Athena Technologies 16C User Manual
SERIES
16C
TEMPERATURE/PROCESS
CONTROLLER
Instruction Manual
(Basic Operations)
1
3
Introduction
Precautions
Features
Congratulations on your purchase of an Athena Series 16C
Temperature/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 menu system. The instrument may then be
automatically or manually tuned to your process for optimum
setpoint control.
A Quick Setup Reference Card is on page 5 and also attached
as a tear-off card to the back of the instruction manual for
experienced users of PID controllers.
As you look through this manual, you will notice blue
italicized text appearing in the margins and adjacent to
operating information. These notes impart important information about the controller and may answer questions you may
have about its setup or operation. If you still have questions
or require any assistance, please contact your Athena representative or call technical support at 1-800-782-6776. Outside
the USA, please call 610-828-2490.
After unpacking, inspect the instrument for any physical
damage that may have occurred in shipping. Save all packing
materials and report any damage to the carrier immediately.
Field-Selectable Thermocouple, RTD, Current or Voltage Input
On/Off Through Full PID Operation
Autotuning - Heat or Cool
Eight-Segment Ramp/Soak
On/Off Output with Adjustable Hysteresis and Deadband
Dual Output Capability
Field-Configurable Process or Deviation Alarms
Bumpless, Auto-Manual Transfer
NEMA 4X Front Panel, “Watertight”
Dual 4-Digit (0.36”), 7-Segment Alphanumeric Display
Selectable Ramp to Setpoint
Alarm Inhibit
Loop Break Alarm Capability
Available Options Include Serial Communications, Contact/
Digital Input, Remote Analog Setpoint, Transducer Excitation,
Auxiliary Output, Dual Alarms, or Electromechanical Relay
Alarm.
Approvals: UL, cUL, CE
© Copyright 2004, Athena Controls, Inc.
Safety Warning
®
U
L
C
®
U
L
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 locate this instrument where it is subject to excessive
shock, vibration, dirt, moisture, oil, or other liquids. The safe
operating temperature range for this unit is 32°F to 140°F
(0°C to 60°C).
This unit has been tested and found to be compliant with
“NEMA Type 4X Enclosure - For Indoor Use Only.” When
properly installed, this controller will maintain the integrity
of a NEMA enclosure and remain “Watertight.” This rating is
only applicable when the controller is properly installed into a
suitably rated NEMA Type 4X housing.
3
1
Table of
Contents
For information and
operating instructions
related to installed
options and digital
communications,
refer to the Series C
Options and Digital
Communications
manual supplied with
your controller.
4
Installation 1
Dimensions and Mounting 2
Wiring 3
Output Types 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
Temperature Input 16
Process (Linear) Input 16
Display Menu 17
Output Menu 17
PID Output and Control Menus 18
On/Off Output and Control Menus 19
Alarm Outputs 20
Autotune Damping 22
Ramp and Soak Menu 23
Supervisor Menu 24
Calibration Menu 25
Options Menu 25
AutoTuning 26
Manual Tuning 28
Error Codes 29
Technical Specifications 30
Ordering Codes 32
Recalibration Procedures 33
Quick–Helps 34
Warranty/Repairs 36
Glossary 39
Installation
Measurements between
centerlines of panel cutouts are the minimum
recommended.
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 the ordering code number indicated on the side
of the controller matches what was ordered.
Figure 1.
Recommended Panel Layout for Multiple Controllers
C
L
2.850” (72.4 mm)
C
L
C
L
2.150” (54.6 mm)
C
L
1
3
Dimensions
2.100"
(53.3m m)
O1
O2
A1
A2
F1
F2
PV
SV
2.100"
(53.3m m)
4.654"
(118.21mm )
3.937"
(100 m m)
0.717"
(8.21 mm)
1.750"
(44.5 mm)
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 minimum of 4” (100 mm) of depth behind the panel is required.
Mounting
When properly
installed through
a NEMA enclosure,
the integrity of the
enclosure will be
maintained and will
remain “Watertight.”
2
Figure 3. Series C Mechanical Components
Insert the Series C through the front panel cutout and slide
the mounting collar back onto the unit from behind the
panel. Push the mounting collar up tight to the back of the
mounting panel.
Bezel
Grips
Gasket
Case Clip
Customer Panel
Wiring
1
2
3
4
5
6
7
8
9
10
13
14
11
12
N.O.
C
N.C.
N.O.
