SERIES SERIES 1X8T/189/1295/25 TEMPERATURE/PROCESS TEMPERATURE/PROCESS CONTROLLER CONTROLLER Instruction Manual Instruction Manual
Quick Setup Instructions - 18/19/25 Temperature Controller Experienced users, already familiar with mounting and wiring the Series 18/19/25 may use these condensed instructions to autotune the controller and get started quickly. These quick setup instructions are not meant as a substitute for reading the full instruction manual. Please be sure to read through the manual for specific details of operation and, most importantly, for safety precautions.
Safety Warning Congratulations on your purchase of an Athena Series 18, 19, or 25 Single-Loop Controller. It is designed for ease of use and reliability wherever accurate closed-loop control is required. Your controller has been configured according to your ordering specifications as either a universal process controller or a dedicated temperature controller. In addition, special functions such as a heater break alarm, digital communications, etc.
Table of Contents Table of Contents Installation 6 Mounting Wiring 8 8 Operation Notes on Outputs Front Panel Controls Parameter Menu Organization Sensor Configuration Available Alarms Parameter Descriptions Tuning Procedures Special Functions Auto/Manual (Standard) Remote Setpoint Select Process Variable Retransmission Heater Break Alarm Transducer Excitation 4 12 12 14 15 20 22 23 29 Limit Controller Option Digital Communications Recalibration Procedure Error Codes Warranty/Repair Information Tech
Installation Measurements between centerlines of panel cutouts are minimum recommended. Installation Figure 1. Recommended Panel Layout for Multiple Controllers CL 4.700" (119.4 mm) Recommended Panel Cutout 3.622" SQ (92 mm SQ) CL Series 25 Figure 2. Case Dimensions Prior to mounting the controller in your panel, make sure that the cutout opening is of the right size, and deburred to enable a smooth fit. A minimum of 4" (100 mm) of depth behind the panel is required. CL 4.300" (109.2mm) CL C L 2.
Mounting If the unit has been shipped with mounting catches already installed in the top and bottom slots in the case housing, they must be removed to allow insertion of the controller into the panel cutout. Wiring Remove static-protective wrapping material from the instrument. Avoid inducing static charges to controller while handling and mounting. Insert the controller into the panel cutout from the front of the panel.
SensorInput Connections Thermocouple circuit resistance should not exceed 100 ohms for rated accuracy; errors will occur at higher resistance values. If shielded thermocouple wire is used, terminate the shield only at panel ground. Use wire with a resistance no greater than 10 ohms. An error of 0.2° F will result for each additional 10 ohms of resistance encountered. If shielded RTD wire is used, terminate the shield only at panel ground. Figure 5.
Operation Throughout this manual, instructions that pertain solely to the process controller, as opposed to the temperature controller, are shown in blue. Athena Series 18/19/25 Universal Controller Output Type The Series 18/19/25 controller is an autotuning PID controller, which can function as either a temperature or linear process controller. (See pages 62-65 for specifications and ordering code). B 5A/3A (120/240 Vac) relay, normally open, used for switching resistive loads.
Operation Operation Figure 9. Front Panel Controls and Indicators Output 1 LED indication of Heat cycle (Output 1 action) Output 2 LED indication of Cool cycle (Output 2 action) Alarm 1 LED indication of Alarm1 condition Alarm 2 LED indication of Alarm 2 condition Function 1 LED indication of Special Function 1 Function 2 LED indication of Special Function 2 After mounting and wiring your controller, you are ready to set the parameter values required of your application.
Operation You cannot enter Standby Mode from menu level “00”. Follow the instructions for changing menu levels to select another level. Operation scrolling through long menus. Menu “05” is used for initial controller configuration and menus “02” and “03” are used for setting or changing parameters. Menus “00” and “01” are used when the controller is in regular unattended operation and are not used for setting parameters.
Operation Operation Menu Level Descriptions Because the controller’s initial configuration affects other menu levels, it is important to set all required parameters in this menu first before accessing other menu levels. Menu “05” (Configuration Setup) This is the menu level used for specifying initial configuration parameters before the controller is placed in Run mode.
Operation The controller may be configured for various temperature ranges or process inputs, but the unit MUSTbe returned to the factory to change function from a temperature controller to a process controller, or vice versa. Operation Sensor Configuration Input Configuration Temperature Controller With the controller set to configuration menu level “05”, press the Parameter/Access key once.
