Athena Technologies 16C manual

1 SERIES 1 6 C TEMPERA TURE/PROCESS CONTROLLER In st ru ct io n Ma nu al (B as ic O pe ra ti on s)[...]

3 I nt r od uc t io n Pr ec au ti ons Congratulations on your purchase of an Athena Series 16C T emperature/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[...]

3 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 l[...]

4 1 T a bl e o f Co nt en ts Installation 1 Dimensions and Mounting 2 Wiring 3 Output T ypes 5 Operation 6 Front Panel Controls 6 Power On 7 Security Levels 8 Operating Modes 9 Menu System Overview 10 Initial Setup Sequence 12 Parameter/Menu Descriptions 14 Input Menu 15 T emperature Input 16 Process (Linear) Input 16 Display Menu 17 Output Menu 17[...]

4 1 In st al lat io n Measur ements between centerlines of panel cut- outs ar e the minimum r ecommended. Unpacking and Inspection 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 th[...]

2 3 Mo un tin g Di me nsi on s Figure 2. Case Dimensions Prior to mounting the Series C in your panel, make sure that the cutout opening is of the right size, 1.771” x 1.771” (45 mm x 45 mm), and deburred to enable a smooth fit. A mini- mum of 4” (100 mm) of depth behind the panel is required. Figure 3. Series C Mechanical Components Insert t[...]

2 3 W iri ng IMPORT ANT : 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 C controller has built-in circuitry to reduce the effects of electrical noise (RFI) from various sources. However , power and signal wires should always be[...]

4 W iri ng Figure 5. Thermocouple Input W iring Make sure that you are using the appropriate thermocouple and extension wire. Connect the negative lead (generally colored red in ISA-type thermocouples) to contact #9; connect the positive lead to contact #10. Extension wires must be the same polarity as the thermo- couple. Figure 6. RTD W iring The [...]

4 5 Ou tp ut T yp es The T ype “B” output is a mechanical device and subject to wear . T o extend the life of the r elay , set the Cycle T ime for the relay output to the longest duration that still affor ds good control. When you ordered your Series C controller specific output types were specified, designated as “B”, “E”, “F”, “[...]

6 7 Op er at ion Mode/Enter Key Used to enter Parameter selections, access operating modes, release 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 [...]

6 7 Po we r On When power is first applied to the Series C, all segments of the LED displays will be momentarily illuminated while the instrument goes through a series of diagnostic checks to verify proper operation. A software version number will then appear in the lower display , followed by a configuration code (upper display) and the communicat[...]

8 S ec uri ty L ev els 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 security levels provided are Key Lockout , Setpoint , Setpoint plus Mode , User , Configuration , and Factory . T o view or change security level from the Process Variable [...]

8 9 Op er ati ng M od es The Series C’ s operating modes are: Manual , Standby , Normal , Autotune , Ramp/Soak Recipe , Run and Hold . T o select a different operating mode, press the Mode/Enter key for three seconds. The operating mode that the controller is currently in will be dis- played. T o index through the available operating modes, press[...]

10 1 1 Me nu Sy st em Ov er vie w The Parameter Menu System is organized into ten basic menus: Input, Display , Output, Control, Alarm, T une, Recipe, Supervisor , Calibration, and Option . T o access the Menus, press and hold the Menu Access key for approxi- mately 3 seconds until a menu label appears in the upper dis- play . There are additional [...]

10 1 1 Me nu Sy st em Ov er vie w Figure 10. Series C Functional Diagram T o r eturn to Pr ocess V alue at any time, pr ess and hold Menu Access key for thr ee seconds for 3 seconds Menu System for 3 seconds Security Levels Pr ocess V ariable Display Mode Selection for 10 seconds for 3 seconds once once[...]

12 Me nu Sy st em Ov er vie w Figure 1 1. Chart of Series 16C Menu System and Security Levels (Continued on Next Page) Mode/ Enter Key Menu Access Key (number) (number) (number) (number) (number) Notes: 1. It is recommended you start with the input menu. 2. Parameter labels displayed will vary , depending upon the controller’ s configuration.[...]

