900M008U00B - Athena 32C
SERIES
32C
TEMPERATURE/PROCESS
CONTROLLER
Instruction Manual
Introduction
Congratulations on your purchase of an Athena Series 32C
Temperature/Process Controller. It is designed for ease of use
and reliability wherever accurate control is required.
After following the instructions for installation, simply step
through and set your operating parameters using the controller’s easy menu system. The instrument may then be automatically or manually tuned to your process for optimum setpoint control. A Qick-Start Reference Card is in the back of the
instruction manual for experianced users of PID controllers.
As you look through this manual, you will notice italizised text
appearing in the margins and adjacent to operating information. These notes impart important information about the controller and may answer questions you may have about its
setup or operation. If you still have questions or require any
assistance, please contact your Athena representative or call
technical support at 1-800-782-6776. Outside the U.S., please
call 610-828-2490.
Precautions
After unpacking, inspect the instrument for any physical damage that may have occured in shipping. Save all packing
materials and report any damage to the carrier immediatley.
Copyright 1999, Athena Controls, Inc.
1
Features
Field-Selectable Thermocouple, RTD, or Voltage Input
Current Input (with External 2.5 Ohm Resistor)
On/Off Through Full PID Operation
Autotuning - Heat or Cool
Adjustable On/Off Output Hysteresis
Dual Outputs
Field-Configurable Process or Deviation Alarms
Output % or Process Value Display
Bumpless, Auto-Manual Transfer
NEMA 4X Front Bezel
4-Digit (0.40") Alphanumeric Display
Approvals: UL, cUL, CE-compliant
Safety Warning
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.
The safe operating temperature range for this unit is 32°F
to 140°F (0°C to 60°C).
2
Table of
Contents
Installation
Dimensions and Mounting
4
Wiring
5
Output Types
8
Operation
3
4
9
Front Panel Controls
9
Power On
9
Security Levels
10
Menu System
11
Initial Setup Sequence
15
Menus and Parameters
16
Operating Modes
22
Alarms
23
Available Control Methods
24
Autotuning
25
Manual Tuning
26
Error Codes
27
Technical Specifications
28
Ordering Code
30
Recalibration Procedures
31
Quick–Helps
32
Warranty/Repairs
35
Quick Setup Instructions
37
Installation
Unpacking and Inspection
1. Inspect shipping carton for obvious signs of mishandling.
Measurements between
centerlines of panel
cutouts are minimum
recommended.
2. After removing the controller from the shipping carton,
inspect it carefully for damage. Never attempt to install
and use a damaged unit.
3. Verify that the ordering code number indicated on the side
of the controller matches what was ordered.
Figure 1.
Recommended Panel Layout for Multiple Controllers
CL
CL
2.10"
(53.34 mm)
CL
1.50"
(38.10 mm)
CL
Dimensions
Figure 2. Case Dimensions
1.890"
(48 mm)
.944"
(23.97 mm)
.328"
(8.33 mm)
1.772"
(45 mm)
.874"
(22.19 mm)
Cutout
3.937"
(99.99 mm)
.870"
(22.09 mm)
Side View
Prior to mounting the Series 32C in your panel, make sure
that the cutout opening is of the right size, 0.874" x 1.772"
(22.19 mm x 45.0 mm), and deburred to enable a smooth fit.
A minimum of 4.5" (113 mm) of depth behind the panel is
required.
4
Mounting
Figure 3. Mounting Diagram
Insert the Series 32C through the front panel cutout and slide
the mounting collar back onto the unit from behind the panel.
Push the mounting collar up tight to the back of the mounting
panel.
Gray Gasket
Bezel
Mounting Collar
Side View
Customer Panel
Black Gasket
(Bevel faces user)
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.
The Series 32C controller has built-in circuitry to reduce
the effects of electrical noise (RFI) from various sources.
However, power and signal wires should always be kept
separate. We recommend separating connecting wires into
bundles: power; signal; alarms; and outputs. These bundles
should then be routed through individual conduits. Shielded
sensor cables should always be terminated at one end only.
If additional 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.
Figure 4. Contact Identification
Output
2
+
-
1
2.5 Ω
2 3
4 5
6 7
8
(current)
+
T/C RTD
Voltage
5
Output
1
+
-
L2 L1
115-230V
50/60 Hz
Wiring
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 one end.
When using an RTD
sensor, an approximate
error of 6 °F (3.3 °C)
will result for each
ohm of resistance
encountered in the
lead wires. If shielded
RTD wire is used,
terminate the shield
only at one end.
The Series 32C accepts Type J, K, or T thermocouples, 100 ohm RTDs and linear inputs
(suppressed or unsuppressed). It is shipped from the factory set for thermocouple or linear
input; however, a shunt jumper is located on the PC board near the rear of the unit. This
jumper (JMP01) is accessible by removing the back portion of the case. It is not necessary
to remove the PC board from the case. See table below.
