Use of this equipment in a manner not specified by the manufacturer may
Warning
impair protection provided by the equipment.
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.
Hazardous potentials exist on components inside the controller. Always
disconnect AC power to the controller when servicing the controller.
Because these temperature controls or associated equipment may not
always fail safe, an approved temperature and/or pressure safety control
should be used for safe operation.
Turn off power to the controller before cleaning the exterior of the
controller.
Failure to observe these precautions can result in exposure to a potentially
lethal shock hazard.
Caution
All wiring should be done by an experienced technician. The controller and
wiring should be installed in accordance with national and local electrical
codes. To avoid serious personal injury and damage to equipment, follow
all warnings and cautions provided in the hardware setup instructions.
If a controller shows signs of having been damaged during shipping, do not
power up or install the controller. Save all packing materials and report any
damage to the carrier immediately.
Do not locate this instrument where it may be subjected to excessive shock,
vibration, dirt, moisture, oil, or other liquids.
This is a Class A product. In domestic environment this product may cause
radio interference in which case the user may be required to take adequate
measures.
Specified operating ambient temperature is 32 to 122 °F (0 to 50 °C).
I
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
Table of Contents
Precautions........................................................................................................... I
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
1. Introduction
1.1 About this Manual
This manual contains all the information needed to configure and operate the RMB/6 and
RMB/12 Non-Modular Hot Runner controllers.
Wiring diagrams, mounting instructions, and other information about installing the
hardware are on the installation diagrams shipped with the unit.
1.2 Features and Benefits of RMB/6 and RMB/12 Controllers
1.2.1 Multi-Zone Control with Convenient User Interface
A single RMB/6 Hot Runner controller can provide microprocessor-based control of up to
six zones; a single RMB/12 Hot Runner controller can control up to twelve zones. Zones
can be configured individually or all zones can be configured simultaneously.
During operation the front panel simultaneously displays the process value and setpoint
for every zone. LEDs for each zone indicate the type of control (open or closed loop),
output status, alarm status, boost status, and standby status. Buttons on the front panel
make it easy to change the setpoint, mode, and configuration parameter values for one
selected zone or all zones.
The front panel also has buttons to:
• start the boost for all zones,
• put all zones in Idle or all Idle zones in the Run state,
• silence the audible alarm.
When necessary, access to function buttons on the front panel can be restricted. See
Section 7 for details.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
RMB 12 Operating Display
1.2.2 PID Control with Autotuning
When an RMB/6 or RMB/12 zone is in Normal (closed loop) mode, Proportional-IntegralDerivative (PID) control is provided. The RMB/6 and RMB/12 Hot Runner controllers also
support Manual (open loop) mode that overrides automatic control. In Manual mode you
control the output by entering a fixed output percentage value.
PID to manual is “bumpless” when the process value is within 9 °F (5 °C) of the setpoint.
Using PID control, the controller modulates output power by adjusting the output power
percentage within a configurable proportional band. Power is proportionally reduced as
the process temperature gets closer to the setpoint temperature.
1
A zone’s transfer from
The configurable derivative action affects the output based on the rate of change of the
process value.
The integral action affects the output based on the duration of the process value’s
variation from the setpoint. In the RMB/6 and RMB/12 Hot Runner controllers, the
integral (reset) action is always equal to six times the configured derivative (rate) action.
An Autotune function is standard on every RMB/6 and RMB/12 Hot Runner controller.
This feature for easy tuning of the proportional and derivative components of the control
algorithm can be initiated every time the controller is powered up, once when the
controller is set up regardless of success (and again by changing a parameter value),
once only if successful (repeated at each power up until successful), or never.
Instructions for tuning the controller automatically and manually are in Section 6.
1.2.3 CompuStep® Soft Start for Heater Bake Out
All RMB/6 and RMB/12 Hot Runner controllers support the CompuStep soft start feature,
which allows slow dissipation of moisture in heaters by gradually applying power to the
heaters. Using this feature helps extend the life of the heaters and the molds. When a
soft start is executed, single cycle bursts start at 5% output power and step up the output
5% every 30 seconds.
•The soft start when the controller is in Normal (closed loop) mode lasts five
minutes or until the process temperature reaches 200 °F (93 °C).
1
Use of a fixed output percentage is also possible under other circumstances. Configuration parameters
let you specify a fixed output to be used as a failsafe action, a different fixed output percentage to be
used in standby mode, and another fixed output percentage used during the boost function described in
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
•The soft start when the controller is in Manual (open loop) mode continues until
the output is the lower of 50% or the target Manual mode output percent.
