Athena SERIES 16 User manual

SERIES
16
TEMPERATURE/PROCESS
CONTROLLER
Instruction Manual

Safety
Warning
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 instru-
ment, 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.
Safe ambient operating temperature range is 32° to 131° F
(0° to 55° C).
NOTES ON CE EMC COMPLIANCE
This unit is compliant with the
following standards when properly
installed in a grounded metal panel:
EN55011 (CISPR 11), Class B
ENS0082-1
Introduction
Precautions
Congratulations on your purchase of an Athena®Series 16
Single-Loop Controller. It is designed for ease of use and
reliability wherever accurate closed-loop control is required.
Your Series 16 has been configured according to your order-
ing specifications as either a universal process controller or
a dedicated temperature controller. In addition, special func-
tions such as a heater break alarm, digital communications,
etc., do not require you to make any internal jumper or DIP
switch settings.
After following the instructions for installation, simply step
through and set your desired parameters using the Series
16’s easy menu system. The instrument may then be auto-
matically or manually tuned to your process for optimum
setpoint control. A Quick-Start Reference Card is attached to
the back of the instruction manual for experienced users of
PID controllers. If you still have questions or require any
assistance in setting up or operating your controller, please
contact your Athena representative or call 1-800-782-6776.
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.

Table of Contents
Installation
Mounting 1
Wiring 2
Operation
Notes on Outputs 4
Parameter Menu Organization 6
Notes on Alarms 10
Tuning 17
Special Functions
Auto/Manual 22
Remote Setpoint Select 22
Process Variable Retransmission 24
Heater Break Alarm 25
Transducer Excitation 26
Digital Communications 27
Recalibration Procedure 34
Error Codes 34
Warranty/Repair Information 35
Technical Specifications 36
Ordering Codes 39

1
Installation
Figure 1. Recommended Panel Layout for Multiple
Controllers
Measurements between
centerlines of panel
cutouts are minimum
recommended.
C
LC
L
C
L
C
L
2.850" (72.4 mm)
2.150" (54.6 mm)
1.171" (45 mm)
Figure 2. Case Dimensions
Prior to mounting the Series 16 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.
Figure 3. Series 16 Mechanical Components
Bezel Case Clip
Grips
Rubber Gasket Customer Panel

2
Sensor Input
Connections
Figure 5. Thermocouple Input Wiring
Make sure that you are using the
appropriate thermocouple and
extension wire. Connect the neg-
ative 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 16 accepts input
from 2- or 3-wire, 100 ohm
platinum resistance tempera-
ture detectors (RTDs). Connect
2-wire RTDs to contacts #9 and
#10, with a jumper across
contacts #8 and #9. Keep
leads short and use heavy
gauge copper extension wire, if necessary, to minimize lead
resistance. For long runs, 3-wire RTDs should be used.
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 panel
ground.
Use wire with a
resistance no greater
than 10 ohms. An error
of 0.2° F will result for
each additional 10
ohms of resistance
encountered. If
shielded RTD wire is
used, terminate the
shield only at panel
ground.
Note: For 2 Wire RTD
Jumper 8 & 9

3
Power Wiring
Figure 7. Process and Linear Input Wiring
Voltage Inputs: Connect the positive
voltage input to contact #10; the
negative input to contact #8.
mV/Current Inputs: Connect the
positive current input to contact
#10; the negative input to #9.
The Series 16 power supply accepts 100 to 250 Vac and 100
to 330 Vdc line power without any switch settings or polarity
considerations. All connections should be made in accor-
dance 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. Be sure that only instrument power input is fused
— not power to the load.
Figure 8. Power Wiring Connection
100 - 250 Vac 50/60 HZ
100 - 330 Vdc (Auto Polarity)
VOLTAGE
CURRENT OR 50 mV
+

