Athena Single Zone RMCP Manual (As RMC Module)

Athena Single Zone RMCP Manual (As RMC Module)
Athena Series RMC
Hot Runner Controller
Quick Set-Up Guide
Who Can Use This Quick Guide
This quick set-up guide contains all the
information you need to set up a new
RMC controller if:
•
you are already familiar with
temperature control concepts,
– and –
•
the factory settings shown on page 2
are OK,
– and –
•
a J thermocouple will supply input to
the RMC,
– and –
•
the unit of measure degrees
Fahrenheit is OK.
Where to Find More Information
The Athena Series RMC Hot Runner
Controller Configuration and Operation
Manual (p/n 900M056U00) contains
detailed instructions for configuring and
operating the controller.
That manual also contains instructions for
changing switch settings to allow the
controller to accept input from a K
thermocouple and/or to display values in
degrees Celsius.
Operating instructions are also in the
Athena Series RMC Hot Runner Controller
Operator’s Manual (p/n 900M056U01).
To learn how to read and write RMC
controller values using a MODBUS host,
see Using the MODBUS Protocol with
Athena Series RMC Hot Runner
Controllers (p/n 900M057U00).
Athena Controls, Inc.
5145 Campus Drive
Plymouth Meeting, PA 19462
Phone: 610-828-2490
Fax: 610-828-7084
[email protected]
athenacontrols.com
900M069U00RevB
Warning
The controllers are shipped with the
SafeChange feature disabled.
Instructions for enabling SafeChange
are in the Athena Series RMC Hot
Runner Controller Configuration and
Operation Manual (p/n 900M056U00).
To avoid serious personal injury and
damage to equipment, read and heed
the warnings and cautions in the
Athena Series RMC Hot Runner
Controller Configuration and Operation
Manual, before installing and using the
controller.
To avoid serious personal injury and
damage to equipment, also follow all
warnings and cautions provided in the
manual supplied with the mainframe.
 2003 Athena Controls, Inc.
1
Series RMC Hot Runner Quick Set-Up Guide
Factory Settings
All Series RMC Hot Runner controllers are shipped with their configuration parameters set
to the values shown in the “Factory Setting” column. You can change any of these values.
For example, you can change the communication protocol to local, and assign the unit to
one of three usage groups. RMC controllers that use local comm can act on commands
from an All Master. Instructions for changing the comm protocol to local are on page 4.
Changing Parameter Values
The procedure for changing any configuration parameter value is: Press MODE to
put the controller in Standby (STANDBY LED lit), press and hold DISPLAY until you see
PId. Press DISPLAY repeatedly until you see the menu you want. Press MODE
repeatedly until you see the parameter you want. Use the and keys to set the value
you want. Press and hold DISPLAY to return to the PV and SP display.
Displayed Menu
Name
PId
(PID control)
bST
(boost)
Stb
(standby)
InP
(input)
ALr
(alarm)
SCI
(serial
communication
interface)
SUP
(supervisor)
900M069U00RevB
Parameters
Factory Setting
Pb (proportional band)
24 °F
rAtE (derivative (rate) action)
7 seconds
At.OP (Autotune operation)
once
tYPE
(type)
open loop
dUr (duration)
off
b.Pct (boost output percent)
0%
tYPE
(type)
S.Pct (standby output percent)
open loop
0%
bIas (input bias)
0 degrees
SP.LL (setpoint low limit)
32 °F
SP.HL (setpoint high limit)
999 °F
AL.OP (alarm operation)
enabled
dE.H (high deviation alarm setpoint)
30 °F
dE.L (low deviation alarm setpoint)
30 °F
InH (alarm inhibit)
0 (off)
Pro (protocol)
MODBUS
S.Id (system ID)
1
bAUd (baud rate)
9600
dAt.F (parity)
none
nnod (IEEE register ordering)
yes
LPb.t (loop break time)
999 seconds
Ht.S (high-temperature safety value)
feature off
FS.A (failsafe action)
output off
HI.t (highest temperature (PV) reading)
read-only value
LO.t (lowest temperature (PV) reading)
read-only value
 2003 Athena Controls, Inc.
2
Series RMC Hot Runner Quick Set-Up Guide
briefly, and then the firmware version
number is displayed.
Set-Up Procedure
1) Prepare the controller.
4) Adjust the setpoint.
a)
Unpack the RMC controller.
b)
Inspect the controller for damage.
c)
Make sure the power switch on the
front of the controller is set to off (O).
If a controller shows signs of having been
damaged during shipping, do not install or
power up the controller. Save all packing
materials and report any damage to the
carrier immediately.
2) Install the controller.
This guide assumes that the mainframe
has already been wired as described in
the Athena Hot Runner Temperature
Control Systems Mainframe Installation
Manual.
a)
Make sure the plunger in the center
of the locking pin is pulled out (or
loosen the locking screw).
b)
With the controller and mainframe
power switches set to off (O), align
the RMC controller’s printed circuit
board with the guide channels in a
slot in the Hot Runner mainframe.
c)
d)
Slide the controller into the
mainframe until the RMC connectors
are firmly seated in the backplane of
the mainframe.