By default, a soft start will be executed:
•every time the controller starts (after being taken out of Idle) and the process
value is less than 200 °F (93 °C), and
•every time the controller is returned to Normal (automatic) operation and the PV
is less than 200°F (93 °C).
1.2.4 Programmable Boost Function
Every RMB/6 and RMB/12 Hot Runner controller supports a boost function. For each
zone you can use the Boost Config menu to configure a special setpoint (closed loop
boost) or a special fixed output percentage (open loop boost) to be used when the boost
button
The boost function will remain active until:
is pressed.
• the configured boost duration time has expired, or
• you use the mode/enter button
expiration of the boost duration.
1.2.5 Process-Protection Features
Process-protection features are standard on all RMB/6 and RMB/12controllers. These
features include:
• high and low deviation alarms
• high temperature safety limit
• loop break detection
• failsafe operation in case of sensor problems
1.2.6 Security
The RMB/6 and RMB/12 front panels include buttons that can be used to change the
selected zone’s setpoint and mode, and to boost the output temporarily by a configurable
amount. Users who know the Supervisor password can limit access to these buttons on
the front panel, plus limit configuration access. (Units are shipped with password
protection disabled.)
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
1.4 What Happens When You Power Up the Controller
When an RMB/6 or RMB/12 Hot Runner controller is powered up using the switch on the
back, all LEDs and all elements in the LCD display light briefly, and then software
versions (of the display and the controller hardware) are displayed.
At the conclusion of the startup process, the process values and setpoints for all zones
are displayed. Only the green LED for the display unit of measure (Fahrenheit or Celsius)
is lit.
All zone outputs will be off because the unit starts up with all zones in the Idle state.
Briefly pressing the run/idle button
currently Idle in the Run state. (Pressing the button again for at least two seconds puts
all zones in Idle.)
In each zone’s column of LEDs, the green LED in the closed loop
row is lit to indicate the type of control.
The green LEDs in the output
lit) or off. For more information about the user interface, see the Section 3.
When zones go into the Run state, the effect on each zone’s output depends on the
value of the Startup Mode parameter configured using the Control Config menu. See 5.4
for details.
on the front of the case puts all zones that are
or open loop
row indicate whether the zones’ outputs are on (LED
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
2. Setup Sequence
The following list summarizes the configuration and startup tasks to be accomplished
once the controllers are wired as shown on the diagrams shipped with the unit.
Information about all configuration parameters, including parameter interactions and valid
ranges, is in Section 5.
Turn on the controller using the switch on the back (shown below). When the unit is
1)
powered up, the controller goes through its startup sequence (see 1.4), and then the
cess value and setpoint for every zone (the standard operating display) are
pro
shown. All zones will be Idle (all outputs off).
If the controller has already been wired to the sensors and heaters, do NOT push
the run/idle
zones and entered custom setpoints. When zones are taken out of Idle, their
outputs may go on unless you change the default parameter values.
button on the front of the case until after you have configured the
2) Take unneeded zones out of service by setting them to Offline.
a) Select a zone by pressing the zone selection button
PV and SP are displayed. (Zone numbers are above the column of status
LEDs for each zone.)
b) Access the mode-selection function by pressing the mode/enter button
c) Step through the possible modes by pressing the
“Offline” is displayed.
d) Exit the mode-selection function by pressing the menu-access/exit button
. A confirmation message will be displayed briefly and then the PV and
SP for the zone will be displayed as “OFF.”
3) Notice that the green F (for Fahrenheit) or C (for Celsius) LED is lit. This LED
indicates the unit of measure for the process values and setpoints displayed.
Units ordered for the “Domestic Market” (see model number breakdown in
subsection 1.3) are set to display temperatures in degrees Fahrenheit. Units
red for “Export” or “CE” are set to display temperatures in Celsius.
orde
If you want to change the unit of measure used for temperature displays:
a) With any zone selected, press and hold the menu-access/exit button
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
c) To access the Display Units parameter, press . The currently selected
unit of measure will alternate with the parameter name on the lower line of
the display. Notice that an asterisk
is displayed instead of a zone number.
This asterisk indicates that the parameter applies to all zones.
d) Change the unit of measure by pressing
e) Exit the menu system by pressing and holding
or .
for several seconds. The
PV and SP for all zones (except any offline zones) will be displayed in the
selected unit of measure. Other temperature values previously entered while
a different unit of measure was in use will be converted automatically.
