Athena RMC Set Up Manual

Athena RMC Set Up Manual
Athena Series RMC
Hot Runner Controller
Configuration and
Operation Manual
Athena and CompuStep are registered trademarks, and
Multi-Comm and SafeChange are trademarks of Athena Controls, Inc.
MODBUS is a registered trademark of AEG Schneider Automation, Inc.
Littlefuse  is a registered trademark of Littlefuse, Inc.
 2009. Athena Controls, Inc. All rights reserved.
Precautions
Warning
Use of this equipment in a manner not specified by the manufacturer may
impair protection provided by the equipment.
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 approved safety controls.
Hazardous potentials exist on components inside the mainframe and
controller. Always disconnect AC power to the mainframe when servicing
the controllers or the mainframe.
Because these temperature controls or associated equipment may not
always fail safe, an approved temperature and/or pressure safety control
should be used for safe operation.
The controller power switch must be in the “OFF” position before you put a
controller into an energized mainframe, or remove a controller from an
energized mainframe. If the mainframe supports the SafeChange feature,
enable SafeChange on the controller to reduce the possibility of damage to
the controller when installing a controller or removing a controller from the
mainframe. Controllers are shipped with the SafeChange feature disabled.
To determine whether the mainframe supports SafeChange and to enable
SafeChange, follow the instructions in Section 3.
Turn off power to the controller before cleaning the exterior of the
controller.
Failure to observe these precautions can result in exposure to a potentially
lethal shock hazard.
Changing DIP switch and jumper settings, and all wiring should be done by
an experienced technician. The controller and wiring should be installed in
accordance with national and local electrical codes. To avoid serious
personal injury and damage to equipment, follow all warnings and cautions
provided in the manual supplied with the mainframe.
I
Caution
If a controller shows signs of having been damaged during shipping, do not
power up or install the controller. Save all packing materials and report any
damage to the carrier immediately.
When the controller is powered up, the output may be activated. Consider
the effects on your process before powering up the controller.
We recommend placing the controller in standby mode until you have
configured the controller for your application. By default, the output is off
in standby mode. However, the standby output is configurable; see
Section 6.
Do not locate this instrument where it may be subjected to excessive shock,
vibration, dirt, moisture, oil, or other liquids.
This is a Class A product. In domestic environment this product may
cause radio interference in which case the user may be required to take
adequate measures.
Specified operating ambient temperature is 32 to 131 °F (0 to 55 °C).
II
Table of Contents
Precautions........................................................................................................... I
1.
Introduction................................................................................................ 1-1
1.1
About this Manual ............................................................................................. 1-1
1.1.1
What It Contains ........................................................................................ 1-1
1.1.2
What to Read ............................................................................................. 1-2
1.2
Features and Benefits of RMC Controllers ....................................................... 1-2
1.2.1
PID Control with Autotuning....................................................................... 1-2
1.2.2
Convenient User Interface ......................................................................... 1-4
1.2.3
CompuStep Soft Start for Heater Bake Out............................................. 1-5
1.2.4
Programmable Boost Function .................................................................. 1-5
1.2.5
Process Protection Features ..................................................................... 1-6
1.2.5.1 Deviation Alarms .................................................................................... 1-6
1.2.5.2 Automatic Shutoff if Process Temperature Exceeds
Programmable Safety High ............................................................... 1-6
1.2.5.3 Loop Break Detection............................................................................. 1-7
1.2.5.4 Failsafe Operation if a Sensor Error is Detected ................................... 1-7
1.2.5.5 Heater Current Monitoring...................................................................... 1-7
1.2.5.6 Output Interruption Relay ....................................................................... 1-8
1.2.5.7 Ground Fault Detection Circuit............................................................... 1-8
1.2.6
RS-485 for MODBUS or Local Communications..................................... 1-10
1.2.6.1 MODBUS Communication ................................................................... 1-10
1.2.6.2 Local Communication with ALL Mastership ......................................... 1-10
1.2.7
Ease of Configuration .............................................................................. 1-10
1.3
Modes of Operation ........................................................................................ 1-12
1.3.1
Control Modes.......................................................................................... 1-12
1.3.2
Configuration............................................................................................ 1-13
1.4
Security ........................................................................................................... 1-14
1.4.1
You Can Control Which Keys and Functions Are Enabled...................... 1-14
1.4.2
Access Levels Available .......................................................................... 1-14
1.5
Switch Setting and Configuration Sequence Matters ..................................... 1-15
1.5.1
Input and Unit of Measure Switches ........................................................ 1-15
1.5.2
Menu and Parameter Sequence.............................................................. 1-15
1.6
What Happens When You Power Up the Controller....................................... 1-17
1.7
Configuration and Startup Activities................................................................ 1-20
1.8
Specifications .................................................................................................. 1-21
1.8.1
Operating Limits....................................................................................... 1-21
1.8.2
Performance ............................................................................................ 1-21
1.8.3
Control Characteristics............................................................................. 1-21
900M050U00B
 Athena Controls, Inc.
i
Series RMC Hot Runner Controller Configuration and Operation Manual
1.8.4
1.8.5
1.8.6
1.8.7
1.8.8
2.
Front Panel Display and Indicators.......................................................... 1-22
Connections and Mounting ...................................................................... 1-22
Inputs ....................................................................................................... 1-22
Output ...................................................................................................... 1-22
Communications ...................................................................................... 1-22
User Interface............................................................................................. 2-1
2.1
Overview ........................................................................................................... 2-1
2.2
Key Functions ................................................................................................... 2-3
2.2.1
MODE Key ................................................................................................. 2-3
2.2.2
DISPLAY Key............................................................................................. 2-3
2.2.3
Up and Down Arrow Keys.......................................................................... 2-3
2.2.4
BOOST Key ............................................................................................... 2-3
2.3
Display .............................................................................................................. 2-4
2.3.1
Introduction ................................................................................................ 2-4
2.3.2
Unit of Measure Displayed......................................................................... 2-4
2.3.3
Cycling Through Available Displayed Values ............................................ 2-4
2.3.4
Control Displays......................................................................................... 2-4
2.3.5
Display During Configuration ..................................................................... 2-6
2.3.5.1 Introduction............................................................................................. 2-6
2.3.5.2 Menus Available ..................................................................................... 2-6
2.4
LEDs ................................................................................................................. 2-8
2.5
Displaying and Changing the Setpoint.............................................................. 2-9
2.6
Using the Boost Function.................................................................................. 2-9
2.7
Changing the Controller Mode .......................................................................... 2-9
2.8
Displaying and Changing the Output in Manual Mode ................................... 2-10
2.8.1
Displaying the Output Percentage in Use................................................ 2-10
2.8.2
Changing the Output Percentage ............................................................ 2-10
2.8.3
Special Cases When a Fixed Output is Used.......................................... 2-10
2.9
Using Local Communication ........................................................................... 2-11
2.10 Working in Configuration Mode....................................................................... 2-12
2.10.1 Entering and Exiting Configuration Mode ................................................ 2-12
2.10.2 Procedure for Viewing and Changing a
Configuration Parameter Value............................................................. 2-12
2.10.3 Configuration Example............................................................................. 2-13
3.
Enabling SafeChange and Setting the Switches .................................... 3-1
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
ii
Introduction ....................................................................................................... 3-1
Checking Mainframe for SafeChange Capability.............................................. 3-2
Enabling the SafeChange Feature.................................................................... 3-3
Location of DIP Switches .................................................................................. 3-4
Factory Switch Settings .................................................................................... 3-5
Specifying the Input Type ................................................................................. 3-5
Selecting Unit of Measure................................................................................. 3-6
Enabling Soft Start ............................................................................................ 3-6
Selecting the Mode to Be Used at Power Up ................................................... 3-7
 Athena Controls, Inc.
900M056U00B
Table of Contents
4.
General Information About Configuration Parameters.......................... 4-1
4.1
Information in This Section ............................................................................... 4-1
4.2
How to Use Sections 5 through 12 ................................................................... 4-1
4.3
Information Provided About Each Parameter ................................................... 4-2
4.3.1
Summary.................................................................................................... 4-2
4.4
Menu and Parameter Display Sequence .......................................................... 4-2
4.5
Using Factory Defaults...................................................................................... 4-4
5.
Boost Parameters – Required If Boost Feature Will Be Used ............... 5-1
5.1
5.2
Introduction ....................................................................................................... 5-1
Specifying Whether Open or Closed Loop Control
Will Be Used During the Boost .............................................................. 5-2
5.2.1
Parameter Used......................................................................................... 5-2
5.2.2
Procedure for Viewing the Currently Selected Boost Type ....................... 5-3
5.2.3
Procedure for Changing the Boost Type Selection ................................... 5-3
5.3
Configuring Boost Parameters When Closed Loop Control Is Used ................ 5-4
5.3.1
Selecting the Duration of the Boost Period................................................ 5-4
5.3.2
Specifying the Boost Setpoint.................................................................... 5-4
5.4
Configuring Boost Parameters When Open Loop Control Is Used .................. 5-5
5.4.1
Selecting the Duration of the Boost Period................................................ 5-5
5.4.2
Specifying the Boost Fixed Output Percentage......................................... 5-5
6.
Standby Parameters – Recommended .................................................... 6-1
6.1
6.2
6.3
6.4
7.
Input Parameters – Required.................................................................... 7-1
7.1
7.2
7.3
8.
Introduction ....................................................................................................... 7-1
Applying a Bias to the Temperature Input ........................................................ 7-2
Specifying the Setpoint Range.......................................................................... 7-3
Alarm Parameters – Optional ................................................................... 8-1
8.1
8.2
8.3
8.4
9.
Introduction ....................................................................................................... 6-1
Specifying Whether Open or Closed Loop Control Will Be Used
While in Standby Mode............................................................................ 6-2
Specifying the Closed Loop Standby Setpoint.................................................. 6-3
Specifying the Open Loop Standby Fixed Output Percentage ......................... 6-3
Introduction ....................................................................................................... 8-1
Enabling the Alarm Feature .............................................................................. 8-2
Specifying the Deviation Alarm High and Low Setpoints.................................. 8-3
Inhibiting the Alarm – Optional.......................................................................... 8-4
Communications Parameters – Recommended ..................................... 9-1
9.1
Introduction ....................................................................................................... 9-1
9.2
Specifying the Communications Protocol to Be Used ...................................... 9-4
9.3
Configuring Communication Parameters for MODBUS Protocol ..................... 9-5
9.3.1
Introduction ................................................................................................ 9-5
9.3.2
Assigning a Unique Controller Address When MODBUS is Used ............ 9-5
9.3.3
Selecting the Baud Rate Applicable to MODBUS Communications ......... 9-5
9.3.4
Selecting the Parity When MODBUS is Used ........................................... 9-6
900M056U00B
 Athena Controls, Inc.
iii
Series RMC Hot Runner Controller Configuration and Operation Manual
9.3.5
Selecting the Sequence for 32-bit IEEE Registers
When MODBUS Is Used....................................................................... 9-6
9.4
Configuring Communication Parameters for Local Communications ............... 9-7
9.4.1
Introduction ................................................................................................ 9-7
9.4.2
Selecting the Baud Rate Applicable to Local Communications................. 9-7
9.4.3
Selecting the Parity for Local Communications ......................................... 9-7
9.4.4
Specifying the Usage Group...................................................................... 9-8
10.
10.1
10.2
10.3
10.4
10.5
10.6
11.
Supervisor Parameters – Recommended .......................................... 10-1
Introduction ..................................................................................................... 10-1
Defining the Loop Break Time ........................................................................ 10-3
Specifying the Safety High Temperature That Will Trigger
Halt of Controller Activity ..................................................................... 10-3
Specifying Failsafe Action: What Should Happen to Output
If Sensor Is Bad ................................................................................... 10-4
Specifying the Failsafe Fixed Output Percentage........................................... 10-4
Viewing the Highest and Lowest Process Value Received
Since Last Reset.................................................................................. 10-5
Tuning the Controller for PID Control – Required............................ 11-1
11.1 Introduction ..................................................................................................... 11-1
11.2 Configuration Sequence and Autotune........................................................... 11-1
11.3 PID Control Parameters.................................................................................. 11-2
11.3.1 Summary.................................................................................................. 11-2
11.3.2 Specifying the Proportional Band for Manual Tuning of PID Control ...... 11-3
11.3.3 Specifying the Derivative (Rate) Action for Manual Tuning
of PID Control..................................................................................... 11-3
11.3.4 Choosing If and When the Autotune Operation Will Be Performed......... 11-4
11.4 Autotuning ....................................................................................................... 11-5
11.4.1 Introduction .............................................................................................. 11-5
11.4.2 Procedure for Autotuning......................................................................... 11-5
11.5 Autotune Error Codes ..................................................................................... 11-7
11.6 Manual Tuning (Zeigler-Nichols PID Method)................................................. 11-8
11.6.1 Introduction .............................................................................................. 11-8
11.6.2 Procedure ................................................................................................ 11-8
12.
12.1
12.2
12.3
12.4
12.5
12.6
13.
13.1
13.2
13.3
iv
Restricting Access to Controller Functions – Recommended ....... 12-1
Introduction ..................................................................................................... 12-1
Access Levels Available ................................................................................. 12-3
Setting Switch to Permit Display of Access Menu .......................................... 12-4
Using the Access Menu to Control Menu Access........................................... 12-4
Using the Access Menu to Enable the MODE Key......................................... 12-4
Using the Access Menu to Enable the Boost Key .......................................... 12-5
Error Messages and Codes................................................................. 13-1
Introduction ..................................................................................................... 13-1
Problem with Process Temperature ............................................................... 13-1
Ground Fault in Controller Output Wiring ....................................................... 13-1
 Athena Controls, Inc.
900M056U00B
Table of Contents
13.4 Loop Break in Sensor Wiring .......................................................................... 13-2
13.5 Failsafe Operation if a Sensor Error is Detected ............................................ 13-2
13.6 Heater Current Monitoring .............................................................................. 13-3
13.7 Problem with Controller................................................................................... 13-4
13.7.1 Introduction .............................................................................................. 13-4
13.7.2 Controller Error Codes ............................................................................. 13-4
13.8 Error Display Priority and Summary................................................................ 13-6
14.
14.1
14.2
14.3
15.
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
16.
Maintenance ......................................................................................... 14-1
Introduction ..................................................................................................... 14-1
Cleaning the Front Panel ................................................................................ 14-1
Replacing the Fuses ....................................................................................... 14-2
Frequently Asked Questions .............................................................. 15-1
Introduction ..................................................................................................... 15-1
How do I change from a J to a K thermocouple (or vice versa)?.................... 15-1
Do I have to calibrate a new controller? ......................................................... 15-1
Why doesn’t the PV displayed match the value on a thermometer
in the process?........................................................................................... 15-1
Why can’t I make changes to the other controllers in the mainframe
using an ALL master? ................................................................................. 15-2
Why doesn’t the controller communicate with the host computer? ................ 15-2
Why does the controller start up in manual mode sometimes?...................... 15-2
I turned on the power; why doesn’t the controller light up? ............................ 15-2
Resetting All Parameters to the Default Values ............................... 16-1
16.1 Introduction ..................................................................................................... 16-1
16.2 Procedure........................................................................................................ 16-1
16.2.1 Loading Defaults ...................................................................................... 16-1
16.2.2 Returning Controller to Service................................................................ 16-2
17.
Index...................................................................................................... 17-1
900M056U00B
 Athena Controls, Inc.
v
Series RMC Hot Runner Controller Configuration and Operation Manual
vi
 Athena Controls, Inc.
900M056U00B
1. Introduction
1.1
About this Manual
1.1.1 What It Contains
This manual contains all the information needed to configure and operate the Series
RMC Hot Runner controllers.
This manual contains:

an overview of the controllers’ capabilities in this section

a description of the user interface and instructions for using the display and
keypad; see Section 2

information about setting the DIP switches that affect the controllers’ functionality;
see Section 3

general information about configuration parameters; see Section 4

detailed information about every configuration parameter used by the controllers;
see Sections 5 through 10

tuning instructions (for automatic and manual tuning); see Section 11

instructions for restricting access to controller functions; see Section 12

error messages and codes displayed on the front panel of the controllers; see
Section 13

instructions for cleaning the front panel of the controller and replacing the fuses;
see Section 14

frequently asked questions; see Section 15

instructions for restoring the factory default values for configuration parameters;
see Section 16
Instructions for wiring1, installing, and troubleshooting the controllers are in the Athena
Hot Runner Temperature Control Systems Mainframe Installation Manual.
Guidelines for using a MODBUS host to communicate with the Series RMC controllers
are in Using the MODBUS Protocol with Athena Series RMC Hot Runner Controllers.
That manual also contains the MODBUS register address for all values stored in the
controllers’ databases.
1
Input and power wiring instructions are included in the mainframe installation manual. Communication
wiring between mainframes, and between a mainframe and the host, must conform to the EIA-RS-485
standard.
900M056U00B
 Athena Controls, Inc.
1-1
Series RMC Hot Runner Controller Configuration and Operation Manual
1.1.2 What to Read
This manual contains a comprehensive discussion of all the controller functions.
Some of the information may not apply to your situation.
If you are a process operator, read Sections 1, 2, and 13. If the controller does not
behave as you expect, read Section 15.
If you are a process engineer responsible for configuring the controller, look at
Sections 1 through 12, reading anything that applies to your application.
If you are a programmer responsible for programming a MODBUS host to
communicate with the controllers, read Section 1 and those portions of Sections 4
through 12 that apply to your application.
1.2
Features and Benefits of RMC Controllers
1.2.1 PID Control with Autotuning
In normal (automatic) mode each Series RMC controller uses a single TRIAC output to
implement Proportional-Integral-Derivative (PID) control. The Series RMC Hot Runner
controllers also support a manual mode that overrides automatic control. In manual
mode you control the output by entering a fixed output percentage value.2 Transfer from
PID to manual is “bumpless” when the process value is within 9 F (5 C) of the setpoint.
Using PID control, the controller modulates output power by adjusting the output power
percentage within a configurable proportional band. Power is proportionally reduced as
the process temperature gets closer to the setpoint temperature.
The configurable derivative action affects the output based on the rate of change of the
process value.
The integral action affects the output based on the duration of the process value’s
variation from the setpoint. In the Series RMC Hot Runner controllers, the integral (reset)
action is always equal to five times the configured derivative (rate) action.
An Autotune function is standard on every Series RMC controller. This feature for easy
tuning of the proportional and derivative components of the control algorithm can be
initiated every time the controller is powered up, once when the controller is set up (and
again by changing a parameter value), or never. Instructions for tuning the controller
automatically and manually are in Section 11.
2
Use of a fixed output percentage is also possible under other circumstances. Configuration parameters
let you specify a fixed output to be used as a failsafe action, a different fixed output percentage to be
used in standby mode, and another fixed output percentage to be used during the boost function
described in 1.2.4.
1-2
 Athena Controls, Inc.
900M056U00B
Introduction
RMC Front Panel
900M056U00B
 Athena Controls, Inc.
1-3
Series RMC Hot Runner Controller Configuration and Operation Manual
1.2.2 Convenient User Interface
The Series RMC controllers are equipped with a bright two-line LED display that is easy
to read over wide viewing angles. During operation in normal (auto) mode the process
value is displayed on the top line, and setpoint is displayed on the lower line. Pressing
the DISPLAY key displays the output (in percent) on the lower line. Pressing DISPLAY
again displays the heater current (in amps) on the lower line. Descriptions of all the
control displays are in 2.3.4.
The RMC keypad consists of five keys.
MODE – Use this key to change the control mode, terminate the boost before the
configured boost duration time has expired, terminate the soft start before its
natural completion, and terminate an Autotune operation before completion.
During configuration, use the MODE key as an “enter” key to write values to the
controller’s database and to step through items within a configuration menu. This
key can be disabled using the  (access) menu’s  (control mode key
enable) parameter.
DISPLAY – Use brief presses of the DISPLAY key to step through the possible
lower line operator displays.
Press and hold the DISPLAY key to access the configuration menu system;
within the menu system use this key to move from menu to menu.
up and
down – Press one of these keys to increase or decrease a
numeric value, or to scroll up or down through lists of configuration choices.
If the controller is configured for local communication, then press the
and
keys simultaneously to make the controller the ALL master (green
ALL LED lit). Pressing the two keys simultaneously again will cancel the ALL
mastership.3 See 1.2.6.2 for information about local communication and ALL
mastership.
BOOST – Used to activate the boost function described in 1.2.4. This key can
be disabled using the  (access) menu’s  (boost key enable) parameter.
Instructions for using these keys to operate the controller are in Section 2. You can
prevent the operator from using the keypad to change the controller mode, setpoint, etc.
if necessary at your site. To limit the operator’s use of the keypad, configure the 
(access) menu’s  (access level) parameter as described in 12.4.4
The front panel of the Series RMC controllers includes LEDs that are used for alarm
annunciation, as well as to signal which controller functions are active. See 2.4 for more
information about these LEDs.
If a controller is configured to support no communication ( (serial communication interface) menu
 (protocol) parameter set to ) or MODBUS ( menu  parameter set to , the default),
3
then when you press the
4
and
key simultaneously, nothing will happen.
The  (Access) menu is displayed only when SW2-switch 7 is ON as described in 12.3.
1-4
 Athena Controls, Inc.
900M056U00B
Introduction
1.2.3 CompuStep Soft Start for Heater Bake Out
All Series RMC Hot Runner controllers support the CompuStep soft start feature, which
allows slow dissipation of moisture in heaters, by gradually applying power to the heaters.
Using this feature helps extend the life of the heaters and the molds. When a soft start is
executed, phase angle firing starts at 5% output power and steps up the output 5% every
30 seconds.

