series - Athena Controls

series - Athena Controls
SERIES
16
TEMPERATURE/PROCESS
CONTROLLER
Instruction Manual
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
Safety
Warning
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
Table of Contents
Installation
Mounting
Wiring
1
2
Operation
Notes on Outputs
Parameter Menu Organization
Notes on Alarms
Tuning
4
6
10
17
Special Functions
Auto/Manual
Remote Setpoint Select
Process Variable Retransmission
Heater Break Alarm
Transducer Excitation
Digital Communications
Recalibration Procedure
Error Codes
Warranty/Repair Information
Technical Specifications
Ordering Codes
22
22
24
25
26
27
34
34
35
36
39
Installation
Measurements between
centerlines of panel
cutouts are minimum
recommended.
Figure 1. Recommended Panel Layout for Multiple
Controllers
CL
CL
2.850" (72.4 mm)
CL
2.150" (54.6 mm)
CL
1.171" (45 mm)
Figure 2. Case Dimensions
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.
Case Clip
Bezel
Grips
Rubber Gasket
1
Customer Panel
Figure 3. Series 16 Mechanical Components
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
appropriate thermocouple and
extension wire. Connect the negative lead (generally colored red
in ISA-type thermocouples) to
contact #9; connect the positive
lead to contact #10. Extension wires must be the same
polarity as the thermocouple.
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.
2
Power Wiring
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.
VOLTAGE
CURRENT OR 50 mV
+
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.
100 - 250 Vac 50/60 HZ
100 - 330 Vdc (Auto Polarity)
Figure 8. Power Wiring Connection
3
Operation
Athena Series 16 Universal Controller
Throughout this
manual, instructions
that pertain solely to
the Series 16 process
controller are shown
in blue.
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 page 39 for
specifications and ordering code).
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).
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:
Output Type
Description
B
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.
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).
4
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.
5
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
Operation
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
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 15.
6
Operation
Standby Mode
You cannot enter
Standby Mode from
menu level “00”.
Follow the instructions
for changing menu
levels to select another
level.
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.
(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.
7
Operation
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.
Operation
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 Level Descriptions
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.
8
Operation
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.
9
Operation
Notes on Alarms
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 .
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”.
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.
10
Operation
Available Alarm Types [ A1.P.d. ] [ A2.P.d. ]
Selectable at menu level “05”, as either Process [ Pr ] or
Deviation [ dE ] and either high or low [ A1.HL ] or [ A2.HL ].
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.
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.
When a latching alarm
has been activated and
the alarm condition
has been removed, the
Mode
key must be
pressed to unlatch the
alarm.
11
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”.
Figure 11. Series 16 Controller Menu Hierarchy
MENU 0
MENU 1
KEY
LOCK
SETPOINT
MENU 2
MENU 3
MENU 4
MENU 5
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
12
Parameter
Descriptions
Series 16 Temperature/Process Controller
Menu “05”
Display
SnSr
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.”
13
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
Thermocouple:
K
J
N
R
T
S
Platinel II
RTD
RTD (decimal range)
Heat PID
Heat On/Off
Alarm
Cool PID
Cool On/Off
Alarm
(0-20mA)
(4-20mA)
PID
On/Off
Alarm
PID
On/Off
Alarm
Code
c.A
J
n
r
t
S
PLII
P
d
Ht.P
Ht.O
ALr
CL.P
CL.O
ALr
U.Su (Unsuppressed)
Su (Suppressed)
999, 99.9, 9.99
0.1, 1, 10
Pid
On.F
ALr
Pid
ON.F
ALr
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).
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
14
Parameter
Descriptions
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.
15
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
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)
Gr.o2
H.HYS
C.HYS
HYS1
HYS2
SPr.2
C.SPr
rAtE
rSEt
dPnG
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.
Figure 12. Typical Lag Processes
Immersion Heater
Lag
Flow
a. Single Lag
a1. Single Lag with
Dead Time
T/C1
Flow
T/C2
T/C
Tank Wall =
Thermal Resistance
b. Two Lag
Strip Heater
Thermal
Resistance
Flow
c. Three Lag
Strip Heater
Thermocouple
in Well
Thermal
Capacity
16
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 19). The controller may also be tuned manually (see page 20).
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
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.)
17
Tuning
Procedures
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”.
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).
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.
18
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.
Figure 13. Typical
“Autotune”
Temperature Profile.
350°F
SV
(Temp)
Stops flashing
tUnE
Initiate
Auto-tune
from Stby
ambient temperature
19
(Time)
Tuning
Procedures
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.
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
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.
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.
20
Tuning
Procedures
11) Repeat for Cycle Time 2 [ CY.t2 ].
