACTORY COMPONENTS WHICH WEAR OR WHICH ARE DAMAGED BY MISUSE ARE NOT WARRANTED THESE INCLUDE CONTACT POINTS FUSES ELECTROMECHANICAL RELAYS AND TRIACS UNITS WHICH HAVE BEEN MODIFIED BY A CUSTOMER IN ANY WAY ARE NOT WARRANTED Other than those expressly stated herein THERE ARE NO OTHER WARRANTIES OF ANY KIND EXPRESS OR IMPLIED AND SPECIFICALLY EXCLUDED BUT NOT BY WAY OF LIMITATION ARE THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE
26. ng the Raise or Lower arrow keys Lower Setpoint Limit prohibits users from adjusting the setpoint lower than the selected value Manual Reset an adjustment that moves the Proportional Band up or down by a fixed percentage so that more or less power is applied at set point It is used to eliminate offset error On Off Output Type In a heating application the controller applies 100 output power if the process temperature is below the setpoint and 096 at the setpoint For a cooling application the controller applies 10096 output power if the process temperature is above the setpoint and 0 output power at the setpoint There are only two output states fully on and fully off Applications for On Off Control 1 When temperature oscillation is acceptable 2 When constant cycling of mechanical devices is prohibited Compressors Blowers etc 3 Under powered processes Output Low Limit 96 Prohibits the controller s output from going below the specified percentage Output High Limit Prohibits the controller s output from going above the specified percentage PID Output Type Proportional Integral Derivative The controller modulates output power by adjusting the output power percentage within a proportional band Power is proportionally reduced as the process temperature gets closer to the setpoint temperature PID control helps reduce overshoot on start up enhances stability and compensates for process lag The PID parame
27. nu Display Parameter Selection Input Type Type J thermocouple HE B thermocouple Type C thermocouple Type E thermocouple Type K thermocouple Type N thermocouple Type NIC thermocouple Type NNM thermocouple Type R thermocouple Type S thermocouple Type T thermocouple Platinel Il thermocouple 100 ohm platinum RTD Input Menu a ees Input Menu continued Display Parameter Selection Input Type 100 ohm compressed RTD 0 20 mA 4 20 mA 0 10 mV 0 50 mV 0 100 mV 99 10 50 mv EAI o i V 0 5 V 0 10 V Input Jumper Settings a with c J JMPO1 JMPO2 Thermocouple Out Out RTD Out Out Voltage 100 mV Voltage 2100 mV Current Process 1 5 V Out In In Out Out In Note When you ordered your controller an input type was specified and the controller was set up accordingly and calibrated for that input type at the factory If you decide to change input type from thermocouple to RTD or vice versa you will need to recalibrate the controller unless you ordered the Calibrate All option Refer to page 56 for information on recalibration If you are changing from a temperature input type to a linear input type you MUST recalibrate and change the jumper settings as indicated in the above table Input Menu es Temperature Input Type Display Parameter Bias Display offset Lower Setpoint Limit Upper Setpoint Limit Filtering lt 8 lt Linear Input
28. oads may be controlled using an external contactor 5 A 120 240 Vac relay but normally closed output 2 only See ordering code on page 55 31 Ordering Codes e Input Calibration Type 16 Standard Options Special Options Code Input Type Code Output 1 32 CT Thermocouple 0 None CR RID B Relay N 0 cs Compressed RTD E 0to20mA CM Millivolt Linear F 4to20mA Volt Linear G High Current Linear Impedance F CA All P 20VdcG935mA CB TD amp T C S Pulsed 20 Vdc T X 0 10 4 Solid State Relay Code Output 2 0 None B Relay 0 E 0to20mA F 41020 High Impedance F P 20Vdc 935 mA S Pulsed 20 Vdc T Solid State Relay Y Relay Code Option Code Option 00 None AB Back Cover Alarms Screw Mount 10 Dual SSR 0 AD No Name Overlay 20 Dual Open Standard Athena Collector Patterns and Colors 2 77 Dual 24vde AZ 24 VaciVdec Supply 22 Dual SSR N C EO SPI Communications 23 Relay N O Protocol Communications 30 RS 232 Athena RS 485 Athena with Contact Digital Input 31 No Switch 36 Switch Close 37 Switch Open 38 5V Input Contact Digital Input with Alarm 40 Switch Closed 41 Switch Open 42 5 V Input RS 485 Modbus with Contact Digital Input 45 No Switch 46 Switch Close 47 Switch Open 48 5V Input Transducer Excitation 50 10 Vdc 51 12 Vdc 52 15