Security Levels (Key Lockout) = No Access (Setpoint) = Setpoint V alue or Output Percentage (Manual Mode) (Setpoint plus Mode) = Plus (User) = Plus (Configuration) = Plus (Factory) = Plus 13 Mode/ Enter Key (three seconds) Functional When Option Card Installed Raise/ Lower Key * See options manual for parameter selections. Figure 1 1. Chart of Seri[...]

Input Used to select sensor -related parameters, such as input type, limits, and scaling. Display Used to set or change decimal position and display units. Output Used to specify output usage, control methods, and alarms. Control Used to select parameters associated with the control methods. Alarm Used to select alarm parameters . Note: This menu i[...]

15 NOTE: FOR A MORE DET AILED DESCRIPTION OF MENU P ARAMETERS, REFER TO THE GLOSSAR Y WHICH BEGINS ON P AGE 64. The first parameter that needs to be set is Input T ype . The remaining Input Menu parameters will change, depending upon whether a linear input type or a temperature input type is selected. Other menu param- eters related to the sensor r[...]

17 Input T ype JMPØ1 JMPØ2 Thermocouple Out Out R TD Out Out V oltage <100 mV Out Out V oltage >100 mV In Out Current Process In In 16 In pu t M en u JMPØ1 JMPØ2 Input Menu (continued) Display Parameter Selection Input T ype 100 ohm compressed RTD 0-20 mA 4-20 mA 0-10 mV 0-50 mV 0-100 mV 10-50 mV 0-1 V 0-5 V 0-10 V 1-5 V Input Jumper Sett[...]

17 Di sp lay M en u JMPØ1 Display Parameter Selection Decimal Position 0-3 Linear Inputs 0-1 T C/R TD Filter 0.1-10.0 sec Units* Fah renh eit Ce lsius Ke lvin *NOTE: Does not appear for linear inputs. Blanking , 0-9999 sec (T ime selected before setpoint diplay turns off.) Ou tp ut Me nu The first parameter that needs to be set in the Output Menu [...]

19 18 Ou tp ut M en u Output 1 Action Reverse-acting (Heating) Direct-acting (Cooling) Output 1 Cycle T ime* 0.2; 1 to 120 seconds Output 1 Low Limit 1-100% Output 1 High Limit 1-100% Output 2 Action Reverse-acting (Heating) Direct-acting (Cooling) Output 2 Cycle T ime* 0.2; 1 to 120 seconds Output 2 Low Limit 1-100% Output 2 High Limit 1-100% *Rec[...]

19 Ou tp ut M en u Co nt ro l Men u Display Parameter Selection Output 1 Action Reverse-acting (Heating) Direct-acting (Cooling) Output 2 Action Reverse-acting (Heating) Direct-acting (Cooling) Display Parameter Selection Deadband 1 Negative span of sensor to positive span of sensor Hysteresis Output 1 1...to span of sensor Deadband 2 Negative span[...]

20 21 No te s O n Al ar ms Outputs can be set up as an alarm, similar to the standard alarm format. Four types of alarms are available: Process, Deviation, Inverse Band, and Normal Band. All alarms may be configured to be inhibited on power -up for a configurable time duration. Process Alarm: Activates at preset value, independent of setpoint. “H[...]

20 21 Ou tp ut Me nu Display Parameter Selection Output 1 Alarm Action (Latching) (Normal) Output 1 Alarm Operation (Process Low) (Process High) (Inverse Band) (Normal Band) (Deviation Low) (Deviation High) Output 1 Alarm Delay 0-9999 sec Output 1 Alarm Inhibit 0-9999 sec Output 1 Alarm Setpoint Span of Sensor Output 2 Alarm Action (Latching) (Norm[...]

22 Display Parameter Selection Damping Low Normal High Au to tun e Da mp ing M en u Note: The damping parameter specifies how aggressively the controller performs its autotuning. The “Normal” setting is a compromise between the fast recovery and overshoot. The “Low” setting provides faster recovery , but with the possibil- ity of overshoot;[...]

