series - Aptec Electronics

series - Aptec Electronics
SERIES 16SERIES
1
6
Temperature/Process
TEMPERATURE/PROCESS
ControllerCONTROLLER
Instruction Manual
Operating Instructions
Safety
Warning
Introduction
Congratulations on your purchase of an Athena® Series 16
Single-Loop Controller. It is designed for ease of use and
reliability wherever accurate closed-loop control is required.
Your Series 16 has been configured according to your ordering specifications as either a universal process controller or
a dedicated temperature controller. In addition, special functions such as a heater break alarm, digital communications,
etc., do not require you to make any internal jumper or DIP
switch settings.
After following the instructions for installation, simply step
through and set your desired parameters using the Series
16’s easy menu system. The instrument may then be automatically or manually tuned to your process for optimum
setpoint control. A Quick-Start Reference Card is attached to
the back of the instruction manual for experienced users of
PID controllers. If you still have questions or require any
assistance in setting up or operating your controller, please
contact your Athena representative or call 1-800-782-6776.
Precautions
After unpacking, inspect the instrument for any physical
damage that may have occurred in shipping. Save all packing
materials and report any damage to the carrier immediately.
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. Electrical connections and wiring should be
performed only by suitably trained personnel.
Do not locate this instrument where it is subject to excessive
shock, vibration, dirt, moisture, oil or other liquids.
Safe ambient operating temperature range is 32° to 131° F
(0° to 55° C).
NOTES ON CE EMC COMPLIANCE
This unit is compliant with the
following standards when properly
installed in a grounded metal panel:
EN55011 (CISPR 11), Class B
ENS0082-1
©Copyright 1998, Athena Controls, Inc.
2
3
Table of
Contents
Table of Contents
Installation
Mounting
Wiring
8
8
Operation
Notes on Outputs
Parameter Menu Organization
Notes on Alarms
Tuning
12
15
20
28
Limit Controller Option
Digital Communications
Recalibration Procedure
Error Codes
Warranty/Repair Information
Technical Specifications
Ordering Codes
41
47
55
56
57
59
62
Special Functions
Auto/Manual
Remote Setpoint Select
Process Variable Retransmission
Heater Break Alarm
Transducer Excitation
4
34
34
36
37
39
5
Installation
Measurements between
centerlines of panel
cutouts are minimum
recommended.
Figure 1. Recommended Panel Layout for Multiple
Controllers
Installation
Figure 2. Case Dimensions
2.100"
(53.3mm)
CL
2.850" (72.4 mm)
CL
O1
O2
A1
2.100" A2
(53.3mm) F1
0.717"
(8.21 mm)
4.654"
(118.21mm) 3.937"
(100 mm)
PV
1.750"
(44.5 mm)
SV
F2
CL
Prior to mounting the Series 16 in your panel, make sure
that the cutout opening is of the right size, 1.771" x 1.771"
(45 mm x 45 mm), and deburred to enable a smooth fit.
A minimum of 4" (100 mm) of depth behind the panel is required.
2.150" (54.6 mm)
Case Clip
Bezel
CL
1.171" (45 mm)
Grips
Rubber Gasket
Customer Panel
Figure 3. Series 16 Mechanical Components
6
7
Mounting
Slide the mounting collar off and remove any wrapping
material from the instrument. (To ease removal of the collar,
gently pry up all three tabs on each side with a thin-blade
screwdriver.)
Insert the Series 16 through the front panel cutout and slide
the mounting collar back onto the unit from behind the panel.
Press the tabs of the mounting collar into the ridges of the
case housing. The case should now be secure in the cutout.
If it can still be moved, reposition the mounting collar until
the unit is completely immobile within the panel.
Shielded sensor cables should always be terminated at panel
ground.
If additional RFI attenuation is required, noise suppression
devices such as an R.C. snubber at the external noise source
may be used. If you wish, you may order this suppressor
directly from Athena, part number 235Z005U01.
Figure 4. Contact Identification
If it is necessary to remove the Series 16 chassis from the
case housing, press the grips on each side of the front panel
bezel firmly until the tabs release. The chassis may then be
pulled out. To re-install, press both bezel grips simultaneously
and carefully push the chassis back into the case housing
until the tabs snap into place.
Wiring
IMPORTANT: All electrical wiring connections should be made
only by trained personnel, and in strict accordance with the
National Electrical Code and local regulations.
Power and signal wires should always be kept separate and
input leads should never be placed in the same conduit as
power leads. We recommend separating connecting wires
into bundles: power, signal, alarms and outputs. These bundles should then be routed through individual conduits.
8
9
Sensor Input
Connections
Thermocouple circuit
resistance should not
exceed 100 ohms for
rated accuracy; errors
will occur at higher
resistance values. If
shielded thermocouple
wire is used, terminate
the shield only at panel
ground.
Use wire with a resistance no greater than
10 ohms. An error of
0.2° F will result for
each additional 10
ohms of resistance
encountered. If shielded RTD wire is used,
terminate the shield
only at panel ground.
Figure 5. Thermocouple Input Wiring
Make sure that you are using the
8
appropriate thermocouple and
extension wire. Connect the neg9
ative lead (generally colored red
in ISA-type thermocouples) to
10
contact #9; connect the positive
lead to contact #10. Extension wires must be the same
polarity as the thermocouple.
Figure 7. Process and Linear Input Wiring
Voltage Inputs: Connect the positive
voltage input to contact #10; the
negative input to contact #8.
mV/Current Inputs: Connect the
positive current input to contact
#10; the negative input to #9.
T/C
Figure 6. RTD Wiring
The Series 16 accepts input
from 2- or 3-wire, 100 ohm
platinum resistance temperature detectors (RTDs). Connect
2-wire RTDs to contacts #9 and
#10, with a jumper across
Note: For 2 Wire RTD
contacts #8 and #9. Keep
Jumper 8 & 9
leads short and use heavy
gauge copper extension wire, if necessary, to minimize lead
resistance. For long runs, 3-wire RTDs should be used.
VOLTAGE
CURRENT OR 50 mV
+
Power Wiring
The Series 16 power supply accepts 100 to 250 Vac and 100
to 330 Vdc line power without any switch settings or polarity
considerations. All connections should be made in accordance with the National Electrical Code and local regulations,
using only NEC Class 1 wiring for all power terminals.
It is advisable, but not necessary, to fuse one leg of the
incoming power line, contact #11, with a 2AG, 0.5 amp
rated fuse. Be sure that only instrument power input is fused
— not power to the load.
3
8
11
12
4
9
5
10
L1
100 - 250 Vac 50/60 HZ
100 - 330 Vdc (Auto Polarity)
L2
Figure 8. Power Wiring Connection
10
11
Operation
Athena Series 16 Universal Controller
Throughout this
manual, instructions
that pertain solely to
the Series 16 process
controller are shown
in blue.
Output Type
B
Just a few easy steps are required before the instrument can
be placed into service. After completing the mounting and
wiring procedures as previously instructed, set your individual process parameter values by stepping through the Series
16’s setup menus, using the simple front-panel keys as
instructed. Then, initiate the autotuning sequence as shown
(or tune manually).
E
0-20 mA
F
4-20 mA, full output to load with 500 ohm
impedance max. (suppressed).
S
20 Vdc pulsed output for solid-state relays.
T
1 A @ 120/240 Vac , solid-state relay, zero
voltage-switched and optically isolated from
drive signal. Only resistive loads to
may be controlled directly. Larger loads
may be controlled using an external
contactor.
Y
5A/3A (120/240 Vac) relay, but normally
closed (output 2 only).
Notes on Outputs
When you ordered your Series 16 controller, a specific output
type was specified, designated as either “B”, “E”, “F”, “S”,
“T” or “Y”. You also had the option of configuring your
controller with either one or two output actions. Generally,
output 1 is a heat (reverse-acting) function and output 2 is a
cool (direct-acting) function. For best results, follow the
recommendations for setting cycle times for the output type
supplied with your controller. A brief description of output
types follows:
12
Description
The Series 16 is a full-function, autotuning PID controller,
calibrated and pre-configured for your application requirements, according to the ordering code specified, either as a
temperature or linear process controller. (See pages 61 - 64
for specifications and ordering code).