The soft start when the controller is in normal (automatic) mode lasts five minutes
or until the process temperature reaches 200 F (93 C).

The soft start when the controller is in manual mode continues until the output is
50% or until the output is less than 5% of the last output percentage stored in
non-volatile memory (EEPROM) before the controller was powered down.5
The green NORMAL LED flashes during soft start in normal (auto) mode. The operator
can stop the soft start by pressing the MODE key.
By default (SW2-switch 1 ON), a soft start will be executed:

every time the controller starts and the process value is less than 200 F (93 C),
and

every time the controller is returned to normal (automatic) operation and the PV
is less than 200F (93 C).
However, you can change a switch setting as described in 3.8 to cause the controller to
execute a soft start only in response to detection of a ground fault interruption. If a
ground fault is detected, the controller will perform the soft start up to three times if
necessary. If the ground fault is still detected after the soft start has been executed three
times, the controller will signal a hard ground fault; see 1.2.5.7. More information about
the start up sequence of events is in 1.6.
1.2.4 Programmable Boost Function
Every Series RMC Hot Runner controller supports a boost function. This function allows
you to configure a special setpoint (closed loop boost) or a special fixed output
percentage (open loop boost) to be used when the operator presses the BOOST key.
While the special boost setpoint or boost fixed output percentage is being used, the
green LED above the BOOST key will be lit. During closed loop boost, the boost setpoint
is included in the display cycle for the lower line. During open loop boost, the configured
boost fixed output percentage is included in the lower line display cycle (see 2.3.4).
The boost function will remain active (and the BOOST LED on) until:

the configured boost duration time has expired, or

the operator presses the BOOST key again before the expiration of the boost
duration.
5
While the controller is in manual mode, the processor periodically compares the output percentage in
use with the manual mode output percentage stored on the EEPROM. If the output has been changed
since the last time the output was stored, the new output percentage is written to the EEPROM.
900M056U00B
 Athena Controls, Inc.
1-5
Series RMC Hot Runner Controller Configuration and Operation Manual
This boost function can be started simultaneously on all controllers in a usage group if
the operator presses the BOOST key on a local communication ALL master (see
1.2.6.2). The boost duration on the various controllers in a usage group can be
configured to expire normally at different times. However, if the operator terminates the
boost before the expiration of the boost duration on the ALL master, the boost will be
stopped on all the other controllers in that usage group, too.
See Section 5 for instructions on configuring the  (boost) menu parameters. If the
boost function is not appropriate for your application, see 12.6 for instructions for
disabling the BOOST key.
1.2.5 Process Protection Features
1.2.5.1 Deviation Alarms
Each Series RMC Hot Runner controller supports two configurable deviation alarms. The
alarm setpoints are configured using the  (alarm) menu.6 If the process value falls
below the setpoint minus the deviation low setpoint, or if the process value exceeds the
setpoint plus the deviation high setpoint, the red ALARM LED on the front panel of the
controller will light.
The alarm status indicator will remain lit as long as the process value is below or above
the deviation setpoints. If the controller is networked with a MODBUS host, the alarm
status is available for the host to read as described in Using the MODBUS Protocol with
Athena Series RMC Hot Runner Controllers.
1.2.5.2 Automatic Shutoff if Process Temperature Exceeds Programmable Safety High
You can use the  (supervisor) menu’s  (high-temperature safety) parameter to
specify a high-temperature safety value to be applied to the process. If the process value
exceeds this value:

controller processing and output activity is halted, and

the ALARM LED is lit, and

the message  alternating with  will be displayed on the lower line.
Once the high-temperature safety value has been exceeded by the PV, the controller will
not resume processing and output activity until you cycle power to the controller.
Instructions for configuring the high-temperature value are in 10.3.
The  menu also contains a parameter that can be used to disable the alarm function, and a
parameter used to specify an optional alarm inhibit time. See Section 8 for details.
6
1-6
 Athena Controls, Inc.
900M056U00B
Introduction
1.2.5.3 Loop Break Detection
You can use the RMC  (supervisor) menu’s  (loop break time) parameter to
specify a time period within which the input value should change at least 1% of supported
sensor span (9.67 F or 5.37 C) if the sensor is working properly and the input wiring is
intact. If the input value does not change within the specified time period while the
controller is operating in normal (automatic) mode or in closed loop standby mode (or
while a closed loop boost is in progress), and a “bad heater” error has not been detected
(see 1.2.5.6), then:

the controller output will be turned off, and

the ALARM LED will be lit (all other LEDs turned off), and

the message  will be displayed on the lower line.
The controller will remain in this alarm and output off state until you cycle the power to
the controller.
1.2.5.4 Failsafe Operation if a Sensor Error is Detected
You can use the RMC  (supervisor) menu’s  (failsafe action) parameter to
specify what should happen to the output if the controller detects a reversed or open
sensor. Your choices are:

output off, or

use a calculated output value based on output values that have typically
successfully maintained the current setpoint for your process in the past, or

use a special configurable failsafe fixed output percentage.
If the controller detects an open or reversed sensor:

the controller output goes to the configured failsafe state, and

the ALARM LED will be lit (all other LEDs turned off), and

the upper display will alternate  and  (reversed sensor), or  and 
(open sensor).
The controller will remain in this alarm and failsafe state until the operator cycles the
power to the controller.
1.2.5.5 Heater Current Monitoring
The present current output to the heater, expressed to the closest tenth of an amp, is
always displayable in the lower line. The operator cycles through the available lower line
display items using the DISPLAY key.
900M056U00B
 Athena Controls, Inc.
1-7
Series RMC Hot Runner Controller Configuration and Operation Manual
1.2.5.6 Output Interruption Relay
An RMC controller constantly checks heater current readings to ensure that they
correlate with output activity.

If the output device is off and a current flow greater than 0.1 amp is detected,
then the controller will post a “TRIAC short” error.

If the output device is on, but no controller current output flow is detected, then
the processor will post a “bad heater” error.7
If either of these error conditions is detected:

the output failure interruption relay will break the connection between the
controller’s TRIAC output and the heater, and

controller processing will cease, and

the red ALARM LED will be lit (all other LEDs turned off), and

an alarm message will be displayed on the lower line:

if a short was detected,  will alternate with 

if a heater problem is detected,  will alternate with 
The controller will remain in this halted state until you cycle power to the controller.
If the controller is the ALL master for local communication at the time that the output
failure is detected, the mastership will be cancelled automatically. (See 1.2.6.2 for more
information about local communication and ALL mastership.)
1.2.5.7 Ground Fault Detection Circuit
An RMC controller is capable of detecting ground faults in the controller output. When a
ground fault is detected, the controller will attempt to perform a normal soft start. As
usual in the case of a soft start, if the process value is less than or equal to 200 F
(93 C), the standard CompuStep soft start described in 1.2.3 will be executed. The
controller will perform the soft start up to three times if necessary. If the ground fault is
detected again after the soft start has been executed three times, the controller will signal
a “hard” ground fault.
If the process value is greater than 200 F (93 C) when the ground fault is detected, the
controller will immediately consider this a “hard” ground fault. The controller will:

interrupt the signal to its own output, in effect “turning off” the output (even if the
controller output was already at the configured failsafe output state), and

an error message  will be displayed on the lower line, and

the red ALARM LED will also be lit (all other LEDs will be turned off).
Following the interrupt in response to a “hard” ground fault, the controller’s output will
remain off until you cycle power to the controller.
7
Other conditions must also be met; see 13.6 for details.
1-8
 Athena Controls, Inc.
900M056U00B
Introduction
If the controller is the ALL master for local communication at the time that the ground fault
is detected, the mastership will be cancelled automatically. (See 1.2.6.2 for more
information about local communication and ALL mastership.)
900M056U00B
 Athena Controls, Inc.
1-9
Series RMC Hot Runner Controller Configuration and Operation Manual
1.2.6 RS-485 for MODBUS or Local Communications
Every Series RMC Hot Runner controller supports RS-485 serial communications. If you
choose to use this communication capability, you have two choices: MODBUS or local
communication. The protocol is selected using the  (serial communication interface)
menu’s  (protocol) parameter.
1.2.6.1 MODBUS Communication
You can network the controllers to a MODBUS host. This host can read and write to
every configuration parameter in a RMC controller’s database. The host can also read
every status value available in the database, including which LEDs are lit.8 Guidelines for
using a MODBUS host to communicate with the controllers are in Using the MODBUS
Protocol with Athena Series RMC Hot Runner Controllers.
1.2.6.2 Local Communication with ALL Mastership
If you select local communication, then you use the  (serial communication interface)
menu’s  (usage group) parameter to assign each RMC controller within a single
mainframe to one of three usage groups. The front panel of any controller in a usage
group can be used to activate the boost, change the mode, change the setpoint, or
change the manual mode output in every controller in the usage group.
This is accomplished by making any one of the controllers in the usage group the ALL
master temporarily by pressing
and
simultaneously. The ALL master’s green
ALL LED will light. While this LED is lit, you can use the ALL master to activate the
boost, change the mode, change the setpoint, or change the manual mode output in
other RMC controllers. An ALL master can communicate with all the other RMC
controllers in the same usage group as the master, if the controllers are in mainframes
that are linked via an RS-485 network with the ALL master’s mainframe.9
If you do not press another key within 5 seconds of pressing
and
simultaneously
(or during any 5 second interval while the ALL LED is lit), ALL mastership will be
cancelled automatically. You can cancel ALL mastership manually before 5 seconds
have passed by pressing
and
again simultaneously.
If the ALL master experiences a problem, such as a ground fault error or a short in the
TRIAC output, ALL mastership is automatically cancelled.
1.2.7 Ease of Configuration
A few basic features are set up using DIP switches, as described in Section 3. For
example, if you plan to use a K thermocouple for input, instead of the default J
thermocouple, you set a DIP switch (SW2-switch 2) to ON.
8
Peer-to-peer communications are not supported by the MODBUS protocol.
9
Series RMB controllers can be installed in the same mainframe with Series RMC controllers. However,
the RMB controllers do not support communication. Therefore, changes to RMB controllers cannot be
implemented using an RMC ALL master.
1-10
 Athena Controls, Inc.
900M056U00B
Introduction
All other configuration parameters can be configured using the front panel display and
keypad or a MODBUS host.
When parameters are configured using the controller’s front panel, the parameters are
displayed grouped (on the basis of function) in menus. Parameters that do not apply to
your control strategy will not be displayed. For example, if you choose to disable the
alarm function, then none of the other alarm-related parameters are displayed (until you
enable alarms again).
Instructions for using a controller’s front panel to view and change configuration
parameters are in Section 2. An overview of all available configuration parameters is in
4.4. Descriptions of all the parameters and the valid values for each are in Sections 5
through 12.
900M056U00B
 Athena Controls, Inc.
1-11
Series RMC Hot Runner Controller Configuration and Operation Manual
1.3
Modes of Operation
1.3.1 Control Modes
The Series RMC Hot Runner controllers support several modes of operation for control,
as well as a special mode used to tune the unit automatically for PID control.
The table below summarizes the control modes and their effects on the controller output.
Use the MODE key to step through these modes in the sequence in which they are listed
in the table. The LEDs to the right of the MODE key signal the controller’s present mode.
The operational display for each mode is in 2.3.4.
Control
Mode
Description
normal
(closed loop)
When the controller is in normal mode (closed loop control), the output is based
on the controller’s calculations of the output action needed to achieve or
maintain the currently active setpoint, in accordance with the configured control
strategy. In closed loop control, the controller is dependent on the input
received.
manual
(open loop)
When the controller is in manual mode (open loop control) the output
percentage used is not influenced by the input value. In manual the output
percentage can be changed by the operator using the front panel of the
controller (see 2.8.2) except under special circumstances (see 2.8.3). Transfer
from normal (auto) to manual is bumpless (if the PV is within 9 F (5 C) of the
SV).
standby
When the controller is in standby mode, the behavior of the output depends on
how the  (standby) menu parameters have been configured.

If the standby type is configured as closed loop, the configured standby
setpoint will be used.

If the standby type is open loop, the configured standby fixed output
percentage will be used.
A special automatic control mode is provided for automatic tuning of the controller (that
is, automatically determining the proportional and derivative values to be used by the PID
control algorithm)10. When Autotune is active, the output is under the control of the
Autotune algorithm, and is dependent on the input received. By default, the Autotune
operation is executed once. If the Autotune is successful, then Autotune is disabled. The
operator can terminate the Autotune operation prematurely by pressing the MODE key.
This does not disable the Autotune feature. If Autotune operation is set to “once”, then
the controller will attempt to perform the Autotune operation again the next time it is
powered up.
Autotune can also be disabled entirely or enabled for every power up. To configure the
Autotune operation, use the  menu’s  (Autotune operation) parameter. See
11.3.4 for details.
10
In the Series RMC controllers the integral value is automatically set to five times the derivative (rate)
value.
1-12
 Athena Controls, Inc.
900M056U00B
Introduction
1.3.2 Configuration
In addition to the operating displays associated with the control modes described in 1.3.1
above, the Series RMC Hot Runner controllers can display configuration parameters.
The parameters are grouped by purpose and organized in menus.
Instructions for viewing and changing configuration parameter values are in 2.10.
An overview of all available configuration parameters is in 4.4. Descriptions of all the
parameters and the valid values for each are in Sections 5 through 12.
Attention
900M056U00B
Before accessing the menu system (or changing a parameter
value using a remote host), we recommend putting the controller
in standby mode as described in 2.7 (or in the manual supplied
with the host software). By default, the output is off in standby
mode. However, the controller’s behavior in standby mode is
configurable; see Section 6.
 Athena Controls, Inc.
1-13
Series RMC Hot Runner Controller Configuration and Operation Manual
1.4
Security
1.4.1 You Can Control Which Keys and Functions Are Enabled
You can configure the Series RMC Hot Runner controllers to limit the functions that
operators can access or the values they can change using the keypad. This access
control is configured using the using the  (access) menu described in Section 12.
The  menu contains an  (access level) parameter, which affects some of the
functions available to the operator (see 1.4.2 and 12.4). For example, the access level
can be set to allow operators to change only the setpoint for normal (auto) mode (closed
loop control) or the output percentage used in manual mode (open loop control).
The  menu also contains the  (control mode key enable) parameter and the
 (boost key enable) parameter that are used to enable and disable the MODE and
BOOST keys.
The  menu can be accessed only when SW2-switch 7 is set to ON (see 12.3).
1.4.2 Access Levels Available
A controller can be set to any of the access levels in the table below. The sequence of
levels in the table is from most restrictive to least restrictive. New RMC controllers are
shipped with the access level set to  (configuration).
Displayed

Access
Level
Description
Value

keypad
lockout
Highest security level; no access.
While the access level is “keypad lockout”, no controller values can be
changed, not even the setpoint. Pressing the MODE and BOOST keys
will have no effect, even if the MODE and BOOST keys have been
enabled using the  menu  and  parameters.

setpoint only
Setpoint or manual output can be adjusted; no access to menus.
When the access level is “setpoint only”, the keypad can be used to
change the setpoint or the manual mode output percentage. Whether
the operator will be able to change the controller from normal
(automatic closed loop control) to manual (open loop control) mode (or
vice versa) depends on whether the MODE key is enabled using the
 menu  parameter. Availability of the boost function
depends on whether the BOOST key is enabled using the  menu
 parameter.

configuration
Setpoint and manual output can be adjusted. Access to all
available menus is permitted.
When the access level is “configuration”, the keypad can be used to
change the setpoint, change the output percentage in manual mode,
and to view and change all configuration parameter values in accessible
menus. Not all menus are accessible all the time. If SW2-switch 7 is
ON, all menus are accessible. If SW2-switch7 is OFF (factory setting),
the  (access) menu is not accessible. See Section 3 for the
location of the option switches.
1-14
 Athena Controls, Inc.
900M056U00B
Introduction
1.5
Switch Setting and Configuration Sequence Matters
1.5.1 Input and Unit of Measure Switches
The DIP switches in a Series RMC Hot Runner controller are set at the factory for J
thermocouple as the input type. The unit of measure set at the factory depends on the
shipping destination: controllers shipped to destinations in North America are set to use
degrees Fahrenheit; controllers shipped to destinations outside North America are set to
use degrees Celsius. If you plan to use a K thermocouple for input, and/or if you plan to
display the process value and enter the setpoint using the temperature scale that is not
the default for your location, you must change these switch settings.
Read the safety warnings in Section 3 before changing switch settings.

When SW2-switch 2 is OFF (the factory setting) the controller expects input
from a J thermocouple. When SW2-switch 2 is ON, the controller is set up to
use input from a K thermocouple.