29. ocess to stabilize before proceeding e g in the case of a heating and cooling process return to ambient temperature Initiate Autotuning Press and hold the Mode Enter key again for three seconds then press the Raise or Lower key repeatedly until appears Finally press the Mode Enter key again The display will alternately indicate and process value as the controller learns the proper proportional band derivative and integral values for the process If unacceptable overshoot occurs on restart shut down the process and increase the damping setting If sluggish response is observed shut down the process and decrease the damping setting Autotuning ee If a tune error condition occurs the upper display will toggle between and a numeric error code for three seconds before the tune process terminates The controller will then automatically go into Standby mode when a tuning error occurs Possible error codes are 02 No PID Device Configured 03 Incorrect Output Action 05 Insufficient Setpoint Process Value Deviation 08 Invalid Tune Results 09 Tune Timeout Autotuning Procedure Diagram Note Keep in mind that the setpoint value must be at least 196 of span above or below the initial setpoint and that the process value must be stable prior to initiating the tune Current Standby S bY Mode Mode Flashes 64 3 Hold for Press Press three Once seconds Standby Autotune Mode Mode Flashes
30. omatically go into Standby mode when a tuning error occurs Possible error codes are 02 No PID Device Configured 03 Incorrect Output Action 05 Insufficient Setpoint Process Value Deviation 08 Invalid Tune Results 09 Tune Timeout Ramp Soak Errors Possible error codes are 02 Recipe Empty i e no non zero ramp times 05 Insufficient Setpoint Process Value Deviation 29 Technical Specifications m Operating Limits 30 Ambient Temperature Relative Humidity Tolerance Power Power Consumption Performance Accuracy Setpoint Resolution Repeatability Temperature Stability TC Cold End Tracking Noise Rejection Process Sampling Control Characteristics Setpoint Limits Alarms Proportional Band Integral Derivative Cycle Time Control Hysteresis Autotune Manual Control Mechanical Characteristics Display Numeric Range Front Panel Cutout Depth Behind Panel Front Panel Rating Operating Temperature Humidity Conditions Parameter Retention Connections Contacts 32 F to 140 F 0 C to 60 C 90 Non Condensing 100 to 250 V 50 60 Hz Single Phase 100 to 250 Vdc 24 Vac dc Less than 6 VA 0 20 of Full Scale 0 10 Typical 1 Digit 1 Count 0 1 Count 1 Count 5 uV C Maximum 0 05 C C Ambient gt 100 dB Common Mode gt 70 dB Series Mode 10 Hz 100 ms Automatically Adjust to Selected TC RTD Adjustable for High Low Selectable Process Dev
31. or for easy reference when setting up a new controller After auto tuning and when your controller is controlling well we suggest you write the displayed value for each of the menu parameters listed below If you do not use a listed param eter indicate N A Using this information to document your parameter settings could reduce your downtime If you have any questions or need further assistance please contact Athena Controls Technical Toll free in USA 800 782 6776 Support Telephone 610 828 2490 Fax 610 828 7084 E Mail techsupport athenacontrols com Website athenacontrols com Configured Parameters Reference Data Series C Temperature Controllers m alin es mie L f mu LILIT Tao JL zl IL Notes 43 For Toll FreeTechnical Assistance the USA Call Toll Free 1 800 782 6776 ATHENA Athena Controls Inc 5145 Campus Drive Plymouth Meeting PA 19462 U S A Tel 610 828 2490 Fax 610 828 7084 Toll Free in U S 1 800 782 6776 Internet www athenacontrols com 900M011U00 REVISION 09 13 2004
32. put Menu the Control Menu will change depending upon the Output Type selected Note These parameters are auto matically set during the autotune procedure We do not recommend altering the value of these control parameters unless your process requires manual tuning Display Parameter Selection Proportional Band 1 1 t0 span of sensor Phe Proportional Band 2 1 to span of sensor ita Derivative Action Rate 0 to 2400 seconds Manual Reset OFF 100 to 100 NOTE The Integral Action Auto Reset parameter appears only if OFF is selected in the Manual Reset parameter TM Integral Action Auto Reset 0 to 9600 seconds Output Menu m gt n Id a lt 00 Control Menu gt r I On Off Output Type Display Parameter Output 1 Action Output 2 Action On Off Output Type Selection Reverse acting Heating Direct acting Cooling Reverse acting Heating Direct acting Cooling dir If both outputs are set to the Output Type Menu the controller will function as a non controlling indicator Control outputs will be disabled and the Operating Modes will not be displayed Display Parameter Deadband 1 Hysteresis Output 1 Deadband 2 bee Hysteresis Output 2 Selection Negative span of sensor to positive span of sensor 1 to span of sensor Negative span of sensor to positive span of sensor 1 to sp
