Athena 6050 Instruction Manual

Instruction

Manual

Athena 6050

Temperature Controllers

-THENIL

INSTRUCTION MANUAL

SPECIFICATIONS:

Inputs:

Line Voltage
Sensor
Power Consumption
Ranges Available

Accuracy:

Temperature Stability
Cold end tracking
Operating ambient for

rated accuracy

Maximum T/C lead

resistance for
rated accuracy

Series mode noise

rejection:

Common mode noise
rejection

T/C break protection:
Dual display:

ATHENA 6050

Automatic Tuning

Temperature Controller

120/240 Vac

+lO%,

-15%,

50, 60

Hz

Thermocouple
Less than 6 VA (Instrument)

J Couple

0-1400°F (O-760°C)

K Couple

0-2500°F (O-137O°C)

0.2% of full scale
5m V/°C

Max 3m

V/°C

typ.

0.05°C/°C

ambient

0 to

55°C

100 Ohm

80

dB

120

dB
Upscale standard
Process temperature displayed

continuously; set point or other
parameters updated on lower display.

1

Display update rate:

5 times per second

Filtering:

Analog and digital filtering
techniques increase stability
of process and display.

°F/°C:

output:

-B Relay (time
proportioning)

-F Current
proportional

-S

Pulsed voltage

-T Triac

time

proportional

Filtered LED display:

T/C linearization:

Connections:

Dimensions:

Mounting:
Weight:

Internal switch selection--

process, set point.
Heating only
SPST relay 7 Amps resistive at

120

Vac,

5 amp resistive at 240

Vac,

50 VA inductive.

4-20mADC

into 500 Ohm max. For driving

SCR

power controllers.

20 Vdc pulsed time proportioning

signal for driving solid state relays.

Solid state plug-in

triac

output.

Rated 1 Amp holding & 10 amps inrush.
4 digits for process, 4 digits for

parameters.
Continuously calculated and updated

using rom based algorithm.

Inputs and outputs via barrier strips

with U.L. approved locking terminals.
Front panel: 96mm X 96mm X

22mm

Case: 92mm X

92mm

X

118mm

Depth behind panel:

96mm (approx.

minus panel thickness)

Channel slides and screws
2 lb

2

3

FRONT PANEL AOJUSTMENTS
Touch Key
1 Index: Allows the following adjustments to be selected.

1)

Set point temperature

O-14OO'F (760°C)
O-2500°F (O-137O°C)

2)

Heat cycle time

3)

Prop. Band (indicated

*1 to 120 seconds

as

gain)

0.25-25%

of span

4)

Rate with tracking reset

**4-255 seconds

5)

Auto Tune

(AT)

Up/Down keys: increases/decreases values of above
adjustments.

Tune/Cancel:

"cancel" puts output on stand-by to

permit set-up

"tune" triggers automatic tuning procedure
E Enter: writes selected value to nonvolatile memory
NOTES: *setting to zero initiates 60

millisecond timebase

for ultra fast cycling. Use

with

external solid

state relays or SCR Power Controllers.

**Setting to zero disables reset and rate action

for proportional only control. Reset is six times
higher than rate

FOR OPTIMUM RESULTS WITH THE AUTO-TUNE MODEL 6050

1.

Set point must be a minimum of 100°F above ambient for

proper start-up.

2. Multi-zone applications require auto-tune units on each

zone and simultaneous warm-up.

4

3.4.Loss of power or turn-off during warm-up requires a
re-start from ambient.

Change of state processes,

i.e.

solid to liquid or
liquid to gas, may introduce erroneous tuning parameters
during process warm-up.

1.

Accurately measures, linearizes and displays temperature
in °F and

°C.

2.

Automatically calculates and displays parameters-heat
gain, and rate/reset time.

3.

Can be field converted from relay output

"B",

to solid

state relay

“T",

to solid state driver

"S"

or to

a 4-20 MA output SCR driver

"F".

4.

Will remember its "entered" settings after power failure
or shut-off and not "Go To Sleep".

GENERAL

CAUTION: HIGH VOLTAGE AN0 HIGH TEMPERATURES CAN CAUSE INJURY
AN0 ARE A FIRE HAZARO. PLEASE REAO ALL INSTRUCTIONS, HAVE
ONLY SKILLED PROFESSIONALS WIRE THE UNIT, AND USE APPROVED
TEMPERATURE AND/OR PRESSURE SAFETY CONTROL. EVEN THE BEST

COMPONENTS CAN BE DAMAGED OR MAY NOT FAIL SAFE.
CONFIGURATION
Depending on the model number of the unit you have ordered,

vou will find one of four basic modules installed. The fifth
digit of the code indicate the output module type.

B- Relay

7A/5A @ 120/240 Vac
F- 4-20 mA (Proportional)
T-

Triac

1 Amp @ 240

Vac
S- 20 VDC Pulsed for driving solid state relays
Example:

6050-F

has proportional 4 to 20 mA heat

output.

Note: If you have not received your controller from the

factory direct, check to confirm that the correct module for
your application is installed. Since the modules plug-in,
and since controller plug into cases as well, previous users
may have changed modules,

which can result in severe

controller damage.

5

Output

Modules

The Athena 6050 offers users field interchangeable output
modules. This unique feature makes it possible to fill

output requirements for a variety of applications with

a single controller model.

Module Type B: This

7A/5A

relay

(at 120/240 Vac)

is used for

driving resistive heaters.

NOTE: Do not use this output module with mechanical

contactors

because they generate an excessive EM1

field which can interfere the 6050's microprocessor.

Instead we

recommend "T"

output modules for this

application.

Module Type F: This 4-20 mA output module can deliver

full output to loads having an input
impedance of 500 Ohms or less. The cycle
time setting must be ZERO for smooth

current output.

A push-on terminal is utilized as a
return for ground currents of the milliamp
source. It is connected internally to the

mating lug on the heat sink. To avoid
ground loops, drive floating (ungrounded)

loads or use isolated thermocouples.

Module Type T: This solid state relay is capable of 1 AM?

at

120/240 Vac.

It is zero voltage switched
and optically isolated from the drive signal.
With

it, resistive loads up to 120 watts at

at 120

Vac

and 240 watts at 240

Vac

may be

controlled directly. Using direct control

there is no lower limit on the cycle time
setting (down to 60 milliseconds). Larger

loads may be controlled utilizing an external
contactor. In this case, it is advisable to use
cycle settings of ten seconds or greater to
minimize contactor wear. External suppression
of the contactor is mandatory.

Module Type S: Similar to F, but pulsed

2OV/2OmA

DC output
for driving solid state relays. Up to 6
(input series connected) solid state relays

can be used. Cycle time can be set to optimize

the load response time requirements without
sacrificing S.S.R. life.

7

INTERNAL SWITCHES

Damping

Control -To allow the controller to provide automatic
tuning for processes with varying heating characteristics and
with varying heating capabilities, the 6050 offers three
damping choices:

High damping: for over-powered heating systems,
systems with multiple heat lags, and/or poor
coupling between the heater and the temperature

sensor.

Normal: for most standard processes where the
heater is properly sized for the system and
there is good coupling between the heater and
the temperature sensor.

Low damping: for adequately powered systems
with excellent coupling between the heater and
the temperature sensor where quick response and
the tightest possible temperature control are
desired.

Keypad Security -Switch 2 in the open position locks the
operator out of access to all parameters except set point.

CELSIUS/FAHRENHEIT DISPLAY SECTION
Switch 1 allows both displays to read in degrees Celsius or

Fahrenheit, and is indicated on front panel

LED's.

WIRING THERMOCOUPLE CIRCUITS
Before wiring, check thermocouple and extension wire to make

sure that they conform to the appropriate thermocouple type
specified on the serial number tag. In thermocouple
circuits, the negative lead is colored red. Extension wires

must

be the same alloy and polarity as the couple. The
thermocouple circuit resistance should not exceed 100 OHMS.
Do not run thermocouple leads in the same conduit as the
power lines. If shielded thermocouple is used, terminate the
shield only at the controller end using the corner screw
provided for that purpose.

STANDARD THERMOCOUPLES

I.S.A.

TYPE

MATERIALS

COLOR CODE

J

Iron Constantan

(I/C)

White(+) Red(-)

K

Chrome1 Alumel

(C/A)

Yellow(+) Red(-)

8

THERMOCOUPLE PLACEMENT
Proper thermocouple placement can eliminate many problems in

the system. The probe should be placed so that it can detect
any temperature change with minimal thermal lag. In a process

that requires fairly constant heat output, the probe should
be placed close to the heater. In processes where the heat
demand is variable, the probe should be close to the work
area. Some experimenting with probe location is often needed
to find its optimum position.

In a bath process, addition of a stirrer will help to
eliminate thermal

lags.

Since the thermocouple is basically
a point measuring device, putting more than one
in parallel will provide an average temperature
produce better results in air heated processes.

thermocouple
reading and

NOTE: If controls with

"F"

or

"S"

outputs drive

grounded or hot input terminals

(not

floating),

thermocouple must be used. Otherwise, when both

loads with
an isolated
input and

output are grounded, ground loop currents

will

result,

causing errors and controller damage.
Standard thermocouple limits of error are 4°F or 0.75% of

sensed temperature (half that for special) plus drift caused
by improper protection or overtemperature. This is far
greater than controller error, and can not be corrected at
the sensor except by selection and replacement.

Start-Up
Before line voltage is applied, double-check the following:

Make sure the thermocouple type is correct, and

properly connected (see section on thermocouples)
to terminals 1 and 2 (red on

2).

Make sure there is no AC or DC voltage leading or
arcing to T/C.

Make sure the proper terminals are selected for

line voltage. (8 & 9 for

12OV,

8 & 10 for

24OV)

Check to assure there are no heater shorts, or

shorts to ground, and no bare wires or frayed insulation.

Make sure correct plug-in module is used.

9

OPERATING INSTRUCTIONS

How to Start the automatic tuning procedure

STEP 1: Energize the unit and proceed immediately to step 2.
STEP 2: Place the unit on standby by holding the "Index"

button until the

"Autotune"

LED lights then press

the Cancel button.
The unit is now ready for set point and cycle time entry.
STEP 3: To enter a set point:

A) Hold "Index" button until
the SP LED lights and B) Use the appropriate touch
key, either up or down to enter set point.

When

you've entered the desired set point, simply
press the enter key. NOTE: Set point must be at
least 100°F above ambient.

STEP 4: Set cycle time by advancing "Index" to "HC" and

select desired value using up or down keys. Cycle

time is shown in seconds, from 1-120. Setting zero

initiates a 60 millisecond cycle time for ultra fast

cycling for use with

"F"

or

"S"

output modules. For

mechanical relays or

contactors

use

l0-120

seconds.
When you've found the desired cycle time press the
enter key.

STEP

5: To start warm up and calculate all PID parameters

advance Index to auto tune again and press the

"tune" button.

The "AT" L.E.D. will light and

"HT"

L.E.D. will
light. You may now index to any parameter for
viewing as process heats. Upon completion of

tuning, the "AT" L.E.D. will be off.

NOTE: The parameters that the 6050 calculates automatically

can be entered on the Athena 6000/6200 to achieve the

same smooth and precise temperature control on your

process.

10

How to override automatic tuning parameters

It is possible to set or fine tune three mode parameters

manually on the 6050.
To manually enter parameters:

1)

Press "Index" button until the LED for the desired

parameter lights.

2)

Enter the new parameter using the up or down key.

3)

Press the "enter" button.

The new parameters will now take control of the process.
To calculate the PID parameters without using the automatic
tuning mode, consult the Athena

6000/6200

instruction manual.

Reading automatically calculated

PID

parameters

Press the "index" key. The LED‘s in the "Index" display will
light in sequence, and as they change, the lower digital
display will show each parameter.

11

TROUBLE SHOOTING

Front dark

-

no

instrument power.

Process display

shows

CCCC - Open thermcouple. Short

terminals 1 and 2. Process display should indicate

temperature at back of case. Repair or replace thermocouple.

About Half or Twice Expected Reading - Check position of
°C/°F

switch. Short 1 and 2 to read room temperature. 22-30

is

°C, 70-85

is

°F.

About

30%

Error- Wrong thermocouple type.

Disconnect

couple.

above 2500°F.

"J"

units over range above

14OO°F, "K"

No Heat

-

No heater power, heater wiring, wrong output module.

Heat Stays On -Welded relay contacts, shorted output module,
or shorted power handler.

Process Display Shows OOOO Or Initially Displays Room
Temperature Then Counts Down Scale As Process

Warns -

Check

for reversed thermocouple.
Display blinks, entered values change - Caused by electromagnetic

interference

(EMI).

Supress arcing contacts in system to

eliminate high voltage spikes,

seperate sensor and controller

power wiring from "dirty" power lines. Ground heated devices.

Unit Repairs

It is recommended that units requiring service be returned
to an authorized service center. When a controller is
returned for service, a note stating the problem should
accompany the unit.

NOTE: Warranty is void when units are modified by the
customer or other non-authorized parties.

A spare parts list can be supplied upon request if complete

model number, serial number and temperature range is supplied.

12

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, Inc. is to
replace and/or repair at its factory, provided the equipment
is returned, transportation prepaid within

(2)

years of its

purchase.

The purchaser agrees that Athena Controls, Inc. shall assume

no liability for consequential damages resulting

from

its

use or packaging of shipments returned to the factory.

Components which wear or which are damaged by misuses are

not warranted. These include contact points, fuses,

triacs,
and modules. Units which have been modified by customer are
not warranted.
Specifications are subject to change without notice.

13

dTHENd

Controls, Inc., 5145 Campus Drive

Plymouth

Meeting,

PA 19462

[phone]