Instruction
Manual
Athena 6050
Temperature Controllers
-THENIL
SPECIFICATIONS:
Inputs:
INSTRUCTION MANUAL
ATHENA 6050
Automatic Tuning
Temperature Controller
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:
120/240 Vac
Thermocouple
Less than 6 VA (Instrument)
J Couple
K Couple
0.2% of full scale
5m V/°C
0.05°C/°C
0 to
100 Ohm
80
dB
120
dB
Upscale standard
Process temperature displayed
continuously; set point or other
parameters updated on lower display.
+lO%,
0-1400°F (O-760°C)
0-2500°F (O-137O°C)
Max 3m
55°C
V/°C
ambient
-15%,
typ.
50, 60
Hz
1
Display update rate:
5 times per second
Filtering:
°F/°C:
output:
-B Relay (time
proportioning)
-F Current
proportional
-S
Pulsed voltage
-T Triac
proportional
Filtered LED display:
T/C linearization:
Connections:
time
Analog and digital filtering
techniques increase stability
of process and display.
Internal switch selection--
process, set point.
Heating only
SPST relay 7 Amps resistive at
120
Vac,
50 VA inductive.
4-20mADC
SCR
20 Vdc pulsed time proportioning
signal for driving solid state relays.
Solid state plug-in
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.
5 amp resistive at 240
into 500 Ohm max. For driving
power controllers.
triac
output.
Vac,
Dimensions:
Mounting:
Weight:
Front panel: 96mm X 96mm X
Case: 92mm X
Depth behind panel:
minus panel thickness)
Channel slides and screws
2 lb
92mm
X
118mm
96mm (approx.
22mm
2
3
FRONT PANEL AOJUSTMENTS
Touch Key
1 Index: Allows the following adjustments to be selected.
1)
Set point temperature
2)
Heat cycle time
3)
Prop. Band (indicated
as
gain)
O-14OO'F (760°C)
O-2500°F (O-137O°C)
*1 to 120 seconds
0.25-25%
of span
4)
Rate with tracking reset
5)
Auto Tune
Up/Down keys: increases/decreases values of above
adjustments.
Tune/Cancel:
permit set-up
E Enter: writes selected value to nonvolatile memory
NOTES: *setting to zero initiates 60
for ultra fast cycling. Use
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
(AT)
"cancel" puts output on stand-by to
"tune" triggers automatic tuning procedure
**4-255 seconds
millisecond timebase
with
external solid
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,
liquid to gas, may introduce erroneous tuning parameters
during process warm-up.
GENERAL
Accurately measures, linearizes and displays temperature
1.
in °F and
Automatically calculates and displays parameters-heat
2.
gain, and rate/reset time.
Can be field converted from relay output
3.
state relay
a 4-20 MA output SCR driver
4.
Will remember its "entered" settings after power failure
or shut-off and not "Go To Sleep".
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.
°C.
“T",
to solid state driver
i.e.
solid to liquid or
"B",
"S"
"F".
or to
to solid
B- Relay
F- 4-20 mA (Proportional)
T-
Triac
S- 20 VDC Pulsed for driving solid state relays
Example:
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,
controller damage.
7A/5A @ 120/240 Vac
1 Amp @ 240
6050-F
has proportional 4 to 20 mA heat
output.
Vac
which can result in severe
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
NOTE: Do not use this output module with mechanical
contactors
field which can interfere the 6050's microprocessor.
Instead we
application.
Module Type F: This 4-20 mA output module can deliver
Module Type T: This solid state relay is capable of 1 AM?
7A/5A
driving resistive heaters.
because they generate an excessive EM1
recommend "T"
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.
at
120/240 Vac.
and optically isolated from the drive signal.
With
it, resistive loads up to 120 watts at
at 120
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.
relay
Vac
and 240 watts at 240
(at 120/240 Vac)
output modules for this
It is zero voltage switched
is used for
Vac
may be
Module Type S: Similar to F, but pulsed
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.
2OV/2OmA
7
DC output
INTERNAL SWITCHES
Damping
tuning for processes with varying heating characteristics and
with varying heating capabilities, the 6050 offers three
damping choices:
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
Control -To allow the controller to provide automatic
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.
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
J
K
MATERIALS
Iron Constantan
Chrome1 Alumel
(C/A)
(I/C)
COLOR CODE
White(+) Red(-)
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
a point measuring device, putting more than one
in parallel will provide an average temperature
produce better results in air heated processes.
lags.
Since the thermocouple is basically
thermocouple
reading and
will
result,
loads with
an isolated
input and
24OV)
NOTE: If controls with
grounded or hot input terminals
thermocouple must be used. Otherwise, when both
output are grounded, ground loop currents
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
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
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.
"F"
or
"S"
outputs drive
(not
floating),
2).
12OV,
8 & 10 for
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"
The unit is now ready for set point and cycle time entry.
STEP 3: To enter a set point:
STEP 4: Set cycle time by advancing "Index" to "HC" and
STEP
button until the
the Cancel button.
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.
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
mechanical relays or
When you've found the desired cycle time press the
enter key.
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
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.
"Autotune"
LED lights then press
A) Hold "Index" button until
"F"
or
"S"
contactors
output modules. For
use
l0-120
seconds.
"HT"
L.E.D. will
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
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.
PID
parameters
11
TROUBLE SHOOTING
no
Front dark
instrument power.
-
Process display
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
About
30%
Disconnect
above 2500°F.
No Heat
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
for reversed thermocouple.
Display blinks, entered values change - Caused by electromagnetic
interference
eliminate high voltage spikes,
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.
Error- Wrong thermocouple type.
couple.
-
No heater power, heater wiring, wrong output module.
is
(EMI).
shows
CCCC - Open thermcouple. Short
°F.
"J"
units over range above
Supress arcing contacts in system to
seperate sensor and controller
14OO°F, "K"
Warns -
Check
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
purchase.
The purchaser agrees that Athena Controls, Inc. shall assume
no liability for consequential damages resulting
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,
and modules. Units which have been modified by customer are
not warranted.
Specifications are subject to change without notice.
(2)
years of its
from
triacs,
its
13
dTHENd
Controls, Inc., 5145 Campus Drive
Plymouth
Meeting,
PA 19462
(215) 828-2490
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