Electronic Controller

Electronic Controller
SERIES
80
TEMPERATURE
CONTROLLERS
Instruction Manual
Note: Not all agency approvals apply to all models. See manual for detailed information.
Series 80 Agency Approvals
LR-52383
Models 82 and 86
E63164 Process Control Equipment, Component
UL-1092 / UL-916, C22.2 No. M142-1987
Models 82-A, 82-B, 86-A &86-B (Vol.1, Sec.1)
Models 88-A, 88-B, 88-L, 89-1 & 89-2 (Vol.1, Sec. 2)
E63164 Process Control Equipment
UL-1092 / UL-916, C22.2 No. M142-1987
Models 82-C, 82-D, 82-E, 82-L, 86-C, 86-D, 86-E & 86-L (Vol.2, Sec.2)
ID. 3012472 Class 3545, Temperature Limit Controllers
Models 86-L & 88-L
Athena Controls, Inc.
5145 Campus Drive
Plymouth Meeting, PA 19462
Phone: 610-828-2490
Fax: 610-828-7084
www.athenacontrols.com
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). The e-mail address for tech
support is [email protected]
Athena® is a registered trademark of Athena Controls, Inc.
© 2003 Athena Controls, Inc. All rights reserved.
Series 80 Temperature Controllers Instruction Manual
Table of Contents
Section 1
1.1
1.2
1.3
Section 2
2.1
2.2
2.3
2.4
2.5
Section 3
3.1
3.2
3.3
3.4
Section 4
4.1
General Introduction
General Description and Cautions................
Configurations............................................... 1
Specifications................................................ 1
2
Preliminary Instructions
Unpacking.....................................................
Locating........................................................ 3
Mounting....................................................... 3
Wiring............................................................ 3
Thermocouple Placement............................. 5
5
Operation / Maintenance
Operation......................................................
Limit Control.................................................. 5
Adjustments.................................................. 5
Maintenance.................................................. 5
6
Troubleshooting
Troubleshooting Steps..................................
7
Series 80 Temperature Controllers Instruction Manual
Section 1
1.1
General Introduction
General Description and Cautions
The Athena Series 80 Controllers are designed for
temperature control of ovens, molds, hot stamping machines,
packaging machinery, heat tracing, and for replacement of bulb
and capillary type temperature controllers. Limit configurations
have FM approval.
CAUTION
Possible fire hazard. 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.
1.2
Configurations
A - Open PCB unit with Setpoint on the PCB
B - Open PCB unit with Remote Setpoint
C - Open PCB unit with Setpoint on PCB with T case
D - T case with Setpoint on the case
E - T case with Remote Setpoint
L - High Limit Controller, D configuration with Reset
button on case
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Series 80 Temperature Controllers Instruction Manual
1.3
Specifications
Setpoint:
Single turn, 270º rotation
Potentiometer (local or remote)
Setpoint Resolution:
1% with circuit board
Potentiometer
1
⁄4% with remote
Potentiometer
Calibration Accuracy:
1% at calibration points with remote
Potentiometer
2% at calibration points
Potentiometer on circuit board
Ambient Temperature Range:
30º to 130º F Series 82 & 86
30º to 150º F Series 88
Cold Junction Compensation:
Internal electrical bridge
Differential/Proportional Band:
Adjustable from Differential of 5º F
to Proportional Band of 25º F
Thermocouple Break Protection:
UPSCALE
Output:
B – S.P.S.T. relay 10A/5A
H – S.P.S.T. relay 15A
S – Pulsed D.C. 0-20Vdc
T – Solid State relay 1Aac, 1ø
(Normally Open)
Supply Voltage:
120/240 ± 10% V 50/60 Hz.
Power Consumption:
2 watts
Weight:
1 pound, 8 oz. (0.68 kg) with case
and cover
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Series 80 Temperature Controllers Instruction Manual
Section 2
2.1
Preliminary Instructions
Unpacking
Carefully unpack the instrument and inspect for shipping damage.
Report any damage to the carrier immediately.
2.2
Locating
Select a location for the controller where it will not be subjected
to excessive shock, vibration, dirt, moisture, and/or oil. The
ambient temperature of the area should be between 30º F and
130º F (Series 82 & 86), 30º F and 150º F (Series 88).
2.3
Mounting (Series 82, 86, 88)
Panel Mounting, External Setpoint: Open-faced circuit board with
or without mounting snap-track, should be mounted in a suitable
approved enclosure to maintain Agency Approvals.
1. Remove knob with small screwdriver and take off the nut
holding the scale to the potentiometer.
2. Mount potentiometer through a 3⁄8” hole in your panel; put
scale over shaft and tighten nut.
3. Turn shaft counterclockwise until it stops.
4. Now put knob back on and line up its indicating mark with the
arrow on scale.
5. Tighten knob. The unit is now aligned.
Metal Mounting Case:
1. Remove the two screws holding the cover. Remove the cover.
2. Carefully spread the plastic holding track and remove the
circuit board.