The unit of measure used by the controller for internal operations, as well as for
external communications, is set by means of SW2-switch 3. When SW2-switch
3 is OFF the controller uses Fahrenheit. When SW2-switch 3 is ON the
controller uses Celsius.
When you change the units of measure switch setting, the controller
recalculates any temperature values that have already been specified. For
example, if you want the setpoint to be 100 C and the controller is set to use
F, then you must change the units from the default F to C before you write
the setpoint of 100 to the controller. If you change the units after you write the
setpoint of 100 to the controller, the controller will convert the 100 F setpoint to
37.8 C. In this case, you would have to reconfigure the setpoint to 100 C to
implement the control needed by your process.
In addition to the input type and the unit of measure, other functions are set up using DIP
switches as described in Section 3. You can save time by making all planned changes to
switch settings before you power up the controller the first time.
1.5.2 Menu and Parameter Sequence
Once you have set the DIP switches, the next step is to power up the controller and put it
in standby mode by repeatedly pressing the MODE key until the STANDBY LED lights.11
Next configure the setpoint range using the  (input) menu’s  (setpoint low limit)
and  (setpoint high limit) parameters. This range will affect the values you can
enter as the boost setpoint and the standby mode setpoint. You can skip configuring the
setpoint range first if you are satisfied to use the default range 32 to 999 F (0 to 537 C),
or if you plan to use open loop control12 during the boost and in standby mode.
11
The number of times you must press the MODE key to enter STANDBY mode depends on whether the
controller is configured to do a soft start, do Autotune, and other factors. See 1.6 for details of what
happens when you power up the controller.
12
When open loop control is used, a configurable fixed output percentage is used. The controller ignores
the input value during open loop control. No setpoint applies to open loop control.
900M056U00B
 Athena Controls, Inc.
1-15
Series RMC Hot Runner Controller Configuration and Operation Manual
Once you have configured the setpoint range using the input menu, we recommend that
you configure the parameters in the sequence in which they are presented in Sections 5
through 12. With the exception of the  (access) menu and  (PID control) menu,
this is the same sequence in which the parameters are displayed.
Although the tuning parameters in the  menu are configured last, they are displayed
first for your convenience. You may need to access the tuning parameters during normal
operation. However, once the controller is configured, you may never need to use any of
the parameters in the other menus again.
Within a menu, the parameters should be configured in order, because the value you
select for a parameter early in a menu sometimes determines the other parameters that
are displayed in that menu. For example, if you use the  (boost) menu’s first
parameter  (type) to specify that during the boost closed loop control will be used,
then the menu includes the  (boost setpoint) parameter. However, if you use the
 parameter to specify open loop control during boost mode, then the menu will
include the  (boost fixed output percentage) parameter.
1-16
 Athena Controls, Inc.
900M056U00B
Introduction
1.6
What Happens When You Power Up the Controller
When an RMC controller is powered up, it lights all segments of the display briefly, then
displays its firmware level.13
The sequence of controller actions that follow and the state of the controller output
depend on:

SW2-switch 1 setting – If SW2-switch 1 is ON (the default), the controller does
a CompuStep soft start if the process value is less than or equal to 200 F (93
C) and the controller is set up to start in normal (auto) mode. If SW2-switch 1 is
OFF, the controller does not do a soft start at power up.

SW2-switch 6 setting – If SW2-switch 6 is OFF (the default), the controller
starts up in normal (auto) mode. If SW2-switch 6 is ON, the controller starts up in
the mode it was in when it was powered down.


if SW2-switch 6 is ON, the last mode used – The last mode used is stored
in non-volatile memory. The controller behaves differently if the controller
was last in normal (auto) mode than it does if the controller was last in
manual mode. (In manual mode, if the last output percentage used was less
than 5%, the controller’s behavior is also influenced.)
 (PID control) menu’s  (Autotune operation) parameter value – If
 is set to  (once) or  (always enabled), and the controller is
starting in normal (auto) mode, Autotune will be attempted.
The interactions between all these factors are diagramed on the following two pages.

The first diagram shows what happens if SW2-switch 6 is OFF (the default), so
that the controller starts in normal (auto) mode.

The second diagram shows what happens SW2-switch 6 is ON, so that the
controller starts in the last mode that was used before shutdown.
You can terminate soft start and Autotune by pressing the MODE key.
13
It is a good idea to make a note of the firmware version number. If you phone for technical support,
you will be asked for this version information, as well as for the complete model number of the controller
in question.
900M056U00B
 Athena Controls, Inc.
1-17
Series RMC Hot Runner Controller Configuration and Operation Manual
START
Is SoftStart
enabled?
Is PV <= 200 F ?
Yes
Do SoftStart
Is Autotune
enabled?
(SEE NOTE 1)
No
Yes
Do Autotune
Enter normal mode
at setpoint saved
in EEPROM
Note 1)
By default, Autotune is enabled
once. When the controller has
completed Autotuning successfully,
the Autotune operation parameter
in the PID menu is set to disabled .
You can use the PID menu to specify
that Autotuning is initiated every
time the controller starts up, or never.
Automatic Startup Sequence If SW2-Switch 6 Is OFF (Default) –
Controller Starts in Normal (Auto) Mode
1-18
 Athena Controls, Inc.
900M056U00B
Introduction
Automatic Startup Sequence If SW2-Switch 6 Is ON –
Controller Starts in the Last Mode Used Before Shutdown
900M056U00B
 Athena Controls, Inc.
1-19
Series RMC Hot Runner Controller Configuration and Operation Manual
1.7
Configuration and Startup Activities
The following table summarizes the configuration and startup tasks to be accomplished once the
controllers are installed and wired as described in the manual supplied with the mainframe. As
described in 1.5, configuration sequence does matter, because there are interdependencies
among parameters. We recommend configuring the controllers in the sequence shown below.
Step
Action
Where
Described
1
Check to see if the mainframe supports the SafeChange feature. If so, enable the
SafeChange feature on the controller by changing a jumper setting.
3.2 and
3.3
2
If you plan to use a K thermocouple as the sensor or plan to display the process
value and setpoint using the temperature scale that is not the default for your
location (Fahrenheit for controllers shipped to destinations in North America;
Celsius for controllers shipped to destinations outside North America), you must
change two DIP switches from their factory settings before using the menus to
configure the controller. Other switch settings that affect how the controller
behaves under certain circumstances can be changed now or later.
3.6
and
3.7
3
Power up the controller.
1.6
4
Put the controller in standby mode.
2.7
5
If you want to use a setpoint range other than the default
32 to 999 F (0 to 537 C) and plan to use closed loop control during the boost or
while in standby mode, configure the setpoint range using the input menu now.
7.3
6
If you plan to use boost mode, specify the type of control to be used during the
boost, and enable the boost function. Specify the setpoint to be used for closed
loop boost or the output percentage to be used for open loop boost.
5
6
Unless the default (open loop control with 0% output) is appropriate for standby
mode at your site, configure the parameters that determine how the controller
implements standby mode.
6
7
Use the input menu to specify any bias that should be applied to the input, and
define the setpoint low limit and setpoint high limit values (if you have not
configured the range already in Step 4).
7
8
If you plan to use the deviation alarms, configure the parameters in the alarm
menu.
8
9
If you plan to use local or MODBUS communications, configure the
communication parameters.14
9
10
Specify the loop break time and the high-temperature safety value, and configure
the output for failsafe operation.
10
11
Adjust the setpoint.
2.5
12
Tune the controller.
11
13
If you want to restrict operators from accessing the configuration menu or from
using the BOOST or MODE keys, power down the controller, change the switch
setting that will allow you to display the access menu, so that you can limit
operator access to controller functions. (After restricting access, you should
change the switch setting again, so no one can “un-do” your restrictions.)
12
14
Put the controller in normal (automatic) mode.
2.7
14
If the controller will be configured using MODBUS, the communication option parameters can be configured first,
permitting you to configure the other parameters using a personal computer. Details of the communication setup
appropriate for MODBUS is described in Using the MODBUS Protocol with Athena Series RMC Hot Runner
Controllers.
1-20
 Athena Controls, Inc.
900M056U00B
Introduction
1.8
Specifications
1.8.1 Operating Limits
Ambient Temperature 32 °F to 131 °F (0 °C to 55 °C)
Relative Humidity Tolerance 10 to 95 % Non-Condensing
Shipping Temperature –40 °F to 158 °F (–40 °C to 70 °C)
Power Requirements 115 to 240 Vac 50 or 60 Hz nominal CE compliant
1.8.2 Performance
Accuracy ± 0.3 % of span
Setpoint Resolution 1 degree Fahrenheit
Repeatability ± 0.1 % of span
Temperature Stability ± 0.5 % of full scale over the ambient range of 32 °F to 131 °F
(0 °C to 55 °C)
Thermocouple Cold-End Tracking automatic, better than 0.02 °F per °F (0.01 °C
per °C)
Noise Rejection Common Mode > 100 dB, Series Mode > 70 dB
Process Sampling Rate 10 Hz
1.8.3 Control Characteristics
Autotune automatic or operator initiated.
Manual mode control operator initiated.
Failsafe action is configurable.
900M056U00B
 Athena Controls, Inc.
1-21
Series RMC Hot Runner Controller Configuration and Operation Manual
1.8.4 Front Panel Display and Indicators
Information about the user interface (including an illustration of the controller front panel)
is in Section 2 of this manual.
Temperature Display Three digits composed of orange seven-segment LED characters;
a decimal point can be displayed.
Setpoint Display Four digits composed of green seven-segment LED characters; a
decimal point can be displayed.
Output Status Indicator orange LED labeled “HEAT”
Alarm Status Indicator red LED labeled “ALARM”
Boost Function Indicator green unlabeled LED above the BOOST key
ALL Master Indicator green LED labeled “ALL”
Standby Mode Indicator green LED labeled “STANDBY”
Normal (Automatic) Mode Indicator green LED labeled “NORMAL”
Manual Mode Indicator green LED labeled “MANUAL”
1.8.5 Connections and Mounting
The Series RMC controllers are designed for installation in an Athena Hot Runner
mainframe; removal of an RMC controller from the mainframe requires removal of a
locking pin (standard controllers) or locking screw (CE-compliant controllers).
1.8.6 Inputs
thermocouple J or K
supported sensor range 32 to 999 F (0 to 537 C)
1.8.7 Output
TRIAC, 15 amps at 120/240 Vac, driven by optically isolated interface circuit. Protected
with a pair of 15 amp field-replaceable fuses. Instructions for replacing the fuses are in
14.3. Replacement fuses must be Type F fast-acting 250 Vac fuses rated at 15 amps.
Suitable fuses are Littlefuse Inc. p/n 314015 and Athena p/n 210B001U01
An 15 amp (120/240 Vac) relay interrupts power to the heater if the controller detects
shorting of the TRIAC output or other system failures.
A ground fault detection circuit is also standard.
1.8.8 Communications
RS 485 standard for local communication among controllers assigned to the same
usage group within a single mainframe (or among mainframes linked by an RS-485
network), or between a MODBUS host and every controller on the network; 9600 baud
maximum
1-22
 Athena Controls, Inc.
900M056U00B
2. User Interface
2.1
Overview
The Series RMC controllers are equipped with a bright two-line LED display that is easy
to read over wide viewing angles. During operation in normal (auto) mode the process
value is displayed on the top line, and setpoint is displayed on the lower line. Pressing
the DISPLAY key displays the output (in percent) on the lower line. Pressing DISPLAY
again displays the heater current (in amps) on the lower line. Descriptions of all the
control displays are in 2.3.4.
The RMC keypad consists of five keys: DISPLAY, BOOST, MODE,
and
. The
functions of these keys are described in 2.2 Instructions for using these keys to operate
the controller are in 2.5 through the end of this section. You can prevent the operator
from using the keypad to change the controller mode, setpoint, etc. if necessary at your
site. The keypad is disabled when the  (access) menu’s  (access level)
parameter is set to  (lockout) as described in 12.4.15 The instructions in this section
assume that the controller’s access level is not set to lockout.
The front panel of the Series RMC controllers also includes LEDs that are used for alarm
annunciation, as well as to signal which controller functions are active. See 2.4 for more
information about these LEDs.
15
The  (Access) menu is displayed only when SW2-switch 7 is ON as described in 12.3.
900M056U00B
 Athena Controls, Inc.
2-1
Series RMC Hot Runner Controller Configuration and Operation Manual
RMC Front Panel
2-2
 Athena Controls, Inc.
900M056U00B
User Interface
2.2
Key Functions
2.2.1 MODE Key
During operation use the MODE key to change the control mode, terminate the boost
before the boost duration time has expired, terminate the soft start before its natural
completion, and terminate an Autotune operation before completion.
During configuration, use the MODE key as an “enter” key to write values to the
controller’s database and to step through items within a configuration menu.
This key can be disabled using the  (access) menu’s  (control mode key)
parameter (see 12.5).
2.2.2 DISPLAY Key
When the controller is in a control mode), use brief presses of the DISPLAY key to step
through the possible lower line operator displays available (see the table in 2.3.4).
To access the configuration menu system, press and hold the DISPLAY key
(approximately three seconds) to access the configuration menu system. If the first
configuration menu is not displayed, the access level of the controller prohibits
configuration from the front panel (see 12.2 and 12.4).
Within the menu system, use this key to move from menu to menu.
2.2.3 Up and Down Arrow Keys
Pressing and releasing the
or
key increases or decreases the numerical value on
the operator display or configuration display one unit. Pressing and holding one of these
keys changes the value more rapidly.
When a string of characters representing a configuration parameter choice or a mode
choice is on display, pressing
or
displays the previous or next choice on the list.
and
If the controller is configured for local communication, then press
simultaneously to make the controller the ALL master (green ALL LED lit). Pressing the
two keys simultaneously again will disable the ALL mastership.16 See 1.2.6.2 for more
information about ALL mastership.
2.2.4 BOOST Key
Use the BOOST key to activate the boost function described in 1.2.4.
This key can be disabled using the  (access) menu’s  (boost key) parameter
(see 12.6).
16
If a controller is configured to use MODBUS (the default), or communication is disabled using the serial
communication interface menu, then when you press
900M056U00B
and
 Athena Controls, Inc.
simultaneously, nothing will happen.
2-3
Series RMC Hot Runner Controller Configuration and Operation Manual
2.3
Display
2.3.1 Introduction
What is displayed on the front panel of the controller depends on the mode of operation
(see 1.3), and whether the controller detects any problems with the input or with its own
operation.
2.3.2 Unit of Measure Displayed
The unit of measure (Fahrenheit or Celsius) is set using SW2-switch 3 as described in
3.7. This unit of measure is used by the controller for internal operations, for external
communications, and for the process value and setpoint display.
2.3.3 Cycling Through Available Displayed Values
Unless the configuration menus have been accessed or the controller has detected an
error, the top line of the display will always show the process value. At any time the
operator can press the DISPLAY key repeatedly to cycle through the other values
available for display on the lower line. The available values always include the output (in
percent) and the heater current (in 0.1 amp increments).
2.3.4 Control Displays
The control displays (when no problems are detected) are summarized in the table
below. The error messages that can be displayed when the controller detects a problem
with the input, the output, or its own operation are explained in Section 13.
Information about the controller’s behavior, and error codes displayed if the controller
detects a problem during Autotune are in Section 11.
The configuration displays are discussed in 2.3.5.
2-4
 Athena Controls, Inc.
900M056U00B
User Interface
What’s Displayed
Example
Top Line
Top Line
Lower Line
Lower Line
Circumstance
normal mode (closed loop
control)
process value
display cycle includes:
NORMAL LED is lit.
setpoint and unit of measure
and
output (in percent)
and
measured heater current (in amps)
manual mode (open loop
control)
process value
display cycle includes:
MANUAL LED is lit.



and

and



output percent value

and
and
measured heater current (in amps)
standby mode
process value
STANDBY LED is lit.
display cycle includes:



output percent value

and
and
measured heater current (in amps)

If standby type is configured as closed loop,
then the display cycle also includes:
configured standby setpoint and unit of
measure
boost function active
process value
BOOST LED is lit.
display cycle includes:


and
and
If boost type is configured as closed loop,
then the display cycle also includes:
configured boost setpoint and unit of
measure
900M056U00B

output percent value
measured heater current (in amps)
Autotune active

process value alternating with 
 Athena Controls, Inc.




2-5
Series RMC Hot Runner Controller Configuration and Operation Manual
What’s Displayed
Example
Top Line
Top Line
Lower Line
Lower Line
Circumstance

setpoint value
2.3.5 Display During Configuration
2.3.5.1 Introduction
When the DISPLAY key has been used to display a menu, you can configure the
controller.
It is recommended that you put the controller in standby mode as described in 2.7 before
going into configuration to change parameter values. By default, the output is off in
standby mode. You can configure the controller to use your choice of standby setpoint or
standby fixed output percentage while the controller is in standby. If you do not put the
controller in standby mode, normal controller output action will continue during
configuration. The effects on your process may be undesireable.
During configuration the top line of the display contains a menu name. The second line
of the display contains a parameter name, alternating with the current value. For
example, when the input menu bias parameter is accessed the display will show the
default value of the bias parameter:


alternating
with


2.3.5.2 Menus Available
To access the menus containing the configuration parameters, press the DISPLAY key
until a text string is displayed on the top line of the display (approximately 3 seconds).
The following table lists all the menus available.
You can see configuration menus only when the access level for the controller is set to
 as described in 1.4 and 12.4. You can change the access level only when SW2switch 7 is ON as described in 12.3. The RMC controllers are shipped with SW2-switch 7
OFF.
To see all the parameters in all the menus, go to Section 4 or the section of this manual
referenced in the following table.
2-6
 Athena Controls, Inc.
900M056U00B
User Interface
Displayed
Abbreviation
Menu
Name
Described
In

PID control
Section 11

boost
Section 5

standby
Section 6

input
Section 7

alarm
Section 8

serial communication interface
Section 9

supervisor
Section 10

access (See Note 1 below.)
Section 12
Note 1: The access menu is displayed in the menu cycle only when SW2-switch 7 is ON;
see 12.3. The RMC controllers are shipped with SW2-switch 7 OFF.
900M056U00B
 Athena Controls, Inc.
2-7
Series RMC Hot Runner Controller Configuration and Operation Manual
2.4
LEDs
The front panel of every Series RMC controller includes seven status LEDs, which are
described in the table below. The status of each of these LEDs can be read by a
MODBUS host as described in Using the MODBUS Protocol with Athena Series RMC
Hot Runner Controllers.
LED Label
Color
Function
HEAT
orange
ALARM
red
alarm status indicator – Lit while the process value
is outside the high or low deviation alarm limits
configured using the alarm menu as described in
Section 8.
BOOST
(See Note 1 below.)
green
boost function indicator – Lit while the controller is
performing the boost operation described in 1.2.4.
(See Section 5 for boost configuration.)
ALL
green
ALL master indicator – The use of this LED
depends on whether the controller is configured
(using the serial communications interface menu) to
use local or MODBUS communications. (If neither is
enabled, the ALL LED never lights.)
output status indicator – Lit while the output is
energized.