Parameter Descriptions Operation Available Alarm Types [ A1.P.d. ] [ A2.P.d. ] Figure 11. Temperature Controller Menu Hierarchy Selectable at menu level “05”, as either Process [ Pr ] or Deviation [ dE ] and either high or low [ A1.HL ] or [ A2.HL ]. Process Alarm: Activates at preset value independent of setpoint. “High” process alarm activates at and above alarm setting. “Low” process alarm activates at and below alarm setting. Deviation Alarm: Activates at a preset deviation value from setpoint.
Parameter Descriptions Parameter Descriptions Series 18/19/25 Temperature/Process Controller Menu “05” Display SnSr The Digital Filtering setting [ FILt ] on the process controller allows the operator to compensate for noise which may cause the last digits of the PV display to become unstable. Sampling rate is not affected. The settings are time constants, in seconds, with 0.1 equivalent to “no filtering.” 24 Parameter Sensor type OUt1 Output 1 action OUt2 Output 2 action Sn.
Parameter Descriptions Setting output cycle time to “00” initiates a 200 ms timebase. A cycle time setting is required for smooth proportional action. Too long a setting may cause proportional ripple; too short may decrease relay contactor life. When changing thermocouple types, be sure to check/adjust upper and lower setpoint limit values.
Parameter Descriptions Tuning Procedures Figure 12. Typical Lag Processes Dead Time For best results in tuning the temperature controller, the setpoint value should be at least 100°F above or below ambient temperature. 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.
Tuning Procedures Tuning Procedures played. (If you scroll past it, just continue scrolling until the parameter menu repeats.) Using the appropriate Raise or Lower key, select the one of the following settings according to the requirements of your process. Note: For autotuning, at least one output MUST be set to PID mode. Mode PID On/Off Output 1 (Heat) Setting [ Ht.P ] [ Ht.O ] Output 2 (Cool) Setting [ CL.P ] [ CL.O ] Press the Parameter/Access key again to step to output 2 [ OUt2 ].
Tuning Procedures If overcooling exists on heat/cool processes after autotuning, decrease Gain Ratio [ Gr.o2 ] in steps of 0.1 until oscillation is minimal. If cooling is sluggish, increase the value in steps of 0.1 until optimum results are achieved. Tuning Procedures Manual Tuning Procedure - Temperature Controller (Zeigler-Nichols PID Method) This tuning method may be used if the spread between ambient temperature and process operating temperature is small.
Tuning Procedures Special Functions 11) Repeat for Cycle Time 2 [ CY.t2 ]. 12) Change to menu level “05”. 13) Set Cooling Type [ CoL.t ] to [ nor ]. 14) Press the Mode key once. Setpoint Value will be displayed. The recording device should now be tracking process temperature. 15) Double the Gain [ Gn.o1 ] until a small, sustained oscillation is visible on the recording device’s trace. 16) Measure the period of one cycle of oscillation (“T” on the diagram below).
Special Functions Special Functions When installed, this option provides the user with a method of inputting several types of analog signals to the controller, typically 1-5 volts or 4-20 milliamps, although it is also capable of 0-5 volts or 0-20 milliamps in the unsuppressed mode. The primary purpose of this feature is to provide an auxiliary analog Second Setpoint function for control of Setpoint Value by remote computer, analog potentiometer or other source.
Special Functions Special Functions Process Variable Retransmit These output values are linear with and dependent upon the sensor being used, i.e., the lowest value of the sensor’s output range corresponds to zero or low for the output function.
Special Functions Special Functions Figure 17. Current Transformer (Can Be Supplied with Heater Break Alarm Option, Part # 580E023UOI) HEATER BREAK ALARM The Heater Break Alarm option is not available on controllers with an “F” type output. With the Heater Break Alarm option, cycle time is limited to greater than 2 seconds. The Controller compares a sensor input signal with the Setpoint and makes a power calculation, which produces an output signal to the load.
Special Functions Special Functions Transducer Excitation The transducer excitation voltage option is used to produce a constant dc voltage of 10, 12 or 15 Vdc out to an external device, eliminating the need for an additional external power supply. Refer to the ordering code if you do not know which voltage output was specified. Option Ordering Code 1 2 3 Figure 18a.