Thermocouple Input Wiring
Using the appropriate thermocouple
and extension wire, connect the negative lead (generally colored red in
ISA-type thermocouples) to contact 2;
connect the positive lead to contact 1.
Extension wires must be the same
polarity as the thermocouple.
RTD Wiring
Connect 2-wire, 100 ohm platinum
RTD to contacts 1 and 2. Keep leads
short and use copper extension wire.
1
2
+
Figure 5.
Thermocouple, RTD,
and Voltage
Connections
6
Wiring
Process and Linear Input Wiring
Voltage Inputs: Connect the positive voltage input to contact
1 and the negative to contact 2 (Figure 5).
1 2
Current Inputs: (Figure 6) Connect the positive current input to contact 1 and the
negative current input to contact 2.
(2.5Ω)
Connect an external 2.5 ohm shunt
+
resistor across the contacts.
Figure 6. Current Input Wiring
The Series 32C accepts both 85 to 265 Vac and 120 to 375
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.
Both of the incoming power lines should be fused with 2AG,
0.5 amp maximum rated fuses. Be sure that only instrument
power input is fused — not power to the load.
7
8
L2
L1
Figure 7. Power Wiring Connection
7
Output Types
The Type “R” output
is a mechanical device
and subject to wear.
To extend the life of
the relay, set the Cycle
Time for the relay
output to the longest
duration that still
affords good control.
When you ordered your Series 32C controller, a specific output device combination was specified. See page 40 for the
ordering code, and compare it to the part number on the
controller label. Your controller was also configured at the
factory with either one or two output actions. Generally, output 1 is used as a reverse-acting (heat) function and output
2 is a direct-acting (cool) function. However, the Series 32C
provides the option of having either or both outputs configured as reverse or direct acting. For best results, follow the
recommendations given below for setting cycle times. A
brief description of output devices follows on the next page.
For Control Output Type —
B (Output 1 Only)
Output #1
B
Select Cycle Time
(in seconds)
15
S
0
T
15
Electromechanical relay, 5A @
120/240 Vac, normally open, used
for switching resistive loads.
S
DC logic output @ 5Vdc pulsed
T*
Solid-state relay, zero voltageswitched and optically isolated from
drive signal. Resistive loads to 1A
@ 120/240 Vac may be controlled
using an external contactor. Larger loads
may be controlled using an external con
tactor.
Output #2
S*
T
DC logic output @ 5Vdc pulsed
Solid-state relay, zero voltageswitched and optically isolated from
drive signal. Resistive loads to 1A
@ 120/240 Vac may be controlled
using an external contactor. Larger loads
may be controlled using an external con
tactor.
*Output combination “TS” is not available
8
Operation
Figure 8. Front Panel Controls and Indicators
Four-Digit LED Display
Displays measured
process value, setpoint,
or parameter labels and
settings.
Output Indicator
Used to indicate
activation of Output 2.
Output Indicator
Used to indicate
activation of
Output 1.
Mode/Enter Key
Used to enter Parameter selections, access operating modes,
silence latched alarms, and index
through menu items.
Lower Key
Used to decrease values.
(Hold for fast-step progression)
Raise Key
Used to increase values.
(Hold for fast-step progression)
Menu Access Key
Used to enter or exit the menu system, index to the next
menu, and enter the Security Level menu.
Power On
The Series 32C controller's functional
hierarchy is organized
into three distinct
user-programmable
groupings: Security
Level, Menu System,
and Operating Mode.
Please provide the
software version
number, along with
the controller’s full
model number, when
contacting us regarding
your controller.
When power is first applied to the Series 32C, all segments of
the LED display will be momentarily illuminated while the
instrument goes through a series of diagnostic checks to
verify proper operation. A software version number will then be
displayed, e.g.,
, followed by the measured process value.
IMPORTANT: On initial startup, there is a possibility that outputs may be activated. We recommend placing the unit in
Standby mode until you have configured the controller according to your application requirements. To place the
controller in Standby, follow this procedure:
1) Press Mode/Enter
2) Press Raise
3) Press Mode/Enter
alternate between
9
key once.
key once.
key again. (The display will
and process value.
Operations Overview
The user interface of the Series 32C allows you to use menus to set up
the instrument, set the desired security level, change the setpoint, and
conveniently change operating modes. Figure 9 provides a functional
representation of the user interface and the key presses necessary to
perform the basic functions.
Security Levels
The controller’s initial
security level, set at the
factory, is Configuration
. When you have
completed configuring the instrument,
we recommend the security level be set to the
most restrictive level
suitable for your application.
The security level feature allows you to limit access to the
menus, setpoint, and operating mode selection according to
the needs of your application. The five security levels provided are Key Lockout, Setpoint, User, Configuration, and
Factory. To view or change security level, press and hold the
Menu Access
key for approximately ten seconds. The
controller will alternately display
(Access Level) and
the current security level label, e.g.,
. Use the Raise
or Lower
keys to index through the security levels. Press
the Mode/Enter
key to select the new security level
desired and return to the Process Value display.