If the controller is configured to enable local
communications, then this LED is lit while the
controller is ALL master. As long as this LED is
lit (while local communications are enabled), you
can use the ALL master to activate the boost,
change the mode, change the setpoint, or
change the manual mode output in all the other
controllers in the same usage group within
mainframes linked via an RS-485 network with
the ALL master’s mainframe (see 1.2.6.2).

If the controller is configured to enable MODBUS
communications, then this LED is lit while the
controller is receiving a message from the
MODBUS host, and while the controller is
sending a message to the MODBUS host.
STANDBY
green
standby mode indicator – Lit while the controller is
in standby mode.
NORMAL
green
normal (automatic) mode indicator – Lit while the
controller is implementing closed loop control (except
during boost). During closed loop control, the PID
control output is calculated based on the setpoint and
the input received from the sensor. This LED flashes
(instead of being lit steadily) during a soft start in
normal mode.
MANUAL
green
manual mode indicator – Lit while the controller is
implementing open loop control (except during
boost). During open loop control, the controller uses
a fixed output percentage, regardless of the sensor
reading.
Note 1: The BOOST LED is not labeled. It is directly above the BOOST key.
2-8
 Athena Controls, Inc.
900M056U00B
User Interface
2.5
Displaying and Changing the Setpoint
The setpoint can be changed only when the controller is in normal (automatic) mode
(NORMAL LED lit) and a CompuStep soft start is not in progress.
To display the setpoint, if the setpoint is not on display in the lower line while the
controller is in normal mode, press the DISPLAY key until the setpoint and unit of
measure are displayed.
To change the setpoint, use the
value.
and
keys to change the displayed setpoint
The setpoint values that can be entered using the controller’s front panel are limited by
the setpoint range configured using the  (input) menu’s  and  parameters
(see 7.3).
If the controller is using a configured boost (closed loop) setpoint or a standby mode
(closed loop) setpoint, then that setpoint can be changed only in configuration.
2.6
Using the Boost Function
Unless the BOOST key has been disabled (see 12.6), the boost function described in
1.2.4 can be used any time that the controller is in normal mode, and is not Autotuning or
displaying an error message.
To start the boost function, press the BOOST key. The LED above the BOOST key
will light, and remain lit until the configured boost duration has expired or you stop the
boost function.
To stop the boost function before the configured boost duration time has expired,
press the BOOST key or the MODE key. The boost will be terminated and the LED
above the BOOST key will go off.
2.7
Changing the Controller Mode
Unless the MODE key has been disabled (see 12.5), you can put the controller in normal
(auto) mode for closed loop control, manual mode for open loop control, or standby
mode.17
To change the controller’s mode, press the MODE key until the LED corresponding to
the desired mode is lit.
Pressing the MODE key while a soft start or Autotune operation is active will stop the
operation. If the controller is going through the sequence of startup actions diagrammed
in 1.6, the processing will move on to the next action in the startup sequence.
17
Whether the controller performs closed loop control using the configured standby setpoint or performs
open loop control using the configured standby fixed output percentage depends on the configuration of
the  (standby) menu parameters; see Section 6.
900M056U00B
 Athena Controls, Inc.
2-9
Series RMC Hot Runner Controller Configuration and Operation Manual
2.8
Displaying and Changing the Output in Manual Mode
2.8.1 Displaying the Output Percentage in Use
If you switch the controller from normal (automatic) mode to manual mode using the
MODE key, then the fixed output used when the switchover occurs depends on whether
the process value was within 9 F (5 C) of the setpoint when the operator switched to
manual.

If the process value is within 9 F (5 C) of the setpoint, bumpless transfer will occur.
That means that the fixed output percentage will be set to a calculated value that
typically maintained this setpoint in the past in normal mode. The operator can
change the output as described below.

If the process value is not within 9 F (5 C) of the setpoint when the switchover
occurs, the fixed output percentage will be set to 0% until the operator changes it as
described below.
To display the output percentage being used when the controller is in manual
mode, if the output percentage is not on display in the lower line while the controller is in
manual mode, press the DISPLAY key until the output percentage is displayed.
2.8.2 Changing the Output Percentage
To change the manual mode output percentage, use the
the displayed output percentage value.
and
keys to change
2.8.3 Special Cases When a Fixed Output is Used
If using a fixed output percentage is the configured failsafe action, that special failsafe
fixed output percentage can be changed as described above. However, the change will
not affect the value stored for the  (supervisor) menu’s  (failsafe output
percentage). The  parameter’s value can be changed only in configuration (that is,
using the supervisor menu).
If the controller is using a fixed output percentage because open loop boost is active, or
because the controller is in open loop standby mode, the output percentage used is the
configured boost fixed output percentage or standby fixed output percentage. You
cannot change the output percentage as described in 2.8.2. The boost output
percentage and the standby output percentage can be changed only in configuration
mode (that is, using the boost or standby menu).
2-10
 Athena Controls, Inc.
900M056U00B
User Interface
2.9
Using Local Communication
If a controller is configured for local communication (see 9.2) and the controller has been
assigned to a usage group (see 9.4.4), then you can use that controller as an ALL
master. When a controller is ALL master, you can use it to activate the boost, change the
mode, change the setpoint, or change the manual mode output in other RMC controllers.
An ALL master can communicate with RMC controllers in the same usage group as the
master, if the controllers are in the ALL master’s mainframe, or in mainframes that are
linked via an RS-485 network with the ALL master’s mainframe.
To make a controller ALL master, press
and
simultaneously.18 The ALL
master’s green ALL LED will light. While this LED is lit, the controller is ALL master.19
You can use its front panel to make changes to the operation of every controller in its
usage group (within its mainframe or among mainframes linked by an RS-485 network).
To make a change to all the controllers in the ALL master’s usage group in
networked mainframes, use the keypad of the ALL master as you ordinarily would.

Mode changes and the activation of the boost are transmitted immediately to all
the other controllers in the ALL master’s group.

Setpoint and output changes are transmitted to the other controllers when you
have completed changing the value on the ALL master.
and
simultaneously
If you do not press another key within 5 seconds of pressing
(or during a 5 second interval while the ALL LED is lit), ALL mastership will be cancelled
automatically. To cancel ALL mastership manually, press
while the ALL master’s green ALL LED is lit.
and
simultaneously
If the ALL master experiences a problem, such as a ground fault error or a short in the
TRIAC output, ALL mastership is automatically cancelled.
Each controller can be assigned to only one usage group. However, up to three
usage groups can co-exist in a single mainframe (or networked mainframes).
Enable ALL mastership on only one controller at a time in a mainframe (or
networked mainframes). If more than one ALL master is active at the same time,
network collisions can occur. The results will be unpredictable and may be
undesirable.
Caution
18
If a controller is configured to use no communication or MODBUS communication (the default), then
pressing
and
simultaneously has no effect.
19
Series RMB controllers can be installed in the same mainframe with Series RMC controllers. However,
the RMB controllers do not support communications. Therefore, changes to RMB controllers cannot be
implemented using an RMC ALL master.
900M056U00B
 Athena Controls, Inc.
2-11
Series RMC Hot Runner Controller Configuration and Operation Manual
2.10 Working in Configuration Mode
2.10.1 Entering and Exiting Configuration Mode
We recommend that you put the controller into standby mode as described in 2.7 before
entering the menu system.
To enter configuration mode, assuming the access level of the controller is set to
configuration (see 12.4), press and hold the DISPLAY key to access the configuration
menu system.
To exit configuration mode, press and hold the DISPLAY key until the process value is
displayed. (If you do not press any keys for 5 minutes while in configuration mode, you
will be timed out automatically.)
2.10.2 Procedure for Viewing and Changing a Configuration Parameter
Value
To view a parameter’s current value:
1. Access configuration mode by pressing and holding the DISPLAY key until  is
displayed on the top line (approximately 3 seconds).  is abbreviated name of the
first menu, PID control.20
2. Press the DISPLAY key repeatedly to step through the available menus.
3. Once the name of the menu of interest is on the top line of the display, press the
MODE key once (briefly) to display the first parameter in the menu. The abbreviated
name of the parameter will be on the lower line, alternating with the current value for
the parameter stored in the controller’s database.
4. To step through the parameters in the displayed menu, press the MODE key
repeatedly.
5. When the parameter of interest is on display, stop pressing the MODE key. The
abbreviated parameter name will alternate with the value or choice currently stored in
the controller’s database.
6. To change the current choice or numeric value, use the
and
keys.
7. When the desired choice or numeric value is on display, press the MODE key once.
The displayed choice or value will be written to the controller’s database. The next
parameter in the menu (or the first parameter if you were at the end of the menu) will
be displayed.
20
The controllers are shipped from the factory with SW2-switch 7 OFF. Therefore, the  (access)
menu is not included in the display cycle. If you set SW2-switch 7 to ON, the  menu will be displayed
before the  menu; see Section 12 for details.
2-12
 Athena Controls, Inc.
900M056U00B
User Interface
At this point you can:

change the value of the newly displayed parameter using the
or

if you like the current value of the parameter on display, you can press the
MODE key to leave the displayed value unchanged and go on through the
parameters in the menu, or

go to the next menu by pressing the DISPLAY key once, then use the MODE key
to step through the parameters in that menu, or

display menus later in the cycle by pressing the DISPLAY key repeatedly, or

exit configuration by pressing and holding the DISPLAY key until the normal
operating display returns to view.
and
keys,
If you do not press any key, eventually you will be timed out of the menu system. The
controller will revert to the operational display that was in view before you entered the
menu system. The value that was on display when you were timed out of configuration
will be saved to the controller’s database automatically.
2.10.3 Configuration Example
Suppose that once the controller is in operation you want to adjust the standby setpoint
and the high-temperature safety value.
1. Press the MODE key repeatedly until the STANDBY LED lights.21
2. Press and hold the DISPLAY key (approximately three seconds) until  is
displayed on the top line, and  alternating with the proportional band value on the
lower line.
3. Press the DISPLAY key once;  (boost) will be displayed on the top line.
4. Press the DISPLAY key again;  (standby) will be displayed on the top line.
5. Press the MODE key until the  (standby setpoint) parameter is on the lower line,
alternating with the current standby setpoint value.
6. Use the
and
keys to change the value.
7. To write this new setting to the controller’s database, press the MODE key once. The
new setting will be saved and  (standby type) will be displayed on the lower line.
(The standby setpoint is the last parameter in the standby menu when closed loop
standby is configured, so the controller goes to the top of the menu and shows you
the first display parameter, standby type.)
21
When you power up the controller, it may begin a CompuStep soft start, followed by an
Autotune operation (see 1.6). In this case, the first time you press the MODE key the soft start
will be stopped. The second time you press the MODE key the Autotune operation will be
stopped. Subsequent presses of the MODE key will affect the controller mode, as you can see by
watching the NORMAL, MANUAL, and STANDBY LEDs.
900M056U00B
 Athena Controls, Inc.
2-13
Series RMC Hot Runner Controller Configuration and Operation Manual
8. To move to the next menu, press the DISPLAY key once. The top line will display
 (input).
9. Press the DISPLAY key repeatedly to move through the menus.
10. When  (supervisor) is on the top line, press the MODE key to step through the
parameters in the supervisor menu.
11. The second parameter in the supervisor menu is  (high-temperature safety
value). The lower line display will alternate  and the current high-temperature
limit value.
12. Use the
and
keys to change the value.
13. To write this new setting to the controller’s database, press the MODE key once. The
new setting will be saved and the name of the next parameter in the supervisor menu
 (failsafe value) will be displayed on the top line.
14. The two configuration changes you wanted to make have been accomplished, so you
can press and hold the DISPLAY key until the process value is again displayed on
the top line.
If you do not press and hold the DISPLAY key, after approximately 5 minutes the
controller will automatically go back to the normal operating display, with the process
value on the top line, and setpoint or other value is displayed on the lower line (see
2.3.4).
If you do not press the DISPLAY key after you change a parameter value, but before you
are timed out, the change will be saved to the controller’s database automatically.
2-14
 Athena Controls, Inc.
900M056U00B
3. Enabling SafeChange and
Setting the Switches
Warning
Use of this equipment in a manner not specified by the manufacturer may
impair protection provided by the equipment.
Hazardous potentials exist on components inside the mainframe and
controller. Always disconnect AC power to the mainframe when servicing
the controllers or the mainframe.
The controller power switch must be in the “OFF” position before you put a
controller into an energized mainframe, or remove a controller from an
energized mainframe. If the mainframe supports the SafeChange feature,
enable SafeChange on the controller to reduce the possibility of damage to
the controller when installing a controller or removing a controller from the
mainframe. Controllers are shipped with the SafeChange feature disabled.
To determine whether the mainframe supports SafeChange and to enable
SafeChange, follow the instructions in this section.
Failure to observe these precautions can result in exposure to a potentially
lethal shock hazard.
Changing DIP switch and jumper settings, and all wiring should be done by
an experienced technician and be installed in accordance with national and
local electrical codes. To avoid serious personal injury and damage to
equipment, follow all warnings and cautions provided in the manual
supplied with the mainframe.
3.1
Introduction
Controllers are shipped with SafeChange disabled, because the controller will not work if
the SafeChange feature is enabled, but the mainframe does not support SafeChange.
You can enable SafeChange quickly and easily using a jumper as described in this
section.
Some basic set up choices are made using DIP switches as described in this section.
The switches in a Series RMC Hot Runner controller are set at the factory for J
thermocouple as the input type. The factory setting for unit of measure depends on the
shipping destination; see 3.5.
If you plan to use a K thermocouple for input and/or if you plan to display the process
value and enter the setpoint in the temperature scale that is not the default for your
location, you must change these switch settings. When you change the unit of measure
(temperature scale) the controller recalculates any temperature values that have already
been specified (such as the setpoint range limits). Therefore, we recommend changing
the unit of measure before doing configuration.
Other switch settings that affect how the controller behaves under certain circumstances
can be changed before or after configuration.
900M056U00B
 Athena Controls, Inc.
3-1
Series RMC Hot Runner Controller Configuration and Operation Manual
3.2
Checking Mainframe for SafeChange Capability
Do not enable SafeChange on a controller unless the mainframe supports this feature.
To check the mainframe for SafeChange capability:
1. Turn off power to the mainframe.
2. Remove a blanking panel or a controller that is OFF, so you can look into the
mainframe.
3. Look at the lower connector block on the backplane.

If a metal clip is in the third position in the connector block, then the mainframe
supports SafeChange (see below). You should enable SafeChange on the
controller before installing it in the mainframe to reduce the possibility of damage
to the controller.
Use of the SafeChange feature does not eliminate the need for careful
installation and removal of controllers.

If the third position in the connector block does not contain a metal clip, then the
mainframe does not support SafeChange.
Location of Clip in Mainframe to Support SafeChange
3-2
 Athena Controls, Inc.
900M056U00B
Enabling SafeChange and Setting Switches
3.3
Enabling the SafeChange Feature
Controllers are shipped with SafeChange disabled, because the controller will not work if
the SafeChange feature is enabled, but the mainframe does not support SafeChange.
You can enable SafeChange quickly and easily.
Location of SafeChange Jumper JP6
To enable the SafeChange feature on a controller, remove the jumper block from JP6.
If you don’t see JP6, the controller in hand may pre-date the SafeChange feature. In
addition to JP6 in the location shown above, controllers that support SafeChange also
have one edge connector shorter than the others. If all the edge connectors are the
same length, the controller does not support the SafeChange feature.
SafeChange Edge Connector
900M056U00B
 Athena Controls, Inc.
3-3
Series RMC Hot Runner Controller Configuration and Operation Manual
3.4
Location of DIP Switches
The location of the bank of setup DIP switches (SW2) is shown below.
Location of DIP Switches
3-4
 Athena Controls, Inc.
900M056U00B
Enabling SafeChange and Setting Switches
3.5
Factory Switch Settings
Every Series RMC Hot Runner controller is shipped from the factory with the switches set
as shown in the table below. The ON position is toward the center of the board.
SW2
Switch
Associated
Function
If OFF
If ON
Factory
Setting
1
soft start
soft start only when
ground fault has been
detected
soft start every time
controller is powered
up
ON
2
input type
J thermocouple
K thermocouple
OFF
3
unit of measure
degrees Fahrenheit
degrees Celsius
depends on
shipping
destination: OFF
for North
America
ON for all others
4
production test
normal operation
production test; factory
use only; do not close
unless told to do so by
a member of our
Technical Support
team
OFF
5
load default
parameters
normal operation
load default parameter
values (except for
communication
parameters) next time
controller is powered
up
OFF
6
start mode
start in normal
(automatic) mode
start in last mode used
OFF
7
expanded menu
no access to menu
used to configure the
access level
access to all menus,
including the access
menu
OFF
8
reserved for future use
Information about the functions of SW2-switches 1, 2, 3, 6, and 7 is in this section.
Instructions for using SW2-switch 5 to load parameter defaults are in Section 16.
Information about using SW2-switch 7 to enable display of the menu used to specify the
access level is in Section 12.
3.6
Specifying the Input Type
The setting of SW2-switch 2 must match the type of sensor used.

If SW2-switch 2 is OFF (the factory setting), the controller is set to receive input
from a J thermocouple.

If SW2-switch 2 is ON, the controller is set to receive input from a K
thermocouple.
900M056U00B
 Athena Controls, Inc.
3-5
Series RMC Hot Runner Controller Configuration and Operation Manual
3.7
Selecting Unit of Measure
The unit of measure (temperature scale) used by the controller for internal operations, for
the controller display, and for external communications, is set by means of SW2-switch 3.

If SW2-switch 3 is OFF (the factory setting for units shipped to destinations in
North America), the controller uses degrees Fahrenheit.

If SW2-switch 3 is ON (the factory setting for units shipped to destinations
outside North America), the controller uses degrees Celsius.
When you change the units of measure switch setting, the controller recalculates any
temperature values that have already been specified, such as the setpoint, setpoint limits,
and high temperature safety value.
For example, if you want the setpoint high limit to be 400 C, but the controller is set to
use F, then you must change the units from F to C before you write the setpoint high
limit of 400 to the controller. If you change the units after you write the setpoint high limit
of 400 to the controller, the controller will convert the 400 F setpoint high limit to 222 C
when you power up the controller after changing the switch. In this case, you would have
to reconfigure the setpoint high limit to 400 C to implement the control needed by your
process.
3.8
Enabling Soft Start
The Series RMC Hot Runner controllers support the CompuStep soft start feature, which
allows slow dissipation of moisture in heaters, by gradually applying power to the heaters.
SW2-switch 1 determines when a soft start will be executed.

If SW2-switch 1 is ON (the factory setting), a soft start will be executed every
time the controller is powered up or upon every return to normal (automatic)
mode, assuming that the process temperature is below 200 F (93 C).

If SW2-switch 1 is OFF, a soft start will be executed only when a controller
detects a ground fault (see 1.2.5.7).
You can change the setting of SW2-switch 1 after the controller has been configured
without adversely affecting the configuration.
3-6
 Athena Controls, Inc.
900M056U00B
Enabling SafeChange and Setting Switches
3.9
Selecting the Mode to Be Used at Power Up
The mode (automatic or manual) used by the controller when it is powered up depends
on the setting of SW2-switcch 6.