4
Output Type Description
B5A/3A (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.
E0-20 mA
F4-20 mA, full output to load with 500 ohm
impedance max. (suppressed).
S20 Vdc pulsed output for solid-state relays.
T1A @ 120/240 Vac , solid-state relay, zero
voltage-switched and optically isolated from
drive signal. Only resistive loads to
may be controlled directly. Larger loads
may be controlled using an external
contactor.
Y5A/3A (120/240 Vac) relay, but normally
closed (output 2 only).
Operation
Athena Series 16 Universal Controller
The Series 16 is a full-function, autotuning PID controller,
calibrated and pre-configured for your application require-
ments, according to the ordering code specified, either as a
temperature or linear process controller. (See page 39 for
specifications and ordering code).
Just a few easy steps are required before the instrument can
be placed into service. After completing the mounting and
wiring procedures as previously instructed, set your individ-
ual process parameter values by stepping through the Series
16’s setup menus, using the simple front-panel keys as
instructed. Then, initiate the autotuning sequence as shown
(or tune manually).
Notes on Outputs
When you ordered your Series 16 controller, a specific output
type was specified, designated as either “B”, “E”, “F”, “S”,
“T” or “Y”. You also had the option of configuring your
controller with either one or two output actions. Generally,
output 1 is a heat (reverse-acting) function and output 2 is a
cool (direct-acting) function. For best results, follow the
recommendations for setting cycle times for the output type
supplied with your controller. A brief description of output
types follows:
Throughout this
manual, instructions
that pertain solely to
the Series 16 process
controller are shown
in blue.

5
Operation
Mode Key Used to access Standby,
Tune, Run or Manual modes.
Lower Key Used to scroll down through
available parameter settings, decrease values
or change menu levels (Hold for fast-step
progression)
Raise Key Used to scroll up through available
parameter settings, increase values or change menu
levels (Hold for fast-step progression)
Parameter/Access Key Used to index through parameters
or to access Menu Levels
After mounting and wiring your
Series 16 controller, you are
ready to set the parameter values
required of your application. Take
a moment to familiarize yourself
with the unit’s front panel con-
trols and indicators.
Process Value
Displays measured
process temperature
in °F or °C or process
value in engineering
units
Setpoint Value
Displays programmed
setpoint temperature
in °F or °C or setpoint
value in engineering
units
Output 1
LED indication
of Heat cycle
(Output 1 action)
Output 2
LED indication
of Cool cycle
(Output 2 action)
Alarm 1
LED indication
of Alarm1 condition
Alarm 2
LED indication
of Alarm 2 condition
Function 1
LED indication of
Special Function 1
Function 2
LED indication of
Special Function 2
Figure 10. Front Panel Controls and Indicators

6
Operation
Power On
When power is first applied to the Series 16, both displays
and all LED indicators are momentarily illuminated. The
Process Value (PV) window then displays [ -At- ] or [ -Ap- ]
and the Setpoint Value (SV) window displays an initialization
code, e.g., [ tf06 ]. The last two digits of this code indicate the
software revision supplied with your controller. Please pro-
vide this revision number when contacting us regarding your
controller. Depending upon whether Setpoint Target Time [
SP.tt ] is enabled, you may also see this symbol: or .
This means that the controller is ramping up or down to set-
point according to its previously programmed parameters.
The default setpoint on initial power up is equal to the
process temperature (process value). Before proceeding
further, wait until the display has stabilized and then use the
Raise or Lower keys to enter or adjust your desired
Setpoint Value.
Parameter Menu Organization
Your Series 16 controller has five distinct menu levels. This
enables quick access to relevant parameters without the need
for scrolling through long menus. Menu “05” is used for
initial controller configuration and menus “02” and “03” are
used for setting or changing parameters. Menus “00” and
“01” are used when the controller is in regular unattended
operation and are not used for setting parameters. For safety
and security purposes, we recommend placing the con-
troller in menu level “00” or “01” when in regular opera-
tion; however, it is not required.
If you wish to “escape” from parameter selection within
these menus at any time, simply press the Mode key
once. A description of the menu hierarchy and a detailed list-
ing of menus and parameters begins on page 15.