33. r Alarms A1 amp A2 can be set up using this same information nenu G2dt Ugi H G25P Alarm Output Type Display Parameter Output 1 Alarm Action Output 1 Alarm Operation Output 1 Alarm Delay Output 1 Alarm Inhibit Output 1 Alarm Setpoint Output 2 Alarm Action Output 2 Alarm Operation Output 2 Alarm Delay Output 2 Alarm Inhibit Output 2 Alarm Setpoint Selection BIET Latching Normal Process Low El Process High Inverse Band Normal Band Deviation Low IIS Deviation High 0 9999 sec Latching Normal Process Low Process High Inverse Band H Normal Band Deviation Low Deviation High 0 9999 sec 0 9999 sec Span of Sensor 29 SS Alarm Delay the time delay between the detection of the alarm condition and the initiation and indication of the output action Alarm Inhibit prevents low setpoint alarm activation during cold startup applications 21 Autotune Damping Menu or m m 2 lt Recipe Ramp Soak Menu mana BEER Display Parameter Selection Damping Low Normal High Note The damping parameter specifies how aggressively the controller performs its autotuning The Normal setting is a compromise between the fast recovery and overshoot The Low setting provides faster recovery but with the possibil ity of overshoot the High
34. return the controller to normal operation While monitoring the recording device decrease the proportional band value by repeatedly halving the value until a small sustained temperature oscillation is observed Measure the period of one cycle of oscillation on the diagram below IR T Divide the period of oscillation T by eight The resulting number is the correct Derivative time in seconds Multiply this number by four This is the correct Integral time in seconds Multiply the bandwidth value obtained in Step 7 by 1 66 and enter this as the new proportional band value Error Codes Ss Ifan error code cannot be cleared by using the actions provided contact factory us n un Plus other 2 Digit Code Autotune Errors Problem Open Sensor Reversed Sensor Loop Break Checksum Error RAM Error Defaults Loaded EEPROM Write Failure Power Fail Resume Feature Disabled Unexpected or Invalid Interrupt Actions Check sensor wiring and Input Check the type selection in the Input menu and check sensor polarity Correct problem and reset controller Press any key to perform a soft reset and reinitialize controller No further resume actions available Reset controllers If a tune error condition occurs the upper display will toggle between and a numeric error code for three seconds before the tune process terminates The controller will then aut
35. ry failure such as EEPROM problems Output 6 High Limits are ignored when the unit enters a Failsafe State NOTE The following seven parameters are only available when multi step ramp is selected Display Parameter Recycle Number Recipe Executions Power Fail Resume Ramp Times 1 8 Ramp Events 1 8 Soak Levels 1 8 Soak Times 1 8 Ef Soak Events 1 8 Ed m Display Parameter EHE Output 1 Failsafe State Output 2 Failsafe State Loop Break Time Highest Reading Lowest Reading Load Default Parameters m a m ui cir 14 2 Selection 0 99 Off On 0 9999 mins Alarm 1 On Alarm 1 Off Alarm 2 On Alarm 2 Off Disabled Display Units FS 0 9999 mins Alarm 1 On Alarm 1 Off Alarm 2 On Alarm 2 Off Disabled Selection 0 to 10096 of output 0 to 100 of output Off 4 9600 sec n a Choosing Yes to Load Default Parameters resets all menu parameters to factory settings Calibration Menu H ES E r o Options Menu co o 3 rn mu a REDE A Toggles with the temperature value that should be input to perform the low calibration operation The low calibration operation is triggered by pressing the up arrow key Toggles with the temperature value that should be input to perform the high calibration operation The high c