4) If the factory settings listed in subsection 3.6 are not appropriate for your
cation, you can change a parameter value for one or all zones.
appli
a) To select one zone, press
repeatedly until only that zone’s PV and SP
are displayed.
To select all zones, press
repeatedly until the PV and SP for all zones
are displayed with asterisks between the PV and SP for Zones 3 and 4 (s
below) on an RMB/6 unit. (On an RMB/12 unit, asterisks will also be
displayed between the PV and SP for Zones 9 and 10.)
b) Press and hold
c) Step through the menus by pressing
to enter the menu system.
repeatedly until the name of the
menu you want is displayed.
d) Step through the menu items by pressing
until the parameter you want is
displayed, alternating with its current value.
ee
e) Change the value by pressing
or . When changing a numerical
value, you can hold down an arrow button for fast changes.
f) Exit the menu system by pressing and holding
for several seconds.
Note that the default High [Temperature] Safety [Limit] (a Supervisor parameter)
is Off by default. If you want the controller to turn off the output to a zone that
exceeds the high limit, change the value of the High Safety parameter.
5) RMB/6 and RMB/12 units are shipped with the Supervisor password set to 100,
which disables password protection. If you want to limit access to the Superv
[Supervisor] Config menu, change the Supervisor password from the default 100.
As long as the password is 100, no password will be required to access all
functions (except settings on the Factory Config menu).
2
6) Change Normal mode (closed loop) setpoints or Manual mode (open loop) output
percentage by selecting a zone, and then pressing
or to change the
setpoint or output percent. A few seconds after you stop pressing an arrow
button, the main display (PV and SP) will return.
Tip: If all zones are in the same mode (Normal or Manual), you can select all
2
The Factory Configuration password is available only from Athena Technical Support.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
zones as described above, and then change the setpoint temperature or manual
mode output percentage for all zones simultaneously.
8) Autotune all zones that will operate in Normal (closed loop) mode; see Section 6.
Whe
n Autotuning has been completed successfully for all Normal zones, the
controller is ready to use. The appropriate green status LED in the column of
LEDs for each zone will be lit:
for Normal (open loop)
for Manual (closed loop)
for Standby
If the zone is configured to start up in Idle after the run/idle button
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
3. User Interface
3.1 Overview
During operation, the front panel contains a two-line display that displays the PV (process
value) and SP (Normal (closed loop) mode setpoint or Manual (open loop) mode output
percentage) for each zone during normal operation. Zone numbers are under the
display. PV and SP values are displayed in the unit of measure (degrees F or degrees
C) indicated by the lit green “F” or “C” LED.
This display can also be used to view and change controller settings as described in
subsection 3.5. Parameters are grouped into menus. An overview of the menus is in
ubsection 3.6
s
If a zone is in
priorities are listed in 4.5.
alarm, an alarm code alternates with the SP value. Alarm codes and
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
A column of LEDs for each zone indicates statuses for the zone and its output. The rows
of LEDs are:
output: lit green when the zone’s output is on
boost: lit green when the zone is in Boost mode
closed loop: lit green when the zone is in a closed
loop mode, such as Normal, Closed Loop Boost,
Normal Soft Start, etc.
open loop: lit green when the zone is in an open
loop mode, such as Manual or Open Loop Boost
standby: lit green when the zone is in Standby
mode or Hardware Standby mode
alarm: flashes red when the zone is in alarm
(more information about alarm indication is in 4.2)
Symbols on LED Rows
Buttons provide access to all controller functions. The purposes of the buttons are shown
below.
3
The Superv [Supervisor] Config menu can be used to disable the boost and mode buttons, and to
prevent operators from changing the setpoint or configuration parameter values. If you cannot make
changes you need, talk to your supervisor.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
3.2 Selecting One or All Zones
To select one zone, press repeatedly until only that zone’s PV and SP are displayed.
To select all zones, press
with asterisks between the PV and SP for Zones 3 and 4 (see below) on an RMB/6, and
between Zones 3 and 4, and Zones 9 and 10 on an RMB/12.
repeatedly until the PV and SP for all zones are displayed
3.3 Mode of Operation
3.3.1 Viewing Current Mode
The current mode of all zones and their output percentages can be displayed by briefly
pressing the menu-access/exit button
in the next subsection.