12) Change to menu level “05”.
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.
15) Double the Gain [ Gn.o1 ] until a small, sustained oscillation is visible on the recording device’s trace.
16) Measure the period of one cycle of oscillation (“T” on the
diagram below).
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 ].
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.
21
Tuning
Procedures
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
Special Functions
In manual control
mode, error conditions
such as A/D errors
and open or reversed
sensors will be
ignored.
Manual Tuning Procedure - Process
Controller (Zeigler-Nichols PID Method)
A chart recorder to monitor the process variable is required.
The controller must be properly scaled and filtering set as
instructed previously.
1) Apply power and place the controller in Standby by holding
the Mode
key for four seconds.
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 ].
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.
Auto/Manual Operation (Standard)
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.
Note: The Series 16 controller can only be ordered with one of
the following Special Functions installed per instrument.
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 39.
22
Special Functions
Option Part #
Description
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
Maximum Input Impedance: 400 ohms @ +5 Vdc , 5 mA
Figure 14. Wiring Diagram for Remote
Setpoint Select Option
23
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.
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
Figure 15. Wiring Diagram for Process
Variable Retransmission
24
Special Functions
The Heater Break
Alarm option is
not available on
controllers with an
“F” type output.
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
Figure 16. Current Transformer Supplied with Heater
Break Alarm Option, Part # 580E023UOI
Figure 17. Wiring Diagram for Heater Break Alarm
25
Special Functions
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
Figure 18. Wire Diagram for 2-Wire Sensor Input with
Transducer Excitation Option
26
Digital
Communications
Two communication
options are available
for the Series 16 which
allow interfacing to
remote devices utilizing
the most common
industry standards,
RS232 and RS485.
WARNING
Signal ground only.
Grounding to frame
may damage the
controller and void
warranty.
27
RS232
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 28).
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
Digital
Communications
Note: Call factory for a
recommended RS485
converter.
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.
Figure 19. Wiring
diagram for digital communications.
*One PC to one controller
only
28
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
Process Value
Setpoint
Access Code
Gain Output 1
Gain Ratio 2
Rate
Reset
Heat Hysteresis
Cool Hysteresis
Cool Spread
Damping
Alarm 1
Alarm 2
Cycle Time 1
Cycle Time 2
Setpoint Target Time
Low Setpoint Limit
High Setpoint Limit
Controller ID
Baud Rate
Display
nnnn
nnnn
Ac.Cd
Gn.o1
Gr.o2
rAtE
rSEt
H.HYS
C.HYS
C.SPr
dPnG
ALr1
ALr2
CY.t1
CY.t2
Sp.tt
L.SP.L
U.SP.L
Id.no
bAUd
Minimum
Maximum
Sensor Dependent
Low Limit
High Limit
00
05
00
400
0.0
2.0
00
900
00
3600
01
100
01
100
00
100
00
Low/Normal/High
Range Dependent
Range Dependent
00
120
00
120
00 (OFF)
100
Sensor Dependent
Sensor Dependent
00
99
300
2400
Table 2. Communications Parameter List
(Process Controller)
Parameter No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
Description
Process Value
Setpoint
Access Code
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
Display
nnnn
nnnn
Ac.Cd
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
Minimum
Low Scale
Low Scale
00
00
0.0
00
00
01
01
00
00
Low Scale
Low Scale
00
00
00 (OFF)
-1999
-1999
00
300
Maximum
High Scale
High Scale
05
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
29
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
Stop
Bits
2
2
2
2
1
1
1
1
Digital
Communications
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.
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>).
30
Digital
Communications
Caution:
Modifying parameter #19 (Baud Rate) by host may cause
loss of data link.
Figure 20. General Communications Message Format
#[controller id] [command] [parameter number]<new value><units> [CR]
OPTIONAL
OPTIONAL
ONE
Character
Upper case
or Lower
case
R Read
MModify
E Enter
Start of
message
Up to TWO
Numeric
Characters
00 to 99
SPECIAL
COMMANDS
Up to TWO
Numeric
Characters
00 to 99
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
ONE
Character
F Deg F
C Deg C
U PROCESS
SENSOR
None for
default
Temperature
units or NONTHERMAL
parameters
Example: For Standby “On”, type #01N0[CR].