36. s to set the value is displayed if Output 1 is a control output is displayed if Output 2 is a control output Used to disable control outputs Normal automatic control Used to initiate the autotuning sequence from Standby only Used to start ramp soak recipe mode Used to enable Run function Used to enable Hold function Menu System Overview pul If a key press is not sensed within five minutes the control ler automatically exits the Menu System and reverts to the Process Value display The Parameter Menu System is organized into ten basic menus Input Display Output Control Alarm Tune Recipe Supervisor Calibration and Option To access the Menus press and hold the Menu Access lt key for approxi mately 3 seconds until a menu label appears in the upper dis play There are additional menus presented when an option is selected under the Option menu however the options are non functional unless the appropriate option board has been installed Pressing the Menu Access lt lt key indexes from menu to menu Pressing the Mode Enter key indexes through the parameters in a particular menu The Raise and Lower A Y keys are used to modify the visible menu parameter Each menu contains a logical group of parameters related to one another Furthermore the sequence of the menus has been carefully chosen to put the most important setup menus first a 3 D 5 A un S on BV E S og
37. s Variable display press and hold the Menu Access 2 key for approximately 10 seconds Ignore the menu label that will appear in the upper display after approximately three seconds The controller will display Access Level and the current security level label e g EISE Use the Raise AX or Lower YY keys to index through the security levels Press the Mode Enter key once to select the new security level desired and return to the Process Value display Security Levels and Access Restrictions Key Lockout Highest security level No access to any controller functions To escape follow instructions above for changing security levels Setpoint access to menus Only allows setpoint value or output percentage manual mode to be changed Setpoint plus Mode No access to menus Only allows setpoint value output percentage manual mode or operating mode to be changed User All Setpoint level privileges as well as access to Operating Mode Autotune and Control menus Configuration All User level privileges as well as Input Output Display and Supervisor menus Factory All Configuration level privileges as well as access to Calibration menu on gt oo JMPOS m 9 NOTE Removing this jumper on the microcontroller board disables the keypad thus preventing any operator access Operating Modes Remember to press the Mode Enter key after making your selection I
38. s properly installed into a suitably rated NEMA Type 4X housing M lt Table of Contents fo For information and operating instructions related to installed options and digital communications refer to the Series C Options and Digital Communications manual supplied with your controller Installation Dimensions and Mounting Wiring Output Types Operation Front Panel Controls Power On Security Levels Operating Modes Menu System Overview Initial Setup Sequence Parameter Menu Descriptions Input Menu Temperature Input Process Linear Input Display Menu Output Menu PID Output and Control Menus On Off Output and Control Menus Alarm Outputs Autotune Damping Ramp and Soak Menu Supervisor Menu Calibration Menu Options Menu AutoTuning Manual Tuning Error Codes Technical Specifications Ordering Codes Recalibration Procedures Quick Helps Warranty Repairs Glossary ON ODO TW N gt Q0 a a a aa af fa 2 A 1 1 HM co Installation centerlines of panel cut outs are the minimum recommended Unpacking and Inspection 1 Inspect shipping carton for obvious signs of mishandling 2 After removing the controller from the shipping carton inspect it carefully for damage Never attempt to install and use a damaged unit 3 Verify that the ordering code number indicate
39. ters are automatically calculated for a par ticular application during the autotune procedure Applications for PID Control 1 Where process temperature lags exist 2 When load changes are present 3 When overshoot is prohibited 4 When very accurate control is required Proportional Band the band expressed in degrees of temperature in which the controller modulates its power percentage Temperature Lag The product of thermal resistance and thermal capac ity Also defined as delay of the transmission of heat from the controlled element to the sensor caused by thermal mass of the process material and or process container or the distance between the control element and the sensor Upper Setpoint Limit prohibits users from adjusting the setpoint higher than the selected value Quick Setup Instructions Series 16C Temperature Controller Experienced users already familiar with the Series 16C and using the controller with PID outputs may follow these condensed instructions to autotune the controller and get started quickly once the instrument is prop erly mounted and wired and the Security Level is set to Once setup is complete we recommend changing the Security Level back to the most restrictive level suitable for your application These quick setup instructions are not meant as a substitute for reading the full instruction manual supplied with the controller Please be sure to read through the manual for specific detai