Security Levels and Access Restrictions
Key Lockout
Highest security level. No access to any
controller functions. To escape, follow
instructions above for changing security
levels.
Setpoint
No access to menus. Only allows setpoint
value, output percentage (manual mode),
or operating mode to be changed.
User
All “Setpoint” level privileges as well as
access to Autotune and Control menus.
Configuration
All “User” level privileges as well as Input,
Output, Display, and Supervisor menus.
Factory
All “Configuration” level privileges as well
as access to Calibration menu.
10
Menu System
If a key press is not
sensed within five minutes, the controller
automatically exits the
Menu System and
reverts to the Process
Value display.
The Menu System is organized into seven menus: Control,
Autotune, Input, Output, Display, Supervisor, and
Calibration. Pressing the Menu Access key indexes from
menu to menu. Pressing the Mode/Enter key indexes through
the parameters in a particular menu. The Raise and Lower
keys are used to modify the visible menu parameter.
Each menu contains a logical group of parameters related to
one another. Furthermore, the sequence of the menus has
been carefully chosen to put the most frequently used menus
first. For example, provided access is permitted, the first
menu presented upon entering the Menu System is the
Setpoint Menu.
11
Figure 9. Series 32C
Functional Diagram
Menu
System
Menu System
Setpoint
Modification
for 3 seconds
Security
Levels
for 10 seconds
Process
Variable
Display
for 3 seconds
Mode
Selection
12
Menu System
Figure 10. Overview of Series 32C Menu System,
Operating Modes, and Security Levels
Menu Access Key
Mode/Enter Key
13
Mode/Enter Key
Raise/Lower Key
Security Levels
(Key Lockout) = No Access
(Setpoint) =
(User) =
Plus
(Configuration) =
(Factory) =
Plus
Plus
14
Initial Setup
Sequence
Many of the menu parameters you will need to set up the controller for your application are interdependent. We recommend
following the steps below when configuring your Series 32C.
1) Place the unit in Standby Mode as follows. Press the
If a key press is not
Mode/Enter
key for three seconds. Display will indicate
sensed within five
minutes, the Menu
. Press the Raise
key to select Standby. Press Mode
System is automatically
key again and the display will alternate between
and the
exited and the
process value.
controller reverts to the
Operating Mode/
2) Input Type. Press Menu Access
key repeatedly until
Process Value display.
These setup instructions apply to PID-type
control outputs. Alarm
or on/off output settings and displays will
be different. Refer to
Output menu
description on page 19.
is displayed. Then press Mode/Enter
key until
appears. Use Raise
or Lower
key to select Input Type.
If Input Type is set to linear
or
, use the Mode/Enter
key to scroll to scaling limits,
ceeding. Use the Raise
or Lower
high scaling limits.
and
, before prokey to set low and
3) Output Type. Press the Menu Access
key to display
.
Use the Mode/Enter
key to index to the Output Type parameter. Using the Raise
or Lower
keys, select the correct Output Type for your application. Follow these steps
(using the Mode/Enter and Raise or Lower keys) to set the
Output Action, Cycle Time, and High Limit parameters for all
control outputs.
4) Set Control Menu parameters by pressing the Menu
Access
key to display
. Then, use the Mode/Enter
key to index through the available selections and the Raise
or Lower
keys to select the appropriate setting.
5) Return to Process Variable Display. Press and hold the Menu
Access
key for three seconds to return to PV display.
6) Adjust setpoint. Press the Menu Access
key once to
display
and use the Raise
or Lower
key to
enter the desired setpoint. Press the Mode/Enter
key to
return to the Standby/Process Value display. Wait for process
to stabilize before proceeding, e.g., in the case of a heating
process, return to ambient temperature. If autotuning the
controller, make sure the Autotune Damping
parameter
is set to normal
and proceed to Step 4 on page 33.
7) Security Level. Press and hold the Menu Access key for
approximately ten seconds. Using the Raise or Lower keys,
set the most restrictive level suited to your application.
15
Menus and
Parameters
IMPORTANT: Upon
entering a new value,
you MUST either press
the Mode/Enter key, the
Menu Access key, or
index to a different
parameter in order for
the new value to register. The Series 32C controller will NOT accept
new values without a
key press.
Menus and Parameters
Setpoint
or
% Output
Used to change the setpoint or Fixed Output Percentage
(Manual operating mode).
Control
Autotune
Input
Used to select parameters associated with the control methods.
Used to set the autotune damping parameter.
Output
Display
Supervisor
Calibration
Used to specify output usage, control methods, and alarms.
Used to select sensor-related parameters, such as input type,
limits, and scaling.
Used to set or change decimal position and display units.
Used to set the failsafe state of the controller.
Used to calibrate the controller.