7
Operation
Standby Mode
When the controller is placed in Standby Mode, outputs are
disabled; however, access is permitted to all menu levels and,
unless the controller is at Run menu levels “00” or “01”,
operating parameters may still be changed. Use this mode for
tuning the controller. To enter Standby Mode, press and hold
the Mode key for four seconds until the lower window
display flashes [ StbY ]. To exit Standby Mode from Menu
Levels “01” to “05”, press and hold the Mode key for four
seconds until the lower window display flashes [ tUnE ].
(If the Damping setting in menu “02” is [ OFF ], then [HEAt ]
or [ Cool ] will be displayed instead of [ tUnE ]. Press and
hold the Mode key for four more seconds until the lower
window returns to a steady display of Setpoint Value.
(This procedure will not affect tuning). Removing power to
the controller will also take the instrument out of Standby
Mode.
Accessing Menu Levels
To access menu levels from Standby Mode from menu
levels “02” to “05”, press the Parameter/Access key
once. From menu levels “00” and “01”, press and hold the
Parameter/Access key for approximately 11 seconds
until the lower window display alternates between [ Ac.Cd ]
and the menu level number last activated.
You cannot enter
Standby Mode from
menu level “00”.
Follow the instructions
for changing menu
levels to select another
level.

8
Operation
Changing or Displaying
Menu Levels
To change menu levels, access the menu level display as
instructed in the previous paragraph, then use the Raise
or Lower key to set the desired menu level number. To
display the current menu level setting in menu levels “02” to
“05”, from Standby or while adjusting/viewing parameters,
press the Parameter/Access key once. For menu levels
“00” and “01”, press and hold the Parameter/Access key
for approximately 11 seconds.
Because the Series 16’s
initial configuration
affects other menu
levels, it is important
to set all required
parameters in this
menu first before
accessing other
menu levels.
Operation
Menu Level Descriptions
Menu “05” (Configuration Setup)
This is the menu level used for specifying initial configuration
parameters before the controller is placed in Run mode.
After changing the access code to “05” as instructed in the
previous paragraph, press the Parameter/Access key to
step through the various control parameters. Available para-
meters will flash in the lower window display, alternating with
the current value for that parameter. To increase or decrease
the value, simply press the appropriate Raise or Lower
key, then press the key to step to the next parame-
ter. To exit the menu at any time, press the Mode key.
Note: When programming in menu level “05”, all outputs are
disabled; however, any active alarms will remain active until
the alarm condition is removed. New alarm conditions will
not be recognized.
Menu “04” (Communications and Calibration Setup)
This menu is used to set up the controller for digital
communications and for recalibrating the controller. If your
Series 16 controller was ordered with the digital communica-
tions option, set these parameters next. To access this menu
level, follow the instructions previously given.

Menu “03” (Alarm, Timing and Limit Setup)
In this menu, alarms, cycle times, setpoint target time and lim-
its are established. After changing the access code to “03”,
press the Parameter/Access key to step through the vari-
ous parameters. To set or change parameter values, follow the
instructions given previously.
Menu “02” (Control)
Gain, Rate and Reset parameters are automatically set during
autotuning. However, they can be manually adjusted by the
operator. To return the controller to the Run mode, change the
menu level access code back to “00” or “01” as previously
shown.
Menu “01” (Run — Limited Access Mode)
The only parameter that can be changed at this menu level is
the Setpoint Value, using the appropriate Raise or Lower
key. To set or change other parameters, the operator must
access another menu level by pressing and holding the
Parameter/Access key for 11 seconds.
Menu “00” (Run — Key Lock Mode)
This menu is automatically active when power is first applied.
Both display windows are illuminated; however, access is
denied to all parameters. To set or change parameters,
the operator must access another menu level as instructed pre-
viously.
9
Operation