5A/3A (120/240 Vac) relay, normally
open, used for switching resistive loads. If
relays or solenoids are to be driven, select
the “T” output. If a “B” output is selected,
order snubber network 235Z005U01.
13
Operation
Operation
Figure 10. Front Panel Controls and Indicators
Output 1
LED indication
of Heat cycle
(Output 1 action)
Output 2
LED indication
of Cool cycle
(Output 2 action)
Alarm 1
LED indication
of Alarm1 condition
Alarm 2
LED indication
of Alarm 2 condition
Function 1
LED indication of
Special Function 1
Function 2
LED indication of
Special Function 2
After mounting and wiring your
Series 16 controller, you are
ready to set the parameter values
required of your application.
Take a moment to familiarize
yourself with the unit’s front
panel controls and indicators.
14
Process Value
Displays measured
process temperature
in °F or °C or process
value in engineering
units
Setpoint Value
Displays programmed
setpoint temperature
in °F or °C or setpoint
value in engineering
units
Mode Key Used to access Standby,
Tune, Run or Manual modes.
Lower Key Used to scroll down through
available parameter settings, decrease values
or change menu levels (Hold for fast-step
progression)
Raise Key Used to scroll up through available
parameter settings, increase values or change menu
levels (Hold for fast-step progression)
Parameter/Access Key Used to index through parameters
or to access Menu Levels
Power On
When power is first applied to the Series 16, both displays
and all LED indicators are momentarily illuminated. The
Process Value (PV) window then displays [ -At- ] or [ -Ap- ]
and the Setpoint Value (SV) window displays an initialization
code, e.g., [ tf06 ]. The last two digits of this code indicate the
software revision supplied with your controller. Please provide this revision number when contacting us regarding your
controller. Depending upon whether Setpoint Target Time [
SP.tt ] is enabled, you may also see this symbol:
or
.
This means that the controller is ramping up or down to setpoint according to its previously programmed parameters.
The default setpoint on initial power up is equal to the
process temperature (process value). Before proceeding
further, wait until the display has stabilized and then use the
Raise
or Lower
keys to enter or adjust your desired
Setpoint Value.
Parameter Menu Organization
Your Series 16 controller has five distinct menu levels. This
enables quick access to relevant parameters without the need
for scrolling through long menus. Menu “05” is used for
15
Operation
You cannot enter
Standby Mode from
menu level “00”.
Follow the instructions
for changing menu
levels to select another
level.
Operation
initial controller configuration and menus “02” and “03” are
used for setting or changing parameters. Menus “00” and
“01” are used when the controller is in regular unattended
operation and are not used for setting parameters. For safety
and security purposes, we recommend placing the controller in menu level “00” or “01” when in regular operation; however, it is not required.
If you wish to “escape” from parameter selection within
these menus at any time, simply press the Mode
key
once. A description of the menu hierarchy and a detailed listing of menus and parameters begins on page 20.
Standby Mode
When the controller is placed in Standby Mode, outputs are
disabled; however, access is permitted to all menu levels and,
unless the controller is at Run menu levels “00” or “01”,
operating parameters may still be changed. Use this mode for
tuning the controller. To enter Standby Mode, press and hold
the Mode key
for four seconds until the lower window
display flashes [ StbY ]. To exit Standby Mode from Menu
Levels “01” to “05”, press and hold the Mode
key for four
seconds until the lower window display flashes [ tUnE ].
(If the Damping setting in menu “02” is [ OFF ], then [HEAt ]
or [ Cool ] will be displayed instead of [ tUnE ]. Press and
hold the Mode key for four more seconds until the lower
window returns to a steady display of Setpoint Value.
16
(This procedure will not affect tuning). Removing power to
the controller will also take the instrument out of Standby
Mode.
Accessing Menu Levels
To access menu levels from Standby Mode from menu
levels “02” to “05”, press the Parameter/Access
key
once. From menu levels “00” and “01”, press and hold the
Parameter/Access
key for approximately 11 seconds
until the lower window display alternates between [ Ac.Cd ]
and the menu level number last activated.
Changing or Displaying
Menu Levels
To change menu levels, access the menu level display as
instructed in the previous paragraph, then use the Raise
or Lower
key to set the desired menu level number. To
display the current menu level setting in menu levels “02” to
“05”, from Standby or while adjusting/viewing parameters,
press the Parameter/Access
key once. For menu levels
“00” and “01”, press and hold the Parameter/Access
key
for approximately 11 seconds.
17
Operation
Operation
Menu Level Descriptions
Because the Series 16’s
initial configuration
affects other menu
levels, it is important
to set all required
parameters in this
menu first before
accessing other
menu levels.
Menu “05” (Configuration Setup)
This is the menu level used for specifying initial configuration
parameters before the controller is placed in Run mode.
After changing the access code to “05” as instructed in the
previous paragraph, press the Parameter/Access
key to
step through the various control parameters. Available parameters will flash in the lower window display, alternating with
the current value for that parameter. To increase or decrease
the value, simply press the appropriate Raise
or Lower
key, then press the
key to step to the next parameter. To exit the menu at any time, press the Mode
key.
Note: When programming in menu level “05”, all outputs are
disabled; however, any active alarms will remain active until
the alarm condition is removed. New alarm conditions will
not be recognized.
Menu “04” (Communications and Calibration Setup)
This menu is used to set up the controller for digital
communications and for recalibrating the controller. If your
Series 16 controller was ordered with the digital communications option, set these parameters next. To access this menu
level, follow the instructions previously given.
18
Menu “03” (Alarm, Timing and Limit Setup)
In this menu, alarms, cycle times, setpoint target time and
limits are established. After changing the access code to “03”,
press the Parameter/Access
key to step through the various parameters. To set or change parameter values, follow
the instructions given previously.
Menu “02” (Control)
Gain, Rate and Reset parameters are automatically set during
autotuning. However, they can be manually adjusted by the
operator. To return the controller to the Run mode, change
the menu level access code back to “00” or “01” as previously shown.
Menu “01” (Run — Limited Access Mode)
The only parameter that can be changed at this menu level is
the Setpoint Value, using the appropriate Raise
or Lower
key. To set or change other parameters, the operator
must access another menu level by pressing and holding the
Parameter/Access
key for 11 seconds.
Menu “00” (Run — Key Lock Mode)
This menu is automatically active when power is first applied.
Both display windows are illuminated; however, access is
denied to all parameters. To set or change parameters,
the operator must access another menu level as instructed
previously.
19
Operation
Operation
Notes on Alarms
Available Alarm Types [ A1.P.d. ] [ A2.P.d. ]
Either [ OUT 1 ] or [OUT 2 ] in menu level “05” (but not both)
may be configured as an alarm [ ALr ] if your Series 16 was
ordered with a “B”, “S” or “T” type of output module. (With
“Y” modules, an alarm may be configured only on [ OUT 2 ])
When one of the two available Outputs is configured as an
alarm, the other Output may be used for control .
Selectable at menu level “05”, as either Process [ Pr ] or
Deviation [ dE ] and either high or low [ A1.HL ] or [ A2.HL ].
When the controller is provided with the Dual Alarm option,
two independent alarms are automatically enabled for both
outputs. DO NOT USE THE [ ALr ] SETTINGS FOR [ OUT 1 ]
OR [ OUT 2 ]. Otherwise, follow the regular instructions for
configuring the Dual Alarms in menu level “05”.
Deviation Alarm: Activates at a preset deviation value from
setpoint. “High” or “Low” deviation alarm activates above or
below setpoint according to the preset deviation value.
The Series 16 offers a unique capability that provides for the
activation of two software alarms (in addition to the dual
alarms) to monitor a total of four possible alarm conditions.
To enable these software alarms, set the [ OUT 1 ] and [ OUT 2 ]
parameter(s) in menu level “05” to on/off mode [ Ht.O ], [ CL.O
] or [ On.F ]. Set the Setpoint Value to your first alarm point.