22 23 Re ci pe (R am p/ So ak ) M en u Pow er F ail Resu me Set ting thi s pa rame ter to O n wi ll c ause the con trol to resu me a r ecip e wh ich was acti ve w hen a po wer fail ure occu rred . Th e rec ipe will res ume at t he s tart of the last act ive ramp or soak seg ment . Ram p/So ak E vent s (1 -8) (If al arms a re con figure d as r amp/s[...]

25 24 NOTE: The following seven parameters are only available when multi-step ramp is selected. Display Parameter Selection Recycle Number 0-99, (Recipe Executions) Power Fail Resume Off On Ramp T imes 1-8 0-9999 mins. Ramp Events 1-8 Alarm 1 On Alarm 1 Off Alarm 2 On Alarm 2 Off Disabled Soak Levels 1 - 8 Display Units, FS Soak T imes 1-8 0-9999 m[...]

25 T oggles with the temperature value that should be input to perform the low calibration operation. The low calibration operation is triggered by pressing the up arrow key . T oggles with the temperature value that should be input to perform the high calibration operation. The high calibration operation is triggered by pressing the up arrow key .[...]

26 27 Aut ot un in g T o place the controller in Autotune mode: 1) Configure the controller by following the directions for Initial Setup Sequence through Step 3 on page 7. Set damping parameter . (See page 22.) 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 th ree seco[...]

26 27 Au to tun in g If a tune error condition occurs, the upper display will toggle between and a numeric error code for three seconds before the tune process terminates. The controller will then automatically go into Standby mode when a tuning error occurs. Possible error codes are: 02 = No PID Device Configured 03 = Incorrect Output Action 05 = [...]

28 Ma nu al T uni ng Manual T uning Procedure (Zeigler -Nichols PID Method) This tuning method may be used for non-temperature control processes or if the spread between ambient temperature and process operating temperature is small. For best results, the use of a recording device is required when tuning with this method. 1) For temperature control[...]

28 29 Er r or Co de s If an err or code cannot be clear ed by using the actions pr ovided, contact factory . Display Problem Actions Open Sensor Check sensor , wiring, and Input. Reversed Sensor Check the type selection in the Input menu, and check sensor polarity . Loop Break Correct problem and reset controller . Checksum Error Press any key RAM [...]

30 T ec hn ic al Sp ec ifi ca ti on s Operating Limits Ambient T emperature 32°F to 140°F (0°C to 60°C) Relative Humidity T olerance 90%, Non-Condensing Power 100 to 250 V 50/60 Hz (Single-Phase) 100 to 250 Vdc 24 V ac/dc Power Consumption Less than 6 VA Performance Accuracy ±0.20% of Full Scale (±0.10% T ypical), ±1 Digit Setpoint Resolutio[...]

30 31 T ec hn ic al Sp ec ifi ca ti on s Input T ype Thermocouple B, C, E, J, K, N, NIC, NNM, R, S, T , Platinel II Maximum lead resistance 100 ohms for rated accuracy RTD Platinum 2- and 3-wire, 100 ohms at 0° C, DIN curve standard (0.00385) 1000 ohms available Linear 0-50 mV/10-50 mV , 0-5 V/1-5 V 0-20 mA/4-20 mA, 0-100 mV , 0-10 V Output Device[...]

32 33 Or de rin g Co de s Code Input T ype C T T hermocouple CR RTD C S Compressed RTD CM M il liv ol t L in ea r CV V olt Linear CC Current Linear CA All CB TD & T/C Code Option 00 None Alarms 10 Dual SSR, N.O . 20 Dual Open Collector 21 Dual 24 Vdc 22 Dual SSR, N.C. 23 Relay, N.O . Communications 30 RS-232/Athena+ RS-485, Athena+ with Contact[...]