16
Setpoint Menu
Display Parameter
Setpoint
In Manual mode,
the setpoint display
is replaced by the
manually controlled
output percentage
display.
Selection
Default
Setpoint limits
72° F
NOTE: In Manual operating mode, setpoint is not displayed.
Manually controlled
output percent when
not configured for two
same-acting outputs. 0...High limit
Bumpless
Manually controlled
output percent for
output 1 when configured
for two same-acting
outputs.
0...High limit
Bumpless
Manually controlled
output percent for
output 2 when configured
for two same-acting
outputs.
0...High limit
Bumpless
NOTE: Output percent parameters are not displayed unless the controller is in Manual operating mode.
Control Menu
Setting Derivative
(Rate) or Integral
(Reset) to
disables that aspect
of PID control.
If BOTH outputs are
set to direct-acting or
BOTH outputs are set
to reverse-acting, then
only one proportional
band selection will be
displayed. The second
proportional band is
not required.
Display Parameter
Default
Proportional Band 1
1...to span of sensor Span
NOTE: Only available if Output 1 has been set for PID control.
Proportional Band 2
1...to span of sensor Span
NOTE: Only available if Output 2 has been set for PID control.
Derivative Action (Rate) 0 to 2400 seconds
0 seconds
Manual Reset
Off
-100% to 100%
NOTE: When OFF is selected for the Manual Reset parameter,
the Integral Action (Int) parameter is active.
Integral Action (Reset)
0 to 9600 seconds
0 seconds
The following parameters are only available if their related
outputs are set for ON/OFF.
Deadband 1
17
Selection
The following parameters are only available if their related
outputs are set for PID.
1...to span of sensor
1° F
Hysteresis Output 1
1...to span of sensor
1° F
Deadband 2
1...to span of sensor
1° F
Hysteresis Output 2
1...to span of sensor
1° F
Autotune
Damping Menu
Display Parameter
Selection
Default
The following parameters are only available if their related
outputs are set for PID.
Proportional Band 1
1...to span of sensor Span
NOTE: Only available if Output 1 has been set for PID control.
Proportional Band 2
1...to span of sensor Span
NOTE: Only available if Output 2 has been set for PID control.
Note: The damping parameter is an autotune feature that allows
you to modify the calculated PID control method used to tune the
controller to suit your specific application requirements. The low
setting provides faster recovery, but with the possibility of overshoot; the high setting a slower recovery, but with no overshoot.
Input Menu
Input Menu
Display Parameter
Low Scale
Selection
Default
-1999 to 9999
0
High Scale
-1999 to 9999
9999
NOTE: Only available if one of the two linear input formats has
been selected.
Lower Setpoint Limit
Span of Sensor
low scale
Upper Setpoint Limit*
Span of Sensor
high scale
Input Type
Changing Low Scale or
High Scale for linear
inputs will reset the
following parameters:
Setpoint High Limit,
Setpoint Low Limit,
Output 1 Alarm
Setpoint, Output 2
Alarm Setpoint,
Proportional Bands.
High Scale and Low
Scale cannot be
adjusted to less than
two display units from
each other.
Type J thermocouple
(Default)
Type K thermocouple
Changing Input Type
will reset the following
parameters to their default
settings:
Setpoint
Proportional Band 1
Proportional Band 2
Output 1 Deadband
Output 1 Hysteresis
Output 2 Deadband
Output 2 Hysteresis
Output 1 Alarm Setpoint
Output 2 Alarm Setpoint.
Type T thermocouple
100 ohm platinum RTD
100 ohm decimal RTD
0-50 mVdc or 0-20 mAdc
10-50 mVDC or 4-20 mAdc
*Note: The SP.HL parameter is the
maximum setpoint that can be
entered. This parameter is limited
to 392° F when displaying
process temperature with 0.1
degree accuracy (Available only
with 100-ohm decimal RTD Input
Type).
18
Output Menu
Display Parameter
Parameters not associated with Output 1
Type or Output 2 Type
selection will not be
displayed. Ex., Alarm
parameters will not be
displayed when PID
control output is
selected.
Selection
Default
Output 1 Type
Output 1 Action
(Reverseacting)
(Direct-acting)
Output 1 Alarm Action
(Latching)
(Normal)
Output 1 Process/
(Process Low)
Deviation
(Process High)
(Inverse Band)
(Normal Band)
(Deviation Low)
(Deviation High)
Output 1 Alarm
Setpoint
Output 1
Alarm Inhibit
Span of Sensor
(Disabled)
(Enabled)
Output 1 Cycle Time 0 to 120 seconds
NOTE: Only available if Output 1 has been set to PID.
Output 1 High Limit
19
25° C
1-100%
0=300 ms
100%
Output Menu
Setting output cycle
time to
initiates a 300 ms cycle
time. The proper 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.