3.3.2 Mode Indicators
In addition to indicators for the selectable modes (see 3.3.3 and 3.3.4), additional mode
indicators are displayed under special circumstances, such as when Autotune or soft
start is active.
. Mode indicators and their meanings are listed
The mode indicators are:
HSB = hardware standby (external signal put whole controller on standby)
NRM = Normal (closed loop)
NTU = Normal auto tuning (Autotuning in process)
NSS = Normal soft start—Gradual warming if the process value is less than the lower of
the setpoint or 200 degrees F (93 degrees C)
NRB = Normal mode boost (using configured boost setpoint)
MAN = manual (open loop)
MAB = manual mode boost (using configured boost percentage)
SBY = standby (using configured standby setpoint in Normal mode or fixed output
percent in Manual mode)
SSS = standby soft start—If zone is set to start up in Standby, it will gradually warm to
the Standby setpoint if process value is less than the lower of the Standby setpoint or 200
degrees F (93 degrees C).
IDL = idle (no output)
FSF = failsafe (in state configured using Superv [Supervisor] menu)
OFF = offline (unused zone)
3.3.3 Changing Mode
To change mode of operation:
1) Select one zone or all zones as described above.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
3) Step through the selectable modes (see below) by pressing the button repeatedly
until the mode you want is displayed.
4) Confirm the selection and exit the mode-selection function by pressing
confirmation message will be displayed briefly, and then the normal operating display
returns.
3.3.4 Modes Available for Selection
The modes available for selection are:
Normal—zone uses closed-loop PID automatic control based on the entered SP and
measured PV
Standby—zone uses Standby Setpoint or Standby Percentage as configured using the
Control Config menu.
Manual—zone uses open-loop control; you set output percentage
Boost—for the configured Boost Duration time, the zone uses the Boost Setpoint or
Boost Percentage configured with Boost Config menu.
Idle—zone’s output is off until another mode is selected using the front panel
— OR —
is pressed to put all Idle zones in the Run state
Offline—zone’s output is off and PV is not monitored by the controller
3.4 Changing the Setpoint
To change Normal mode (closed loop) setpoint or Manual mode (open loop) output
percentage:
. A
1) Select a zone or, if all zones are in the same mode (Normal or Manual), select all
zones as described in subsection 3.2.
2) Press
or to change the setpoint or output percent.4 A few seconds after you
stop pressing an arrow button, the main display (PV and SP) will return.
3.5 Changing a Configuration Parameter Value
To view and change parameter values:
1) Select one zone or all zones as described in subsection 3.2.
Press and hold
2
3) Step through the menus by pressing
want is displayed. Notice that if you selected all zones before entering the menu
system (or if the parameter, such as Display Units, applies to all zones), an asterisk
is displayed instead of a zone number. This asterisk indicates that the change will
apply to all zones.
4
The Superv [Supervisor] Config menu can be used to disable the boost and mode buttons, and to
prevent operators from changing the setpoint or configuration parameter values. If you cannot make
changes you need, talk to your supervisor.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
Menu Parameters Factory Setting
Display
Config
Alarm
Config
Superv.
Config
[Supervisor]
Startup Mode (when zone is taken
out of Idle with run/idle button
)
Display Units
Last Active Mode (most recent operating
mode)
Degrees F if “D” is “Market” choice in
model number
Degrees C if “X” or “CE” is “Market” choice
in model number (see 1.3)
ies to all zones
Appl
Inhibit Seconds 0 (off)
High Dev Setpoint [High Deviation] 30 degrees F (17 degrees C)
Low Dev Setpoint [Low Deviation] 30 degrees F (17 degrees C)
Alarm Silence Seconds 120 seconds—applies to all zones
Set Superv. Password 100 = OFF (password protection
disabled)—applies to all zones
Fail Safe Action Auto Average (use a calculated output
value based on output values that have
typically successfully maintained the
current setpoint for your process in the
past; if no history of Normal mode
operation, then output is set to zero)—
applies to selected zone
Low Reading
High Reading
not applicable
not applicable
High [Temperature] Safety [Limit] OFF—applies to selected zone
Fail Safe FOP [Fixed Output Percent] 0 %—applies to selected zone
Loop Break Time 300 seconds—applies to selected zone
Soft Start (CompuStep
warming)
®
gradual
Enable—applies to all zones that are in
Normal (closed loop) mode
Mode Key Enable Enable—applies to all zones
Boost Key Enable Enable—applies to all zones
SP [Setpoint] Change Enable Enable—applies to all zones
Config. Enable Enable—applies to all zones
Reset PID Parameters No—applies to selected zone
Load Defaults No—applies to selected zone (but all zones
must be in Idle; changes take effect after
power has been cycled)
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
4. Alarms and Alarm Indication
4.1 Types of Alarms
The RMB/6 and RMB/12 Hot Runner controllers support high and low deviation alarms,
configurable separately for each zone (see subsection 5.6). The unit also recognizes
cess problems (such as loop break, reversed and open sensors, and process
pro
temperature exceeding configured safety limit) and problems with its own operation.