Limit Controller Option ED Limit Controller Option ED Series 18/19/25 Limit Controller Menu Hierarchy Parameter Descriptions Menu “04” Display IntP 44 Parameter Sensor type LItp Limit type AltP ALSL Alot oPSL dECP FILt UnIt Alarm type Alarm select Alarm output Selection Thermocouple Platinel II S T R N J K RTD RTD (decimal range) Platinel II (special) High Limit Low Limit Process/Deviation High/Low Alarm Normal/Latching (Not Functional) (Not Functional) Decimal point Digital filtering Measurement
Limit Controller Option ED Limit Controller Option ED Parameter Descriptions (continued) Parameter Descriptions (continued) Menu “03” Display Idno Menu “02” Display ALSP SPLo bAUD CALL CALH Parameter Device ID number (remote communications) Baud, parity and data bit selection Calibration low Calibration high Allowable Values 00 to 99 See next page under the heading of “Available Communications Settings” Preset at factory Preset at factory SPHI Parameter Alarm setpoint Setpoint low (lower setpoint
Limit Controller Option ED Limit Controller Option ED Operation High Limit Operation — During normal operation the mechanical relay in output “1” is closed. If the process temperature exceeds the high limit setting, then the mechanical relay in output “1” will open (“01” LED is now lit) cutting off power to the load. When the process temperature drops back down to below the limit setting, output “1” will remain open until you press the mode key to reset the controller.
Digital Communications Digital Communications RS232 Two communication options are available which allow interfacing to remote devices utilizing the most common industry standards, RS232 and RS485. WARNING Signal ground only. Grounding to frame may damage the controller and void warranty. 50 This method allows bidirectional data transfer via a threeconductor cable consisting of signal ground, receive input and transmit output.
Digital Communications Digital Communications Table 1. Communications Parameter List (Temperature Controller) Parameter No. 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 Description Process Value Setpoint Access Code Gain Output 1 Gain Ratio 2 Rate Reset Heat Hysteresis Cool Hysteresis Cool Spread Damping Alarm 1 Alarm 2 Cycle Time 1 Cycle Time 2 Setpoint Target Time Low Setpoint Limit High Setpoint Limit Controller ID Baud Rate Display nnnn nnnn Ac.Cd Gn.o1 Gr.o2 rAtE rSEt H.HYS C.HYS C.
Digital Communications Digital Communications Figure 20. General Communications Message Format Interface Examples This section describes the protocol for communication between the controller and either a video display terminal or computer ( referred to below as “the host”). Message strings may be of two types — commands to controller or responses from controller. Caution: Modifying parameter #19 (Baud Rate) by host may cause loss of data link.
Digital Communications Communications Notes Figure 21.
Recalibration Only qualified individuals utilizing the appropriate calibration equipment should attempt recalibration of the controller. For assistance, contact your Athena representative or call 1-800-782-6776. Error Codes Your controller has been calibrated at the factory, and need not be adjusted during the life of the controller unless sensor type is changed from thermocouple to RTD, or vice versa. In the event that recalibration is warranted, follow these procedures.
Warranty/Repair Information Warranty/Repair 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.
Technical Specifications Technical Specifications Performance Accuracy Setpoint Accuracy Temperature Stability TC Cold End Tracking Noise Rejection Process Sampling Rate Inputs Thermocouple RTD Linear ±0.2% of full scale, ± one digit 1 degree/0.1 degree 5 µV/°C max; 3 µV/°C typical 0.05° C/°C ambient Common mode >100 dB Series Mode >70 dB 10 Hz (100 ms) K, J, N, R, T, S, Maximum lead resistance 100 ohms for rated accuracy Platinum 2- and 3-wire, 100 ohms at 0° C, DIN curve standard (0.
Technical Specifications Ordering Codes Damping Setpoint Target Time (Ramp-to-Setpoint) Autotune Manual General Line Voltage Display 18 and 19 25 Power Consumption Panel Cutout 18 19 25 Depth Behind Panel Front Panel Rating Operating Temperature Humidity Conditions Parameter Retention Connections 64 Alarm1 Configuration Code 0 = None B = Relay T = S.S. Relay Contacts Selectable (low, normal, high, off) 0 (off) to 100 minutes Alarm2 Configuration Code 0 = None B = Relay T = S.S.
Quick Setup Instructions - 18/19/25 Temperature Controller Experienced users, already familiar with mounting and wiring the Series 18/19/25 may use these condensed instructions to autotune the controller and get started quickly. These quick setup instructions are not meant as a substitute for reading the full instruction manual. Please be sure to read through the manual for specific details of operation and, most importantly, for safety precautions.
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 E-Mail: sales@athenacontrols.com Internet: www.athenacontrols.com Athena Controls, Ltd. P.O. Box 176 Stockport SK3 OLF England Tel: +44 (0) 161 428 9966 Fax: +44 (0) 161 428 9977 E-mail: AthenaUK@aol.