Output 2 Type
Output 2 Action
(Reverseacting)
(Direct-acting)
Output 2 Alarm Action
(Latching)
(Normal)
Output 2 Process/
Deviation
(Process Low)
(Process High)
(Inverse Band)
If both outputs are
set to
, the
Series 32C
will function as a noncontrolling indicator.
Control outputs will be
disabled and the
Operating Modes will
not be
displayed.
(Normal Band)
(Deviation Low)
(Deviation High)
Output 2 Alarm
Setpoint
Output 2
Alarm Inhibit
Span of Sensor
(Disabled)
(Enabled)
Output 2 Cycle Time 0 to 120 seconds
NOTE: Only available if Output 2 has been set to PID.
Output 2 High Limit
25° C
1-100%
0=300 ms
100%
20
Display and
Supervisor Menu
Display Parameter
Selection
Default
Decimal Position
OR
NOTE: This parameter selection is available only for the “100-ohm
decimal RTD” Input Type. It does not appear for thermocouple or
non-decimal 100-ohm platinum RTD inputs (see page 25). Changing
Decimal Position will cause changes in the following parameters:
Setpoint High Limit, Setpoint Low Limit, Low Scale, High Scale,
Setpoint, Proportional Bands, Hysteresis.
Display Units
NOTE: Does not appear for linear inputs.
The Failsafe State is
only enforced when a
problem is detected
with the process input.
It is not reliably
enforceable in
instances of internal
circuitry failure such
as EEPROM problems.
Output % High Limits
are ignored when the
unit enters a Failsafe
State.
21
Supervisor Menu
Display Parameter
Selection
Default
Failsafe State
(Reverse-acting)
(Direct-acting)
NOTE: The Failsafe State is used when an open-sensor, over range, or
underrange condition exists. The “OFF” setting deactivates both outputs. The “rE” setting activates reverse-acting outputs and deactivates direct-acting outputs.The “dir” setting activates direct-acting
outputs and deactivates reverse-acting outputs.
Note on Calibration Menu:
Your Series 32C was calibrated at the factory. If recalibration should
become necessary, see page 41.
Operating Modes
Remember to press the
Mode/Enter key after
making your selection.
If both outputs are
set to
or
,
the
Series 32C will
function as a noncontrolling indicator.
Control outputs will
be disabled and the
Operating Modes will
not be displayed.
The Series 32C features four operating modes: Manual, Standby,
Normal, and Autotune. To select a different operating mode, press
the Mode/Enter key for three seconds. The first option displayed is
Manual (Fixed Output Percentage) Mode
. To index through
the available operating modes, press the Raise
or Lower
keys. When the desired mode is displayed, press the Mode/Enter
key once to select the mode.
Manual
Autotune
Normal
Standby
(only available when unit is
placed in Standby mode.)
A description of the available operating modes
is provided on the next page.
22
Operating Modes
Manual operating
mode overrides automatic control, allowing
you to control the
outputs using a fixed
percentage of output
power, regardless of the
process variable
or setpoint.
An Output High Limit,
which restricts the output percentage possible
in Manual mode may
be entered in the
Output
menu.
If current automatic
control is PID, transfer
to Manual mode is
“bumpless.”
Manual
Used to set control output percentage
(Fixed Output Percentage) independent of Process Value. To set percentage, use the Menu Access
key to
select
and the Raise or Lower
keys to set the value. If BOTH outputs
are direct-acting or BOTH outputs are
reverse-acting, then two FOP percentages will be displayed.
and
.
Standby
Used to disable control outputs.
Normal
Normal automatic control.
Autotune
Used to initiate the autotuning
sequence (from Standby only).
Alarms
Deviation, Inverse
Band, and Normal
Band Alarm track with
setpoint.
Four types of alarms are available on both Output 1 and
Output 2: Process, Deviation, Inverse Band, and Normal
Band. Both output alarms may be configured to be inhibited
on power-up (until the process reaches setpoint for the
first time).
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/Enter
key
must be pressed to
unlatch the alarm.
23
Inverse Band Alarm: Activates when the process is within
a specified band centered around the
setpoint.
Normal Band Alarm: Activates when the process exceeds
a specified band centered around the
setpoint.
Latching Alarms
The Series 32C’s alarms may also be configured as latching
alarms by selecting
in the Output 1 or Output 2 Alarm
Action
or
parameter selection.
Available Control
Methods
The user-selectable control method options provided by the
Series 32C controller are On/Off, PID (including subsets P, PI,
PD, P/Manual Reset, PD/Manual Reset), or Manual. Use the
Output menu to select On/Off or PID output action and the
Control menu to enable or disable the derivative, integral,
and manual reset selections as desired. Use the
(Fixed Output Percentage) operating mode to enable Manual
operation.
Output Menu
Control Menu
(PID)
Select PID
Proportional
Band 1
or On/Off
Proportional
Band 2
Derivative
Manual Reset
Integral
24
Autotuning
To place the Series 32C in Autotune mode:
In order for the controller to autotune
properly, the setpoint
value must be at least
1% of span above or
below the initial
process value.
