Electronic Controller

Electronic Controller
SERIES
32C
TEMPERATURE/PROCESS
CONTROLLER
Instruction Manual
Introduction
Features
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.
Field-Selectable Thermocouple, RTD, or Voltage Input
Current Input (with External 2.5 Ohm Resistor)
On/Off Through Full PID Operation
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 Quick-Start Reference Card is attached to the back of the
instruction manual for experienced users of PID controllers.
As you look through this manual, you will notice blue italicized 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 1-800782-6776. Outside the U.S., please call 610-828-2490.
Precautions
After unpacking, inspect the instrument for any physical
damage that may have occurred in shipping. Save all packing
materials and report any damage to the carrier immediately.
©Copyright 1999, Athena Controls, Inc.
2
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
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).
3
Table of
Contents
Installation
Installation
Dimensions and Mounting
Wiring
Output Types
Operation
4
5
6
7
10
Front Panel Controls
Power On
Security Levels
Menu System
Initial Setup Sequence
Menus and Parameters
Operating Modes
Alarms
Available Control Methods
Autotuning
Manual Tuning
12
12
13
14
15
20
21
29
31
32
33
34
Error Codes
Technical Specifications
Ordering Code
Recalibration Procedures
Quick – Helps
Warranty/Repairs
Quick Setup Instructions
36
37
40
41
42
45
48
Unpacking and Inspection
Measurements between
centerlines of panel
cutouts are minimum
recommended.
1. Inspect shipping carton for obvious signs of mishandling.
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
2.10"
(53.34 mm)
CL
CL
1.50"
(38.10 mm)
CL
5
Dimensions
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.
Figure 2. Case Dimensions
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.
Mounting
Prior to mounting the controller 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.
Figure 3. Mounting Diagram
Insert the controller through the front panel cutout and slide
Gray Gasket
the mounting collar
Bezel
back onto the unit
Mounting Collar
from behind the panel.
Push the mounting
collar up tight to the
Side View
back of the mounting
panel.
Black Gasket
(Bevel faces user)
6
If additional RFI attenuation is required, noise suppression
devices such as an R.C. snubber at the external noise source
may be used. If you wish, you may order this suppressor
directly from Athena, part number 235Z005U01.
Figure 4. Contact Identification
Customer Panel
7
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.
8
Wiring
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.
Figure 5. Thermocouple,
RTD Wiring
RTD, and Voltage
Connect 2-wire, 100 ohm platinum
Connections
RTD to contacts 1 and 2. Keep leads
short and use copper extension wire.
Process and Linear Input Wiring
Voltage Inputs: Connect the positive voltage input to contact
1 and the negative to contact 2 (Figure 5).
Current Inputs: (Figure 6) Connect the positive current input to contact 1 and the
negative current input to contact 2.
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.
Figure 7. Power Wiring Connection
9
Output Types
The Type “B” 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.
Output Types
When you ordered your controller, a specific output device
combination was specified for outputs #1 and #2. 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 configuring either or both outputs
as reverse or direct acting from the front panel. 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)
Select Cycle Time
(in seconds)
15
S
0
T
15
Output #1
B
Electromechanical relay, 5A @ 120/240
Vac, normally open, used for switching
resistive loads.
S
DC logic output @ 5 Vdc pulsed
T*
Solid-state relay, zero voltage-switched
and optically isolated from drive signal.
Resistive loads to 1 A @ 120/240 Vac may
be controlled directly. Larger loads may be
controlled using an external contactor.
Output #2
S*
DC logic output @ 5 Vdc pulsed
T
Solid-state relay, zero voltage-switched
and optically isolated from drive signal.
Resistive loads to 1 A @ 120/240 Vac may
be controlled directly. Larger loads may be
controlled using an external contactor.
*Output combination “TS” is not available.
10
11
Operation
Power On
Figure 8. Front Panel Controls and Indicators
Output Indicator
Used to indicate
activation of Output 1.
Four-Digit LED Display
Displays measured
process value, setpoint,
or parameter labels and
settings.
Output Indicator
Used to indicate
activation of Output 2.
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.
12
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 controller, 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
key once.
key once.