10
Operation
Notes on Alarms
Either [ OUT 1 ] or [OUT 2 ] in menu level “05” (but not both)
may be configured as an alarm [ ALr ] if your Series 16 was
ordered with a “B”, “S” or “T” type of output module. (With
“Y” modules, an alarm may be configured only on [ OUT 2 ])
When one of the two available Outputs is configured as an
alarm, the other Output may be used for control .
When the controller is provided with the Dual Alarm option,
two independent alarms are automatically enabled for both
outputs. DO NOT USE THE [ ALr ] SETTINGS FOR [ OUT 1 ]
OR [ OUT 2 ]. Otherwise, follow the regular instructions for
configuring the Dual Alarms in menu level “05”.
The Series 16 offers a unique capability that provides for the
activation of two software alarms (in addition to the dual
alarms) to monitor a total of four possible alarm conditions.
To enable these software alarms, set the [ OUT 1 ] and [ OUT 2 ]
parameter(s) in menu level “05” to on/off mode [ Ht.O ], [ CL.O
] or [ On.F ]. Set the Setpoint Value to your first alarm point.
Switch to menu level “02” and set Spread [ C.Spr ] [ Spr.2 ]
to the desired deviation value from the first alarm point. Set
[H.HYS] and [C.HYS] to 1. Then switch to menu level “03”
and set the desired values for the third and fourth alarm
points at [ ALr 1 ] and [ ALr 2 ], respectively. Press the Mode
key to resume operation.

11
Operation
Available Alarm Types [ A1.P.d. ] [ A2.P.d. ]
Selectable at menu level “05”, as either Process [ Pr ] or
Deviation [ dE ] and either high or low [ A1.HL ] or [ A2.HL ].
Process Alarm: Activates at preset value independent of
setpoint. “High” process alarm activates at and above alarm
setting. “Low” process alarm activates at and below alarm
setting.
Deviation Alarm: Activates at a preset deviation value from
setpoint. “High” or “Low” deviation alarm activates above or
below setpoint according to the preset deviation value.
Latching Alarms
The Series 16’s alarms may also be configured as latching
alarms by selecting “LAt” in the [ A1.O.P.] or [ A2.O.P.] para-
meter selection at menu level “05”.
When a latching alarm
has been activated and
the alarm condition
has been removed, the
Mode key must be
pressed to unlatch the
alarm.

12
KEY
LOCK
SETPOINT
MENU 0 MENU 1 MENU 2 MENU 3 MENU 4 MENU 5
Figure 11. Series 16 Controller Menu Hierarchy
With heater break
option, [id.no] changes
to [Ht.rd]; [baud]
changes to [Ht.SP]
in menu level “04”.
= temperature
controller only
= process
controller only
= temperature and
process controller

13
Parameter
Descriptions
Series 16 Temperature/Process Controller
Menu “05”
Display Parameter Selection Code
SnSr Sensor type Thermocouple:
Kc.A
JJ
Nn
Rr
Tt
SS
Platinel II PLII
RTD P
RTD (decimal range) d
OUt1 Output 1 action Heat PID Ht.P
Heat On/Off Ht.O
Alarm ALr
OUt2 Output 2 action Cool PID CL.P
Cool On/Off CL.O
Alarm ALr
SN.00 Input Zero Level (0-20mA) U.Su (Unsuppressed)
(4-20mA) Su (Suppressed)
Dec.P Decimal Point 999, 99.9, 9.99
FILt Digital Filtering 0.1, 1, 10
OUt1 Output 1 action PID Pid
On/Off On.F
Alarm ALr
OUt2 Output 2 action PID Pid
On/Off ON.F
Alarm ALr
The Digital Filtering
setting [ FILt ] on the
Series 16 process con-
troller allows the oper-
ator to compensate for
noise which may cause
the last digits of the PV
display to become
unstable. Sampling rate
is not affected. The set-
tings are time con-
stants, in seconds, with
0.1 equivalent to “no
filtering.”