31
Digital
Communications
Figure 21. Sample Communications Commands
STANDBY ‘ON’ COMMAND TO CONTROLLER
STANDBY RESPONSE FROM CONTROLLER
STANDBY
Controller Id
End of
Message
< >
< >
‘#01N0 CR
< >< >
‘ LF #01N0 CR LF ’
Command
Executed
ON (Select)
Command
Start of Message
STANDBY ‘OFF’ COMMAND TO CONTROLLER
STANDBY RESPONSE FROM CONTROLLER
STANDBY
Controller Id
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
End of
Message
< >
Standby STATUS
is ‘off’
N
Status REQUEST
Command
Start of Message
< >< >
‘ LF #01F0 CR LF ’
< >
‘#01?0 CR
Standby STATUS
is ‘on’
Figure 22. Requesting a Parameter from a Controller
SAMPLE: READ, MODIFY, ENTER COMMANDS
READ MESSAGE TO CONTROLLER
READ RESPONSE FROM CONTROLLER
Parameter Number
Controller Id
Units
End of
Message
< >
< >
‘#01R00 CR ’
< >< >
‘ LF #01R00 = 0120F CR LF ’
Value read from controller
Read
Command
Start of Message
MODIFY COMMAND TO CONTROLLER
MODIFY RESPONSE FROM CONTROLLER
Parameter Number
Controller Id
Units
Units
< >
< >
‘#01M01 0200F CR ’
Start of Message
< >< >
‘ LF #01M00 = 0200F CR LF ’
End of
message
New Value
‘space’ for
Positive
Modified Value
Modify Command
ENTER COMMAND TO CONTROLLER
ENTER RESPONSE FROM CONTROLLER
Parameter Number
Controller Id
Units
Units
< >
< >
‘#01E01 0200F CR ’
Start of Message
New Value
‘space’ for
Positive
< >< >
‘ LF #01E00 = 0200F CR LF ’
End of
message
Entered Value
Enter Command
32
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.
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.
33
Recalibration
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.
Error Codes
Display
Problem
Action
[ Err.H ]
Open sensor
Check sensor and wiring
Check type of sensor
Recalibrate
[ 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
34
Warranty/Repair
Information
Two-Year Limited Warranty
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.
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.
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.
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.
35
Technical
Specifications
Performance
Accuracy
Setpoint Accuracy
Temperature Stability
TC Cold End Tracking
Noise Rejection
±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
Process Sampling Rate 10 Hz (100 ms)
Inputs
Thermocouple
RTD
Linear
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
36
Technical
Specifications
Outputs
#1
#2
B
E
F
S
T
@ 25° C
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
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
37
Technical
Specifications
Gain
0 to 400
Gain Ratio
0 to 2.0 (in 0.1 increments)
Control Hysteresis
1 to 100 units (on/off configuration)
Cool Spread, Output 2 0 to 100° F/C (above setpoint)
(Temperature Controller)
Spread 2, Output 2
0 to 100 units (above setpoint)
(Process Controller)
Damping
Selectable (low, normal, high, off)
Setpoint Target Time
0 (off) to 100 minutes
(Ramp-to-Setpoint)
Autotune
Operator-initiated from front panel
Manual
Operator-initiated from front panel
General
Line Voltage
Display
play
115 to 230 V ±10%, 50-60 Hz
115 to 300 Vdc ±10% (Auto-Polarity)
Dual, 4-digit 0.36" (9.2 mm) LED dis-
Process Value: Orange
Setpoint Value/Menu: Green
Power Consumption
Less than 6 VA (@ 120/240 Vac)
Panel Cutout
1.771" x 1.771" (45 mm x 45 mm)
Depth Behind Panel
3.937" (100 mm)
Front Panel Rating
NEMA 4X
Operating Temperature 32 to 131° F (0 to 55° C)
Humidity Conditions
90% R.H. max., non-condensing
Parameter Retention
Solid-state, non-volatile memory
Connections
Input and output via barrier strip
with locking terminals
Contacts
Twin bifurcated
38
Ordering Codes
Model 16
Input
"K" TC
"K" TC
"J" TC
"J" TC
"N" TC
"N" TC
"R" TC
"R" TC
"T" TC
"T" TC
"S" TC
"S" TC
Platinel II
Platinel II
100 ohm RTD
100 ohm RTD
100 ohm RTD
DF
100 ohm RTD
1 to 5 V
10 to 50 mV
4 to 20 mA *
0 to 5 V
0 to 50 mV
0 to 20 mA*
0 to 10 V
2 to 10 V
0 to 1V
Range
Code
0 to 2460° F
KF
-18 to 1349° C KC
0 to 1400° F
JF
-18 to 760° C
JC
0 to 2370° F
NF
-18 to 1299° C NC
0 to 3200° F
RF
-18 to 1760° C RC
-200 to 600° F TF
-129 to 316° C TC
0 to 3200° F
SF
-18 to 1760° C SC
0 to 2372° F
LF
-18 to 1300° C LC
-328 to 1562° F PF
-200 to 850° C PC
-199.0 to 450.0 ° F
-128.8 to 232.2° CDC
Scaleable
L1
Scaleable
L2
Scaleable
L3
Scaleable
L4
Scaleable
L5
Scaleable
L6
Scalable
L7
Scalable
L8
Scalable
L9
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
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
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
39
Special Options See List
If NONE: Enter 00
(Consult Factory)
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.