4.2 Alarm Indication
When a zone is in alarm:
•its red alarm
detected, but the problem does not affect operation now. For example, a zone’s
red alarm LED flashes slowly if an open thermocouple is detected, but the zone
is operating in Manual mode (in which no sensor value is used by the controller
to calculate the output)
• the alarm relay closes
• a code for the type of alarm alternates with display of the setpoint (Normal
mode or other closed-loop mode such as closed-loop boost) or output
percentage (Manual mode or other open-loop mode such as open-loop
standby); and
•unit beeps until the alarm condition is cleared or the zone is put in Idle mode or
the alarm is silenced (see below).
LED flashes rapidly (Slow flashes mean an alarm was
4.3 Silencing Alarm Beep
You can temporarily silence the alarm beep by pressing the alarm silence button .
Beeping will be silenced for the configured number of seconds. (The default is 120
seconds.)
4.4 External Indication
An output on the back of the controller allows external devices (such as horns or lights) to
be connected to the controller for alarm annunciation. For more information about this
feature, see the diagrams shipped with the controller.
This alarm output is not affected when the alarm silence button
controller is pressed.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
5. Parameter Characteristics
5.1 Introduction
This section contains information about every configuration parameter, including valid
ranges, control mode(s) to which the parameter applies, and interactions among
parameters.
For an overview of configuration menus and parameters, see subsection 3.6.
5.2 Input Parameters
5.2.1 Introduction
You can use the Input Config menu to specify for the selected zone(s):
• bias (if any) to be applied to the input,
• setpoint range, and
• input type
5.2.2 Input Parameters and Settings
Applies to
Name
Control
All Zones
Selected Zones
Bias
Low Setpoint Limit X X
High Setpoint Limit X X
Input Type X X X J Thermo
X X X
Closed Loop
Range/
Choices
Control
Open Loop
–100 to 100 °F
–55 to 55 °C
32 to 999 °F
0 to 537 °C
32 to 999 °F
0 to 537 °C
K Thermo
Default Description & Interactions
zero
degrees
32 °F
0 °C
999 °F
537 °C
input
type
specified
when
unit was
ordered
number of degrees that will be added to
or subtracted from the measured
process value before it is displayed
lowest and highest values that can be
entered as setpoint (before bias is
applied); also limits configurable range of
boost setpoint and standby setpoint
switching to input type that does not
match the type specified when the unit
was ordered can cause small errors (1–5
degrees) in temperature measurements
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
5.4 Control Parameters
5.4.1 Introduction
You can use the Control Config menu to specify how the selected zone(s) will be
controlled:
•at startup (after you have pressed the run/idle button
to take the controller
out of Idle),
• during Normal operation,
• when the
button has been used to put the zone in Standby or when a zone
configured to start up in Standby mode comes out of Idle, and
•when an external signal has been used to put the whole controller in Hardware
Standby.
The Control Config menu is also used to specify whether and how often Autotuning
(described in Section 6) is done.
5.4.2 Control Parameters and Settings
Applies to
Name
Control
All Zones
Selected Zones
Standby Type
Standby Setpoint
Standby Percentage X X 0 to 100 % zero output percent used when zone is in
Proportional Band
Derivative (rate) X X 0.0 to 999
X X X Open Loop
X X
X X
Closed Loop
Range/
Choices
Control
Open Loop
Closed Loop
Low Setpoint
Limit to High
Setpoint Limit
(from Input
Config menu)
1 to 999 °F
1 to 537 °C
seconds
Default Description & Interactions
Open
Loop
77 °F
25 °C
24 °F
13 °C
7
seconds
type of control used while the controller’s
front panel buttons have been used to
put the selected zone(s) in standby
mode: closed loop (Standby Setpoint
used) or open loop (Standby Percentage
used)
Note: When an external signal puts all
zones in Hardware Standby mode, this
Standby Type value is ignored. If a zone
is closed-loop when the Hardware
Standby signal is received, the
configured Standby Setpoint is used. If a
zone is open-loop when the Hardware
Standby signal is received, the
configured Standby Percentage is used.