C
SENSOR
INPUT
T/C
OUTPUT 1
OUTPUT 2
RT
D
L1 L2
100 - 250 V 50/60 Hz
100 - 250 Vdc (Auto Polarity)
24 Vac/Vdc (Auto Polarity)
A2
232/485
GND
ALARM
&
COMM.
COM
N.O.
N.O.
RCV
B (-)
COM
XMT
A (+)
A1
RS 232
RS 485
ALARM & COMM.
IMPORTANT: 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 kept
separate. We recommend separating connecting wires into
bundles: power; signal; alarms; and outputs. These bundles
should then be routed through individual conduits. Shielded
sensor cables should always be terminated at one end only.
If additional RFI attenuation is required, noise suppression
devices such as an R.C. snubber at the external noise source
may be used. If you wish, you may order this suppressor
directly from Athena, part number 235Z005U01.
Figure 4. Contact Identification
3
Wiring
8
9
10
RTD
8
9
10
T/C
3
4
5
8
9
10
11
12
L1 L2
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 one end.
Wiring
Figure 5. Thermocouple Input Wiring
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 thermocouple.
Figure 6. RTD Wiring
The Series C accepts input from
2- or 3-wire, 100 ohm platinum
resistance temperature detectors
(RTDs). Connect 2-wire RTDs
to contacts #9 and #10, with a
jumper across contacts #8 and
#10. Keep leads short and use
heavy gauge copper extension
wire, if necessary, to minimize
Note: For 2-Wire RTD
lead resistance. For long runs,
3-wire RTDs should be used.
Figure 7. Process and Linear Input Wiring
Voltage Inputs: Connect the positive
voltage input to contact #10; the
negative input to contact #9.
Current Inputs: Connect the positive
current input to contact #10; the
negative input to contact #9.
Jumper 8 & 10
The Series C power supply accepts
100 to 250 Vac and 100
to 250 Vdc line power without any switch settings or
polarity considerations. All connections should be made
in accordance with the National Electrical Code and local
regulations, using only NEC Class 1 wiring for all power
terminals.
It is advisable, but not necessary, to fuse one leg of the
incoming power line, contact #11, with a 2AG, 0.5 amp
rated fuse. It is recommended that instrument power and load
power be fused independently.
Figure 8. Power Wiring Connection
4
100 - 250 V 50/60 Hz
100 - 250 Vdc (Auto Polarity)
Output Types
The Type “B” output
is a mechanical device
and subject to wear.
To extend the life of
the relay, set the Cycle
Time for the relay
output to the longest
duration that still
affords good control.
When you ordered your Series C controller specific output
types were specified, designated as “B”, “E”, “F”, “G”, “S”,
“T” or “Y”. You also had the option of configuring your controller with either one or two output actions. The numbers
below are suggested for most typical applications.
For Control Output Type — Select Cycle Time
(in seconds)
B >15
E 0.2
F 0.2
G 0.2
S 0.2
T 15*
Y >15
* “T” outputs directly driving non-inductive loads (small heaters) can have
cycle times as low as 0.2 seconds.
Output Type Description
B 5 A (120/240 Vac) relay, normally open, used
for switching resistive loads. If relays or solenoids are to be driven, select the “T” output. If
a “B” output is selected, order snubber network
235Z005U01.
E 0-20 mA
F 4-20 mA, full output to load with 500 ohm
impedance max. (suppressed).
G High impedance ‘F’ (800 ohms).
S 20 Vdc pulsed output for solid-state relays.
T 1 A @ 120/240 Vac, solid-state relay, zero volt-
age-switched and optically isolated from drive
signal. Only resistive loads to 1A may be controlled directly. Larger loads may be controlled
using an external contactor.
Y 5 A (120/240 Vac) relay, but normally
closed (output 2 only).
5
7
Operation
Figure 9. Front Panel Controls and Indicators
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 next
menu, and enter the Security Level menu.
6
Power On
The Series C controller’s
functional hierarchy
is organized into three
distinct user-programmable groupings:
Security Level, Menu
System, and Operating
Mode.
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 communications protocol which is
supported (lower display).
Please provide the
software version
number, communications
protocol, and the
controller’s full model
number, when contacting
us regarding your
controller.
IMPORTANT: On initial startup, there is a possibility that
outputs may be activated. We recommend placing the unit
in Standby mode until you have configured the controller
according to your application requirements. To place the
controller in Standby, follow this procedure:
1) Press and hold Mode/Enter key until
a menu label appears in upper display
(approximately three seconds).
2) Press Raise or Lower key until
appears in the lower display.