14
Parameter
Descriptions
With the Heater Break
Alarm option, [ Id.no ]
changes to Heater
Current Reading
[ Ht.rd ] (indication
only) and [ bAUd ]
changes to Heater
Break Alarm Setpoint
[ Ht.SP ] (indication
only, either 00-30 A or
00-60 A).
CoL.t* Cooling type Water H2o (non-linear output)
Normal nor (linear output)
A1.H.L. Alarm 1 select Enable Lo/HI
A1.P.d. Alarm 1 type Process/Deviation Pr/dE
A1.O.P. Alarm 1 output Off/Normal/Latching OFF/nor/LAt
A2.H.L. Alarm 2 select Enable Lo/HI
A2.P.d. Alarm 2 type Process/Deviation Pr/dE
A2.O.P. Alarm 2 output Off/Normal/Latching OFF/nor/LAt
Unlt Measurement units °F or °C F/C
* For water-cooled extruders, select H2o.
Menu “04”
Display Parameter Allowable Values
Id.no Device ID number 00 to 99
(remote communications)
bAUd Baud, parity and See chart below
data bit selection
CAL.L Calibration low Preset at factory
CAL.H Calibration high Preset at factory
Available Communications Settings
Display Description
Baud Rate Parity Data Bits Stop Bits
3.o.7 300 odd 7 2
6.o.7 600 odd 7 2
12.o.7 1200 odd 7 2
24.o.7 2400 odd 7 2
3.n.8 300 none 8 1
6.n.8 600 none 8 1
12.n.8 1200 none 8 1
24.n.8 2400 none 8 1

15
Parameter
Descriptions
Menu “03”
Display Parameter Allowable Values
ALr1 Alarm 1 preset Dependent on sensor range
ALr2 Alarm 2 preset Dependent on sensor range
(if ordered)
CY.t1 Cycle time output 1 00 to 120 seconds
CY.t2 Cycle time output 2 00 to 120 seconds
SP.tt Setpoint target time Off/1 to 100 minutes
(ramp-to-setpoint)
L.SP.L Lower setpoint limit Dependent on sensor range
U.SP.L Upper setpoint limit Dependent on sensor range
L.SCL Low scale setting -1999 to 9999
H.SCL High scale setting -1999 to 9999
Output Type Recommended Setting (seconds)
B (5A/3A) 15 to 120
E (0-20 mA) 00
F (4-20 mA) MUST be set to 00
S (pulsed 20 Vdc) 00 to 120
T (S.S. relay) 15 to 120
Y (5A/3A) N.C. 15 to 120 (Output 2 only)
Setting output cycle
time to “00” initiates
a 200 ms timebase. A
cycle time setting is
required for smooth
proportional action.
Too long a setting will
cause proportional
ripple; too short will
decrease relay contac-
tor life.
When changing
thermocouple types,
be sure to check/adjust
upper and lower set-
point limit values.
Notes on Setpoint Target Time: The [ SP.tt ] parameter allows the operator to enter a time delay for the
process to reach setpoint temperature (ramp to setpoint), from disabled [ OFF ] or 1 to 100 minutes. When
enabled, the ramp sequence starts on power-up. The ramp-to-setpoint feature will also be initiated whenever a
new setpoint target time is entered AND the Setpoint Value is 5° F or more from the current process temperature.
In operation, the controller’s lower window display will flash or to indicate that it is “ramping” up or
down to setpoint. The Setpoint Value cannot be changed during this procedure. After it is finished, the operator
can adjust the setpoint temperature to the desired value.
While in ramp startup, the ramp-to-setpoint mode can be aborted and the controller returned to regular
operation by pressing the Parameter/Access key until parameters are displayed and then pressing the
Mode key once.
Note: Shorter cycle times
may be used when driving
heater loads directly.