Switch to menu level “02” and set Spread [ C.Spr ] [ Spr.2 ]
to the desired deviation value from the first alarm point. Set
[H.HYS] and [C.HYS] to 1. Then switch to menu level “03”
and set the desired values for the third and fourth alarm
points at [ ALr 1 ] and [ ALr 2 ], respectively. Press the Mode
key to resume operation.
20
Process Alarm: Activates at preset value independent of
setpoint. “High” process alarm activates at and above alarm
setting. “Low” process alarm activates at and below alarm
setting.
When a latching alarm
has been activated and
the alarm condition
has been removed, the
Mode
key must be
pressed to unlatch the
alarm.
Latching Alarms
The Series 16’s alarms may also be configured as latching
alarms by selecting “LAt” in the [ A1.O.P.] or [ A2.O.P.] parameter selection at menu level “05”.
21
Parameter
Descriptions
Series 16 Temperature/Process Controller
Figure 11. Series 16 Controller Menu Hierarchy
Menu “05”
Display
SnSr
With heater break
option, [id.no] changes
to [Ht.rd]; [baud]
changes to [Ht.SP]
in menu level “04”.
= temperature
controller only
= process
controller only
= temperature and
process controller
22
Note: Series 16 Limit Controller Menu
Hierarchy appears on page 43.
The Digital Filtering
setting [ FILt ] on the
Series 16 process controller allows the operator to compensate for
noise which may cause
the last digits of the PV
display to become
unstable. Sampling rate
is not affected. The settings are time constants, in seconds, with
0.1 equivalent to “no
filtering.”
Parameter
Sensor type
OUt1
Output 1 action
OUt2
Output 2 action
SN.00
Input Zero Level
Dec.P
FILt
OUt1
Decimal Point
Digital Filtering
Output 1 action
OUt2
Output 2 action
Selection
Code
Thermocouple:
K
c.A
J
J
N
n
R
r
T
t
S
S
Platinel II
PLII
RTD
P
RTD (decimal range) d
Heat PID
Ht.P
Heat On/Off
Ht.O
Alarm
ALr
Cool PID
CL.P
Cool On/Off
CL.O
Alarm
ALr
Unsuppressed
U.Su
Suppressed
Su
999, 99.9, 9.99
0.1, 1, 10
PID
Pid
On/Off
On.F
Alarm
ALr
PID
Pid
On/Off
ON.F
Alarm
ALr
23
Parameter
Descriptions
Parameter
Descriptions
CoL.t*
Cooling type
A1.H.L. Alarm 1 select
A1.P.d.
Alarm 1 type
A1.O.P. Alarm 1 output
A2.H.L. Alarm 2 select
A2.P.d.
Alarm 2 type
A2.O.P. Alarm 2 output
Unlt
Measurement units
Water
Normal
Enable
Process/Deviation
Off/Normal/Latching
Enable
Process/Deviation
Off/Normal/Latching
°F or °C
H2o (non-linear output)
nor (linear output)
Lo/HI
Pr/dE
OFF/nor/LAt
Lo/HI
Pr/dE
OFF/nor/LAt
F/C
* For water-cooled extruders, select H2o.
With the Heater Break
Alarm option, [ Id.no ]
changes to Heater
Current Reading
[ Ht.rd ] (indication
only) and [ bAUd ]
changes to Heater
Break Alarm Setpoint
[ Ht.SP ] (indication
only, either 00-30 A or
00-60 A).
24
Menu “04”
Display
Id.no
bAUd
CAL.L
CAL.H
Parameter
Device ID number
(remote communications)
Baud, parity and
data bit selection
Calibration low
Calibration high
Allowable Values
00 to 99
See chart below
Preset at factory
Preset at factory
Available Communications Settings
Display
3.o.7
6.o.7
12.o.7
24.o.7
3.n.8
6.n.8
12.n.8
24.n.8
Baud Rate
300
600
1200
2400
300
600
1200
2400
Description
Parity
Data Bits
odd
7
odd
7
odd
7
odd
7
none
8
none
8
none
8
none
8
Stop Bits
2
2
2
2
1
1
1
1
Setting output cycle
time to “00” initiates
a 200 ms timebase. A
cycle time setting is
required for smooth
proportional action.
Too long a setting will
cause proportional
ripple; too short will
decrease relay contactor life.
When changing
thermocouple types,
be sure to check/adjust
upper and lower setpoint limit values.
Menu “03”
Display
ALr1
ALr2
Parameter
Allowable Values
Alarm 1 preset
Dependent on sensor range
Alarm 2 preset
Dependent on sensor range
(if ordered)
CY.t1
Cycle time output 1
00 to 120 seconds
CY.t2
Cycle time output 2
00 to 120 seconds
SP.tt
Setpoint target time
Off/1 to 100 minutes
(ramp-to-setpoint)
L.SP.L
Lower setpoint limit
Dependent on sensor range
U.SP.L
Upper setpoint limit
Dependent on sensor range
L.SCL
Low scale setting
-1999 to 9999
H.SCL
High scale setting
-1999 to 9999
Output Type
Recommended Setting (seconds)
B (5A/3A)
15 to 120
Note: Shorter cycle times
E (0-20 mA)
00
may be used when driving
F (4-20 mA)
MUST be set to 00
heater loads directly.
S (pulsed 20 Vdc) 00 to 120
T (S.S. relay)
15 to 120
Y (5A/3A) N.C.
15 to 120 (Output 2 only)
Notes on Setpoint Target Time: The [ SP.tt ] parameter allows the operator to enter a time delay for the
process to reach setpoint temperature (ramp to setpoint), from disabled [ OFF ] or 1 to 100 minutes. When
enabled, the ramp sequence starts on power-up. The ramp-to-setpoint feature will also be initiated whenever
a new setpoint target time is entered AND the Setpoint Value is 5° F or more from the current process temperature. In operation, the controller’s lower window display will flash
or
to indicate that it is
“ramping” up or down to setpoint. The Setpoint Value cannot be changed during this procedure. After it is
finished, the operator can adjust the setpoint temperature to the desired value.
While in ramp startup, the ramp-to-setpoint mode can be aborted and the controller returned to regular
operation by pressing the Parameter/Access
key until parameters are displayed and then pressing the
Mode
key once.
25
Parameter
Descriptions
Setting Rate (Derivative)
or Reset (Integral) to
[ 00 ] disables that
aspect of PID control.
The ratio for non-zero
settings of rate-to-reset
is limited to a minimum
of 1:4, i.e., Reset value
cannot be set any lower
than four times Rate.
The parameters of Heat
Hysteresis, Cool
Hysteresis and Cool
Spread are only available when Output 1
and/or Output 2 are set
to on/off mode [Ht.O] or
[CL.O]. They replace
Gain Output 1 and
Gain Ratio Output 2,
respectively.
Menu “02”
Display
Gn.o1
Gr.o2
H.HYS
C.HYS
HYS1
HYS2
SPr.2
C.SPr
rAtE
rSEt
dPnG
Figure 12. Typical Lag Processes
Parameter
Gain Output 1
(PID heat gain)
Gain Ratio Output 2
(PID cool gain ratio)
Heat Hysteresis
Cool Hysteresis
Output 1 Hysteresis
Output 2 Hysteresis
Spread Adjustment, Output 2
Cool Spread
PID rate
PID reset
Damping (see notes)
Allowable Values
00 to 400 (This value may
0.0 to 2.0
exceed 400 during
autotuning.)
01 to 100°
01 to 100°
1 to 100 units
1 to 100 units
0 to 100 units
0 to 100°
00 to 900 seconds
00 to 3600 seconds
Lo, nL, Hi, Off
Notes on Damping: The damping parameter is an autotune feature that
enables more precise control of setpoint overshoot during recovery from
process upsets in which thermal or transfer lag is a factor. See Figure 12.
Use the correct setting prior to autotuning to compensate for power and
load/sensor coupling characteristics.
Lo = Fast recovery with slight overshoot. For single-lag processes.
Ex. Adequate power and excellent load/sensor coupling.
nL = Normal recovery with no overshoot. For two-lag processes.
Ex. Properly sized heaters or components and good load/sensor
coupling.
Hi = Slow recovery with no overshoot. For three-lag processes.