Lock the controller in the frame by
pushing in the locking pin plunger
(or by tightening the locking screw).
3) Apply power to the
mainframe and controller.
When the controller is powered up, the
output may be activated.
a)
Before powering up the controller,
consider the effects on your process
if the output is activated. Take sitespecific precautions.
b)
Turn on the power to the mainframe.
c)
Set the power switch on the front of
the controller to on (I).
When the controller is powered up, all
segments of the display and all LEDs light
900M069U00RevB
When the controller is powered up, it will
automatically do a CompuStep soft start
for heater bake out if the process value is
below 200 °F. (PV is on the top line of the
display. SP is on the lower line.) During
the soft start the NORMAL LED flashes.
During the soft start (which lasts five
minutes or until the PV is 200 °F), adjust
the setpoint to a value that is representative of the setpoint you expect to use
1
when the controller is in service.
To adjust the setpoint press the
or
key.
5) Wait for the controller to
tune itself.
New RMC controllers are set to do a soft
start every time they are powered up (if
the PV is less than 200 °F), and then to do
an Autotune operation each time the
controller is powered up until a successful
Autotune is completed.
Let the Autotune proceed without
interruption. During Autotune, the
process value alternates with tun.
At the conclusion of a successful
Autotune, the flashing tun disappears.
The display reverts to the normal mode
operating display: PV on top line, SP on
lower line. The proportional band and rate
values calculated by the controller during
2
the Autotune have been saved.
RMC controllers do not require calibration.
The controller is ready to use.
1
If the PV is greater than 200 °F, then the
controller will skip the soft start, and will Autotune as
soon as you power up the controller the first time.
However, the tuning will not be valid, because you
have not yet entered the appropriate setpoint for
your process. Press MODE once to interrupt the
Autotune. With the controller in normal mode
(NORMAL LED lit), adjust the setpoint, and then
cycle power to start Autotune again with a valid
setpoint.
2
The integral (reset) action for PID control is
always set to five times the rate (derivative) value in
an RMC controller.
 2003 Athena Controls, Inc.
3
Series RMC Hot Runner Quick Set-Up Guide
If Autotune is Unsuccessful
At the conclusion of an unsuccessful
Autotune, you will see Er plus a one-digit
error code (alternating with tun). The
controller goes to the configured failsafe
action automatically. (Default is output
off.) Tuning errors and remedies are
discussed in the Series RMC Hot Runner
Controller Configuration and Operation
Manual.
Tip: For Autotune to work, the PV must
be at least 9 °F less than the SP. If you
are replacing a controller in a working
system, the difference between the PV
and SP may be less than 9 °F. If you see
Er5, press MODE twice to put the
controller in standby, wait until the PV
drops, and then cycle power to Autotune
again.
Autotune Is Disabled
Automatically
After a successful Autotune, the controller
automatically sets itself to disable
Autotune. Autotune remains disabled,
even if you cycle power to the controller,
until you enable Autotune again.
Instructions for enabling Autotune are in
the Series RMC Hot Runner Controller
Configuration and Operation Manual.
(Soft start is always enabled, unless you
change a switch setting as described in
the configuration and operation manual.)
Athena and CompuStep are registered trademarks,
and SafeChange is a trademark of
Athena Controls, Inc.
MODBUS is a registered trademark of
AEG Schneider Automation, Inc.
Local Communication
RMC controllers are shipped from the
factory set for MODBUS communications. However, you can set the
communication protocol to “local” and
assign the controller to one of three
usage groups: Tip, Manifold, or Other.
You can use any local comm controller
in an RMC usage group as All Master.
To make a controller All Master, press
c)
Set the protocol to local: When
in the serial communications
interface menu, press MODE once
to display Pro (protocol) on the
lower line. It alternates with the
default setting buS (MODBUS).
d)
Press
e)
Select a usage group: When you
select local communication
protocol, the controller is assigned
to the usage group “Other”. If this
is OK, go to step (f).
and keys at the same time.
the
(ALL LED lights.)
Use the All Master’s front panel to
activate the boost, change the mode,
change the setpoint, or change the
manual mode output in all the RMC
controllers in the All Master’s usage
group within the same mainframe (or in
mainframes that are linked via an
RS-485 network).
However, you can assign the
controller to the group “tip” or the
group “manifold”. Press MODE
repeatedly to accept the default
values for the baud rate and data
format parameters.
Stop pressing MODE when you
see U.USE (usage group).
To set up local communication:
a)
Put the controller in standby:
Press the MODE key repeatedly
until the STANDBY LED lights.
b)
Go to the serial communication
menu: Press and hold the
DISPLAY key until PId is displayed
on the top line, and then press
DISPLAY repeatedly until you see
SCI.
900M069U00RevB
to select LocL (local).
and to select tiP (tip) or
Use
FoLd (manifold).
f)
Return the controller to normal
(auto) mode:
Press the MODE key repeatedly
until the NORMAL LED lights.
 2003 Athena Controls, Inc.
4
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