3. Mount the base and plastic track with the appropriate
hardware (not supplied) through the two 11⁄64” dia.
mounting holes.
4. Replace circuit board by aligning one side in track and then
gently press in the opposite side. Replace the cover and
cover screws after wiring.
2.4
Wiring
Consult the wiring diagrams on page 4. The unit can be operated
with 120/240V 50/60 Hz line voltage. Be certain that the correct
voltage is applied to the proper terminals. Cooling loads can be
driven from the Normally Closed terminal. There is no fusing on
the circuit board, therefore to prevent damage to the control
3
Series 80 Temperature Controllers Instruction Manual
Series 86/88 Wiring & Mounting
120 Volt Units
Height = 1 11⁄16”
3 5/32"
HOT
Common
T/C
Normally Closed
JUMPER
Normally Open
37/64"
240 Volt
HEATER
120 Volt
NEUTRAL
Line
4 5/8"
6"
Series 86/88 Wiring & Mounting
240 Volt Units
Height = 1 11⁄16”
3 5/32"
L1
Common
T/C
Normally Closed
JUMPER
Normally Open
37/64"
240 Volt
HEATER
120 Volt
L2
Line
4 5/8"
6"
Notes:
1.
2.
3.
Model 86 is shown. Model 88 uses push-on connectors instead of
terminal blocks.
For cooling application use Normally Closed in place of Normally Open.
Models 82 and 83 have different terminal location than models 86 and 88.
Series 86 only:
11/64" DIA. MOUNTING HOLES
(2 PLACES / BOTTOM)
11/32"
5 5/8"
2 11/16"
NOTE: With Reset
Button on "L"
Limit Control
7"
7/8" DIA.
CONDUIT KO
(2 PLACES)
1 21/32"
3 5/16"
4
Series 80 Temperature Controllers Instruction Manual
circuitry and load relay, the customer must provide adequate fusing. Separate fusing for the control circuitry and load relay is preferred, however a single fuse is acceptable. Proper segregation
must be provided between the Class 2 thermocouple /RTD input,
potentiometer and the Class 1 circuits. Wiring should be in compliance with local and National Electrical Codes.
2.5
Thermocouple Placement
Proper thermocouple placement can eliminate many problems in
the system. The probe should be placed so that it can detect any
temperature change with little thermal lag. In a process that
requires fairly constant heat output, the probe should be placed
close to the heater. In processes where heat demand is variable,
the probe should be close to the work area. Some experimenting
with probe location will provide optimum results. Thermocouple
extension wire must be of sufficient size so that on long runs the
thermocouple circuit resistance does not exceed 100 ohms.
Section 3 Operation / Maintenance
3.1
Operation
After all connections are completed, adjust the Setpoint Knob to
the desired temperature and apply line voltage. Adjust the Band
Potentiometer as per section 3.3. If Proportional operation has
been selected, the output will cycle on and off continuously. If OnOff mode has been selected, the output will change state only as
temperature varies around the setpoint.
3.2
Limit Control
Adjust the Setpoint Knob to the desired limit temperature. Apply
power and press the Manual Reset Button. The Control Relay is
now energized, the normally open and common contacts closed.
When the process temperature being monitored by the limit thermocouple reaches the set value, the limit relay will change state
and latch in that state until the monitored temperature falls below
the setpoint and the Manual Reset Button is depressed. An option
is available to provide automatic reset of the limit upon application
of control power.
3.3
Adjustments
The Band adjustment allows the control mode to be Proportional
to On-Off.
For processes requiring very accurate control, adjust the MODE
Potentiometer clockwise in the Proportional sector until the
process temperature oscillations just stop.
5
Series 80 Temperature Controllers Instruction Manual
For processes such as
mechanical refrigeration
systems, fans, solenoid
valves, and wherever
continuous cycling would
be detrimental to the load
handler, On-Off control
should be used. Adjusting
the Band Potentiometer
counterclockwise from its
center of travel provides
On-Off control. The amount of hysteresis
(differential) is increased with further counterclockwise
adjustments of the Band Potentiometer. Adjustment here
provides a compromise between tight temperature control
and minimum cycling of the load handler.
Band Adjustments
3.4
Maintenance
1. Keep the controller clean and protect it from dirt, water, and
corrosive fumes.
2. Periodically recheck electrical connections
3. If relay problems are seen, return for repair.
WARNING
Applying incorrect voltage will damage controller.
Shorted heaters or wires can damage the relay.
For maximum protection, fuse incoming
power lines with a quick-acting fuse.
6
Series 80 Temperature Controllers Instruction Manual
Section 4
Troubleshooting
Prior to checking controller operation, insure system peripherals
are functional as follows:
• Wiring: Circuit correctly wired
• Thermocouple: Correct type, continuity ok
• Line voltage: Within specification
• Load handler: Functional
Note: When lit, the LED display only indicates output activation.