Ex. Overpowered with multiple lags. Poor load/sensor
coupling.
Off = Autotune disabled; manual output control.
26
27
Tuning
Procedures
Tuning
Procedures
Introduction
For best results in tuning the temperature
controller, the setpoint
value should be at least
100°F above or below
ambient temperature.
The Series 16 is an “on demand” autotuning controller that
automatically sets PID parameter values (Proportional Band,
Reset and Rate) before the process reaches setpoint. A damping setting (menu level “02”) MUST be selected for autotuning
to take place. (see Notes on Damping, page 28). The controller may also be tuned manually (see page 33).
Autotuning the Series 16 Temperature
Controller
While some processes
other than heat or cool
applications may
respond successfully to
autotuning procedures,
the controller must be
manually tuned for
most non-temperature
processes.
1) With the power off and the process at ambient, apply
power and immediately put the controller in Standby mode
by holding the
key for four seconds until [ StbY ]
flashes in the lower display window.
2) Enter the desired Setpoint Value using the appropriate
Raise
or Lower
key. [ StbY ] will continue to flash.
3) If controller is in menu level “00” or “01”, hold the
Parameter/ Access
key for 11 seconds until [ Ac.Cd ]
appears. Then change to menu level “05”. Otherwise,
press the
key once and use the
key to select
menu level “05”.
4) Press the Parameter/Access
key twice until [ SnSr ] is
displayed to make sure that the proper sensor has been
selected. Then set the controller’s heating mode or alarm
functions by pressing the Parameter/Access
key again
28
until [ OUt1 ] is displayed. (If you scroll past it, just
continue scrolling until the parameter menu repeats.) Using
the appropriate Raise
or Lower
key, select the one
of the following settings according to the requirements of
your process. Note: For autotuning, at least one output
MUST be set to PID mode.
Mode
PID
On/Off
Alarm
Output 1 (Heat) Setting
[ Ht.P ]
[ Ht.O ]
[ ALr ]
Output 2 (Cool) Setting
[ CL.P ]
[ CL.O ]
[ ALr ]
Press the Parameter/Access
key again to step to output
2 [ OUt2 ]. Repeat the selection process for cooling mode or
alarm. (If only one output is PID, set the other output to
either On/Off or Alarm.)
5) Press the Parameter/Access
key again to display the
Cooling Type parameter [ CoL.t ], and select either
Normal/Linear output [ nor ] or Water-Cooled/Non-Linear
output [ H2o ].
6) Exit menu level “05” by pressing the Mode
key once.
The lower window will flash [StbY]. Now press the
Parameter/Access
key once. The lower window will
display [Ac.Cd ] and [ 05 ]. Press the Lower
key twice
to select menu level “03”.
7) Press the Parameter/Access
key and select Cycle Time
for Output 1 [ CY.t1 ] and Cycle Time for Output 2 [ CY.t2 ].
For Control Output type B, T or Y, enter “15”. For Control
Output type E, F or S, enter “00”.
29
Tuning
Procedures
Before autotuning can
take place, you must
select a damping setting. If the damping
parameter does not
appear on the menu,
you have not selected a
PID option for outputs
1 or 2. Refer back to
step (4) and select the
proper setting(s).
During autotuning, the
process temperature
will gradually cycle
from ambient to setpoint. When autotuning
is complete, the [ tUnE ]
display will stop flashing and the Gain, Rate
and Reset numbers
"learned" will be kept in
memory for subsequent
startups.
30
Tuning
Procedures
8) Press the Parameter/Access key until Setpoint Target Time
[ SP.tt ] is displayed. Select [ OFF ].
9) Press the Mode
key once. The lower window will again
flash [StbY]. Press the Parameter/Access
key once and
the lower window will display [Ac.Cd ] and [ 03 ]. Press the
Lower
key once to select menu level “02”.
10) Press the Parameter/Access
key and scroll through
the displayed parameters. If Gain Ratio [ Gr.o2 ] is displayed, set it to [ 1.0 ]. Otherwise, continue scrolling until
[dPnG ] appears. Set Damping initially to Normal [ nL ].
(This setting may have to be changed later. See Notes on
Damping, page 28).
11) Press and hold the Mode
key until [ tUnE ] flashes
in the lower display window. The controller is now autotuning. When it stops flashing, the autotuning procedure is
completed and the controller is ready for your process.
As a security measure, you may wish to place the controller
in Key Lock “00” or Limited Access “01” Run mode by
changing menu levels as instructed previously.
Note: Re-tune controller only from ambient temperature.
Autotuning will not function when process is at setpoint.
Figure 13. Typical
“Autotune”
Temperature Profile.
If overcooling exists on
heat/cool processes
after autotuning,
decrease Gain Ratio
[ Gr.o2 ] in steps of 0.1
until oscillation is
minimal. If cooling is
sluggish, increase the
value in steps of 0.1
until optimum results
are achieved.
Manual Tuning Procedure - Temperature
Controller (Zeigler-Nichols PID Method)
This tuning method may be used if the spread between ambient temperature and process operating temperature is small.
For best results, the use of a recording device is suggested
when tuning with this method.
1) Disable any cooling device used.
2) Apply power and place the controller in Standby by
pressing and holding the Mode
key for four seconds.
3) Using Raise
desired value.
or Lower
key, adjust setpoint to
4) Access menu level “02” following instructions given
previously.
Gain ratio [ Gr.o2 ] is
the cooling gain
expressed as a factor
of the heating gain.
Ex. [ Gn.01 ] = 100
Cooling Gain = 50
[ Gr.o2 ] = .5
5) Using the Parameter/Access
[ Gn.o1 ]. Select [ 01 ].
key, index to Heat Gain
6) Index to Gain Ratio [ Gr.o2 ] and select [ 1.0 ].
7) Index to Rate [ rAtE ] and select [ 00 ].
8) Index to Reset [ rSEt ] and select [ 00 ]. Note: In order to
set Reset to [ 00 ] , Rate must first be set to [ 00 ].
9) Change to menu level “03”.
10) Index to Cycle Time 1 [ CY.t1 ] and select the timebase,
in seconds, appropriate to the device being controlled.
(See note on page 27.)
31
Tuning
Procedures
Tuning
Procedures
11) Repeat for Cycle Time 2 [ CY.t2 ].
Manual Tuning Procedure - Process
Controller (Zeigler-Nichols PID Method)
12) Change to menu level “05”.
A chart recorder to monitor the process variable is required.
The controller must be properly scaled and filtering set as
instructed previously.
13) Set Cooling Type [ CoL.t ] to [ nor ].
14) Press the Mode
key once. Setpoint Value will be
displayed. The recording device should now be tracking
process temperature.
1) Apply power and place the controller in Standby by holding
the Mode
key for four seconds.
15) Double the Gain [ Gn.o1 ] until a small, sustained oscillation is visible on the recording device’s trace.
2) Adjust the setpoint to the desired value.
3) Access menu level “05” and select one output: [ OUt 1 ]
for reverse-acting control or [ OUt 2 ] for direct-acting
control. Set the active output to PID [ Pid ] and the unused
output to Alarm [ ALr ] or On/Off [ On.F ].
16) Measure the period of one cycle of oscillation (“T” on the
diagram below).
T
17) Divide the period of oscillation (T) by eight (8). The
resulting number is the correct Rate time [ rAtE ] in seconds. Multiply this number by four. This is the correct
Reset time [ rSEt ] in seconds.
18) Multiply the gain (from step #15) by 0.6 and enter this
number as Gain [ Gn.o1 ].
32
19) Enable the cooling device. If overcooling exists, decrease
the Gain Ratio [ Gr.o2 ] in steps of 0.1 until temperature
oscillation stops. If cooling is sluggish, increase the Gain
Ratio in steps of 0.1 until optimum results are achieved.
Calculate and enter these
numbers:
Rate [ rAtE ] = T/8
Reset [ rSEt ] = T/2
Gain [ Gn.01 ] = Gain from
Step (6)
On noisy processes,
where Rate cannot be used:
Gain [ Gn.01 ] = from Step
(6) x 0.45
Reset [ rSEt ] = T/1.2
T
4) Access menu level “02” and set [ Gn.01 ] to 1.0; [ Gr.o2 ] to
1.0; and [ rAtE ] and [ rSEt ] to “00”.