3) Press Mode/Enter key. (The upper display will
alternate between and process value.)
Operations Overview
The user interface of the Series C allows you to use menus to
set up the instrument, set the desired security level, change
the setpoint, and conveniently change operating modes.
Figure 9 on page 15 provides a functional representation of
the user interface and the key presses necessary to perform
the basic functions.
7
Security Levels
The controller’s initial
security level, set at the
factory, is Configuration
. When you have
completed configuring
the instrument, we
recommend the security
level be set to the most
restrictive level suitable
for your application.
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. To view or change security
level from the Process Variable display, press and hold the
Menu Access key for approximately 10 seconds.
(Ignore the menu label that will appear in the upper display
after approximately three seconds.) The controller will display
(Access Level) and the current security level label,
e.g., . Use the Raise or Lower keys to index
through the security levels. Press the Mode/Enter key
once to select the new security level desired and return to the
Process Value display.
Security Levels and Access Restrictions
Key Lockout Highest security level. No access to any
Setpoint No access to menus. Only allows setpoint
Setpoint
plus Mode No access to menus. Only allows setpoint
User All “Setpoint” level privileges as well as
Configuration All “User” level privileges as well as Input,
Factory All “Configuration” level privileges as well
controller functions. To escape, follow
instructions above for changing security
levels.
value or output percentage (manual mode)
to be changed.
value, output percentage (manual mode),
or operating mode to be changed.
access to Operating Mode, Autotune, and
Control menus.
Output, Display, and Supervisor menus
as access to Calibration menu.
JMPØ3
NOTE: Removing this jumper on the microcontroller board disables
the keypad, thus preventing any operator access.
8
Operating Modes
Remember to press the
Mode/Enter key after
making your selection.
If both outputs are
set to or ,
the Series C will function as a non-controlling indicator. Control
outputs will be disabled
and the Operating
Modes will not be
displayed.
The Series C’s operating modes are: Manual, Standby, Normal,
Autotune, Ramp/Soak Recipe, Run and Hold. To select a different
operating mode, press the Mode/Enter key for three seconds.
The operating mode that the controller is currently in will be displayed. To index through the available operating modes, press the
Raise or Lower keys. When the desired mode is displayed,
press the Mode/Enter key once to select the mode.
Manual
Standby
Normal
Autotune
(Only available when unit is placed in Standby mode
and one output is PID.)
Start Ramp/Soak Recipe
(Only when programmed.)
Run
(Only available when recipe is active.)
Hold
(Only available when recipe is active.)
Operating Modes
Manual operating
mode overrides automatic control, allowing
you to control the
outputs using a fixed
percentage of output
power, regardless of
the process variable
or setpoint.
If current automatic
control is PID, transfer
to Manual mode is
“bumpless.”
Manual Used to set control output percentage
(Fixed Output Percentage) independent
of Process Value. To set percentage,
use the Menu Access key to select
and the Raise or Lower keys
to set the value.
Output 1 is a control output.
is displayed if Output 2 is a control
.
output
Standby Used to disable control outputs.
Normal Normal automatic control.
Autotune Used to initiate the autotuning
sequence (from Standby only).
Ramp/Soak Used to start ramp/soak recipe mode.
Recipe
Run Used to enable Run function
Hold Used to enable Hold function
is displayed if
9
11
Menu System
Overview
If a key press is not
sensed within five
minutes, the controller automatically exits
the Menu System and
reverts to the Process
Value display.
The Parameter Menu System is organized into ten basic
menus: Input, Display, Output, Control, Alarm, Tune,
Recipe, Supervisor, Calibration, and Option. To access the
Menus, press and hold the Menu Access key for approximately 3 seconds until a menu label appears in the upper display. There are additional menus presented when an option
is selected under the Option menu; however, the options
are non-functional unless the appropriate option board has
been installed. Pressing the Menu Access key indexes
from menu to menu. Pressing the Mode/Enter key
indexes through the parameters in a particular menu. The
Raise and Lower
keys are used to modify the visible
menu parameter.
Each menu contains a logical group of parameters related
to one another. Furthermore, the sequence of the menus
has been carefully chosen to put the most important setup
menus first.
10
Menu System
Overview
To return to Process
Value at any time,
press and hold Menu
Access key for
three seconds
System
Menu
Figure 10. Series C Functional Diagram
for 3 seconds
once
for 3 seconds
Variable
Display
Process
for 3 seconds
for 10 seconds
once
Security
Levels
Selection
Mode
11
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