Figure 12. Typical Lag Processes
Immersion Heater
a. Single Lag
Strip Heater
Strip Heater
Tank Wall =
Thermal Resistance
Thermal
Resistance
Thermal
Capacity
Thermocouple
in Well
b. Two Lag
c. Three Lag
a
1
. Single Lag with
Dead Time
Lag
T/C2
T/C1
T/C
Flow
Flow
Flow
Parameter
Descriptions
Menu “02”
Display Parameter Allowable Values
Gn.o1 Gain Output 1 00 to 400
(PID heat gain)
Gr.o2 Gain Ratio Output 2 0.0 to 2.0
(PID cool gain ratio)
H.HYS Heat Hysteresis 01 to 100°
C.HYS Cool Hysteresis 01 to 100°
HYS1 Output 1 Hysteresis 1 to 100 units
HYS2 Output 2 Hysteresis 1 to 100 units
SPr.2 Spread Adjustment, Output 2 0 to 100 units
C.SPr Cool Spread 0 to 100°
rAtE PID rate 00 to 900 seconds
rSEt PID reset 00 to 3600 seconds
dPnG Damping (see notes) Lo, nL, Hi, Off
Setting Rate (Derivative)
or Reset (Integral) to
[ 00 ] disables that
aspect of PID control.
The ratio for non-zero
settings of rate-to-reset
is limited to a minimum
of 1:4, i.e., Reset value
cannot be set any lower
than four times Rate.
The parameters of Heat
Hysteresis, Cool
Hysteresis and Cool
Spread are only avail-
able when Output 1
and/or Output 2 are set
to on/off mode [Ht.O] or
[CL.O]. They replace
Gain Output 1 and
Gain Ratio Output 2,
respectively.
Notes on Damping: The damping parameter is an autotune feature that
enables more precise control of setpoint overshoot during recovery from
process upsets in which thermal or transfer lag is a factor. See Figure 12.
Use the correct setting prior to autotuning to compensate for power and
load/sensor coupling characteristics.
Lo = Fast recovery with slight overshoot. For single-lag processes.
Ex. Adequate power and excellent load/sensor coupling.
nL = Normal recovery with no overshoot. For two-lag processes.
Ex. Properly sized heaters or components and good load/sensor
coupling.
Hi = Slow recovery with no overshoot. For three-lag processes.
Ex. Overpowered with multiple lags. Poor load/sensor
coupling.
Off = Autotune disabled; manual output control.
(This value may
exceed 400 during
autotuning.)
16

17
Tuning
Procedures
Introduction
The Series 16 is an “on demand” autotuning controller that
automatically sets PID parameter values (Proportional Band,
Reset and Rate) before the process reaches setpoint. A damp-
ing setting (menu level “02”) MUST be selected for autotuning
to take place. (see Notes on Damping, page 19). The con-
troller may also be tuned manually (see page 20).
Autotuning the Series 16 Temperature
Controller
1) With the power off and the process at ambient, apply
power and immediately put the controller in Standby mode
by holding the key for four seconds until [ StbY ]
flashes in the lower display window.
2) Enter the desired Setpoint Value using the appropriate
Raise or Lower key. [ StbY ] will continue to flash.
3) If controller is in menu level “00” or “01”, hold the
Parameter/ Access key for 11 seconds until [ Ac.Cd ]
appears. Then change to menu level “05”. Otherwise,
press the key once and use the key to select
menu level “05”.
4) Press the Parameter/Access key twice until [ SnSr ] is
displayed to make sure that the proper sensor has been
selected. Then set the controller’s heating mode or alarm
functions by pressing the Parameter/Access key again
until [ OUt1 ] is displayed. (If you scroll past it, just
continue scrolling until the parameter menu repeats.)
Using the appropriate Raise or Lower key, select
the one of the following settings according to the require-
ments of your process. Note: For autotuning, at least one
output MUST be set to PID mode.
Mode Output 1 (Heat) Setting Output 2 (Cool) Setting
PID [ Ht.P ] [ CL.P ]
On/Off [ Ht.O ] [ CL.O ]
Alarm [ ALr ] [ ALr ]
Press the Parameter/Access key again to step to out-
put 2 [ OUt2 ]. Repeat the selection process for cooling
mode or alarm. (If only one output is PID, set the other
output to either On/Off or Alarm.)
For best results in
tuning the temperature
controller, the setpoint
value should be at least
100° F above or below
ambient temperature.
While some processes
other than heat or cool
applications may
respond successfully to
autotuning procedures,
the controller must be
manually tuned for
most non-temperature
processes.