5) Press the Mode
key for four seconds until display
flashes [ tUnE ]. Press the Mode key for another four seconds and the process will run in closed loop mode.
6) While monitoring the chart, increase Gain [ Gn.o1 ] by doubling the gain number until the process variable becomes
unstable. Then decrease Gain until the process oscillations
are sustained, neither increasing nor decreasing in amplitude as a result of momentary setpoint change.
7) Multiply the Gain from Step (6) by 0.6.
8) Measure the period of one complete cycle of oscillation,
“T”, in seconds.
33
Special Functions
In manual control
mode, error conditions
such as A/D errors
and open or reversed
sensors will be
ignored.
Special Functions
Auto/Manual Operation (Standard)
Option Part #
Description
To put the controller in manual mode, set the damping [dPnG]
parameter in menu level “02” to [ OFF ]. Press and hold the
Mode
key for four seconds until the lower display window flashes [ StbY ]. Hold down the Mode key for another
four seconds to initiate manual operation. The lower display
window will flash percentage of output power, from 100 to
-100, alternating with the output controlled (temperature
controllers will flash [ HEAt ] or [ CooL], process controllers
will flash [ OUt1 ] or [OUt2 ].) To take the controller out of
manual mode, press and hold Mode
key to four seconds.
40
External switch wired to terminals 6 and 7
Switch Open: Normal operation, first setpoint enabled
Switch Closed: Second setpoint enabled
Setpoint Adjustments: Made from front panel
41
External switch wired to terminals 6 and 7
Switch Closed: Normal operation, first setpoint enabled
Switch Open: Second setpoint enabled
Setpoint Adjustments: Made from front panel
42
0-5 Vdc signal at pins 6 and 7
0 Vdc: First setpoint enabled
5 Vdc: Second setpoint enabled
Setpoint Adjustments: Made from front panel
Note: The Series 16 controller can only be ordered with one
of the following Special Functions installed per instrument.
Maximum Input Impedance: 400 ohms @ +5 Vdc , 5 mA
N.O.
Common
Remote Setpoint Select
If your Series 16 controller was ordered with this option, you
may select either of two setpoints for your process. The second setpoint can be enabled only by an external switch or signal, according to your ordering specifications. The "F2" LED
on the front panel will illuminate when a second setpoint is
selected. If you do not know how your Series 16 was configured, refer to the ordering code and description on page 64.
34
Figure 14. Wiring
Diagram for
Remote Setpoint
Select Option
A1 & A2
N.O. N.C.
N.O.
5V Input
OUTPUT 1
C
N.C.
N.O.
T/C
OUTPUT 2
RTD
SENSOR
INPUT
C
L1 L2
100 - 250 V 50/60 Hz
100 - 330 Vdc (Auto Polarity)
35
Special Functions
These output values
are linear with and
dependent upon the
sensor being used,
i.e., the lowest value
of the sensor’s output range corresponds to zero or
low for the output
function.
For voltage output,
a jumper must be
installed between
terminals 13 and 14.
Special Functions
Process Variable Retransmission
If your Series 16 controller was ordered with this option, you
may retransmit the signal representing the process variable
for analysis or storage to an external device that accepts analog input, such as a chart recorder, datalogger, or process
control computer. These outputs are:
Suppressed: 1-5 Vdc/4-20 mAdc
Unsuppressed: 0-5 Vdc/0-20 mAdc
Process Variable Retransmission Specifications
Iout (current output) = 0-20 mA/4-20 mA
Voltage Headroom = 8 Vdc (standard) 18 Vdc
(for multiple recording devices)
Vout (voltage output) = 0-5Vdc/1-5 Vdc
Iout Max = 20 mA
MA OUT
Figure 15. Wiring
Diagram for
Process Variable
Retransmission
With the Heater
Break Alarm option,
cycle time is limited
to greater than 2
seconds.
Heater Break Alarm (Series 16 Temperature Controller)
The heater break alarm option detects failures in the load or
power handler and provides an alarm output. It uses an external current transformer to monitor the load current. If the
load current falls below a set current value, the alarm output
is activated.
With this option, a heater current reading [ Ht.rd ] from a
current transformer is displayed at menu level “04”, along
with the preset Heater Current Alarm Setpoint Value [ Ht.SP ],
either 00-30 A or 00-60 A.
Current Transformer Specifications
.29 Dia. Opening
INDICATING RANGE: 2 thru 100 A
MAX. CONT. CURRENT: 100 A
MAX. TRANSIENT CURRENT: 150 A for 5 sec.
WORKING CLASS: 600 • FREQUENCY: 50-60 Hz
WEIGHT: .5 Oz (14 grams)
LEAD WIRE: #22 AWG UL Style 1213
CASE COLOR: Black • CASE MATERIAL: Thermoplastic
N.O.
VOLTS OUT
OUTPUT 1
C
N.C.
N.O.
OUTPUT 2
36
The Heater Break
Alarm option is not
available on controllers with an “F”
type output.
T/C
RTD
SENSOR
INPUT
C
L1 L2
100 - 250 V 50/60 Hz
100 - 330 Vdc (Auto Polarity)
37
Special Functions
Special Functions
Figure 16. Current Transformer Supplied with Heater
Break Alarm Option, Part # 580E023UOI
Figure 17. Wiring Diagram for Heater Break Alarm
Transducer Excitation
The transducer excitation voltage option is used to produce
a constant dc voltage of 10, 12 or 15 Vdc out to an external
device, eliminating the need for an additional external power
supply. Refer to the ordering code if you do not know which
voltage output was specified.
Option Ordering Code
50
51
52
53
Voltage Output
10 V
12 V
15 V
5V
Maximum Current = 22 mA
S.S.R. Alarm Out
100 mA Max.
120/240 Vac
Heater Lead
N.O.
OUTPUT 1
Current
Transformer
C
N.C.
N.O.
OUTPUT 2
T/C
RTD
SENSOR
INPUT
C
L1 L2
100 - 250 V 50/60 Hz
100 - 330 Vdc (Auto Polarity)
38
39
Limit Controller
Option ED
Special Functions
Figure 18. Wire Diagram for 2-Wire Sensor Input with
Transducer Excitation Option
Series 16 Limit Controller Menu Hierarchy
Jumper
2 Wire Transducer
40
41
Limit Controller
Option ED
42
Limit Controller
Option ED
Parameter Descriptions
Parameter Descriptions (continued)
Menu “04”
Display
IntP
Menu “03”
Display
Idno
Parameter
Sensor type
LItp
Limit type
AltP
ALSL
Alot
oPSL
dECP
FILt
UnIt
Alarm type
Alarm select
Alarm output
Selection
Thermocouple
Platinel II
S
T
R
N
J
K
RTD
RTD (decimal range)
High Limit
Low Limit
Process/Deviation
High/Low Alarm
Normal/Latching
(Not Functional)
(Not Functional)
Decimal point
Digital filtering
Measurement units F-deg or C-deg
Code
PLII
S
t
r
n
J
c.A
P
d
HI
Lo
Pr/dE
HI/Lo
nor/LAt
00
02/01/00
10.0/1.0/0.1
F/C
bAUD
CALL
CALH
Parameter
Device ID number
(remote communications)
Baud, parity and
data bit selection
Calibration low
Calibration high
Allowable Values
00 to 99
See next page under the
heading of “Available
Communications Settings”
Preset at factory
Preset at factory
43
Limit Controller
Option ED
Limit Controller
Option ED
Parameter Descriptions (continued)
Operation
Menu “02”
Display
ALSP
SPLo
High Limit Operation — During normal operation the
mechanical relay in output “1” is closed. If the process
temperature exceeds the high limit setting, then the
mechanical relay in output “1” will open (“01” LED is
now lit) cutting off power to the load. When the process
temperature drops back down to below the limit setting,
output “1” will remain open until you press the mode key
to reset the controller.