40. to load changes Failsafe State designates the percentage of power output that the con troller defaults to after it detects a loop break condition and after the loop break time has elapsed Filter in Display menu changes the filtering speed for the process value display only It does not affect control This parameter is mainly used to slow down the flickering of the display when the decimal position chosen is greater than zero Filtering in Input menu sets the time period over which the process value is averaged Highest Reading records the highest process value read by the controller It may be reset to zero by using the Raise or Lower arrow keys Hysteresis In On Off temperature control hysteresis represents the band where the output changes state from deactivated to activated It prevents chattering around the setpoint and prevents rapid output cycling Integral automatic reset slowly adjusts the position of the Proportional Band range of power output to eliminate offset error Loop Break a condition where the input is not changing or responding properly to the output action This could be caused by a thermocouple or 39 Glossary 40 input failure or a heater or load failure Loop Break Time the time interval from when the controller detects a loop break condition and the initiation of the failsafe state Lowest Reading records the lowest process value read by the controller May be reset to zero by usi
41. ve signal Only resistive loads to 1A may be con trolled directly Larger loads may be controlled using an external contactor 5 A 120 240 Vac relay but normally closed output 2 only Operation Es Figure 9 Front Panel Controls and Indicators Mode Enter Key Used to enter Parameter selections access operating modes release latched alarms and index through menu items Lower Key yvy Used to decrease values Hold for fast step progression Raise Key Used to increase values Hold for fast step progression A Cv Menu Access Key Used to enter or exit the menu system index to the next menu and enter the Security Level menu Power On ay The Series C controller 5 functional hierarchy is organized into three distinct user program mable groupings Security Level Menu System and Operating Mode Please provide the software version number communications protocol and the controller 5 full model number when contacting us regarding your controller SAY When power is first applied to the Series C all segments of the LED displays will be momentarily illuminated while the instrument goes through a series of diagnostic checks to verify proper operation A software version number will then appear in the lower display followed by a configuration code upper display and the communications protocol which is supported lower display IMPORT
42. with the unit This should expedite return of the unit to you This document is based on information available at the time of its publication While efforts have been made to render accuracy to its content the information contained herein does not purport to cover all details or variations in hardware nor to provide for every possible contingency in connection with the installation and maintenance Features may be described herein which are not present in all hardware Athena Controls assumes no obligation of notice to holders of this document with respect to changes subsequently made Proprietary information of Athena Controls Inc is furnished for customer use only No other use is authorized without the written permission of Athena Controls Inc 37 Requirements USE OF THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY eel THE MANUFACTURER MAY IMPAIR PROTECTION PROVIDED A BY THE EQUIPMENT The maximum supply current is line voltage dependent 230 mA for a 24 Vac dc input fuse rating 700 mA 60 mA for 85 250 Vac input fuse rating 100 mA Output Specifications Output Type Max current Voltage Leakage B 5A 250 Vac 1000 M ohms T 1A 250 Vpk 1mA 5 20 mA 5V NA CLEANING INSTRUCTIONS 1 Remove power from the unit prior to any cleaning operation 2 Useacotton cloth to gently and sparingly apply isopropyl alcohol only Do not use cleaners or other solvents as they may damage the unit 3 Allow the unit to dry complet
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