setpoint used when zone is in closed
loop standby mode
open loop standby mode
width of the band below the setpoint
within which the controller will modulate
the output as the process value
approaches the setpoint; Autotuning sets this value automatically; see
Section 6
time period used by the derivative
component of the control algorithm when
analyzing load changes; Autotuning sets this value automatically; see
Section 6
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
Applies to
Name
PID Autotune
Control
All Zones
Selected Zones
Closed Loop
X X Disable
Range/
Choices
Control
Open Loop
Once (then
disabled
after
successful
Autotune)
Enable
(Autotunes
every time
controller is
powered up)
One Try
Only (and
then
disabled,
even if
Autotune
was not
successful)
Startup ModeX X X Auto
(Normal
closed loop)
Standby
Manual
(open loop)
Idle
(remains in
Idle after
is pushed to
set controller
to Run state)
Last Active
Mode
(same mode
as last time
controller
was running)
Default Description & Interactions
The integral action for PID control is not
configurable; the integral (reset) action is
always equal to six times the configured
derivative (rate) action.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
5.5 Display Units
5.5.1 Introduction
On the front panel the lit green LED labeled F or C indicates the units of measure for the
process values and setpoints displayed.
Units ordered for the “Domestic Market” (“D” as the “Market” character in the model
number on the tag on the case) are set to display temperatures in Fahrenheit. Units
ordered for “Export” (“X” as the “Market” character) or “CE” (“CE” as “Market” characters;
see model number breakdown in 1.3) are set to display temperatures in Celsius.
You can u
se the Display Config menu to change the unit of measure used for displayed
temperatures.
5.5.2 Display Parameter and Settings
Applies to
Name
Display Units
Control
All Zones
Selected Zones
X X X Degrees F
Closed Loop
Range/
Choices
Control
Open Loop
Degrees C
Default Description & Interactions
Degrees F unit of measure used for all zones for
all displayed temperatures, including
parameter values; changing Display
Units causes all temperatures
already entered as parameter values
or setpoints to be converted to the
newly selected unit of measure when
displayed
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
5.7 Supervisor Parameters
5.7.1 Introduction
You can use the Superv [Supervisor] Config menu to specify the values of several
parameters related to process protection for the selected zones. You can also use this
menu to set up parameters that apply to the whole controller.
The Superv Config menu can be password protected. RMB/6 and RMB/12 controllers
are shipped with the Supervisor password set to 100, which disables this feature. You
can use this menu to specify a different password. Only users who know your new threedigit password will be able to view and change parameters in the Superv Config menu.
5.7.2 Supervisor Parameters and Settings
Applies to
Name
Control
All Zones
Selected Zones
Set Superv. Password X X X 100 to 999 100 = Off password needed to access parameters in
Fail Safe Action
Low Reading X X X — —
High Reading X X X — —
High Safety (High
Temperature Safety
Limit)
Fail Safe FOP (fixed
output percentage)
Loop Break Time (sec.) X X X OFF
Soft Start X X Disable
Mode Key Enable X X X Disable
Boost Key Enable X X X Disable
SP Change Enable X X X Disable
Config. Enable X X X Disable
Reset PID Parameters X X Yes
Load Defaults X X X Yes
X X X Off
X X X
X X 0 to 100% 0 % output percent used only if open or
Closed Loop
Range/
Choices
Control
Open Loop
Auto
Average
Fixed Output
Pct.
33 to 999 °F
1 to 537 °C
10 to 999
seconds
Enable
Enable
Enable
Enable
Enable
No
No
Default Description & Interactions
Superv [Supervisor] Config menu
Auto
Average
OFF output will be turned off if process value
300
seconds
Enable gradual increase of output to slowly
Enable
Enable
Enable enables/disables use of front panel
Enable enables/disables use of front panel
No return tuning parameters to their default
No return configuration parameter values to
output action to be used when controller
detects an open or reversed sensor: off,
automatically calculated based on past
good output values (if no history of Normal
mode output values, then zero), or failsafe
fixed output percent
lowest process value for selected zone
since the last time the reading was reset
by pressing the up or down arrow button
highest process value for selected zone
since the last time the reading was reset
by pressing the up or down arrow button
reaches this temperature
reversed sensor is detected and Fail Safe
Action is set to Fixed Output Pct.
time period during which the input should
change 1% of supported sensor span
(9.67 °F or 5.37 °C) in response to output
action if the sensor is working correctly
and the input wiring is intact
dissipate moisture in heaters; see 1.2.3
enables/disables
enables/disables
buttons to change Normal mode setpoint
and Manual mode output percentage
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
6. Tuning the Controller for PID Control
6.1 Introduction
RMB/6 and RMB/12 Hot Runner Controllers support automatic tuning for control of zones
running in CompuCycle
By default, every RMB/6 and RMB/12 controller is configured to execute the Autotune
operation the first time it is powered up, then to disable the Autotune feature, even if
Autotune was not successful.