4.1
Troubleshooting Steps
1. Connect simulated sensor input, as follows:
Millivolt input: thermocouple units
Resistance bridge: RTD units
2. Disconnect AC wiring (except for “T” output) from load terminal
before connecting output measurement device:
“B” output
Ohmmeter
“T” output
AC Voltmeter. Controller output connected
to load device and power supply (see pg 4).
“S” output
DC Voltmeter
“F” output
DC Milliammeter
3. Adjust the MODE Potentiometer fully counterclockwise.
4. Connect and apply line voltage.
5. Adjust setpoint to mid-range.
6. Adjust the simulated sensor input to below setpoint and
observe output on; calling for heat.
7. Adjust the simulated sensor input to above setpoint and
observe output off; not calling for heat.
8. If no output state change in steps 6 & 7, possible:
Defective output device
Defective controller electronics
9. Call Athena Controls technical support 1-800-782-6776 for
assistance and, if needed, return instructions.
10. Return controller to an authorized service center for
electronics repairs.
7
Series 80 Temperature Controllers Instruction Manual
Two-Year Limited Warranty
THIS EQUIPMENT IS WARRANTED TO BE FREE FROM DEFECTS OF MATERIAL
AND WORKMANSHIP. IT IS SOLD SUBJECT TO OUR MUTUAL AGREEMENT THAT
THE LIABILITY OF ATHENA CONTROLS, INCORPORATED IS TO REPLACE OR
REPAIR THIS EQUIPMENT AT ITS FACTORY, PROVIDED THAT IT IS RETURNED
WITH TRANSPORTATION PREPAID WITHIN TWO (2) YEARS OF ITS PURCHASE.
THE PURCHASER AGREES THAT ATHENA CONTROLS, INCORPORATED ASSUMES
NO LIABILITY UNDER ANY CIRCUMSTANCES FOR CONSEQUENTIAL DAMAGES
RESULTING FROM ITS USE OR FROM IMPROPER HANDLING OR PACKAGING OF
SHIPMENTS RETURNED TO THE FACTORY.
COMPONENTS WHICH WEAR OR WHICH ARE DAMAGED BY MISUSE ARE NOT
WARRANTED. THESE INCLUDE CONTACT POINTS, FUSES, ELECTROMECHANICAL
RELAYS, AND TRIACS. UNITS WHICH HAVE BEEN MODIFIED BY A CUSTOMER IN
ANY WAY ARE NOT WARRANTED.
Other than those expressly stated herein, THERE ARE NO OTHER WARRANTIES
OF ANY KIND, EXPRESS OR IMPLIED, AND SPECIFICALLY EXCLUDED BUT NOT
BY WAY OF LIMITATION, ARE THE IMPLIED WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE AND MERCHANTABILITY.
IT IS UNDERSTOOD AND AGREED THE SELLER’S LIABILITY WHETHER IN
CONTRACT, IN TORT, UNDER ANY WARRANTY, IN NEGLIGENCE OR OTHERWISE
SHALL NOT EXCEED THE RETURN OF THE AMOUNT OF THE PURCHASE PRICE
PAID BY THE PURCHASER AND UNDER NO CIRCUMSTANCES SHALL SELLER BE
LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THE PRICE STATED FOR THE EQUIPMENT IS A CONSIDERATION IN LIMITING
SELLER’S LIABILITY. NO ACTION, REGARDLESS OF FORM, ARISING OUT OF THE
TRANSACTIONS OF THIS AGREEMENT MAY BE BROUGHT BY PURCHASER MORE
THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED.
SELLER’S MAXIMUM LIABILITY SHALL NOT EXCEED AND BUYER’S REMEDY IS
LIMITED TO EITHER (i) REPAIR OR REPLACEMENT OF THE DEFECTIVE PART OR
PRODUCT, OR AT SELLER’S OPTION (ii) RETURN OF THE PRODUCT AND REFUND
OF THE PURCHASE PRICE, AND SUCH REMEDY SHALL BE BUYER’S ENTIRE AND
EXCLUSIVE REMEDY. THE SPECIFICATIONS PUT FORTH IN THIS MANUAL ARE
SUBJECT TO CHANGE WITHOUT NOTICE.
Authorized Athena Service Centers
Athena Controls, Inc.
5145 Campus Drive
Plymouth Meeting, PA 19462
610-828-2490
Athena Controls, Inc.
1640 E. Acorn Lane
Glendora, CA 91740
818-963-5045
8
Allied Instrument Service
3136 Clarence Avenue
Berwyn, IL 60402
708-788-1912
For free technical assistance in the U.S.,
call toll free 1-800-782-6776 or
email [email protected]
Athena Controls, Inc • 5145 Campus Drive • Plymouth Meeting, PA 19462 USA
Tel: 610-828-2490 • Fax: 610-828-7084 • [email protected] • athenacontrols.com
900M005U01RevB-0803-500-Mimeo
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