Ex. sensor span =
1548 (Type J thermocouple); acceptable
setpoint value = ±16
(15.4) units from the
initial process value.
Tuning accuracy
increases as the
spread between ambient and setpoint value
increases.
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) Configure the controller by following the directions for
Initial Setup Sequence through Step 5 on page 15. Set
damping to normal
. (See page 18.)
2) If the controller is not already in Standby mode, place it
in Standby now as follows. Press and hold the
Mode/Enter
key for 3 seconds. Display will indicate
. Press the Raise
key to select Standby. Press
Mode key again and the display will alternate between
and the process value.
3) If Setpoint Value has not been entered, adjust setpoint
now by pressing the Menu Access
key once. The
Setpoint menu
, alternating with the Setpoint Value,
will flash. (If not, press the Menu Access key for three
seconds to return to the Standby/Process Value display,
then press it once again.) Use the Raise or Lower key to
set the desired setpoint. Press the Mode/Enter key to
return to the Standby/Process Value display. Wait for
process to stabilize before proceeding, e.g., in the case
of a heating process, return to ambient temperature.
4) Initiate Autotuning. Press and hold the Mode/Enter key
for 3 seconds, then press the Lower key once
.
Finally, press the Mode/Enter key again. The display will
alternately indicate
and process value as the controller “learns” the proper gain, derivative, and integral
values for the process.
If unacceptable overshoot occurs on restart, shut down
the process and re-tune at the high
damping setting. If sluggish response is observed, shut down the
process and re-tune using low
damping.
25
Manual Tuning
Manual Tuning Procedure - Heating Process
(Zeigler-Nichols PID Method)
This tuning method may be used if the spread between ambient and operating temperature is small, and the autotuner is,
therefore, disabled. It may also be used on non-temperature
reverse-acting processes.
1) Disable cooling device.
2) Turn off the Direct-Acting output.
3) Under the Control menu, set derivative
to zero, and the proportional band
to its maximum setting.
and integral
or
4) Adjust the setpoint to the desired value.
5) While monitoring the recording device, decrease the proportional band value by repeatedly halving the value until
a small, sustained temperature oscillation is observed.
Measure the period of one cycle of oscillation (“T” on the
diagram below).
T
6) Divide the period of oscillation (T) by eight. The resulting
number is the correct Derivative
time in seconds.
Multiply this number by four. This is the correct Integral
time
in seconds.
7) Multiply the bandwidth value obtained in Step 7 by 1.66
and enter this as the new proportional band value.
26
Error Codes
Display
If an error code
through
cannot
be cleared by using the
actions provided, contact factory.
Problem
Actions
RAM Diagnostic Test Failure
ROM Diagnostic Test Failure
EEPROM Range Test Failure
or EEPROM Update Failure
SPI/EEPROM Interface Failure
Default EEPROM Load Warning
Press any key to
perform a soft
reset and
reinitialize
controller.
Open Sensor
Check sensor,
wiring, and Input
Type selection in
the Input menu.
Reversed Sensor
Technical
Specifications
Operating Limits
Ambient Temperature
32°F to 131°F (0°C to 55°C)
Relative Humidity Tolerance 90%, Non-Condensing
Power
85 to 250 Vac
50/60 Hz (Single-Phase)
Power Consumption
Less than 6 VA
Performance
Accuracy
Setpoint Resolution
Repeatability
Temperature Stability
TC Cold-End Tracking
Noise Rejection
Process Sampling
±0.20% of Full Scale
(±0.10% Typical), ±1 Digit
1 Count / 0.1 Count
±1 Count
5 µV /°C (Maximum)
0.05°C /°C Ambient
>100 dB Common Mode,
>70 dB Series Mode
3.7 Hz (270ms)
Control Characteristics
Setpoint Limits
Alarms
Proportional Band
Integral
Derivative
27
Automatically Adjust to
Selected TC / RTD
Adjustable for High / Low;
Selectable Process
or Deviation
1 to Span of Sensor
0 to 9600 Seconds
0 to 2400 Seconds
Technical
Specifications
Operating Limits
Ambient Temperature
32°F to 131°F (0°C to 55°C)
Relative Humidity Tolerance 90%, Non-Condensing
Power
85 to 250 Vac
50/60 Hz (Single-Phase)
Power Consumption
Less than 6 VA
Performance
Accuracy
Setpoint Resolution
Repeatability
Temperature Stability
TC Cold-End Tracking
Noise Rejection
Process Sampling
Control Characteristics
Setpoint Limits
Alarms
Proportional Band
Integral
Derivative
Cycle Time
Control Hysteresis
Autotune
Manual Control
±0.20% of Full Scale
(±0.10% Typical), ±1 Digit
1 Count / 0.1 Count
±1 Count
5 µV /°C (Maximum)
0.05°C /°C Ambient
>100 dB Common Mode,
>70 dB Series Mode
3.7 Hz (270ms)
Automatically Adjust to
Selected TC / RTD
Adjustable for High / Low;
Selectable Process
or Deviation
1 to Span of Sensor
0 to 9600 Seconds
0 to 2400 Seconds
0 = 300 ms; 1 to 120 sec
1 to Span of Sensor
Operator Initiated from
Front Panel
Operator Initiated from
Front Panel
Mechanical Characteristics
Display
Numeric Range
Display Height
Color
Front-Panel Cutout
Bezel Outside Dimensions
Bezel Height
Case Depth
Weight
Connections
7-segment LED,
alphanumeric
-1999 to 9999
0.400"
Green
0.874" x 1.772"
(22.19 mm x 45 mm)
0.944" x 1.890"
(24 mm x 48 mm)
0.328" (8.33 mm)
3.937" (100 mm)
3.04 oz (86.18 g)
Input and output via 28
removable barrier strip.