If SW2-switch 6 is OFF (the factory setting), the controller will start in normal
(automatic) mode. The controller’s behavior at start up in normal mode is also
affected by the SW2-switch 1 setting and the  (PID control) menu’s 
(Autotune operation) parameter setting (see 1.6 and 11.3.4).

If SW2-switch 6 is ON, the controller will always start in the last mode used
before power was removed.

If the controller was in normal (automatic) mode, the controller will be in
normal when it is powered up. The controller’s behavior at start up in
normal mode is also affected by the SW2-switch 1 setting and the 
(PID control) menu’s  (Autotune operation) parameter setting (see
1.6 and 11.3.4). With or without soft start and Autotune, the setpoint
stored on the EEPROM will be used.

If the controller was in manual mode, the controller will be in manual
when it is powered up. Depending on the SW2-switch 1 setting, a
manual mode soft start may be used. The fixed output percentage used
(at the conclusion of the soft start, if any) will be the last one stored on
the EEPROM by the controller.22 (A new controller will use 0%.)
22
If SW2-switch 6 is ON and the controller is in manual mode, then every 10 seconds the output percent
value being used will be compared to the most recent manual mode output stored on the EEPROM. If
the values do not match, the currently used output value will be written to the EEPROM.
900M056U00B
 Athena Controls, Inc.
3-7
Series RMC Hot Runner Controller Configuration and Operation Manual
3-8
 Athena Controls, Inc.
900M056U00B
4. General Information About
Configuration Parameters
4.1
Information in This Section
This section contains general information about the configuration parameters used by the
Series RMC controllers. Sections 5 through 12 contain information about functional
groups of parameters. Each section describes the parameters in a single configuration
menu.
4.2
How to Use Sections 5 through 12
You do not have to read all of Sections 5 through 12. You can skip any sections marked
“optional” that do not apply to your application. You can also skip some parts of some of
the required sections. The path you take as you read will be determined by your control
strategy.
For example, in Section 5 everyone needs to know about the information in 5.1 and 5.2,
so there are no stop signs to interrupt your reading. However, when you get to the end of
5.2 you will see:
What’s next after you have specified the boost control type?
If you chose closed loop control, go to 5.3.
If you chose open loop control go to 5.4.
This means that you should look at either 5.3 or 5.4, but you do not have to read both. If
a parameter (in this case, boost duration) applies to both closed loop and open loop
boost, it is included in both 5.3 and 5.4.
900M056U00B
 Athena Controls, Inc.
4-1
Series RMC Hot Runner Controller Configuration and Operation Manual
4.3
Information Provided About Each Parameter
4.3.1 Summary
Each menu consists of a functional group of parameters. For each parameter the
following information is provided:

parameter name

abbreviated name as displayed

when displayed – This paragraph indicates whether the parameter applies
to all control strategies (“always”) or only under certain circumstances (which
are identified).

choices or range – If you must make a selection from a list, all the choices
are listed in the sequence in which they appear if you scroll through the list
key. If you must specify a numerical value, then the range of
using the
valid values is defined.
4.4

factory default value – The default value is shown for each configuration
parameter. The configuration parameter values can be returned to their
default values using the procedure in Section 16.

description – The purpose of the parameter and any special information you
need to know to use this parameter is provided.

effect on other parameters – For some parameters, additional information
is included. If applicable, this paragraph tells how the value selected for a
parameter affects other parameters.
Menu and Parameter Display Sequence
The menus and parameters are displayed in the sequence shown in the following table.
When a new controller is powered up, the menu sequence starts with the  (PID
control) menu, because the  (access) menu is displayed only when SW2-switch 7 is
ON. Controllers are shipped with SW2-switch 7 OFF.
Within the menus, the parameters are displayed in the sequence shown in the following
table. However, not all parameters apply to every application.
If a parameter does not apply to a particular control strategy, then that parameter will not
be displayed. For example, if you specify that the communication protocol is “local”, then
only parameters that apply to local communication are displayed in the SCI menu.
4-2
 Athena Controls, Inc.
900M056U00B
General Information About Configuration Parameters
Displayed
Abbreviation
(menu name)

(access)

(PID control)

(boost)

(standby)

(input)

(alarm)

(serial
communication
interface)

(supervisor)
Access
Enabled
(see Note 1 below)
Parameters
Described
In



Only when SW2-switch 7 is
ON.
Section 12



Whenever the access level is
set to  (configuration).
Section 1


 (closed loop boost)
 (open loop boost)
Whenever the access level is
set to  (configuration).
Section 5

 (closed loop standby)
 (open loop standby)
Whenever the access level is
set to  (configuration).
Section 6



Whenever the access level is
Section 7




Whenever the access level is
set to  (configuration).
Section 8

 (MODBUS only)


 (MODBUS only)
 (local only)
Whenever the access level is
set to  (configuration).
Section 9



 (if failsafe action is to use a
Whenever the access level is
Section 10
set to
set to
 (configuration).
 (configuration).
failsafe fixed output percent)
 (read-only value; can be reset)
 (read-only value; can be reset)
Note 1: The access level is configured using the  menu’s  parameter. The access
menu is displayed only when SW2-switch 7 is ON. Controllers are shipped with SW2-switch 7
OFF.
900M056U00B
 Athena Controls, Inc.
4-3
Series RMC Hot Runner Controller Configuration and Operation Manual
4.5
Using Factory Defaults
Sections 5 through 12 include the factory default value for every parameter. If you want
to use the default for a particular parameter, you do not have to take any action. You do
not have to access the parameter at all. For example, if you are content to use the
default values for all the parameters in the  (input) menu, then when you have
completed configuration of the  (standby) menu, you can press the DISPLAY key to
step to the  menu, then immediately press DISPLAY again to move on to the 
(serial communications interface) menu.
4-4
 Athena Controls, Inc.
900M056U00B
5. Boost Parameters – Required If Boost
Feature Will Be Used
5.1
Introduction
Although the  (PID control) menu is the first displayed, do not configure it now.
Once you have set the switches, the next step is to power up the controller, and put it in
standby by pressing the MODE key repeatedly until the STANDBY LED lights. Next,
configure the setpoint range using the  (input) menu’s  (setpoint low limit) and
 (setpoint high limit) parameters as described in 7.3. This range will affect the
values you can enter as the boost setpoint described in this section, and the standby
mode setpoint described in 6.3. You can skip configuring the setpoint range if you are
satisfied to use the default range 32 to 999 F (0 to 537 C), or if you plan to use open
loop control during the boost and in standby mode.
If you want the operator to be able to use the boost function described in 1.2.4, next use
the  (boost) menu to specify the type of control that will be used during the boost.
Your choices for the type of control used during the boost are:

open loop (the default), in which the input from the sensor has no effect on the
output used; in this mode a configurable boost fixed output percentage is used

closed loop, in which the input from the sensor will be used by the controller to
calculate the output based on the configured boost setpoint
You also must specify the length of time the boost will last.
Depending on the type of control you select for the boost, you then configure the boost
fixed output or the boost setpoint.
If you do not want the boost function to be available to the operator, you must disable the
BOOST button as described in 12.6.
The bST (boost) menu is displayed whenever configuration is enabled using the 
(access) menu. New RMC controllers are shipped from the factory with configuration
enabled.
The boost parameters are shown in the table below. Descriptions of the individual
parameters are later in the subsection.
Item
Parameter Name
When Displayed

Boost Control Type
always

Boost Duration
always

Boost Setpoint
if boost type is closed loop
900M056U00B
 Athena Controls, Inc.
5-1
Series RMC Hot Runner Controller Configuration and Operation Manual

Boost Fixed Output Percentage
if boost type is open loop
The process of configuring the boost parameters is diagramed below.
5.2 Specifying Whether Open or Closed Loop Control Will Be
Used During the Boost
5.2.1 Parameter Used
Parameter Name:
Name as Displayed:

When Displayed:
always
Choices:
Default:
Description:
Effect on Other
Parameters:
5-2
Boost Control Type
 open loop
 closed loop
open loop
The type of control used during the boost. With open loop
control the input from the sensor has no effect on the output
used; the output will be the boost fixed output percentage. With
closed loop control the input from the sensor will be used by the
controller to calculate the output based on the configured boost
setpoint.
Determines whether you can configure a fixed output percentage
or a setpoint for the boost function.
 Athena Controls, Inc.
900M056U00B
Boost Parameters
5.2.2 Procedure for Viewing the Currently Selected Boost Type
To view the boost type currently set for the controller:
1. Press the MODE key until the controller is in standby mode (STANDBY LED lit).
2. Access the configuration menus by pressing the DISPLAY key until  is displayed
on the top line (approximately 3 seconds). This is the abbreviated name of the first
menu, PID control.
3. Press the DISPLAY key once; , the name of the boost menu is displayed on the
top line.
4. Press the MODE key briefly. The lower line displays  alternating with the
currently configured choice for this parameter. For example, in an out-of-the box
controller,  will alternate with the display of  (open loop).
5.2.3 Procedure for Changing the Boost Type Selection
To change the boost type selection:
1. Press
or
to cycle through the two boost type choices until the boost type you
want is displayed on the lower line.
2. Press the MODE key once to write the configuration change to the controller’s
EEPROM and display the next parameter () in the boost menu.
What’s next after you have specified the boost control type?
If you chose closed loop control, go to 5.3.
If you chose open loop control go to 5.4.
900M056U00B
 Athena Controls, Inc.
5-3
Series RMC Hot Runner Controller Configuration and Operation Manual
5.3
Configuring Boost Parameters When Closed Loop Control
Is Used
5.3.1 Selecting the Duration of the Boost Period
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Default:
Description:
Boost Duration

always
off
15 seconds
30 seconds
45 seconds
60 seconds
75 seconds
90 seconds
105 seconds
120 seconds
off
The duration of the boost in seconds.
5.3.2 Specifying the Boost Setpoint
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Boost Setpoint

if the boost control type is closed loop
 to  (setpoint low limit to setpoint high limit from
input menu) (See Note 1 below.)
Default:
Description:
100 F
38 C (See Note 2 below.)
The setpoint used for the duration of the boost.
Note 1: If the setpoint range is changed after the boost setpoint has been configured,
and the boost setpoint is not within the new setpoint range, then the boost setpoint value
will automatically be set to match the new setpoint low limit.
Note 2: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
If you are using closed loop control during the boost, you have
finished configuration of boost parameters. The remainder of
this chapter does not apply to your application.
Go to Section 6 – Standby Parameters.
5-4
 Athena Controls, Inc.
900M056U00B
Boost Parameters
5.4
Configuring Boost Parameters When Open Loop Control
Is Used
5.4.1 Selecting the Duration of the Boost Period
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
Boost Duration

always
off
15 seconds
30 seconds
45 seconds
60 seconds
75 seconds
90 seconds
105 seconds
120 seconds
off
The duration of the boost in seconds.
5.4.2 Specifying the Boost Fixed Output Percentage
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
900M056U00B
Boost Fixed Output Percentage

if the boost control type is open loop
0 to 100 percent
0%
The fixed output percentage used for the duration of the boost.
 Athena Controls, Inc.
5-5
Series RMC Hot Runner Controller Configuration and Operation Manual
5-6
 Athena Controls, Inc.
900M056U00B
6. Standby Parameters – Recommended
6.1
Introduction
The  (standby) menu is used to customize the behavior of the controller while the
operator has placed it in standby mode, assuming the MODE key has not been disabled
using the  (access) menu (see 12.5).
Your choices for the type of control used while the controller is in standby mode are:

open loop (the default), in which the input from the sensor has no effect on the
output used; in this mode a configurable standby fixed output percentage is
used

closed loop, in which the input from the sensor will be used by the controller to
calculate the output based on the configured standby setpoint
Depending on the type of control you select for standby mode, you then configure the
standby fixed output or the standby setpoint.
The Stb (standby) menu is displayed whenever configuration is enabled using the 
(access) menu. New RMC controllers are shipped from the factory with configuration
enabled.
The standby parameters are shown in the table below. Descriptions of the individual
parameters are later in the subsection.
Item
Parameter Name
When Displayed

Standby Control Type
always

Standby Setpoint
if standby type is closed loop

Standby Fixed Output Percentage
if standby type is open loop
900M056U00B
 Athena Controls, Inc.
6-1
Series RMC Hot Runner Controller Configuration and Operation Manual
The process of configuring the standby parameters is shown below.
6.2
Specifying Whether Open or Closed Loop Control Will Be
Used While in Standby Mode
Parameter Name:
Standby Control Type
Name as Displayed:

When Displayed:
always
Choices:
Default:
 open loop
 closed loop
open loop
Description:
The type of control used while the controller is in standby mode.
With open loop control the input from the sensor has no effect on
the output used; the output will be the standby fixed output
percentage. With closed loop control the input from the sensor
will be used by the controller to calculate the output based on
the configured standby setpoint.
Effect on Other
Parameters:
Determines whether you can configure a fixed output percentage
or a setpoint for standby.
Which standby parameters apply to your application?
If you chose closed loop control, 6.3.
If you chose open loop control, go to 6.4.
6-2
 Athena Controls, Inc.
900M056U00B
Standby Parameters
6.3
Specifying the Closed Loop Standby Setpoint
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Standby Setpoint

if the standby control type is closed loop
 to  (setpoint low limit to setpoint high limit from
input menu) (See Note 1 below.)
Default:
Description:
100 F
38 C (See Note 2 below.)
The setpoint used while the controller is in standby mode.
Note 1: If the setpoint range is changed after the standby setpoint has been configured,
and the standby setpoint is not within the new setpoint range, then the standby setpoint
value will automatically be set to match the new setpoint low limit.
Note 2: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
If you are using closed loop control in standby, you have finished
configuration of standby parameters. The remainder of this
chapter does not apply to your application.
Go to Section 7 – Input Parameters.
6.4
Specifying the Open Loop Standby Fixed Output
Percentage
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
900M056U00B
Standby Fixed Output Percentage

if the standby control type is open loop
0 to 100 percent
0%
The fixed output percentage while the controller is in standby
mode.
 Athena Controls, Inc.
6-3
Series RMC Hot Runner Controller Configuration and Operation Manual
6-4
 Athena Controls, Inc.
900M056U00B
7. Input Parameters – Required
7.1
Introduction
Every Series RMC controller is shipped with SW2-switch 2 OFF. That means that the
controller is ready to accept input from a J thermocouple. If you plan to use a K
thermocouple to provide the input to the controller, set SW2 switch 2 to ON.
Read the safety warnings in Section 3 before changing switch settings.
The  (input) menu is used to specify the bias (if any) to be applied to the input, and to
specify the setpoint range.
The input menu is displayed whenever configuration is enabled using the  (access)
menu. New RMC controllers are shipped from the factory with configuration enabled.
The input parameters are shown in the table below. Descriptions of the individual
parameters are later in the subsection.
Item
Parameter Name
When Displayed

Input Bias
always

Setpoint Low Limit
always

Setpoint High Limit
always
900M056U00B
 Athena Controls, Inc.
7-1
Series RMC Hot Runner Controller Configuration and Operation Manual
The process of configuring the input parameters is shown below.
7.2
Applying a Bias to the Temperature Input
Parameter Name:
Input Bias
Name as Displayed:

When Displayed:
always
Range:
Default:
–100 to 100 F
–56 to 56 C (See Note 1 below.)
0
Description:
Applying bias allows you to compensate for any difference (plus
or minus) between sensor reading and the location to be
measured. The displayed process variable and setpoint will be
offset by the value entered here.
Effect on Other
Parameters:
No effect on other configuration parameters. However, the bias
will be applied to the displayed PV and the active setpoint.
Note 1: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
7-2
 Athena Controls, Inc.
900M056U00B
Input Parameters
7.3
Specifying the Setpoint Range
Configure the setpoint range, that is, the range of setpoint values the operator can enter
using the front panel. The range specified here also limits the values that can be
configured for the boost setpoint and standby setpoint.
The Setpoint Low Limit and the Setpoint High Limit must not be set to the same value.
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
Parameter Name:
Name as Displayed:
When Displayed:
Range
Default:
Description:
Setpoint Low Limit

always
32 to 999 F
0 to 537 C (See Note 1 below.)
32 F
0 C
This is the lowest value that can be entered by the operator as a
setpoint (before bias is applied). This is also the lowest value
that can be configured as the boost setpoint (see 5.3.2) and the
standby setpoint (see 6.3).
Setpoint High Limit

always
32 to 999 F
0 to 537 C (See Note 1 below.)
999 F
537 C
This is the highest value that can be entered by the operator as
a setpoint (before bias is applied). This is also the highest value
that can be configured as the boost setpoint (see 5.3.2) and the
standby setpoint (see 6.3).
Note 1: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
900M056U00B
 Athena Controls, Inc.
7-3
Series RMC Hot Runner Controller Configuration and Operation Manual
7-4
 Athena Controls, Inc.
900M056U00B
8. Alarm Parameters – Optional
8.1
Introduction
Each Series RMC Hot Runner controller supports two deviation alarms, each with its own
configurable alarm setpoint. If the process value falls below the setpoint minus the
deviation low setpoint, or if the process value exceeds the setpoint plus the deviation high
setpoint, the red ALARM LED on the front panel of the controller will light. The alarm
status indicator will remain lit as long as the process value is below or above the
deviation setpoints.
Alarm configuration is done using the  (alarm) menu.
The alarm menu is displayed whenever configuration is enabled using the  (access)
menu. New RMC controllers are shipped from the factory with configuration enabled.
The alarm parameters are shown in the table below. Descriptions of the individual
parameters are later in the subsection.
Item
Parameter Name
When Displayed

Alarm Operation
always

High Deviation Alarm Setpoint
always

Low Deviation Alarm Setpoint
always

Alarm Inhibit
always
900M056U00B
 Athena Controls, Inc.
8-1
Series RMC Hot Runner Controller Configuration and Operation Manual
The process of alarm configuration is shown below.
8.2
Enabling the Alarm Feature
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Default:
Description:
Effect on Other
Parameters:
8-2
Alarm Operation

always


disabled
enabled
enabled
Determines whether the controller will use the alarm function.
If alarm operation is disabled, the other parameters in the alarm
menu will not be displayed.
 Athena Controls, Inc.
900M056U00B
Alarm Parameters
If you disabled the alarm function, the remainder of this chapter
does not apply to your application (although you can continue to
configure alarm values for future use).
Go to Section 9 – Communication Parameters.
8.3
Specifying the Deviation Alarm High and Low Setpoints
Parameter Name:
High Deviation Alarm Setpoint
Name as Displayed:

When Displayed:
always
Range:
Default:
Description:
Parameter Name:
1 to 967 F
1 to 537 C (See Note 1 below.)
30 F
17 C
Number of degrees the process value must exceed the setpoint
to trigger the alarm state.
Low Deviation Alarm Setpoint
Name as Displayed:

When Displayed:
always
Range:
Default:
Description:
Effect on Other
Parameters:
1 to 967 F
1 to 537 C (See Note 1 below.)
30 F
17C
Determines whether the controller will use the alarm function.
Number of degrees the process value must fall below the
setpoint to trigger the alarm state.
Note 1: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
900M056U00B
 Athena Controls, Inc.
8-3
Series RMC Hot Runner Controller Configuration and Operation Manual
8.4
Inhibiting the Alarm – Optional
If you specify an alarm inhibit time, the controller will not signal an alarm state following
power up until the alarm inhibit time has elapsed. This is particularly useful for preventing
activation of low alarms during startup (before the process has had time to reach
operating temperature).
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
8-4
Alarm Inhibit

always
0 to 999 seconds
0 (off)
Used to specify the number of seconds the controller should wait
after power up before signaling an alarm condition.
 Athena Controls, Inc.
900M056U00B
9. Communications Parameters –
Recommended
9.1
Introduction
Every Series RMC Hot Runner controller supports RS-485 serial communications. If you
choose to use this communication capability, you have two choices: MODBUS or local
communication.