32 33 The Series C contr oller is pr ecalibrated at the factory . Under normal cir cumstances, the factory calibration should be valid for the life of the instrument. If r ecalibration should be r equired, allow the contr oller to warm up for 15 minutes and follow these steps car efully . Re ca lib ra ti on Pr oc ed ur es 1) Remove power from the c[...]

34 Qu ic k-H el ps 1. T o return the unit to last operating mode (Normal, Standby , FOP , or T une): Action Display From Menu System: Press and hold PV + SV + Mode for 3 sec. From Security Level Menu: Press PV+ SV + Mode 2. T o enter Standby operating mode: Action Display From Normal Press and hold operating mode: for 3 sec. Press Press + PV + SV F[...]

34 35 Qu ic k-H el ps 5. T o abort Autotuning Action Display and return to normal Press and hold operation: for 3 sec. Press Press PV + SV 6. T o enter FOP (Manual) Action Display operating mode: Press and hold for 3 sec. Press + PV + % of Power Value Press to set new % of Power Value Press to + PV + set % of Power % of Power for Output 2 Value if [...]

36 W arr an ty/ Re pa irs T wo-Y ear Limited Warranty THIS EQUIPMENT IS WARRANTED TO BE FREE FROM DEFECTS OF MA TERIAL AND WORKMANSHIP . IT IS SOLD SUB JECT TO OUR MUTU AL A GREE MENT THA T THE LIAB ILIT Y OF A THENA CONTROLS, INCORPORA TED IS TO REPLACE OR REP AIR THIS EQUIPMENT A T ITS FACTOR Y , PROVIDED THA T IT IS RETURNED WITH TRANSPORT A TIO[...]

37 W arr an ty/ Re pa irs 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 ser vice center nearest you. In man y ca ses, the pro blem can be clea red up o ver the tele phon e. When the unit needs to be returned, the service cente[...]

38 39 IE C Re qu ir em ent s The maximum supply current is line voltage dependent: 230 mA for a 24 Vac/dc input fuse rating=700 mA 60 mA for an 85 - 250 Vac input fuse rating=100 mA Output Specifications Output T ype Max current Voltage Leakage B 5 A 250 V ac 1000 M ohms T 1 A 250 Vpk 1 mA S 20 mA 5 V NA CLEANING INSTRUCTIONS 1. Remove power from t[...]

38 39 Alarm Delay - the time delay between the detection of the alarm condi- tion and the initiation and indication of the output action. Alarm Inhibit - prevents low setpoint alarm activation during cold startup applications. Bias - allows the operator to compensate for any difference between sensor temperature and the point to be measured. The pr[...]

40 41 input failure, or a heater or load failure. Loop Break Time - the time interval from when the controller detects a loop break condition and the initiation of the failsafe state. Lowest Reading - records the lowest process value read by the controller . May be reset to zero by using the Raise or Lower arrow keys. Lower Setpoint Limit - prohibi[...]

40 41 Quick Setup Instructions - Series 16C T emperature Controller Experienced users, already familiar with the Series 16C, and using the controller with PID outputs, may follow these condensed instructions to autotune the controller and get started quickly once the instrument is prop- erly mounted and wired, and the Security Level is set to . Onc[...]

42 43 Keep This Information in a Safe Place Configured Parameters Reference Data Series C T emperature Controllers Model Number Zone Location Firmware Version No. (Displayed when the controller is powered up after all the segments on both lines of the display have been tested.) Dear Customer: Please keep this information handy – in case your cont[...]

42 43 No te s[...]

44 At hen a Con tro ls , I nc . 51 45 Ca mpu s D ri ve P ly mo u th M e et in g , P A 19 46 2 U. S .A . T el : ( 61 0) 828 -2 490 Fa x: (6 10) 82 8- 708 4 T ol l-F re e i n U .S .: 1- 800 -78 2- 677 6 In ter ne t: www . at hen ac ont rol s. com For T oll-FreeT echnical Assistance in the USA, Call T oll Free: 1-800-782-6776 900M 011U0 0 REV ISION ?[...]