Technical
Specifications
Inputs
Thermocouple
RTD
Linear
Input Impedances
J, K, T
Maximum lead resistance
100 ohms for rated accuracy
Platinum 2-wire, 100 ohms
at 0°C, DIN curve standard
(0.00385)
0-50 mV/10-50 mV, 0-20
mA/4-20 mA with external
2.5 ohm shunt resistor
0-50 mV/10-50 mV: 1 K ohm ±1%
0-20 mA/4-20 mA: 2.5 ohm ±1%
Outputs
Type R
Type T
Type DC
29
Electromechanical relay, 5 A @
120 Vac, 5 A @ 240 Vac
Solid-state relay, 120/250 Vac,
zero voltage-switched, 1 A
continuous / 10 A surge @ 25°C.
5 Vdc pulsed (open collector)
Ordering
Information
32C U
Outputs (Heat/Cool)*
Outputs
Special Options
Code
BS = Output #1 Relay, #2 Pulsed (Logic)
TT = Outputs #1 and #2 S.S. Relay
BT = Output #1 Relay, #2 S.S. Relay
SS = Outputs #1 and #2 Pulsed (Logic)
ST = Output #1 Pulsed (Logic), #2 S.S. Relay
Code
Consult Factory
1 = 24 Vac/dc power
*Note: Both outputs must be configured in
the field as either direct-acting or reverseacting.
Input Ranges (Inputs are field-configurable from the front-panel
menu and calibrated at the factory for all input types. No recalibration
is required when switching from one input type to another.
T/C
RTD
Input
K
J
T
˚F
-220 to 2462˚
-398 to 1400˚
-202 to 752˚
˚C
-140 to 1350˚
-100 to 760˚
-130 to 400˚
100 ohm RTD
100 ohm RTD
(Decimal)
-328 to 1562˚
-199.0 to 392.0˚
-200 to 850˚
-128.8 to 200.0˚
Linear Scaleable
10 to 50 mV
4 to 20 mA
0 to 50 mV
0 to 20 mA
30
Recalibration
Procedures
The Series 32C controller is precalibrated
at the factory. Under
normal circumstances,
the factory calibration
should be valid for the
life of the instrument. If
recalibration should be
required, allow the
controller to warm up
for 15 minutes and
follow these steps
carefully.
1) Remove power from the controller, then all wires from
terminals 1 through 6. Attach an appropriate sensor
emulator to input terminals 1 and 2.
2) Power on the sensor emulator, making sure that the current
emulated value is not outside the range of the Series 32C.
Then, power on the Series 32C.
3) Index to the Calibration Low
menu item in the
Calibration Menu. (You must have the Security Level set to “Factory”
to access this menu.)
4) For thermocouples and RTDs, dial the low calibration
values into the sensor emulator using the table below.
For linear inputs, calibrate from low scale.
Sensor Type
Calibration Low
Calibration High
J
0° C/32° F
760° C/1400° F
K
0° C/32° F
1350° C/2462° F
T
0° C/32° F
400° C/ 752° F
RTD
0° C/32° F
850° C/1562° F
RT.D (decimal)
0° C/32° F
200.0° C/392.0°F
5) Use the Raise or Lower Keys to match the values shown on
the display to the extracted table value.
6) Push the Mode/Enter Key to index to the Calibration High
menu item.
7) Repeat Steps 4 and 5 for the Calibration High
setting.
8) Press the Menu Access key for three seconds to return to
the Process Value display.
31
Quick-Helps
1. To return the unit to last operating mode (Normal, Standby,
FOP, or Tune):
From Menu System:
From Security Level Menu:
2. To enter Standby operating mode:
From Normal operating mode:
Action
Display
Press and hold
for 3 sec.
PV/Mode
Press
PV/Mode
Action
Press and hold
Display
for 3 sec.
Press
From FOP (Manual) operating mode
From Menu System:
From Security Level Menu:
Press
Press and hold
for 3 sec.