MODBUS communication using a MODBUS master – You can network the
controllers to a MODBUS host. This host can read and write to every
configuration parameter in a RMC controller’s database. The host can also
read every status value available in the database, including which LEDs are
lit. 23 Guidelines for using a MODBUS host to communicate with the Series RMC
Hot Runner controllers are in Using the MODBUS Protocol with Athena Series
RMC Hot Runner Controllers.

local communication using an ALL master – You can assign each RMC
controller to one of three usage groups. The front panel of any controller in a
usage group can be used to activate the boost, change the mode, change the
setpoint, or change the manual mode output in all other RMC controllers in the
same usage group (within the same mainframe or in mainframes that are linked
via an RS-485 network).
This is accomplished by making any one of the controllers in the usage group
the ALL master temporarily by pressing
and
simultaneously. The ALL
master’s green ALL LED will light, and remain lit while the controller is ALL
master. (If you do not press another key within 5 seconds of pressing
and
simultaneously (or during a 5 seconds interval while the ALL LED it lit), ALL
mastership is cancelled automatically; see 2.9.)
The  (serial communications interface) menu is used to specify the type of
communication to be used (if any), and to configure the parameters associated with the
type of communication you specify.
The serial communication menu is displayed whenever configuration is enabled using the
 (access) menu. New RMC controllers are shipped from the factory with
configuration enabled.
If you use SW2-switch 5 as described in Section 16 to return configuration parameter
values to the defaults, the communication parameter values will not be changed.
23
Peer-to-peer communications are not supported by the MODBUS protocol.
900M056U00B
 Athena Controls, Inc.
9-1
Series RMC Hot Runner Controller Configuration and Operation Manual
The communication parameters are shown in the table below. Descriptions of the
individual parameters are later in the subsection.
Item
9-2
Parameter Name
When Displayed

Communication Protocol
always

System ID (controller address)
if MODBUS protocol is selected

Baud Rate
if MODBUS or local communication is
selected

Data Format (Parity)
if MODBUS or local communication is
selected

IEEE Register Ordering
if MODBUS protocol is selected

Usage Grouping
if local communication is selected
 Athena Controls, Inc.
900M056U00B
Communication Parameters
The process of configuring the controller for serial communications is shown below.
900M056U00B
 Athena Controls, Inc.
9-3
Series RMC Hot Runner Controller Configuration and Operation Manual
9.2
Specifying the Communications Protocol to Be Used
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Default:
Description:
Effect on Other
Parameters:
Communication Protocol

always
 no communication enabled

MODBUS protocol
 local communication
MODBUS
The type of serial communication that will be used by the
controller.
Determines which other communication parameters are
displayed for configuration.
Which communication parameters apply to your application?
If you chose no communication, go to Section 10.
If you chose MODBUS protocol, go to 9.3.
If you chose local communication, go to 9.4.
9-4
 Athena Controls, Inc.
900M056U00B
Communication Parameters
9.3
Configuring Communication Parameters for MODBUS
Protocol
9.3.1 Introduction
The items that appear on the  (serial communications interface) menu in controllers
that are configured to use MODBUS protocol are different from the  menu items
displayed if the controller is configured to use local communications. The MODBUS
communication parameters presented briefly below are described in more detail in Using
the MODBUS Protocol with Athena Series RMC Hot Runner Controllers. We recommend
that you consult that manual before setting up your MODBUS network and configuring
these communication parameters.
9.3.2 Assigning a Unique Controller Address When MODBUS is Used
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
System ID (Controller Address)

if MODBUS protocol is selected
1 to 247
1
Used to assign a unique address to each controller on the
MODBUS network.
9.3.3 Selecting the Baud Rate Applicable to MODBUS Communications
Parameter Name:
Name as Displayed:
When Displayed:

whenever communications are enabled
Choices:
4800
9600
Default:
9600
Description:
900M056U00B
Baud Rate
Used to select the baud rate.
 Athena Controls, Inc.
9-5
Series RMC Hot Runner Controller Configuration and Operation Manual
9.3.4 Selecting the Parity When MODBUS is Used
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Parity

whenever communications are enabled



none
odd
even
(See Note 1 below)
Default:
Description:
none
Used to select the type of parity to be used, if any.
Note 1: Regardless of the parity selected, a Series RMC controller that is configured to
use MODBUS protocol always uses 1 start bit, 8 data bits, and 1 stop bit.
9.3.5 Selecting the Sequence for 32-bit IEEE Registers When MODBUS Is
Used
Parameter Name:
Name as Displayed:
When Displayed:
IEEE Register Ordering

if MODBUS protocol is selected
Choices:


Default:
yes
Description:
MODBUS standard ordering: low register before high
non-standard ordering: high register before low
Used to choose whether the two registers that make up a single
32-bit IEEE floating point value are transmitted in standard
MODBUS sequence (low before high), or not in standard
sequence (high before low)
If you are configuring MODBUS serial communications, you have
finished configuring the communication parameters. The
remainder of this section does not apply to your application
Go to Section 10.
9-6
 Athena Controls, Inc.
900M056U00B
Communication Parameters
9.4
Configuring Communication Parameters for Local
Communications
9.4.1 Introduction
The items that appear on the  (serial communications interface) menu in controllers
that are configured to use local communications are different from the  menu items
displayed if the controller is configured to use MODBUS communications.
9.4.2 Selecting the Baud Rate Applicable to Local Communications
Parameter Name:
Name as Displayed:
When Displayed:
Baud Rate

whenever communications are enabled
Choices:
4800
9600
Default:
9600
Description:
Used to select the baud rate.
9.4.3 Selecting the Parity for Local Communications
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Parity

whenever communications are enabled



none
odd
even
(See Note 1 below)
Default:
Description:
none
Used to select the type of parity to be used, if any.
Note 1: Regardless of the parity selected, a Series RMC controller that is configured to
support local communications always uses 1 start bit, 8 data bits, and 1 stop bit.
900M056U00B
 Athena Controls, Inc.
9-7
Series RMC Hot Runner Controller Configuration and Operation Manual
9.4.4 Specifying the Usage Group
Parameter Name:
Name as Displayed:
When Displayed:
Usage Grouping

if local communication is selected
Choices:



Default:
other
Description:
tip
manifold
other (See Note 1 below)
Used to select the usage group to which the controller will
belong.
Note 1: If you want all the controllers in all the networked mainframes to receive the
same communications from the ALL master, then assign all the controllers to  (other)
group.
9-8
 Athena Controls, Inc.
900M056U00B
10. Supervisor Parameters – Recommended
10.1 Introduction
You can use the  (supervisor) menu to specify several safety-related parameters.
If you specify a loop break time, the controller will turn off the output if the input value
does not change 1% of supported sensor span (9 F or 5 C) in response to output action
within the configured time. Controller activity will not resume until the operator cycles the
power to the controller; see 1.2.5.3 and 10.2.
You can specify a high-temperature safety value. If the process value exceeds this
value, controller processing and output activity is halted. Once the high-temperature
safety value has been exceeded by the PV, the controller will not resume processing and
output activity until the operator cycles power to the controller; see 1.2.5.2 and 10.3.
You can also select the output action to be taken if the controller detects a problem with
the sensor (reversed or open sensor); see 1.2.5.4 and 10.4. One of the failsafe action
choices is using a fixed output percentage, which is also configurable using this menu;
see 10.5.
You can also use this menu to see the highest and lowest process value received by the
controller since it was powered up (or the last time the values were reset); see 10.6.
The  (supervisor) menu is displayed whenever configuration is enabled using the 
(access) menu. New RMC controllers are shipped from the factory with configuration
enabled.
The configuration parameters (and stored viewable values) in the  menu are listed in
the table below. Detailed descriptions are in the following pages.
Item
Parameter Name
When Displayed

Loop Break Time
always

High-Temperature Safety Value
always

Failsafe Action
always

Failsafe Fixed Output
Percentage
if failsafe action selected is failsafe fixed
output percentage

Highest Temperature (PV)
Reading
always

Lowest Temperature (PV)
Reading
always
900M056U00B
 Athena Controls, Inc.
10-1
Series RMC Hot Runner Controller Configuration and Operation Manual
The sequence of configuring the supervisor parameters is shown below:
10-2
 Athena Controls, Inc.
900M056U00B
Supervisor Parameters
10.2 Defining the Loop Break Time
The loop break time parameter is used to specify the length of the time period during
which the input should change 1% of supported sensor span (9.67 F or 5.37 C) in
response to output action if the sensor is working correctly, and the input wiring is intact.
If a loop break is detected, the controller output will be turned off. (See 1.2.5.3 and 13.4
for more information about loop break detection.) This time period is also used when the
controller tests for a “bad heater” error; see 13.6.
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
Loop Break Time

always
9 = off
10 to 999 seconds
999 seconds
Used to specify the time period during which the input should
change 1% of supported sensor span (9.67 F or 5.37 C) in
response to output action if the sensor is working correctly and
the input wiring is intact; see 13.4. This time period also is used
when the controller tests for a “bad heater” error; see 13.6.
10.3 Specifying the Safety High Temperature That Will Trigger
Halt of Controller Activity
The high-temperature safety value parameter is used to specify the process value that
will trigger a halt of controller processing and output activity.
In this case the output will not go to the failsafe state. Instead, the output will be set to
off. The controller processing and output activity will remain off until the operator cycles
the power to the controller.
Parameter Name:
High-Temperature Safety Value
Name as Displayed:

When Displayed:
always
Range:
Default:
Description:
whole number within the range
33 to 999 F
1 to 537 C
or 
(See Note 1 below.)
off
Used to specify the high temperature (PV) that will trigger a halt
of controller processing and output activity.
Note 1: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
900M056U00B
 Athena Controls, Inc.
10-3
Series RMC Hot Runner Controller Configuration and Operation Manual
10.4 Specifying Failsafe Action: What Should Happen to Output
If Sensor Is Bad
The failsafe action is used when the controller detects a problem with the input: open
sensor or reversed sensor. You cannot rely on the controller taking this action if the
controller’s internal circuitry fails.
Parameter Name:
Failsafe Action
Name as Displayed:

When Displayed:
always
Choices:
 = output off
 = use a calculated output value based on output values that
have typically successfully maintained the current setpoint
for your process in the past
 = use fixed output percentage specified with Failsafe Fixed
Output Percentage parameter (see 10.5)
Default:
Description:
off
Used to select the output action to be used when the controller
detects a problem with the input from the sensor.
At the conclusion of an unsuccessful Autotune operation, the
controller also goes to the configured failsafe state automatically.
10.5 Specifying the Failsafe Fixed Output Percentage
If the failsafe action is configured to use the failsafe fixed output percentage, use this
parameter to specify that percentage. Once the controller has gone to the failsafe state,
the operator will be able to change the output percentage in use at that time. However,
the changes will not affect the value stored for the failsafe fixed output percentage
parameter. The next time the controller goes to the failsafe state, the percentage
configured here will again be used as the initial failsafe output percentage.
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
10-4
Failsafe Fixed Output Percentage

if failsafe action is set to use the failsafe fixed output percentage
0 to 100%
0
Used to specify the fixed output percentage the controller will
use if it detects a problem with the input while the failsafe action
is set to use the failsafe fixed output percentage.
 Athena Controls, Inc.
900M056U00B
Supervisor Parameters
10.6 Viewing the Highest and Lowest Process Value Received
Since Last Reset
The highest and lowest process values received from the input sensor. These are readonly values. The displayed values are the highest and lowest process values stored in
RAM since the controller was most recently powered up, or the values were reset.
Every 30 minutes the controller compares the value in RAM with the value in non-volatile
memory (on the EEPROM). If a higher or lower reading has been received in the last 30
minutes, the new highest or lowest value is written to the EEPROM.24
To reset one of these values (in RAM) to its default, press the
value is on display.
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
or
key while the
Highest Temperature (PV) Reading and Lowest Temperature
(PV) Reading
 and 
always
32 to 999 F
0 to 537 C
(See Note 1 below.)
for high: 32 F (0 C)
for low: 999 F (537 C)
Used to view read-only highest and lowest sensor readings
received by the controller since last power up or reset.
Note 1: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
24
The values stored on the EEPROM cannot be viewed using the controller’s front panel. However, they
can be read (and reset) by a MODBUS host.
900M056U00B
 Athena Controls, Inc.
10-5
Series RMC Hot Runner Controller Configuration and Operation Manual
10-6
 Athena Controls, Inc.
900M056U00B
11. Tuning the Controller
for PID Control – Required
11.1 Introduction
The Series RMC Hot Runner controllers use Proportional-Integral-Derivative (PID) control
to modulate the 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. The integral action affects the output based on the
duration of the process value’s variation from the setpoint, and the derivative action
affects the output based on the rate of change of the process value.
The proportional band and derivative action (rate) are automatically adjusted by the
Autotune operation. The integral (reset) action used by an RMC controller is always
equal to five times the configured derivative (rate) action.
If your process experiences extremely long lag time, Autotuning may be unsuccessful. If
this is the case, an error message will be displayed to alert you to that fact (see 11.5). If
Autotuning is not possible, you can tune the controller manually as described in 11.6.
The  menu allows you to view and change the proportional band and derivative (rate)
action manually if necessary.
Unless display of the  (access) menu has been enabled by setting SW2-switch 7 to
ON, the  menu is usually displayed first when configuration is enabled. New RMC
controllers are shipped from the factory with configuration enabled and with display of the
 menu disabled.
11.2 Configuration Sequence and Autotune
By default, every Series RMC controller is configured to execute the Autotune operation
the first time it is powered up, then to disable the Autotune feature after a successful
Autotune has been completed. When the Autotune feature is disabled, the  (PID
control) menu  (Autotune operation) parameter is set to  (disabled). If the
Autotune is not successfully completed, either because the operator interrupts it by
pressing the MODE key or because an Autotune error condition is detected, the Autotune
feature will not be disabled automatically.
The controller must be configured before it is tuned. When you first power up the
controller, it will attempt to do through the normal startup procedure described in 1.6.
Press the MODE key until the controller is in standby mode and configure the controller.
Once all the parameters described in Sections 5 through 10 have been configured,
perform Autotune as described in 11.4.
900M056U00B
 Athena Controls, Inc.
11-1
Series RMC Hot Runner Controller Configuration and Operation Manual
11.3 PID Control Parameters
11.3.1 Summary
The parameters in the  menu are summarized in the table below.
Item
11-2
Parameter Name
When Displayed

Proportional Band
always

Derivative (Rate) Action
always

Autotune Operation
always
 Athena Controls, Inc.
900M056U00B
Tuning the Controller for PID Control
11.3.2 Specifying the Proportional Band for Manual Tuning of PID Control
Do not change the value of this parameter if you plan to rely on Autotuning.
Parameter Name:
Name as Displayed:
When Displayed:
Range:
Default:
Description:
Proportional Band

always
0.1 to 999 F
0.1 to 537 C (See Note 1 below.)
24 F
13 C
Used to specify the width of the band below the setpoint within
which the controller will modulate the output as the process
value approaches the setpoint.
Note 1: The unit of measure used depends on whether SW2-switch 3 is OFF (degrees
Fahrenheit) or ON (degrees Celsius).
11.3.3 Specifying the Derivative (Rate) Action for Manual Tuning of PID
Control
Do not change the value of this parameter if you plan to rely on Autotuning.
Parameter Name:
Derivative (Rate) Action
Name as Displayed:

When Displayed:
always
Range:
Default:
Description:
Effect on Other
Parameters:
900M056U00B
0.0 to 999 seconds
7 seconds
Used to specify the time period used by the derivative
component of the control algorithm when analyzing load
changes.
The integral term for PID control is not configurable in the Series
RMC Hot Runner controllers; the integral (reset) action is always
equal to five times the configured derivative (rate) action.
 Athena Controls, Inc.
11-3
Series RMC Hot Runner Controller Configuration and Operation Manual
11.3.4 Choosing If and When the Autotune Operation Will Be Performed
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Autotune Configuration

always



Default:
Description:
Autotune disabled
Autotune once at next power up, then disable Autotune
only if the Autotune was successful.
Autotune enabled every time controller is powered up
(See Notes 1 and 2 below.)
once
Used to choose if and when the Autotune operation will occur.
Note 1: If the Autotune is not successfully completed, either because the operator
interrupts it by pressing the MODE key or because an Autotune error condition is
detected, the Autotune feature will not be disabled automatically.
Note 2: Regardless of the  setting, the Autotune operation will not be invoked
automatically if SW2-switch 6 is ON to cause the controller to start in the last mode
active, and the controller was in manual mode when powered down. See 1.6 for a fuller
explanation of the factors that affect the controller’s operation following power up.
11-4
 Athena Controls, Inc.
900M056U00B
Tuning the Controller for PID Control
11.4 Autotuning
11.4.1 Introduction
By default, every Series RMC controller is configured to execute the Autotune operation
the first time it is powered up, then to disable the Autotune feature after a successful
Autotune has been completed. When the Autotune feature is disabled, the  (PID
control) menu  (Autotune operation) parameter is set to  (disabled). If the
Autotune is not successfully completed, the Autotune feature will not be disabled
automatically.
The Autotune operation overwrites any existing proportional band and derivative (rate)
parameter values that were previously configured.
All RMC controllers in a single process should be Autotuned simultaneously, so that
interactions between zones during tuning parallel the interactions expected while the
controllers are in use.
11.4.2 Procedure for Autotuning
To Autotune:
1. After configuring any parameters described in Sections 5 through 10 that apply to
your application, exit configuration by pressing and holding the DISPLAY key until
the PV is displayed on the top line of the display in place of the menu name.
2. Use the
and
keys to enter a setpoint that is representative of the setpoint you
expect to use when the controller is in normal operation.
3. Cycle the power to the controller.
900M056U00B
 Athena Controls, Inc.
11-5
Series RMC Hot Runner Controller Configuration and Operation Manual
4. At this point the controller may execute a CompuStep soft start (NORMAL LED
flashing). (See 1.6 for an explanation of the factors that affect whether a soft start
occurs when you power up the controller.)

If you want to terminate the soft start, press the MODE key once.