SPHI
Parameter
Alarm setpoint
Setpoint low
(lower setpoint limit)
Setpoint high
(upper setpoint limit)
Allowable Values
0 to 8191
Dependent on sensor range
Dependent on sensor range
Available Communications Settings
Display
24.n.8.
12.n.8.
6.n.8.
3.n.8.
24.o.7.
12.o.7.
6.o.7.
3.o.7.
Baud Rate
2400
1200
600
300
2400
1200
600
300
Description
Parity
Data Bits
none
8
none
8
none
8
none
8
odd
7
odd
7
odd
7
odd
7
Stop Bits
1
1
1
1
2
2
2
2
Low Limit Operation — During normal operation the
mechanical relay in output “1” is closed. If the process
temperature drops below the low limit setting, then the
mechanical relay in output “1” will open (“01” LED is
now lit) cutting off power to the load. When the process
temperature rises back above the limit setting, output “1”
will remain open until you press the mode key to reset
the controller.
Mode Key (Reset Button) — Operates as a reset button.
The Parameter Access Key — Used to index through
parameters or to access menu levels.
Raise Key — Used to scroll up through available parameter
settings, increase values or change menu levels (Hold for
fast-step progression).
44
Lower Key — Used to scroll down through available
parameter settings, decrease values or change menu levels
(Hold for fast-step progression).
45
Limit Controller
Option ED
Digital
Communications
Operation (continued)
Warning: Do not
change the values in
the CALL or CALH
menu parameters.
If this is done, the
controller may need
to be recalibrated.
Tech Tip: After setting
up your controller,
index through the
entire menu system
and write down the
value or setting of each
menu parameter. Keep
this hard copy on hand
in the event that an
operator accidently
changes the values or
settings. Then you can
refer back to this list of
settings and values to
correctly set up the
controller.
46
Quick Start Procedure
1) Apply power to the controller.
2) Press parameter access key to access the menu system.
3) Using the up/down arrow keys, select menu level “04”.
4) Press the parameter access key once until you reach the
sensor type (IntP).
RS232
Two communication
options are available
for the Series 16 which
allow interfacing to
remote devices utilizing
the most common
industry standards,
RS232 and RS485.
5) Select the sensor type that you will be using by pressing
the up/down arrow keys (refer to parameter descriptions
for menu “04” described earlier).
6) Press the parameter access key again to reach the limit
type (LItP).
7) Using the up/down arrows keys, select High or Low limit.
8) Press the mode key to return to limit setting.
9) Set your limit to the desired value by pressing the
up/down arrow keys.
10) To deny controller access through the front panel, press
the parameter access key once, then using the up/down
arrow keys, select menu level “00”. Press the mode key
once. The controller is now in lockout mode. To regain
controller access you must hold the parameter access key
in for 11 seconds.
WARNING
Signal ground only.
Grounding to frame
may damage the
controller and void
warranty.
This method allows bidirectional data transfer via a threeconductor cable consisting of signal ground, receive input
and transmit output. It is recommended for communication
distances less than fifty feet between the computer terminal
and the instrument. Note: Multiple instruments cannot be
connected to the same port.
The RS232 port is optically isolated to eliminate ground loop
problems. Typically, “Data Out” of the computer/terminal connects to the “RCV” terminal. “Data In” connects to the “XMT”
terminal. If shielded cable is used, it should be connected to
the frame ground at one end only. Signal ground is to be connected at appropriate ground terminals (refer to wiring diagram, page 50).
RS485
The RS485 multipoint capability allows up to 32 controllers to
be connected together in a half-duplex network or up to 100
controllers with an appropriate communications repeater. This
method allows bidirectional data transfer over a shielded
twisted pair cable. The twisted pair cable is a transmission
line; therefore, terminating resistors are required at the most
distant ends of the line to minimize reflections (typically 60
ohms from each line to signal ground). The RS485 circuit is
fully optically isolated, eliminating ground loop problems.
Parallel drops from the transmission lines should be kept as
47
Digital
Communications
Note: Call factory for a
recommended RS485
converter.
Digital
Communications
short as possible; however, the line may be daisy-chained at
each controller. The polarity of the line is important and each
device will specify an “A” (+) and “B” (-) connection.
*One PC to one
controller only
Figure 19. Wiring
diagram for digital
communications.
Table 1. Communications Parameter List
(Temperature Controller)
Parameter No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
Description
Display Minimum
Maximum
Process Value
nnnn
Sensor Dependent
Setpoint
nnnn
Low Limit
High Limit
Access Code
Ac.Cd
00
05
Gain Output 1
Gn.o1
00
400
Gain Ratio 2
Gr.o2
0.0
2.0
Rate
rAtE
00
900
Reset
rSEt
00
3600
Heat Hysteresis
H.HYS
01
100
Cool Hysteresis
C.HYS
01
100
Cool Spread
C.SPr
00
100
Damping
dPnG
00
Low/Normal/High
Alarm 1
ALr1
Range Dependent
Alarm 2
ALr2
Range Dependent
Cycle Time 1
CY.t1
00
120
Cycle Time 2
CY.t2
00
120
Setpoint Target Time Sp.tt
00 (OFF)
100
Low Setpoint Limit
L.SP.L
Sensor Dependent
High Setpoint Limit
U.SP.L
Sensor Dependent
Controller ID
Id.no
00
99
Baud Rate
bAUd
300
2400
Table 2. Communications Parameter List
(Process Controller)
48
Parameter No.
00
01
02
Description
Process Value
Setpoint
Access Code
Display
nnnn
nnnn
Ac.Cd
Minimum
Maximum
Low Scale
High Scale
Low Scale
High Scale
00
05
49
Digital
Communications
Digital
Communications
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
Gain Output 1
Gain Ratio 2
Rate
Reset
Hysteresis 1
Hysteresis 2
Spread 2
Damping
Alarm 1
Alarm 2
Cycle Time 1
Cycle Time 2
Setpoint Target Time
Low Scale
High Scale
Controller ID
Baud Rate
Gn.o1
Gr.o2
rAtE
rSEt
HYS.1
HYS.2
SPr.2
dPnG
ALr1
ALr2
CY.t1
CY.t2
Sp.tt
L.SCL
H.SCL
Id.no
bAUd
00
0.0
00
00
01
01
00
00
Low Scale
Low Scale
00
00
00 (OFF)
-1999
-1999
00
300
400
2.0
900
3600
100
100
100
Low/Normal/High
High Scale
High Scale
120
120
100
9999
9999
99
2400
Table 3. Serial Communications Data Format
Baud
Code
0
1
2
3
4
5
6
7
50
Baud
Rate
300
600
1200
2400
300
600
1200
2400
Parity
Odd
Odd
Odd
Odd
None
None
None
None
Data
Bits
7
7
7
7
8
8
8
8
Interface Examples
This section describes the protocol for communication
between an Series 16 controller and either a video display terminal or computer ( referred to below as “the host”).
Message strings may be of two types — commands to controller or responses from controller.
General Comments
One host and multiple controllers may be interconnected on a
single bus. The host may send commands to any controller
and may receive responses from any controller. Each controller on the bus is assigned an identification code between
00 and 99. No two controllers on a given bus may have the
same identification code. Controllers are not capable of communicating with other controllers.
Every valid message begins with a pound-sign (#) character.
Stop
Bits
2
2
2
2
1
1
1
1
Every valid message ends with a carriage-return (<CR>)
character.
A valid message is composed of: Start Message, Controller ID
Code, Command, Parameter and Data.
Every response begins with a line-feed (<LF>) character and
ends with a carriage-return, line-feed pair (<CRLF>).
51
Digital
Communications
Digital
Communications
Figure 20. General Communications Message Format
Figure 21. Sample Communications Commands
STANDBY ‘ON’ COMMAND TO CONTROLLER
Caution:
Modifying parameter
#19 (Baud Rate) by
host may cause loss of
data link.
#[controller id] [command] [parameter number]<new value><units> [CR]
< >
OPTIONAL
Start of
message
Up to TWO
Numeric
Characters
00 to 99
Up to TWO
Numeric
Characters
00 to 99
SPECIAL
COMMANDS
N
ON
(Select)
F
OFF
(Deselect)
?