Press
Press and hold
for 3 sec.
Press and hold
for 3 sec.
Press
Press
Press and hold
for 3 sec.
Press
Press
Press
+ PV
+ PV
+ PV
PV
+ PV
32
Quick-Helps
3. To escape from Standby operating mode:
Action
Press and hold
Display
for 3 sec.
Press
Press
Press
4. To initiate Autotuning:
PV
Action
Display
Enter Standby
operating mode
(See Quick-Help #2)
Press and hold
for 3 sec.
Press
Press
5. To abort Autotuning:
Action
+ PV
Display
Press and hold
for 3 sec.
Press
+ PV
Press and hold
for 3 sec.
Press
Press
33
PV
Quick-Helps
6. To enter FOP (Manual) operating mode:
Action
Display
Press and hold
for 3 sec.
Press
Press
+ PV
+
% of Power
Value or
+
% of Power
Value
Press
to set new
% of Power Value
Press
+ PV
7. To escape from FOP (Manual) operating mode:
Action
Display
Press and hold
for 3 sec.
Press
Press
PV
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
IEC
Requirements
USE OF THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY
THE MANUFACTURER MAY IMPAIR PROTECTION PROVIDED
BY THE EQUIPMENT!
The maximum supply current is line voltage dependent:
230 mA for a 24 Vac input
60 mA for an 85 -265 Vac input
fuse rating=700 mA
fuse rating=100 mA
Output Specifications
Output Type
R
T
DC
Max current
5A
1A
20 mA
Voltage
380 Vac
400 Vpk
5V
Leakage
1000M Ohms
1 mA
NA
CLEANING INSTRUCTIONS
1. Remove power from the unit prior to any cleaning operation.
2. Use a cotton cloth to gently and sparingly apply isopropyl
alcohol only. Do not use cleaners or other solvents as they may
damage the unit.
3. Allow the unit to dry completely prior to reapplying power.
36
Quick Setup Instructions - Series 32C Temperature Controller
Experienced users, already familiar with the Series 32C, and
using the controller with PID outputs, may follow these condensed instructions to autotune the controller and get started
quickly once the instrument is properly mounted and wired, and
the Security Level is set to
. Once setup is complete, we
recommend changing the Security Level back to the most
restrictive level suitable for your application.
These quick setup instructions are not meant as a substitute for reading the full instruction manual supplied with the controller. Please be sure to read through the manual for specific details of
operation and, most importantly, for safety precautions. If you have any questions, or experience
problems with setting up your controller, consult the full instruction manual first and, if you still
need assistance, contact your Athena representative or call 610-828-2490.
Menu Access
Raise
Lower
Mode/Enter
1.
Apply power. After self-check display stops, place controller in Standby mode by pressing and holding the
key for 3 seconds, the
key once, and then the
key again.
will flash, alternating with the
Process Value.
2.
Press
or
repeatedly until
is displayed. Then press the
to select sensor input type.
key repeatedly until
3.
Press
to display
. Use
. Then press
once to display
or
appears. Use
to select
.
4.
37
Press the
key until Output 1 Action
is displayed. Select the desired output action using the
or
keys.
= Heating
= Cooling
5.
Press
again to display the Output 1 Cycle Time
parameter. Select the desired cycle time according to the output device used. If unsure, refer to the ordering code on page 40 of the instruction manual
and compare it to the number on the label.
Recommended cycle times are:
For Control Output Device —
Select Cycle Time (in seconds)
R (Output 1 only)
15
DC
0
T
15
IMPORTANT: IF ONLY ONE OUTPUT IS PID, SET THE OTHER OUTPUT TO EITHER ON/OFF, ALARM, OR OFF.
6.
Press the
key to display the next output parameter, Output 1 High Limit
value using the
or
keys.
, and select the desired
7.
Repeat Steps 3 through 6 for Output 2 if required; otherwise, repeat Step 3 to select other Output Type.
8.
Press the
repeatedly until
parameter is set to normal
9.
Press and hold the Menu Access key
is displayed, then press
and make sure autotune damping
. If not, use
or
to change it to the normal setting.
for 3 seconds until
flashes.
10. Initiate autotuning per chart below.
Flashes
Hold for
3 Seconds
Press
Press Once.
Appears Once
in Window
The Controller
Is Now
Autotuning
11. If unacceptable overshoot occurs, shut down the process and allow it to stabilize. Re-tune at the high
damping setting. If response is sluggish, use the low damping setting.
38
For technical assistance, call toll free
1-800-782-6776 (in the U.S.)
or 610-828-2490 (from anywhere in the
world), or e-mail
[email protected]
Athena Controls, Inc.
5145 Campus Drive
Plymouth Meeting, PA 19462 USA
Toll-free: 800.782.6776
Tel: 610.828.2490
Fax: 610.828.7084
[email protected]
athenacontrols.com
900M008U00 REV “B” / 11-10-2004
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