If you want the soft start to continue to its normal conclusion (recommended), do
not press any keys.
5. When the Autotune operation begins, the process value on the top line of the display
will alternate with . Unless you want to terminate the Autotune by pressing the
MODE key, do not press any keys during the Autotune operation. The lower line will
continue to display the setpoint your entered in Step 2.
6. When the controller has completed Autotuning successfully, the flashing  will
disappear. The display will revert to the normal mode operating display, with the
process value on the top line and the setpoint on the lower line. The controller will
save the tuning parameter values in the proportional band and rate parameters. (The
new tuning values can be viewed in the  menu.)
If the Autotune was unsuccessful, the top line will display  plus a one-digit error
code (alternating with ). Refer to 11.5 for the Autotune error codes. If the
controller detects an Autotune error condition, the controller will go to the configured
failsafe state automatically. (The effect on the output depends on how you
configured the  (failsafe action) parameter in the  (supervisor) menu; see
10.4.)
7. To clear the error display and put the controller in standby mode, press the MODE
key once. (The effect on the output depends on the configuration selections you
made with the  (standby) menu.)
8. Fix the problem and try tuning again. (If  was displayed, your process is not
responsive enough for the Autotune algorithm to work successfully. Tune the
controller manually as described in 11.6).
9. Once Autotune has been completed successfully, and the PV and SV are on display,
the controller is controlling the process in normal (auto) mode.
Once Autotune is complete, we recommend changing the security access level to the
most restrictive level suitable for your application. See Section 12 for details.
11-6
 Athena Controls, Inc.
900M056U00B
Tuning the Controller for PID Control
11.5 Autotune Error Codes
If an Autotune error occurs, the top line of the display will alternately show  and an
error code (which will be displayed until you press the MODE key). If the Autotune
operation is terminated by the controller because of an error condition, the controller is
placed in the failsafe state configured using the  (supervisor) menu. The Autotune
error codes are in the table below.
Error Code
900M056U00B
Description

Setpoint is higher than the process value. Look at the setpoint.
If it is realistic for your process, then check the thermocouple
leads; maybe they are reversed.

There is not enough difference between initial PV and the
setpoint. For Autotune to work, the difference must be at least
9 F (5 C).

The startup curve (change in PV) was not acceptable to the
Autotune algorithm. This could be caused by a process upset
that occurred during tuning. Try Autotuning again when the
process is stable. If the error recurs, your process is not suitable
for Autotuning. Use manual tuning as described in 11.6.

The Autotuning timed out, because the process was
unresponsive (or extremely slow). Your process is not suitable
for Autotuning. Use manual tuning as described in 11.6.
 Athena Controls, Inc.
11-7
Series RMC Hot Runner Controller Configuration and Operation Manual
11.6 Manual Tuning (Zeigler-Nichols PID Method)
11.6.1 Introduction
This tuning method may be used if the spread between initial process temperature and
process operating temperature is small, or if the process is too slow for Autotuning.
Manual tuning requires that the PV be tracked over time. (Graph the displayed PV
against time manually.)
The procedure below is used to do manual tuning using the front panel of an RMC
controller. You can also use a MODBUS master to change the mode, and to view and
change tuning parameter values for the controller.
These instructions assume that:

SW2-switch 6 is OFF (the factory setting) so that the controller starts in normal
(automatic) mode, and

SW2-switch 1 is OFF (not the factory setting), so that the controller will not do a
soft start when powered up.
After you have finished manual tuning, you can set SW2-switch 6 and/or SW2-switch 1 to
ON if appropriate for your site.
Read the safety warnings in Section 3 before changing switch settings.
11.6.2 Procedure
To perform manual tuning:
1. After configuring any parameters described in Sections 5 through 10 that apply to
your application, exit configuration by pressing and holding the DISPLAY key until
the PV is displayed on the top line of the display in place of a menu name.
2. Immediately use the
and
keys to enter a setpoint that is representative of the
setpoint you expect to use when the controller is in normal operation.
3. Press and hold the DISPLAY key until the  (PID control) menu’s name is
displayed on the top line. The lower line will display  (proportional band),
alternating with the default value  ().
4. Press the MODE key to accept the default value (for now) and display  (rate)
alternating with its default value  (seconds).
5. Use the
and
keys to change the  value to .
6. Press the MODE key to write the change to the controller’s database. The lower line
will display  (Autotune operation), alternating with  (once), the factory
setting. Use the
11-8
and
keys to change the  value to  (disabled).
 Athena Controls, Inc.
900M056U00B
Tuning the Controller for PID Control
7. Exit configuration by pressing and holding the DISPLAY key until the PV is displayed
on the top line in place of a menu name.
8. Plot a graph of the displayed PV against time or record time period between
temperature peaks. (Be patient. It may be several minutes before you see oscillation
in the PV for a manifold zone.)
9. If the temperature (PV) will not oscillate, then decrease the proportional band value
by repeatedly halving the value until a small, sustained temperature oscillation is
observed.
Alternatively, if the temperature (PV) oscillates severely, double the proportional band
value repeatedly until a small, sustained temperature oscillation is observed.
10. Measure the period in seconds of one cycle of oscillation (“T” on the diagram below).
T
11. Divide the period of oscillation (T) by 8. The resulting number (quotient) is the correct
 (derivative) time in seconds.
12. Display the  menu and enter the value obtained in Step 11 as the . The
integral time will be set automatically to 5 times the rate. (You cannot view the
integral term value.)
13. If the process is stable, manual tuning is completed. However, if slight oscillation is
observed, multiply the proportional band value used in Step 10 (to obtain T in Step
11) by 1.66 and enter the product as the new proportional band value to complete the
tuning procedure.
Once tuning has been completed, we recommend changing the security access level to
the most restrictive level suitable for your application. See Section 12 for details.
900M056U00B
 Athena Controls, Inc.
11-9
Series RMC Hot Runner Controller Configuration and Operation Manual
11-10
 Athena Controls, Inc.
900M056U00B
12. Restricting Access to Controller
Functions – Recommended
12.1 Introduction
You can configure the Series RMC Hot Runner controllers to limit the functions that
operators can access or the values they can change using the keypad. This access
control is configured using the  (access) menu.
The  menu contains an  (access level) parameter, which affects some of the
functions available to the operator (see 12.4). For example, the access level can be set to
allow operators to change only the setpoint or the manual mode (closed loop control)
output percentage.
The  menu also contains a  (mode key enable) parameter and a  (boost
key enable) parameter that are used to enable or disable the MODE and BOOST keys
(see 12.5 and 12.6).
The  (access) menu is displayed only when SW2-switch 7 is ON (see 12.3). The
controllers are shipped from the factory with SW2-switch 7 OFF.
After you have configured the controller for your application, set the access level to the
most restrictive level appropriate for your site, then set SW2-switch 7 to OFF.
Read the safety warnings in Section 3 before changing switch settings.
900M056U00B
 Athena Controls, Inc.
12-1
Series RMC Hot Runner Controller Configuration and Operation Manual
The diagram below shows the sequence of  menu parameters.
12-2
 Athena Controls, Inc.
900M056U00B
Restricting Access to Controller Functions
12.2 Access Levels Available
A controller can be set to any of the access levels in the table below. The sequence of
levels in the table is from most restrictive to least restrictive. New RMC controllers are
shipped from the factory with the access level set to  (configuration).
Displayed

Access
Level
Description
Value

keypad
lockout
Highest security level; no access.
While the access level is “keypad lockout”, no controller values can be
changed, not even the setpoint. Pressing the MODE and BOOST keys
will have no effect, even if the MODE and BOOST keys have been
enabled using the  menu  and  parameters.

setpoint only
Setpoint or manual output can be adjusted; no access to menus.
When the access level is “setpoint only”, the keypad can be used to
change the setpoint or the manual mode output percentage. Whether
the operator will be able to change the controller from normal
(automatic closed loop control) to manual (open loop control) mode (or
vice versa) depends on whether the MODE key is enabled using the
 menu  parameter. Availability of the boost function
depends on whether the BOOST key is enabled using the  menu
 parameter.

configuration
Setpoint and manual output can be adjusted. Access to all
available menus is permitted.
When the access level is “configuration”, the keypad can be used to
change the setpoint, change the output percentage in manual mode,
and to view and change all configuration parameter values in accessible
menus. Not all menus are accessible all the time. If SW2-switch 7 is
ON, all menus are accessible, including  (access). If SW2-switch 7
is OFF (factory setting), the  access menu is not accessible. See
Section 3 for the location of the option switches.
900M056U00B
 Athena Controls, Inc.
12-3
Series RMC Hot Runner Controller Configuration and Operation Manual
12.3 Setting Switch to Permit Display of Access Menu
The  (access) menu is displayed in the menu cycle only when SW2-switch 7 is ON.
The RMC controllers are shipped with SW2-switch 7 OFF.
After you have configured the controller for your application, set the access level to the
most restrictive level appropriate for your site, then set SW2-switch 7 to OFF.
Read the safety warnings in Section 3 before changing switch settings.
12.4 Using the Access Menu to Control Menu Access
When SW2-switch 7 is ON, the  (access menu) is included at the beginning of the
sequence of menus. Its first parameter is used to choose the access level that will limit
or permit access to the controller’s database via the front panel and through local
communication from an ALL master.
The access level configured here will place no limitations on access to the controller’s
database using a MODBUS master.
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Access Level

when SW2-switch 7 is ON



keypad lockout
setpoint only
configuration
These access levels are explained in 12.2.
Default:
Description:
Effect on Other
Parameters:
configuration
The access level that will apply to changes made using the
controller’s front panel or an ALL master.
When this is set to keypad lockout or setpoint only, no access to
the configuration menus will be permitted while SW2-switch 7 is
ON.
12.5 Using the Access Menu to Enable the MODE Key
If you do not want the operator to use the front panel of this controller or an ALL master
to change the mode of this controller, use this parameter to disable the MODE key.
Even though the MODE key is disabled, a MODBUS master will be permitted to change
the mode of the controller.
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Default:
Description:
12-4
Control Mode Key Enable

when SW2-switch 7 is ON


enabled
disabled.
enabled
This parameter is used to enable/disable the front panel MODE key.
 Athena Controls, Inc.
900M056U00B
Restricting Access to Controller Functions
12.6 Using the Access Menu to Enable the Boost Key
If you do not want the operator to use the front panel of this controller or an ALL master
to start the boost function on this controller, use this parameter to disable the BOOST
key.
Even though the BOOST key is disabled, a MODBUS master will be permitted to activate
the boost function.
Parameter Name:
Name as Displayed:
When Displayed:
Choices:
Default:
Description:
900M056U00B
Boost Key Enable

when SW2-switch 7 is ON


enabled
disabled.
enabled
This parameter is used to enable/disable the front panel BOOST
key.
 Athena Controls, Inc.
12-5
Series RMC Hot Runner Controller Configuration and Operation Manual
12-6
 Athena Controls, Inc.
900M056U00B
13. Error Messages and Codes
13.1 Introduction
As described in Section 2, usually the controller displays the process variable on the top
line and the setpoint on the lower line of the display. You can see other values on the
lower line by pressing the DISPLAY key. However, when the controller detects a
problem with the process (other than a deviation alarm) or with its own operation,
messages and codes are displayed to alert you to conditions that require your immediate
attention.
13.2 Problem with Process Temperature
You can use the  (supervisor) menu’s  (high-temperature safety) parameter to
specify a high-temperature safety value to be applied to the process. If the process value
exceeds this value:

controller processing and output activity is halted, and

the ALARM LED is lit, and

the message  alternating with  will be displayed on the lower line.
Once the high-temperature safety value has been exceeded by the PV, the controller will
not resume processing and output activity until you cycle power to the controller.
Instructions for configuring the high-temperature safety value are in 10.3.
13.3 Ground Fault in Controller Output Wiring
The RMC controller is capable of detecting ground faults in the controller output wiring.
When a ground fault is detected, the controller will attempt to perform a normal soft start.
As usual in the case of a soft start, if the process value is less than or equal to 200 F
(93 C), the standard CompuStep soft start described in 1.2.2 will be executed. In this
special case, the soft start will be executed up to three times. If the ground fault is still
detected, the controller will consider this a “hard” ground fault. The effect on the
controller will be the same as when the PV is greater than 200 F (93 C) when the
ground fault is detected as described below.
If the process value is greater than 200 F (93 C) when the ground fault is detected, the
controller will consider this a “hard” ground fault. The controller will:

interrupt the signal to its own output, in effect “turning off” the output (even if the
controller output was already at the configured failsafe output state), and

an error message  will be displayed on the lower line, and

the red ALARM LED will also be lit (all other LEDs will be turned off).
Following the interrupt in response to a “hard” ground fault, the controller’s output will
remain off until you cycle power to the controller.
900M056U00B
 Athena Controls, Inc.
13-1
Series RMC Hot Runner Controller Configuration and Operation Manual
If the controller is the ALL master for local communication at the time that the ground fault
is detected, the mastership will be cancelled automatically. (See 1.2.6.2 for more
information about local communication and ALL mastership.)
13.4 Loop Break in Sensor Wiring
You can use the RMC  (supervisor) menu’s  (loop break time) parameter to
specify a time period within which the input value should increase at least 1% of
supported sensor span (9.67 F or 5.37 C) if the sensor is working properly and the input
wiring is intact. If the input value does not change within the specified time period while
the controller is operating in normal (automatic) mode or in closed loop standby mode (or
while a closed loop boost is in progress), and a “bad heater” error has not been detected
(see 13.6), then:

the controller output will be turned off, and

the ALARM LED will be lit (all other LEDs turned off), and

the message  will be displayed on the lower line.
The controller will remain in this alarm and output off state until you cycle power to the
controller.
13.5 Failsafe Operation if a Sensor Error is Detected
You can use the RMC  (supervisor) menu’s  (failsafe action) parameter to
specify what should happen to the output if the controller detects a reversed or open
sensor.25 Your choices are:

output off, or

use a calculated output value based on output values that have typically
successfully maintained the current setpoint for your process in the past, or

use a special configurable failsafe fixed output percentage.
If the controller detects an open or reversed sensor:

the controller output goes to the configured failsafe state, and

the ALARM LED will be lit (all other LEDs turned off), and

the upper display will alternate  and  (reversed sensor), or  and 
(open sensor).
The controller will remain in this alarm and failsafe state until the condition clears or you
cycle power to the controller.
25
When an Autotune error condition is detected, the controller goes to the failsafe state automatically. In
this case, an Autotune error message will be displayed; see 11.5.
13-2
 Athena Controls, Inc.
900M056U00B
Error Messages and Codes
13.6 Heater Current Monitoring
The present current output to the heater, expressed to the closest tenth of an amp, is
always displayable in the lower line. Cycle through the available lower line display items
using the DISPLAY key. The controller constantly checks heater current readings to
ensure that they correlate with output activity.

If the output is off and a current flow greater than 0.1 amp is detected, then the
controller will post a “TRIAC short” error.

If the output is on, but no controller current output flow is detected, then the
processor will post a “bad heater” error. (This condition is checked only if loop
break detection is enabled, the PV has not changed 1% of supported sensor
span during the configured loop break time period while the controller is in
normal (auto) mode, and the PV is not within the proportional band.26)
If either of these error conditions is detected:

the output failure interruption relay will break the connection between the
controller’s TRIAC output and the heater, and

controller processing will cease, and

the red ALARM LED will be lit (all other LEDs turned off), and

an alarm message will be displayed on the lower line:

if a short was detected,  will alternate with 

if a heater problem is detected,  will alternate with 
The controller will remain in this halted state until you cycle power to the controller.
If the controller is the ALL master for local communication at the time that the output
failure is detected, the mastership will be cancelled automatically. (See 1.2.6.2 for more
information about local communication and ALL mastership.)
26
If the input has not changed 1% during the loop break period, but the current output flow is OK, then
the loop break error will be displayed; see 13.4.
900M056U00B
 Athena Controls, Inc.
13-3
Series RMC Hot Runner Controller Configuration and Operation Manual
13.7 Problem with Controller
13.7.1 Introduction
If the controller detects a problem with its own operation, it displays  on the top line
instead of the process value and displays an error code on the lower line instead of the
setpoint. For example, if the controller detects a checksum error, the display will show:


13.7.2 Controller Error Codes
The table below lists the error messages and codes that the RMC controllers display in
place of the setpoint value when a self-diagnostic test has failed.
All errors of this type will shut down controller activity (except for display of error
message). Output will go off. A host computer cannot communicate with a controller that
is displaying one of these messages.
Display

alternating
with
Error Condition
Operator Action
Heater conversion error
Cycle power to clear the message.
There is a problem getting a reading
from the analog to digital converter.
Note the error code and call for service.
PROM checksum error
Cycle power to clear the message.
This message is usually displayed
only at startup, before any outputs
are calculated.
Note the error code and call for service.
RAM error
Cycle power to clear the message.
This message is usually displayed
only at startup, before any outputs
are calculated.
Note the error code and call for service.
Default parameter values were
loaded automatically, because the
controller found corrupted values
stored on the EEPROM. (This
message is not displayed when you
use the procedure in 16.2 to set the
default values intentionally.)
Cycle power to clear the message.

(See Note 1)



Re-configure all configuration parameter
values.
This message is usually displayed
only at startup, before any outputs
are calculated.