STATUS
0
1
2
3
9
Up to SIX
Characters
ONE Leading
Sign
‘-’,‘+’ or
Space and
FOUR
Numeric
Characters
with decimal
for decimal
parameters
Standby
Autotune
Manual
Ramp
Version
(Status Only)
End of
Message
STANDBY ‘OFF’ COMMAND TO CONTROLLER
End of
message
Command
Executed
Controller Id
STANDBY RESPONSE FROM CONTROLLER
STANDBY
End of
Message
< >
< >
‘#01F0 CR
< >< >
‘ LF #01F0 CR LF ’
Command
Executed
OFF (Deselect)
Command
Start of Message
STANDBY ‘?’ COMMAND TO CONTROLLER
STANDBY RESPONSE FROM CONTROLLER
STANDBY
Controller Id
ONE
Character
F Deg F
C Deg C
U PROCESS
SENSOR
None for default
Temperature units
or NON-THERMAL
parameters
< >< >
‘ LF #01N0 CR LF ’
ON (Select)
Command
Start of Message
< >
End of
Message
< >
Start of Message
< >< >
‘ LF #01F0 CR LF ’
‘#01?0 CR
N
Status REQUEST
Command
Standby STATUS
is ‘off’
Standby STATUS
is ‘on’
Figure 22. Requesting a Parameter from a Controller
SAMPLE: READ, MODIFY, ENTER COMMANDS
READ MESSAGE TO CONTROLLER
Parameter Number
READ RESPONSE FROM CONTROLLER
Controller Id
Units
< >
End of
Message
‘#01R00 CR ’
Example: For Standby “On”, type #01N0[CR].
< >
‘#01N0 CR
OPTIONAL
ONE
Character
Upper case
or Lower case
R Read
M Modify
E Enter
STANDBY RESPONSE FROM CONTROLLER
STANDBY
Controller Id
< >
Value read from
controller
Read
Command
Start of Message
< >< >
‘ LF #01R00 = 0120F CR LF ’
MODIFY COMMAND TO CONTROLLER
Parameter Number
MODIFY RESPONSE FROM CONTROLLER
Controller Id
Units
Units
< >
< >
‘#01M01 0200F CR ’
Start of Message
Modify Command
< >< >
‘ LF #01M00 = 0200F CR LF ’
End of
message
New Value
‘space’ for
Positive
ENTER COMMAND TO CONTROLLER
Parameter Number
Modified Value
ENTER RESPONSE FROM CONTROLLER
Controller Id
Units
Units
< >
‘#01E01 0200F CR ’
52
Start of Message
Enter Command
New Value
‘space’ for
Positive
< >
< >< >
‘ LF #01E 00 = 0200F CR LF ’
End of
message
Entered Value
53
Communications
Notes
Caution:
Wherever possible,
avoid using the
“Enter” command
and use “Modify” or
“Read” instead. The
“Enter” command
makes permanent
changes to the
NOVRAM in the Series
16’s microprocessor,
and after accepting a
maximum capacity of
100,000 “Enter” statements, it will have to be
returned to the factory
and replaced.
Recalibration
1. The controller will respond with <LF>ERROR<CR><LF>
for messages containing invalid/incorrect commands,
parameter number or data (with decimal, if needed).
2. Process Value is a read-only parameter; therefore, a modify or enter command for Process Value will result in a
<LF>ERROR<CR><LF> response.
3. For modify or enter command: if the new value is out of
the parameter’s range, the controller will default to the
highest or lowest allowable parameter value.
4. Parameters with decimal data must contain a decimal
character in the data portion of the message.
5. Ramp “on” command (Setpoint Target Time) will not be
executed if ramp time is set to zero or absolute deviation
between Setpoint and Process Value is less than or
greater than 5 temperature or process units.
6. Autotune, manual and ramp commands are mutually
exclusive, i.e., selecting manual while autotune is enabled
will abort the autotune mode.
7. If the controller is in Standby mode, selecting autotune,
manual or ramp will de-select Standby.
8. Setpoint should not be modified while the controller is in
autotune or ramp mode.
9. The Setpoint Value enter command should not be executed while the controller is in manual mode.
54
Only qualified individuals utilizing the
appropriate calibration equipment
should attempt
recalibration of
the controller. For
assistance, contact
your Athena representative or call
1-800-782-6776.
Your Series 16 has been calibrated at the factory, and need
not be adjusted during the life of the controller unless sensor
type is changed from thermocouple to RTD, or vice versa. In
the event that recalibration is warranted, follow these procedures.
1) Access menu level “05” as previously instructed and
select the sensor type.
2) Use a calibrator with a range appropriate for the unit to be
calibrated and set the range, and a low or zero value.
3) Access menu level “04” and then the Parameter/Access
key until [ CAL.L ] is displayed. Then, press the Raise
or Lower
key until the number in the controller’s
upper (PV) display window matches the indicated value of
the calibration instrument.
4) Enter a value on the calibration instrument corresponding
with the high-end value of the sensor range (span).
5) Again, in menu level “04”, press the Parameter/Access
key until [ CAL.H ] is displayed. Then, press the Raise
or Lower
key until the number in the controller’s
upper (PV) display window matches the indicated value of
the calibration instrument.
6) Repeat steps 3 through 5 until all readings agree.
7) Return the controller to regular operation by pressing the
Mode
key.
55
Warranty/Repair
Information
Error Codes
Display
Problem
Action
Two-Year Limited Warranty
[ Err.H ]
Open sensor
Check sensor and wiring
Check type of sensor
Recalibrate
Other than those expressly stated herein, THERE ARE
[ Err.L ]
Reversed sensor
Check sensor and wiring
Check type of sensor
Recalibrate
[ Err.O ]
A/D error
Return to factory
[ Err.J ]
A/D error
Return to factory
----
Display out-of-range
Sensor over- or under-range
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.
56
57
Technical
Specifications
Unit Repairs
It is recommended that units requiring service be returned to
an authorized service center. Before a controller is returned
for service, please consult the service center nearest you.
In many cases, the problem can be cleared up over the telephone. When the unit needs to be returned, the service center
will ask for a detailed explanation of problems encountered
and a Purchase Order to cover any charge. This information
should also be put in the box with the unit. This should
expedite return of the unit to you.
Performance
Accuracy
Setpoint Accuracy
Temperature Stability
TC Cold End Tracking
Noise Rejection
This document is based on information available at the time
of its publication. While efforts have been made to render
accuracy to its content, the information contained herein does
not cover all details or variations in hardware, nor does it
provide for every possible contingency in connection with
installation and maintenance. Features may be described
herein which are not present in all hardware. Athena Controls
assumes no obligation of notice to holders of this document
with respect to changes subsequently made.
RTD
Proprietary information of Athena Controls, Inc. is furnished
for customer use only. No other use is authorized without the
written permission of Athena Controls, Inc.
58
Process Sampling Rate
Inputs
Thermocouple
Linear
±0.2% of full scale, ± one digit
1 degree/0.1 degree
5 µV/°C max; 3 µV/°C typical
0.05° C/°C ambient
Common mode >100 dB
Series Mode >70 dB
10 Hz (100 ms)
K, J, N, R, T, S,
Maximum lead resistance 100 ohms
for rated accuracy
Platinum 2- and 3-wire, 100 ohms at
0° C, DIN curve standard (0.00385)
0-50 mV/10-50 mV, 0-5 V/1-5 V
0-20 mA/4-20 mA
Input Impedances
0-50 mV/10-50 mV: 1 K ohm ± 1%
0-5/1-5 V: 100 K ohms ± 1%
0-20 mA/4-20 mA: 2.5 ohms ± 1%
0-10 V/2-10 V: 200 K ohms
59
Technical
Specifications
Technical
Specifications
Outputs
#1
#2
B
E
F
S
T
Y (Output 2 only)
Reverse acting (heating or alarm)
Direct acting (cooling or alarm)
Relay, 5 A @ 120 Vac resistive
3 A @ 240 Vac
0-20 mAdc
4-20 mAdc, 500 ohms max.