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
or
until “05” appears.
4. Press
until [ SnSr ] flashes. Then use
or
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
[ ALr ] = Alarm
Important: If only one output is PID, set the other output to either On/Off or Alarm.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Select Cooling Type [ CoL.t ].
[ nor ] = standard/no cooling
[ H2o ] = water-cooled extruders
Select Alarm [ AI.H.L.], either [ HI ] or [ Lo ].
Select Alarm Type [ A1.P.d. ], either Process [ Pr ] or Deviation [ dE ].
Select Alarm Operation [ Al.O.P.], either Normal [ nor ], Latching [ LAt ] or Off [ OFF ].
Repeat Steps 7 through 9 for Alarm 2, if applicable.
Select Temperature Units [ Unlt ], either [ F ] or [ C ], then press Mode
key once to display setpoint.
Use
or
keys to select Setpoint Value.
Press
key once to return controller to [ Ac.Cd ] display.
Press
key twice to select menu level “03”.
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 ].
Select Cycle Times [ CY.t1 ] and/or [ CY.t2 ] as follows:
For Control Output Type —
Select Cycle Time (in seconds)
B
15
E
00
F
00
S
00
T
15
Y
15 (Output 2 only)
Scroll to Setpoint Target Time [ SP.tt ] and set to [ OFF ].
Select Lower Setpoint Limit [ L.SP.L ] and Upper Setpoint Limit [ U.SP.L ] to the desired value.
Press Mode
key once, then
key once to restore [ Ac.Cd ] display. Change to menu level “02”.
Use the
key to scroll through to the Damping menu parameter [ dPnG ]. Select normal [ nL ]. Note:
If your process is subject to thermal lag.
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.
40
Keep This Information in a Safe Place
Configured Parameters Reference Card
Series 16/18/19/25 Temperature Controllers
Model Number
Zone Location
Firmware Version No.
(Displayed when the controller is powered up after all the segments on both lines of the display have been
tested.)
Dear Customer:
Please keep this information handy – in case your controller should lose its configured
initial parameter values or for easy reference when setting up a new controller.
After auto-tuning, and when your controller is controlling well, we suggest you
write the displayed value for each of the menu parameters below. If you do not use a
listed parameter, indicate “N/A”. Using this information to document your parameter settings could reduce your downtime. If you have any questions, or need further assistance, please contact Athena Controls Technical Support:
Toll-free (in USA): 800.782.6776
Telephone: 610.828.2490
Fax: 610.828.7084
E-Mail: techsupport@athenacontrols.com
Website: athenacontrols.com
Configured Parameters Reference Information
Series 16/18/19/25 Temperature Controllers
Menu 2
Menu 3
Menu 4
41
Menu 5
NOTES
42
Keep This Information in a Safe Place
Configured Parameters Reference Card
Series 16/18/19/25 Temperature Controllers
Model Number
Zone Location
Firmware Version No.
(Displayed when the controller is powered up after all the segments on both lines of the display have been
tested.)
Dear Customer:
Please keep this information handy – in case your controller should lose its configured
initial parameter values or for easy reference when setting up a new controller.
After auto-tuning, and when your controller is controlling well, we suggest you
write the displayed value for each of the menu parameters below. If you do not use a
listed parameter, indicate “N/A”. Using this information to document your parameter settings could reduce your downtime. If you have any questions, or need further assistance, please contact Athena Controls Technical Support:
Toll-free (in USA): 800.782.6776
Telephone: 610.828.2490
Fax: 610.828.7084
E-Mail: techsupport@athenacontrols.com
Website: athenacontrols.com
Configured Parameters Reference Information
Series 16/18/19/25 Temperature Controllers
Menu 2
Menu 3
Menu 4
43
Menu 5
NOTES
44
For technical assistance, call toll free
1-800-782-6776 (in the U.S.) or 610-8282490 (from anywhere in the world), or
e-mail techsupport@athenacontrols.com.
Athena Controls, Inc.
5145 Campus Drive
Plymouth Meeting, PA 19462 USA
Toll-free: 800.782.6776
Tel: 610.828.2490
Fax: 610.828.7084
techsupport@athenacontrols.com
athenacontrols.com
900M006U00 REV “C” - 082405
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