3) Press Mode/Enter
key again. (The display
will alternate between
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 on page 16 provides a functional representation of
the user interface and the key presses necessary to perform
the basic functions.
13
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.
Menu System
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.
14
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.
15
Menu System
Figure 9. Series 32C Functional Diagram
Security
Levels
for 10 seconds
for 3 seconds
Menu
System
Setpoint
Modification
Process
Variable
Display
Mode
Selection
for 3 seconds
16
17
Menu System
Figure 10. Overview of Series 32C Menu System, Operating Modes, and Security Levels
Mode/Enter Key
Raise/Lower Key
Menu Access Key
Mode/Enter Key
Security Levels
(Key Lockout) = No Access
(Setpoint) =
(User) =
Plus
(Configuration) =
(Factory) =
18
Plus
Plus
19
Initial Setup
Sequence
Menus and
Parameters
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 controller.
If a key press is not
sensed within five minutes, the Menu System is
automatically exited and
the controller reverts to
the Operating Mode/
Process Value display.
Make sure that the 2position setswitch is set
properly for the input
type being used (see
page 8).
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 26.
5) Return to Process Variable Display. Press and hold the Menu
Access
key for three seconds to return to PV display.
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.
1) Place the unit in Standby Mode as follows. Press the
Mode/Enter
key for three 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.
2) Input Type. Press Menu Access
key repeatedly until
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,
and
or
, before proceeding. Use the Raise
Lower
key to set low and high scaling limits.
,
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.
20
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.
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 types, output actions, 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.
21
Setpoint Menu
Control Menu
Display Parameter
In Manual mode,
the setpoint display
is replaced by the
manually controlled
output percentage
display.
Setpoint
Selection
Setpoint limits
Manually controlled
output percent for
output 1 when configured
for two same-acting
outputs.
0...High limit
Manually controlled
output percent for
output 2 when configured
for two same-acting
outputs.
0...High limit
22
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
Display Parameter
Default
Bumpless
Bumpless
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.
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.
Derivative Action (Rate)
0 to 2400 seconds
0 seconds
Manual Reset
-100% to 100%
Off
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
1...to span of sensor
1° F
Bumpless
Hysteresis Output 1
1...to span of sensor
1° F
NOTE: Output percent parameters are not displayed unless the controller is in Manual operating mode.
Deadband 2
1...to span of sensor
1° F
Hysteresis Output 2
1...to span of sensor
1° F
23
Autotune
Damping Menu
Input Menu
Display Parameter
Damping
Selection
Lo
nL (normal)
Hi
Default
Input Menu
Display Parameter
Normal
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.
Low Scale
-1999 to 9999
Default
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.
24
Selection
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).
25
Output Menu
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 Action
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.
(Reverseacting)
(Direct-acting)
Output 1 Alarm Action
(Latching)
(Normal)
Output 1 Process/
Deviation
(Process Low)
(Process High)
When changing
thermocouple types,
be sure to check/adjust
upper and lower
setpoint limit values.
(Inverse Band)
(Normal Band)
(Deviation Low)
(Deviation High)
Output 1 Alarm
Setpoint
Output 1
Alarm Inhibit
Span of Sensor
Output 1 High Limit
25° C
(Disabled)
(Enabled)
Output 1 Cycle Time 0 to 120 seconds
NOTE: Only available if Output 1 has been set to PID.
26
Output 2 Type
Output 1 Type
1-100%
0=300 ms
If both outputs are
set to
, the
controller will function
as a noncontrolling
indicator. Control outputs will be disabled
and the Operating
Modes will not be
displayed.
Output 2 Action
(Reverseacting)
(Direct-acting)
Output 2 Alarm Action
(Latching)
(Normal)
Output 2 Process/
Deviation
Output 2 Alarm
Setpoint
Output 2
Alarm Inhibit
(Process Low)
(Process High)
(Inverse Band)
(Normal Band)
(Deviation Low)
(Deviation High)
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%
100%
27
Display and
Supervisor Menu
Operating Modes
Display Parameter
Selection
Default
Decimal Position
OR
Remember to press the
Mode/Enter key after
making your selection.
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.