Calibration value corrupted.
Cycle power to clear the message.
Note the error code and call for service.
13-4
 Athena Controls, Inc.
900M056U00B
Error Messages and Codes
Display


Error Condition
EEPROM write failure
Cycle power to clear the message.
This message is usually
displayed when a
configuration value is
written.
Try the write operation again. If the message
recurs and persists, the EEPROM may be
worn out. Call for service. (See Note 2 below.)
Line frequency
determination error.
Cycle power to clear the message.
The controller was unable to
determine whether the line
frequency was 50 Hz or 60
Hz.


through


Operator Action
interrupt-related problem
While one of these
messages is on display, the
controller output is off.
Check the line frequency. If it is OK, but the
message recurs and persists, call for service.
Cycle the power to the controller. If the
message recurs and persists, call for service.
Note1: In this case, the PV is displayed on the top line.
Note 2: A host computer can wear out the EEPROM by writing to it too many
times. Do not write the setpoint to the EEPROM when you are writing a
temporary setpoint to the controller, such as when you are ramping to a final
setpoint under the direction of a MODBUS master.
900M056U00B
 Athena Controls, Inc.
13-5
Series RMC Hot Runner Controller Configuration and Operation Manual
13.8 Error Display Priority and Summary
If more than one error occurs simultaneously, only the highest priority error will be
displayed. The following table shows the priority of the RMC error codes and messages.
Displayed
Code or
Message
Description
Output State
Where to
Find More
Information
Highest Priority – No communication with MODBUS host possible

 or other
controller has detected a
problem with its own operation
off
13.7
4-digit code
High Priority – Communication with MODBUS host still possible. PV is displayed on top line,
unless an input error (medium priority) occurs simultaneously. In that case, the top line is
blank; no valid PV is available.
If two high priority error states are detected, the one ranked highest will be displayed on the
lower line (see numbers below).
1) 
hard ground fault detected
2) 
off
13.3
heater problem detected
off (output failure relay will
interrupt output)
13.6
3) 
output is off, but current flow is
detected
off (output failure relay will
interrupt output)
13.6
4) 
configured high temperature
safety value has been
exceeded
off
13.2
5) 
PV has not increased at least
1% of supported sensor span
in the configured loop break
time
off
13.4
6) 
heater conversion error
off
13.7
Medium Priority – Communication with MODBUS host still possible. SV is displayed on lower
line. These conditions cannot occur simultaneously.

thermocouple open
goes to configured
failsafe state
13.5

thermocouple leads reversed
goes to configured
failsafe state
13.5
Low Priority – Communication with MODBUS host still possible. SV is displayed on lower
line. Only one Autotune error will be displayed.
13-6

initial SV is less than PV
goes to configured
failsafe state
11.5

not enough difference between
initial SV and PV
goes to configured
failsafe state
11.5

change in PV not acceptable
to Autotune algorithm; possible
process upset during tuning
goes to configured
failsafe state
11.5

Autotune timed out; process
unresponsive or very slow
goes to configured
failsafe state
11.5
 Athena Controls, Inc.
900M056U00B
14. Maintenance
14.1 Introduction
This section contains instructions for cleaning the front panel of the controller and
instructions for replacing the fuses.
Except for fuses, the controller contains no user-serviceable parts.
14.2 Cleaning the Front Panel
Do not attempt to clean any part of a controller other than the front panel.
Warning
If you want to clean the front panel of a single controller, use the power
switch on the front of the controller to turn it off, then remove the controller
from the mainframe.
If you want to clean the front panel of several controllers, turn off power to
the mainframe before cleaning the controllers while they are installed in the
mainframe.
While cleaning a controller’s front panel, do not allow alcohol to enter the
switch.
Allow controllers and mainframes to dry thoroughly before restoring power.
Do not use a heater or compressed air to dry the units.
Failure to observe these precautions can result in exposure to a potentially
lethal shock hazard.
The controller power switch must be in the “OFF” position before you put a
controller into an energized mainframe, or remove a controller from an
energized mainframe. Failure to observe these precautions can result in
damage to the connectors and printed circuit boards.
900M056U00B
 Athena Controls, Inc.
14-1
Series RMC Hot Runner Controller Configuration and Operation Manual
To clean an RMC controller:
1. Read the safety warnings on the previous page before you start cleaning a controller.
2. To clean the front panel of a single controller, put the controller power switch in the
“OFF” position, and then remove the controller from the energized mainframe by
removing the locking pin or locking screw, and pulling on the handle on the front of
the controller.
Alternatively, if you plan to clean the front panel of several controllers, put the power
switch of every controller in the mainframe in the “OFF” position, and then turn off
power to the entire mainframe. After the mainframe has been de-energized, you can
clean the controllers while they are in the mainframe.
3. Use a cotton cloth to gently and sparingly apply isopropyl alcohol to the front panel of
the controller. Do not use cleaning solutions or other solvents. Use of anything other
than isopropyl alcohol can result in damage to the controller.
Do not allow alcohol to enter the power switch on the controller’s front panel.
4. Allow the controller to air-dry thoroughly. Do not use a heater or compressed air to
dry the unit.
5. Inspect all surfaces to make sure that they are completely dry.
6. When the controller is completely dry, re-install it and return it to service.
14.3 Replacing the Fuses
Each RMC controller contains two fuses, located on the main printed circuit board.
To replace the fuses in an RMC controller:
1. Make sure that you have appropriate replacement fuses. The fuses used in an RMC
controller are Type F fast-acting 250 Vac fuses rated at 15 amps. Suitable fuses are
Littlefuse Inc. p/n 314015 and Athena p/n 210B001U01.
2. Put the power switch of the controller in the “OFF” position.
3. Remove the locking pin or locking screw.
4. Use the handle on the front of the controller to pull it out of the mainframe.
5. Replace the fuses.
6. Re-install the controller and return it to service.
14-2
 Athena Controls, Inc.
900M056U00B
15. Frequently Asked Questions
15.1 Introduction
You can reach our technical support team by phoning 1-800-782-6776 (from the United
States) or 610-828-2490 (from anywhere in the world).
Before you call, please look at this section to see if your question is covered here. If you
do call for technical assistance, be ready to supply the following information:

complete model number of controller

symptoms of the problem

unusual events, if any, that preceded the problem

remedies you have already tried
15.2 How do I change from a J to a K thermocouple (or vice
versa)?
Every Series RMC controller is shipped ready to accept input from a J thermocouple. If
you plan to use a K thermocouple for input, you must set SW2-switch 2 to ON as
described in Section 3. Read the safety warnings in Section 3 before changing
switch settings.
After you have set SW2-switch 2 to ON, configure the controller and tune it.
If you later decide to use the controller with a J thermocouple, you must set SW2-switch 2
to OFF, change any configuration settings affected by your new control strategy, and
tune the controller again.
15.3 Do I have to calibrate a new controller?
No
15.4 Why doesn’t the PV displayed match the value on a
thermometer in the process?
Unless the thermometer and the sensor providing input to the controller are very close to
one another, their readings will not match in some applications, because of temperature
variations within the process. However, if you want the controller to maintain the
setpoint value at the location of the thermometer, instead of at the location of the sensor,
use the  (input) menu’s  (bias) parameter. Applying bias allows you to
compensate for any difference between sensor reading and the location to be measured.
The process variable and setpoint will be offset by the value entered for the bias
parameter (see 7.2).
900M056U00B
 Athena Controls, Inc.
15-1
Series RMC Hot Runner Controller Configuration and Operation Manual
For example, suppose you want the process to be 150 F. However, the sensor
providing input to the controller is so close to the heater that it reads 50 degrees higher
than the process at the location of interest to you. Enter -50 as the bias value. Enter the
setpoint of 150. The setpoint 150 will be displayed. However, the controller will use a
setpoint of 200. The process value displayed will also be offset, so that when the reading
at the sensor location next to the heater is 206 F, the controller shows 156, the
temperature at the location of interest in the process.
15.5 Why can’t I make changes to the other controllers in the
mainframe using an ALL master?
In order for other RMC controllers to receive instructions from the ALL master, the other
controllers must all be configured for local communication and must be assigned to the
same usage group as the ALL master. The controllers must also be in the same
mainframe as the ALL master, or in mainframes that are linked via an RS-485 network
with the ALL master’s mainframe.
Check the  (serial communication interface) menu’s  (protocol) parameter setting
in all the non-responsive controllers. Their protocol may still be set to the default 
(MODBUS). Change the setting to  (local) when appropriate. Also, make sure that
the controllers with which you are trying to communicate are all assigned to the same
usage group using the  parameter in the  menu.
If the configuration parameters have been set correctly and local communications are still
not successful, check the communication wiring.
15.6 Why doesn’t the controller communicate with the host
computer?
When a controller has been communicating successfully with a MODBUS master, then
stops communicating, the cause is most likely damage to the network wiring. However,
before going to search for the fault, take a quick look at the communication settings on
the  (serial communication interface) menu. Make sure that the controller address
configured using the  (system ID) parameter has not been changed, and that the
other communication settings match those used by the host. (See Section 9 in this
manual and Using the MODBUS Protocol with Athena Series RMC Hot Runner
Controllers.)
15.7 Why does the controller start up in manual mode
sometimes?
If SW2 switch 6 is OFF, which is the factory default, then the controller always starts up in
normal (auto) mode. However, if SW2-switch 6 has been set to ON, then the controller
starts up in the last mode used before the controller was powered down. See 3.9 for
more information.
15.8 I turned on the power; why doesn’t the controller light up?
If SafeChange is enabled on the controller, but the mainframe does not support
SafeChange, the controller will not work. Instructions for checking to see if a mainframe
supports SafeChange are in 3.2.
15-2
 Athena Controls, Inc.
900M056U00B
16. Resetting All Parameters to the
Default Values
16.1 Introduction
Using this function returns all configuration parameter values to their defaults except the
communication parameters described in Section 9.
The calibration of the controller will not be affected.
Read the safety warnings in Section 3 before changing switch settings.
16.2 Procedure
16.2.1 Loading Defaults
To reset all configuration parameters (except communication parameters) to their
default values:
1. Put the power switch on the front of the controller in the “OFF” position.
2. Remove the locking pin or locking screw.
3. Use the handle on the front of the controller to pull it out of the mainframe.
4. Set SW2-switch 5 to ON to enable loading the defaults at power up. The location of
the switch is shown in 3.1.
5. Return the controller to the mainframe.
6. Insert the locking pin or locking screw.
7. Power up the controller. The display will briefly show  on the top line and 
on the bottom line while the configuration parameter values are returned to their
defaults. When all the defaults have been written to the controller’s database, the
display will show  over .
8. Put the power switch on the front of the controller in the “OFF” position.
9. Remove the locking pin or locking screw.
10. Use the handle on the front of the controller to pull it out of the mainframe.
11. Set SW2-switch 5 to OFF to disable loading of the defaults at power up.
900M056U00B
 Athena Controls, Inc.
16-1
Series RMC Hot Runner Controller Configuration and Operation Manual
12. If the configuration defaults shown in Sections 5 through 11 are not appropriate for
your application and the  (access) menu’s  (access level) parameter is
currently set to  (lockout) or  (Setpoint), also set SW2-switch 7 to ON to enable
you to use the access menu to change the access level to  (configuration).
13. Return the controller to the mainframe.
14. Insert the locking pin or screw.
16.2.2 Returning Controller to Service
To customize the configuration and return the controller to service:
1. Turn on power to the controller.
2. If you want to change configuration parameter values, press the MODE key
repeatedly until the STANDBY LED lights.
3. Configure the controller (see 2.10).
4. Tune the controller (see Section 11).
5. Change the access level to “lockout” or “setpoint” (see 12.4).
6. Put the power switch on the front of the controller in the “OFF” position.
7. Remove the locking pin or locking screw.
8. Use the handle on the front of the controller to pull it out of the mainframe.
9. Set SW2-switch 7 to OFF to disable display of the  (access) menu.
10. Return the controller to the mainframe.
11. Insert the locking pin or locking screw.
12. Power up the controller.
The controller is ready for use.
16-2
 Athena Controls, Inc.
900M056U00B
17. Index
A
ACC menu. See Access menu
access level
affecting menu access, 1-14, 12-3
changing, 12-4
described, 1-14, 12-1
factory setting, 1-14, 12-3
access menu, 4-3, 12-1, 12-4
address for controller, 9-5
ALARM LED, 2-8
alarm menu, 4-3, 8-1
alarms
configuration, 8-1
inhibiting, 8-4
methods of annunciation, 1-4, 1-6, 2-1
ALL LED, 2-8
ALL mastership, 1-10, 2-11
ALr menu. See alarm menu
auto reset, 1-2, 11-9
automatic mode. See normal mode
Autotune
configuring operation, 1-17, 11-4
display, 2-5
effect on startup sequence, 1-17
mode described, 1-12
Autotune procedure, 11-5
B
bad Htr error message, 1-8, 13-3
baud rate, 9-5, 9-7
bias, 15-1
boost function, 1-5, 2-5
BOOST key
disabling, 1-14, 12-3, 12-5
function, 1-5, 2-3
BOOST LED, 2-8
boost menu, 4-3, 5-1
bST menu. See boost menu
bumpless transfer, 1-2, 2-10
C
calibration, 15-1
calibration value corrupted error, 13-4
changing
mode, 2-9
setpoint, 2-9
checksum error, 13-4
cleaning controllers, 14-1
communication
protocols supported, 1-10, 9-1
troubleshooting, 15-2
communication menu, 9-1
CompuStep. See soft start
900M056U00B
configuration
display, 2-6
effect on output state, 2-6
example, 2-13
general information, 4-1
parameter display sequence, 4-2
permission to access, 1-14, 12-3
recommended sequence, 1-16, 1-20
standby mode, 1-13
configuration (access level), 1-14, 12-3
control menu. See PID control menu
controller addresses, 9-5
D
data format, 9-6, 9-7
default values
accepting, 4-4
message when loaded automatically, 13-4
restoring, 16-1
derivative action, 1-2, 11-1, 11-3, 11-6, 11-8
deviation alarms
annunciation, 1-6
configuration, 8-1
DIP switches. See SW2
DISPLAY key, 2-3
displays
affected by problem with controller, 13-1, 13-4
description, 1-4, 2-1
selecting, 2-3
down key, 2-3
E
EEPROM write error, 13-5
error codes, 13-1
F
factory default values
accepting, 4-4
message when loaded automatically, 13-4
restoring, 16-1
failsafe action, 1-7, 2-10, 10-4, 11-6, 13-2
fixed output percentage
display, 2-5
permission to change, 1-14, 12-3
when used, 1-12
front panel, 1-4, 2-1
fuses, 14-2
 Athena Controls, Inc.
17-1
Series RMC Hot Runner Controller Configuration and Operation Manual
G
M
gFI error message, 1-8, 13-1
ground fault detection, 1-8, 13-1
group, 9-8
maintenance, 14-1
MANUAL LED, 2-8
manual mode
bumpless transfer, 2-10
described, 1-2, 1-12
display, 2-5
permission to change outputs, 1-14, 12-3
manual reset, 1-2
manual tuning procedure, 11-8
menu system
display sequence, 2-6, 4-2
permission to access, 1-14, 12-3
MODBUS protocol, 1-10, 9-1
configuring communication parameters, 9-5, 15-2
manual tuning with, 11-8
programming controllers with, 1-2
reading error codes, 13-4
MODE key
disabling, 1-14, 12-3, 12-4
function, 2-3
modes of operation
described, 1-12
displays, 2-4
permission to change, 1-14, 12-3
selecting, 2-3
H
HEAT LED, 2-8
heater conversion error, 13-4
highest reading, 10-5
high-temperature safety value
configuring, 10-3
error message, 1-6, 13-1
HT.rd Err message, 13-4
Ht.S error message, 1-6, 13-1
I
IEEE register ordering, 9-6
inhibiting alarms, 8-4
InP menu. See input menu
input
bias, 7-2, 15-1
failure, 1-7, 10-4, 13-2
switch setting, 1-10, 3-5, 7-1, 15-1
swtich setting, 3-5
input failure, 10-3, 10-4
input menu, 4-3, 7-1
integral action, 1-2, 11-1, 11-3, 11-9
interrupt (unexpected or invalid), 13-5
N
NORMAL LED, 2-8
normal mode
described, 1-2, 1-12
display, 2-5
J
J thermocouple, switch setting for, 1-10, 3-5, 7-1, 15-1
jumper setting, 3-1, 3-3, 3-7
K
K thermocouple, switch setting for, 1-10, 3-5, 7-1, 15-1
keypad
described, 1-4, 2-1
disabling, 12-4
using, 2-9
keypad lockout (access level), 1-14, 12-3
L
line frequency determination error, 13-5
loading default parameter values, 16-1
local communication
ALL mastership, 1-10, 2-11, 9-1
configuration, 9-7
lockout (access level), 12-3
loop break error message, 1-7, 13-2
loop break time, 1-7, 10-3, 13-2
lowest reading, 10-5
LPbr error message, 1-7, 13-2
17-2
O
open sensor, 1-7, 10-4, 13-2
operator displays
description, 1-4, 2-1
selecting, 2-3
Out Shrt error message, 1-8, 13-3
output
affected by control mode, 1-12
bad heater, 1-8, 13-3
displaying, 2-5
functions, 1-2
state during standby mode, 2-6
state on power up, 1-17
TRIAC short error, 1-8, 13-3
output failsafe value, 10-4
P
parameter display sequence, 4-2
parity, 9-6, 9-7
part number for fuses, 14-2
permission levels, 1-14, 12-1
phone number for tech support, 15-1
PID control menu, 1-16, 4-3, 11-1
PID control tuning, 11-1
powering up controller, 1-17
 Athena Controls, Inc.
900M056U00B
Index
process value
display, 1-4, 2-1
displaying, 2-5
highest, 10-5
lowest, 10-5
proportional band, 1-2, 11-1, 11-3, 11-6, 11-8, 11-9
Proportional-Integral-Derivativel. See PID
protocols for communication, 1-10
PV. See process value
R
RAM error, 13-4
rate, 1-2, 11-1, 11-3, 11-6, 11-8
register ordering, 9-6
replacing fuses, 14-2
reversed sensor, 1-7, 10-4, 13-2
S
SafeChange feature, 3-1, 3-3, 3-7, 15-2
safety information, I, 3-1, 3-7, 14-1
safety value. See high-temperature safety value
SCI menu. See serial communications menu
security access level
affecting menu access, 1-14, 12-3
changing, 12-4
described, 1-14, 12-1
factory setting, 1-14, 12-3
self-diagnostics failed, 13-4
sensor failure, 10-3, 10-4
sensor type, switch setting for, 1-10, 3-5, 7-1, 15-1
serial communication
protocols supported, 1-10, 9-1
troubleshooting, 15-2
serial communication interface menu, 4-3
setpoint
changing, 2-9
displaying, 1-4, 2-1, 2-5
specifying range, 7-3
setpoint only (access level), 1-14, 12-3
setting up controller, importance of sequence, 1-16
soft start
described, 1-5
switch setting, 1-5, 3-6
when ground fault detected, 1-8
span calibration, 15-1
STANDBY LED, 2-8
standby menu, 4-3, 6-1
standby mode
before configuration, 1-13
described, 1-12
display, 2-5
startup mode, 1-17, 3-5, 3-7
Stb menu. See standby menu
SUP menu. See supervisor menu
supervisor menu, 4-3, 10-1
SW2-switch 1, 1-5, 1-17, 3-5, 3-6, 3-7, 11-8
SW2-switch 2, 1-10, 1-15, 3-1, 3-5, 7-1, 15-1
SW2-switch 3, 1-15, 2-4, 3-1, 3-5, 3-6
SW2-switch 4, 3-5
SW2-switch 5, 3-5, 16-1
SW2-switch 6, 1-17, 3-7, 11-8
SW2-switch 7, 1-14, 3-5, 4-2, 4-3, 12-1, 12-3, 12-4, 162
SW2-switch 8, 3-5
switch 1, 1-5, 1-17, 3-5, 3-6, 3-7, 11-8
switch 2, 1-10, 3-1, 3-5, 7-1, 15-1
switch 3, 3-1, 3-5, 3-6
switch 4, 3-5
switch 5, 3-5, 16-1
switch 6, 1-17, 3-7, 11-8
switch 7, 1-14, 3-5, 4-2, 4-3, 12-1, 12-3, 12-4, 16-2
switch 8, 3-5
switch setting
and access level, 1-14, 12-3
for soft start, 1-5, 3-6
for type of input, 1-10, 1-15, 3-1, 3-5, 7-1, 15-1
for unit of measure, 1-15, 2-4, 3-1, 3-5, 3-6
safety warnings, 3-1, 3-7
system ID, 9-5
T
tc oPn error message, 1-7, 13-2
tc rEv error message, 1-7, 13-2
technical support, 15-1
temperature scale switch setting, 3-6
TRIAC short error message, 1-8, 13-3
troubleshooting, 13-1, 15-1
tuning
Autotune procedure, 11-5
manual procedure, 11-8
parameters, 11-1, 11-6, 11-8, 11-9
tuning parameters, 1-16
U
units of measure switch setting, 1-15, 2-4, 3-1, 3-5, 3-6
up key, 2-3
usage grouping, 9-8
user interface, 1-4, 2-1
user-serviceable parts, 14-1
Z
zero calibration, 15-1
900M056U00B
 Athena Controls, Inc.
17-3
Series RMC Hot Runner Controller Configuration and Operation Manual
17-4
 Athena Controls, Inc.
900M056U00B
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement