Athena 6075 Instruction Manual

SERIES
6075

TEMPERATURE CONTROLLERS

WITH AUTO-TUNING

PID AND

PLUG-IN COMPUTER INTERFACE

Warranty Limitations

Other than those expressly stated

herein,THERE

ARE NO OTHER

WARRANTIES OF ANY KIND, EXPRESS OR

lMPLlED, AND

SPECIFI-

CALLY EXCLUDED BUT NOT BY WAY OF

LlMlTATlON, 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 RETURN
OF THE AMOUNT OF THE PURCHASE PRICE PAID BY THE PUR­CHASER AND UNDER NO CIRCUMSTANCES SHALL 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 LIMITEDTO 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

PRlCE, AND

SUCH REMEDY SHALL BE BUYER’S ENTIRE AND

EXCLUSIVE REMEDY.

SERIES 6075

AUTO-TUNING

PID

TEMPERATURE CONTROLLER

CONTENTS

PAGE

SECTION 1 GENERAL INTRODUCTION . . . . . . . . . 1

1.1

General Description and Cautions . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 Model Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2 INSTALLATION INSTRUCTIONS . . . . . 5

2.1 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Locating. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Removing Unit. . . . . . . . . . . . . . . . . . . . . . . . . 5

2.5 Case Dimensions. . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 3 OUTPUT MODULES. . . . . . . . . . . . . . . . 7

3.1 Module Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 4 BASIC WIRING. . . . . . . . . . . . . . . . 8

4.1 Typical Wiring Examples. . . . . . . . . . . . . . . . . . . . 8

4.2 Wiring Thermocouple and RTD Circuits. . . . . . . . . . . . . . 9

SECTION 5 OPERATION. . . . . . . . . . . . . . . . . . . 12

5.1 Front Panel Features. . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2 Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.3 Tuning The Controller. . . . . . . . . . . . . . . . . . . . . 20

5.3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 20

5.3.2 Automatic

PlD

Tuning Procedure. . . . . . . . . . . . . . . 20

5.3.2.1 Damping

Settings. . . . . . . . . . . . . . . . . . . 20

5.3.2.2 Operating Instructions. . . . . . . . . . . . . . . . . . . . . 21

5.3.3 Manual Tuning procedure. . . . . . . . . . . . . . . . . . . . . . 22

SECTION 6 COMMUNICATIONS . . . . . . . . . . . 26

6.1 Communications Modules . . . . . . . . . . . . . . . . . . . . . . . 26

6.1.1 RS485. . . . . . . . . . . . . . . . . . . . . . . . . 26

6.1.2

RS232C. . . . . . . . . . . . . . . . . . . . . . . . . 26

6.1.3 20

mA

Current Loop. . . . . . . . . . . . . . . . . . . 27

6.2

Installing the Communications Modules. . . . . . . . . . . . . 28

6.3 Interface Examples. . . . . . . . . . . . . . . . . . . . . . 30

6.3.1 Read Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.3.2 Modify (Temporary). . . . . . . . . . . . . . . . . . . . . . . . . 31

6.3.3 Modify and Store. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION 7 CALIBRATION. . . . . . . . . . . . 33

7.1 Zero and Span Adjustments. . . . . . . . . . . . . . . . . . . . . . . 33

(Factory Set)

SECTION 8 TROUBLESHOOTING. . . . . . . . . . . . 34

8.1 Troubleshooting - General. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.2

Troubleshooting - Communications. . . . . . . . . . . . . . . . 35

FIGURES

1.1

Ordering Code

-

Model Number. . . . . . . . . . . . . . . . 4

2.1

Series

6075 Dimensions. . . . . . . . . . . . . . . . . . . 6

4.1 Wiring Examples. . . . . . . . . . . . . . . . . . . . . . 8

5.1 6075 Front Panel Features. . . . . . . . . . . . . . . . . . 13

5.2

Configuration

Code Chart. . . . . . . . . . . . . . . . . . . 17

5.3 Ziegler

- Nichols Graph. . . . . . . . . . . . . . . . . . . . 23

6.1 Connector Pin Identification. . . . . . . . . . . . . . . . . . . . . 28

6.2 Wiring for

Communications. . . . . . . . . . . . . . . . . . 29

z

GENERAL INTRODUCTION
SECTION

1

1.1

General Description and Cautions
Athena Controls, Inc. is proud of the Series 6075 which you will now use It

has been manufactured to our

exacting

production standards, and packed

for

maximum

protection in shipment You will get years of reliable

service
from the unit if the information in the manual is followed regarding location,
adjustments, and general operation.

CAUTlON

High Voltage and High Temperature can cause injury and are a
Fire Hazard. Please read all instructions, have only skilled profes­sionals

wire the unit, and use an approved temperature

and/or
pressure safety control. Even the best components can be
damaged or may not failsafe.

Warning Notes:

1. "B"

Output for resistance load only.

2.

An open thermocouple will disable the INDEX function.

3.

Note also that in units utilizing only heating output the cooling

gain

should be set by user to the equivalent heating gain. The inverse IS

also true.

4.

A unique algorithm in the Model 6075 prevents continual buildup of

oscillation due to grossly misadjusted rate/reset

(-rt-)

or gain. When

this occurs the unit

will

control at some point higher or lower than set

point

outside the proportional band. If this occurs -rt- was probably set

too low and/or gain set too high.

5.

-rt-

sets Rate

(Derivative)

and Reset (Integral) action. The number dis­played is the Rate time in seconds. This is tracked by the Reset time in
seconds (1:6 ratio).

SECTION 2 INSTALLATION INSTRUCTIONS

2.1

Unpacking
Unpack the instrument and inspect for shipping damage. Report any

damage to the carrier immediitely.

2.2 Locating
Select a

location

for the controller where it will not be subject to excessive
shock vibration, dirt moisture or oil. The ambient temperature of the area
should be between

32º

and 131 ºF (A model

DC-15

dust, oil and water

resis-

tant cover is available to protect from harsh environments.)

2.3

Mounting
Mount the controller into a 92 mm (3

5/8”)

square cutout See figure for the
cutout and case dimensions. The plug-in controller does not have to be
removed from its housing for mounting. Remove two screws that hold the
mounting slides and then remove the slides. Insert case from front panel

and

re-install

the two slides and two screws. Do not over-tighten screws. The

length of the slides must be reduced if the controller is to be mounted in an

extra thick

panel.

If the controller has been unplugged from its housing, the

top of the housing can be determined because it features the serial tag.

2.4

Removing

Unit

The 6075 can be removed

from

its housing by pulling firmly on the black

front bezel. If a communication port is connected, it should be removed
first

SECTION 3 OUTPUT MODULES

3.1

Module

Description

The Athena 6075 offers 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

resis-

tive

heaters.

NOTE:

Do not use this output module with mechanical

contactors

because they generate an excessive

EMI

field which can interfere

with the

6075’s

microprocessor, Instead, we recommend

“T’

output modules for this application

Module Type

F: This 4-20mA

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.

Module Type S: Similar to

F.

but pulsed 20 Vdc 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.

“F’ & “S”

MODULE

NOTE:

A

push-on

terminal is

utilized

as a return for ground

currents

of

the

milliamp

source. It is connected internally by the mating lug

on the circuit board. To avoid ground loops, drive floating

(ungrounded) loads.

Module Type T:

This solid state relay is capable of 1

amp at 120/240 Vac.

It is

zero voltage switched and

optically

isolated from the drive signal. With it

resistive loads up to

I20

watts at

I20 Vac

and 240 watts at 240

Vac

may

be