28
If both outputs are
set to
or
,
the controller 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
Supervisor Menu
Display Parameter
Selection
Default
Failsafe State
Standby
(only available when unit is
placed in Standby mode.)
(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 directacting outputs.The “dir” setting activates direct-acting outputs and
deactivates reverse-acting outputs.
A description of the available operating modes
is provided on the next page.
Note on Calibration Menu:
Your Series 32C was calibrated at the factory. If recalibration should
become necessary, see page 41.
29
Alarms
Operating Modes
Manual
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.”
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).
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).
Deviation, Inverse
Band, and Normal
Band Alarm track with
setpoint.
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.
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 controller’s alarms may also be configured as latching
alarms by selecting
in the Output 1 or Output 2 Alarm
Action
or
parameter selection.
30
31
Available Control
Methods
Autotuning
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, PID, or Manual control methods 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 (see page 29).
Output Menu
Control Menu
(PID)
Select PID
Proportional
Band 1
or On/Off
Proportional
Band 2
Derivative
Manual Reset
Integral
32
To place the controller 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 20. Set
damping to normal
. (See page 24.)
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.
33
Manual Tuning
Manual Tuning
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.
T
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
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.
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 on the next page).
34
35
Technical
Specifications
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.
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
Reversed Sensor
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
36
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
37
Technical
Specifications
Technical
Specifications
Cycle Time
Control Hysteresis
Autotune
Manual Control
0 = 300 ms; 1 to 120 sec
1 to Span of Sensor
Operator Initiated from
Front Panel
Operator Initiated from
Front Panel
Inputs
Thermocouple
RTD
Mechanical Characteristics
Display
Numeric Range
Display Height
Color
Front-Panel Cutout
Bezel Outside Dimensions
Bezel Height
Case Depth
Weight
Connections
38
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
removable barrier strip.
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 B
Type T
Type S
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)
39
Ordering
Information
32C
Recalibration
Procedures
U
Special Options
Consult Factory
Outputs (Heat/Cool)*
Code
BS =
TT =
BT =
SS =
ST =
Options
Output #1 Relay, #2 Pulsed (Logic)
Outputs #1 and #2 S.S. Relay
Output #1 Relay, #2 S.S. Relay
Outputs #1 and #2 Pulsed (Logic)
Output #1 Pulsed (Logic), #2 S.S. Relay
1 = 24 Vac/dc power
*Note: Both outputs must be configured in the field as either direct-acting or reverse-acting.
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.)
Input
“K”
“J”
“T”
˚F
-220 to 2462˚
-398 to 1400˚
-202 to 752˚
˚C
-140 to 1350˚
-100 to 760˚
-130 to 400˚
RTD
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
T/C
40
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 controller.
Then, power on the controller.
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
400° C/ 752° F
T
0° C/32° 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.
41
Quick-Helps
Quick-Helps
1. To return the unit to last operating mode (Normal, Standby,
FOP, or Tune):
Action
Press and hold
Action
Display
From Menu System:
Press and hold
for 3 sec.
PV/Mode
From Security Level Menu:
Press
PV/Mode
2. To enter Standby operating mode:
From Normal operating mode:
Action
Press and hold
3. To escape from Standby operating mode:
for 3 sec.
Press
Press
Press
Display
4. To initiate Autotuning:
for 3 sec.
Press
From FOP (Manual) operating mode
From Menu System:
From Security Level Menu:
42
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
Display
PV
Action
Display
Enter Standby
operating mode
(See Quick-Help #2)
Press and hold
+ PV
for 3 sec.
Press
+ PV
Press
5. To abort Autotuning:
Action
+ PV
Display
Press and hold
+ PV
for 3 sec.
Press
+ PV
Press and hold
PV
for 3 sec.
Press
+ PV
Press
PV
43
Warranty/Repair
Information
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
Two-Year Limited Warranty
THIS EQUIPMENT IS WARRANTED TO BE FREE FROM
DEFECTS OF MATERIAL AND WORKMANSHIP. IT IS SOLD
SUBJECT TO OUR MUTUAL AGREEMENT THAT THE LIABILITY
OF ATHENA CONTROLS, INCORPORATED IS TO REPLACE OR
REPAIR THIS EQUIPMENT AT ITS FACTORY, PROVIDED THAT
IT IS RETURNED WITH TRANSPORTATION PREPAID WITHIN
TWO (2) YEARS OF ITS PURCHASE.