The Autotune operation overwrites any existing proportional band and derivative (rate)
parameter values that were previously configured.
All RMB/6 and RMB/12 controllers in a single process should be Autotuned
simultaneously, so that interactions between zones during tuning parallel the interactions
expected while the controllers are in use.
Normal (closed loop) mode.
6.2 Procedure for Autotuning
To Autotune:
1) Make sure the controller is in Idle state (only the green F or C LED lit).
2) After configuring any parameters that you want to change from the defaults, enter a
setpoint that is representative of the setpoint you expect to use when the selected
zones are in Normal mode operation.
3) If Autotuning has been attempted in the past, the Autotune feature may be disabled.
To force an Autotune operation, use the Control Config menu to set the PID Autotune
parameter to Enable.
4) Cycle the power to the controller.
5) At this point the controller may execute a CompuStep soft start.
•If you want the soft start to continue to its normal conclusion
(recommended), do not press any buttons.
•If you want to terminate the soft start (not recommended), use the mode
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
During the Autotune operation, the display for the selected zones blinks “Tun.”
Unless you want to terminate the Autotune by changing a zone’s mode, do not press
any buttons during the Autotune operation. The lower line will continue to display the
setpoint you entered in Step 2.
When the controller has completed Autotuning a zone successfully, the controller will
save the tuning parameter values in the Proportional Band and Derivative (rate)
parameters for all zones that have Autotuned successfully. (The new tuning values
can be viewed using the Control Config menu.)
If Autotune was unsuccessful for a zone, the zone will:
• use default values for PID parameters,
• go into alarm (red LED lit in the
row),
•display its process value alternating with one of the tuning error codes listed
in 6.3, and
go to configured failsafe state; the effect on a zone’s output depends on
•
how you configured the Fail Safe Action parameter in the Superv
[Supervisor] Config menu.
To clear the error display and put the zone(s) in standby mode, use the mode button
. (The effect on each zone’s output depends on the standby configuration
selections you made using the Control Config menu.)
Fix the problem (see error code meanings in next subsection) and try tuning again.
Once Autotune has been completed successfully for all Normal zones (“NRM” mode
displayed) use the Control Config menu to disable PID Autotune.
RMB/6 Hot Runner Controller Configuration and Operation Manual
6.3 Autotune Errors
The Autotune error codes are in the table below.
Error Code Description
Tu3
Tu5
Tu8
Tu9
Tun0
Setpoint is lower than the process value. Look at the setpoint.
If it is realistic for your process, then check the thermocouple leads;
maybe they are reversed.
The initial process value and the setpoint are not far enough apart.
For Autotune to work, the difference must be at least 9 degrees F
(5 degrees C).
The startup curve (change in PV) was not acceptable to the
Autotune algorithm. This problem could be caused by a process
upset that occurred during tuning. Try Autotuning again when the
process is stable. If the error recurs, your process is not suitable for
Autotuning. Use manual tuning as described in 6.4.
The Autotuning timed out, because the process was unresponsive
(or extremely slow to respond). Your process is not suitable for
Autotuning. Tune the controller manually as described in 6.4.
The Autotune operation failed for a reason other than those listed
above. Try Autotuning again when the process is stable.
6.4 Manual Tuning (Zeigler-Nichols PID Method)
6.4.1 Introduction
This tuning method may be used if the spread between initial process temperature and
process operating temperature is small, or if the process is too slow for Autotuning.
Manual tuning requires that zones be tuned one at a time and that the PV be tracked
over time. (Graph the displayed PV against time manually.) All zones should be running
while manually tuning one zone.
After you have finished manual tuning, you can change the Startup Mode parameter
setting and enable soft start (recommended).
6.4.2 Procedure
To do manual tuning:
1) After configuring any parameters that apply to your control strategy, enter a setpoint
that is representative of the setpoint you expect to use when the selected zone is in
Normal operation.