20 Vdc pulsed
Solid-state relay, 120/240 Vac,
zero voltage-switched,
1 A continuous, 10 A surge @ 25° C
N.C. Relay, 5 A @ 120 Vac resistive
3 A @ 240 Vac
Alarms
Electromechanical relay, 5 A @ 120 Vac,
3 A @ 240 Vac (Output 1 OR 2 only)
Dual-Alarm option: Two solid-state
relays, 120/240 Vac, zero voltageswitched, 1 A continuous, 10 A surge
@ 25°C
Control Characteristics
Setpoint Limits
Limited to configured range
Alarms
Adjustable for high/low; selectable
process or deviation
Rate
0 to 900 seconds
Reset
0 to 3600 seconds
Cycle Time
0.2 (zero setting) to 120 seconds
60
Gain
Gain Ratio
Control Hysteresis
Cool Spread, Output 2
(Temperature Controller)
Spread 2, Output 2
(Process Controller)
Damping
Setpoint Target Time
(Ramp-to-Setpoint)
Autotune
Manual
General
Line Voltage
Display
Power Consumption
Panel Cutout
Depth Behind Panel
Front Panel Rating
Operating Temperature
Humidity Conditions
Parameter Retention
Connections
Contacts
0 to 400
0 to 2.0 (in 0.1 increments)
1 to 100 units (on/off configuration)
0 to 100° F/C (above setpoint)
0 to 100 units (above setpoint)
Selectable (low, normal, high, off)
0 (off) to 100 minutes
Operator-initiated from front panel
Operator-initiated from front panel
115 to 230 V ±10%, 50-60 Hz
115 to 300 Vdc ±10% (Auto-Polarity)
Dual, 4-digit 0.36" (9.2 mm) LED display
Process Value: Orange
Setpoint Value/Menu: Green
Less than 6 VA (@ 120/240 Vac)
1.771" x 1.771" (45 mm x 45 mm)
3.937" (100 mm)
NEMA 4X
32 to 131° F (0 to 55° C)
90% R.H. max., non-condensing
Solid-state, non-volatile memory
Input and output via barrier strip
with locking terminals
Twin bifurcated
61
Ordering Codes
Notes
Model
Input
62
Range
Code
"K" TC
0 to 2460° F
KF
"K" TC
-18 to 1349° C
KC
"J" TC
0 to 1400° F
JF
"J" TC
-18 to 760° C
JC
"N" TC
0 to 2370° F
NF
"N" TC
-18 to 1299° C
NC
"R" TC
0 to 3200° F
RF
"R" TC
-18 to 1760° C
RC
"T" TC
-200 to 600° F
TF
"T" TC
-129 to 316° C
TC
"S" TC
0 to 3200° F
Output 1
Options
Code
0 = None
B = Relay
F = 4-20 mA
S = Pulsed 20 Vdc
T = S.S. Relay
E = 0-20 mA
Standard Options
00 = None
Output 2
SF
"S" TC
-18 to 1760° C
SC
Platinel II
0 to 2372° F
LF
Platinel II
-18 to 1300° C
LC
100 ohm RTD
-328 to 1562° F
PF
100 ohm RTD
-200 to 850° C
PC
100 ohm RTD
-199.0 to 450.0 ° F
DF
100 ohm RTD
-128.8 to 232.2° C
DC
1 to 5 V
Scaleable
L1
10 to 50 mV
Scaleable
L2
4 to 20 mA *
Scaleable
L3
0 to 5 V
Scaleable
L4
0 to 50 mV
Scaleable
L5
0 to 20 mA*
Scaleable
L6
0 to 10 V
Scalable
L7
2 to 10 V
Scalable
L8
0 to 1V
Scalable
L9
Code
0 = None
B = Relay
F = 4-20 mA
S = Pulsed 20 Vdc
T = S.S. Relay
E = 0-20 mA
Y = N.C. Mechanical
Relay Contacts
Output #2 0nly
Special Options See List
If NONE: Enter 00
(Consult Factory)
Dual Alarms
10 = S.S. Relay
20 = Floating Transistor
Open Collector Switch
21 = 24 Vdc drive
22 = S.S. Relay - N.C.
Communications
30 = RS-232
31 = RS-485
Remote Setpoint
Select (w/ alarm)
40 = Switch Close
41 = Switch Open
42 = 5 volt Input
Transducer Excitation
50 = 10 Vdc
51 = 12 Vdc
52 = 15 Vdc
Process Variable
Retransmit Signal
60 = 4-20 mA
61 = 1-5 Vdc
62 = 0-20 mA
63 = 0-5 Vdc
Heater Break Alarm
70 = 5-30 Amps
71 = 10-60 Amps
63
Notes
64
Notes
65
Quick Setup Instructions - Series 16 Temperature Controller
Experienced users, already familiar with mounting and wiring the Series 16 may use these condensed instructions to autotune the controller and get started quickly.
These quick setup instructions are not meant as a substitute for reading the full
instruction manual. Please be sure to read through the manual for specific details
of operation and, most importantly, for safety precautions. If you have questions,
or experience problems with setting up your controller, consult the full instruction
manual first and, if you still need assistance, contact your Athena representative or
call 1-800-782-6776.
9.
Select Alarm Operation [ Al.O.P.], either Normal [ nor ], Latching [ LAt ] or Off [ OFF ].
10. Repeat Steps 7 through 9 for Alarm 2, if applicable.
11. Select Temperature Units [ Unlt ], either [ F ] or [ C ], then press Mode
Use
or
keys to select Setpoint Value.
12. Press
key once to return controller to [ Ac.Cd ] display.
13. Press
key twice to select menu level “03”.
key once to display setpoint.
14. Select Alarm Trip Points [ ALr1 ] and/or [ ALr2 ], if applicable. Note: This menu parameter will not
appear if Alarm Operation (Step #9) is set to [ OFF ].
15. Select Cycle Times [ CY.t1 ] and/or [ CY.t2 ] as follows:
For Control Output Type —
Access
Raise
Lower
Mode
1.
Apply power. After self-check display stops, immediately place the controller into Standby mode by
pressing and holding the
key for four seconds until [ StbY ] flashes.
2.
Press
key until [Ac.Cd. ] flashes. (This can take anywhere from one to eleven
seconds, depending on the menu level at which the controller is currently set.)
3.
If the controller is not at menu level “05”, press
4.
Press
until [ SnSr ] flashes. Then use
or
or
until “05” appears.
to select Sensor Type.
NOTE: Unless otherwise instructed, the following steps require that you first press the Parameter/Access
key, and then the Raise
or Lower
key to select the appropriate
parameter value.
5.
Select Heating Mode or Alarm on Output 1 [ OUt 1 ].
[ Ht.P ] = PID
[ Ht.O ] = On/Off
[ ALr ] = Alarm
Repeat for Cooling Mode on Output 2 [OUt 2 ].
[ CL.P ] = PID
[ CL.O ] = On/Off
Select Cycle Time (in seconds)
B
E
F
S
T
Y
15
00
00
00
15
15 (Output 2 only)
16. Scroll to Setpoint Target Time [ SP.tt ] and set to [ OFF ].
17. Select Lower Setpoint Limit [ L.SP.L ] and Upper Setpoint Limit [ U.SP.L ] to the desired value.
18. Press Mode
key once, then
key once to restore [ Ac.Cd ] display. Change to menu level “02”.
19. Use the
key to scroll through to the Damping menu parameter [ dPnG ]. Select normal [ nL ]. Note:
If your process is subject to thermal lag, (see page 28)
20. Press and hold the
key until [ tUnE ] appears. When the display stops and the Setpoint Value
appears, the controller is tuned. For safety and security purposes, you may want to change to key-lockout menu level “00” or Limited Access Run menu level “01” before beginning your process operations.
[ ALr ] = Alarm
Important: If only one output is PID, set the other output to either On/Off or Alarm.
66
6.
Select Cooling Type [ CoL.t ].
[ nor ] = standard/no cooling
7.
Select Alarm [ AI.H.L.], either [ HI ] or [ Lo ].
8.
Select Alarm Type [ A1.P.d. ], either Process [ Pr ] or Deviation [ dE ].
[ H2o ] = water-cooled extruders
67
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