THE PURCHASER AGREES THAT ATHENA CONTROLS,
INCORPORATED ASSUMES NO LIABILITY UNDER ANY
CIRCUMSTANCES FOR CONSEQUENTIAL DAMAGES
RESULTING FROM ITS USE OR FROM IMPROPER HANDLING
OR PACKAGING OF SHIPMENTS RETURNED TO THE FACTORY.
COMPONENTS WHICH WEAR OR WHICH ARE DAMAGED BY
MISUSE ARE NOT WARRANTED. THESE INCLUDE CONTACT
POINTS, FUSES, ELECTROMECHANICAL RELAYS, AND TRIACS.
UNITS WHICH HAVE BEEN MODIFIED BY A CUSTOMER IN
ANY WAY ARE NOT WARRANTED.
Other than those expressly stated herein, THERE ARE NO
OTHER WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED,
AND SPECIFICALLY EXCLUDED BUT NOT BY WAY OF
LIMITATION, ARE THE IMPLIED WARRANTIES OF FITNESS
FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.
IT IS UNDERSTOOD AND AGREED THE SELLER’S LIABILITY
WHETHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY,
IN NEGLIGENCE OR OTHERWISE SHALL NOT EXCEED THE
44
45
Warranty/Repair
Information
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
purport to cover all details
or variations in hardware,
nor to provide for every
possible contingency in
connection with the installation and maintenance.
Features may be described
here in 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.
46
RETURN OF THE AMOUNT OF THE PURCHASE PRICE PAID
BY THE PURCHASER AND UNDER NO CIRCUMSTANCES
SHALL SELLER BE LIABLE FOR SPECIAL, INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES. THE PRICE
STATED FOR THE EQUIPMENT IS A CONSIDERATION IN
LIMITING SELLER’S LIABILITY. NO ACTION, REGARDLESS
OF FORM, ARISING OUT OF THE TRANSACTIONS OF THIS
AGREEMENT MAY BE BROUGHT BY PURCHASER MORE
THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED.
SELLER’S MAXIMUM LIABILITY SHALL NOT EXCEED AND
BUYER’S REMEDY IS LIMITED TO EITHER (i) REPAIR OR
REPLACEMENT OF THE DEFECTIVE PART OR PRODUCT, OR
AT SELLER’S OPTION (ii) RETURN OF THE PRODUCT AND
REFUND OF THE PURCHASE PRICE, AND SUCH REMEDY
SHALL BE BUYER’S ENTIRE AND EXCLUSIVE REMEDY.
THE SPECIFICATIONS PUT FORTH IN THIS MANUAL ARE
SUBJECT TO CHANGE WITHOUT NOTICE.
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.
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
B
T
S
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.
47
Quick Setup Instructions - Series 32C Temperature Controller
5.
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 1-800-782-6776.
Menu Access
1.
Raise
Lower
Mode/ Enter
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.
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)
B (Output 1 only)
15
S
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.
2.
3.
Press
or
Press
repeatedly until
is displayed. Then press the
to select sensor input type.
to display
. Then press
once to display
key repeatedly until
appears. Use
Flashes
. Use
or
to select
.
4.
48
Press the
key until Output 1 Action
is displayed. Select the desired output action using the
or
keys.
= Heating
= Cooling
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.
49
Notes
50
Notes
51
For Technical Assistance in the U.S.,
Call Toll Free: 1-800-782-6776
CORPORATE HEADQUARTERS
EUROPE
Athena Controls, Inc.
5145 Campus Drive
Plymouth Meeting, PA 19462 U.S.A.
Tel: (610) 828-2490
Fax: (610) 828-7084
Toll-Free in U.S.: 1-800-782-6776
Internet: www.athenacontrols.com
E-Mail: [email protected]
Athena Controls, Ltd.
P.O. Box 176
Stockport SK3 0LF
England
Tel: +44 (0) 161 428 9966
Fax: +44 (0) 161 428 9977
E-mail: [email protected]
32C-699-2.5M-J
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