2) Go to the Control Config menu.
3) For now, leave the Proportional Band set to 24 °F (13 °C), but change the Derivative
(PID rate) to 0 seconds.
4) In the Control Config menu, set the PID Autotune parameter to Disable.
5) Return to the standard operating display and watch the behavior of the displayed
process value. When the temperature reaches setpoint, plot a graph of the
displayed process value against time or record the time period between temperature
peaks. (Be patient. It may be several minutes before you see up and down changes
(oscillation) in the process value for a manifold zone.)
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
6) If the temperature (process value) will not oscillate, then decrease the proportional
band value by repeatedly halving the value (dividing it by 2) until a small, sustained
temperature oscillation is seen.
Alternatively, if the temperature (process value) oscillates severely, double the
proportional band value (multiple it by 2) repeatedly until a small, sustained
temperature oscillation is observed.
7) Measure the period in seconds of one cycle of oscillation (“T” on the diagram below).
8) Divide the period of oscillation (T) by 8. The resulting number (quotient) is the correct
Derivative parameter value (rate) time in seconds.
9) Access the Control Config menu and enter the Derivative value obtained in Step 8.
The integral time will be set automatically to 6 times the rate. (You cannot view the
integral term value.)
10) If the process is stable, manual tuning is completed. However, if slight oscillation is
observed, multiply the current proportional band value by 1.66 and enter the product
as the new PID Proportional Band value to complete the tuning procedure for this
zone.
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
8. Resetting Parameters to the Default
Values
8.1 Introduction
Using this function returns all configuration parameter values for the selected zone(s) to
their defaults (shown in Section 5). The setpoints for the selected zone(s) will be
nged to 77 degrees F (25 degrees C).
cha
Reloading defaults never affects the following settings that apply to the whole controller:
display units, input type. These settings that apply to the whole controller are not reset,
even if all zones are selected before loading defaults.
When all zones have been selected for resetting defaults, some settings that apply to the
whole controller WILL be reset to the defaults shown in shown in Section 5. These values
that are retu
100, disabling password protection) and access control settings described in Section 7.
rned to the defaults include the Supervisor password (which will be reset to
After loading
resume operation.
defaults, you will need to cycle power to the controller before you can
8.2 Procedure
To load defaults to selected zones:
1) Put the controller in the Idle state by pressing
whole controller is in the Idle state, only the green F or C LED will be lit.)
2) Select the zone for which you want to load defaults by pressing
zone’s SP and PV are displayed. Alternatively, select all zones by pressing
all zones’ SP and PV are displayed with asterisks
3 and 4 (RMB/6), or between 3 and 4, and 9 and 10 (RMB/12).
2) Access the menu system by pressing
press
3) Step through the parameters by pressing
displayed.
4) Choose “Yes” by pressing
5) Exit the menu system by pressing and holding
displayed.
repeatedly until the name of the Superv Config menu is displayed.
for at least two seconds. (When the
until only that
until
between the values for zones
until a menu name is displayed, and then
repeatedly until Load Defaults is
or .
until “Power Cycle the System” is
6) Cycle power to the controller. When powered up, the controller will use the default
settings for the zone(s) selected in step 2.
hardware installation instructions, where to find, 1
Hardware Standby mode, 10, 18
HID alarm, 15
High Dev Setpoint parameter, 13, 21
high deviation alarm message, 15
High Reading parameter, 13, 22
High Safety parameter, 6, 13, 15, 22
High Setpoint Limit parameter, 12, 16
high temperature safety limit. See High Safety
RMB/6 and RMB/12 Hot Runner Controller Configuration and Operation Manual
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 the seller is to replace or repair
this equipment at its factory, provided that the equipment is returned with transportation
prepaid within the warranty period, which starts when the unit is purchased. The
warranty period is two years.
The purchaser agrees that the seller assumes no liability under any circumstances for
consequential damages resulting from use of this equipment or from improper handling or
packaging of shipments returned to the factory.
Components which wear or which are damaged by misuse are not warranted. These
include contact points, fuses, electromechanical relays, and triacs. Units which have
been modified by a customer in any way are not warranted.
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.
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 seller 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
two years after the cause of action has accrued.
Seller’s maximum liability shall not exceed and buyer’s remedy is limited to 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 price, and such remedy shall be buyer’s entire and
exclusive remedy. The specifications put forth in this manual are subject to change
without notice.