Athena 4000 Series User manual

 4000



2
Introduction
Precautions
Congratulations on your purchase of an Athena® Series 4000. It is a U.L. listed, 1/4-DIN digital indicating
temperature controller for use in a variety of applications. The Series 4000 is more accurate than an
analog unit, and, most importantly, the digital indicator eliminates parallax errors and operator interpolation,
problems common to full scale analog controllers.
If you have questions or require any assistance with your controller or with any temperature control problem,
please contact your Athena representative.
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.
Locating
Select a location for the controller where it will not be subject- ed to excessive shock, vibration, dirt, moisture
or oil. The ambient temperature of the area should be between 30° and 130° F. (Dust, oil, water resistant
cover is available to protect from harsh environments. Contact factory for details.)
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 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.
Approvals
E66598 Temperature Indicating and
Regulating Equipment.
E66598 Temperature Indicating and
Regulating Equipment.

3
Table of Contents
Preliminary Instructions 2
Mounting 4
Output Configurations 4
Power Wiring Circuits 4
Thermocouple Wiring Circuits 6
RTD Wiring Circuits 6
Thermocouple Placement 7
Operation 7
Front Panel Layout 8
Output Function Switches 8
Adjustments 9
Maintenance 10
Specifications 11
Ordering Codes 12
Troubleshooting 12
Warranty 14
Unit Repairs 14
DATE DESCRIPTION REVISION
TITLE
DWG
DATE SCALE DRAWN CHECKED
Model 4000 Operation Manual
900M508U01
3/15/2020 A

4
Mounting
Measurements between centerlines of panel cutouts are the minimum recommended.
Power Wiring
Circuits
Mount controller into 92 mm (3-5/8”) square cutout (1/4-DIN). See Figure 1 for cutout and case dimensions.
The plug-in controller does not have to be removed from its housing for mounting.
Remove the two screws in the back of the case that hold the mounting slides, and then remove the slides.
Insert case from front of panel and reinstall the two slides and two screws. The length of the slides must be
reduced if the controller is to be mounted in an extra thick panel. If the controller has been unplugged from
its housing, the top of the housing can be determined by the serial number tag.

Consult serial tag on the unit and select power wiring diagram for the model specified. All wires are connect-
ed to the terminals on the back of the case. Screw terminals are provided. Make appropriate connections
using proper size wire for rated controller load power circuits. (On -B output model, use AWG #14 wire; for
-F, -S and -T outputs use #14, 16, or 18 wire.) The unit can be supplied with 120 V or 240 Vac, 50/60 Hz.
Select proper terminal for the voltage used.
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 4000 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 1: Cutout and case dimensions
Type “B” Relay with 7 A at 120 V and 5 A at 240 V contacts, on-o󰀨 and time proportioning
Type “F” Signal current, 4-20 mAdc
Type “T” Solid state relay 1 A, 120/240 V resistive load; 1 A, 120/240 V, 10 A inrush, inductive load
(not U.L. rated)
Type “S” Pulsed 20 Vdc, for driving solid state relays
Output
Configurations

5
Wiring
Typical Wiring Diagrams for -T & -B Outputs
B-Type -
840 W maximum. 120 Vac heater. (Non-inductive loads only) For larger loads, replace heater connections
with contactor, as required. Maximum inductive load rating is 3 A at 120 V and 1.5 A at 240 V. The N.C.
contacts can be used for cooling. Note: For 240 Vac supply move the connection shown on terminal 9 to
terminal 10 and fuse both of the supply legs.
T-Type -
solid state relay with SPST contacts. The -T units can handle contactors or resistive loads up to 1 A with 10 A
inrush maximum. For -T units use a 1 A, 250 V fast blow fuse.











Figure 2. Typical 120 Vac for -B & -T Output

6
Wiring
-F, -S Output - 120/240 Vac
The -F output is 20 mA at the low temperature end of the proportional band and 4 mA at the upper end of
the proportional band. Maximum load resistance is 1000 ohms.
The -S output is a time-proportioned 20 Vdc signal. These controllers cannot be used with a device that
does not have an isolated input. An ungrounded thermocouple must be used if there is ac leakage or a
ground in the input of the device connected to the controller’s output.
Thermocouple
Wiring
Circuits
Use thermocouple and extension wire that conforms to the appropriate thermocouple type specified on the
serial number tag. In thermocouple circuits, the negative lead is colored red. Extension wires must be of suf-
ficient size so that on long runs the thermocouple circuit resistance does not exceed 100 ohms.
Do not run thermocouple leads in the same conduit as the power lines. If shielded thermocouple wire is
used, terminate the shield only at the controller end using the corner screw provided for that purpose.
Standard Thermocouples
I.S.A. Type Materials Color Code (U.S.A.)
J Iron-Constantan (I/C) White (+)/Red(-)
K Chromel-Alumel (C/A) Yellow (+)/Red (-)
T Copper-Constantan Blue (+)/Red (-)
Figure 3: Typical 120/240 Vac for -F & -S Output
RTD Wiring
Circuits
The 4200 units are designed for 100 ohm platinum RTDs. Two-wire RTDs are connected to terminals -1
and -2 with a jumper connecting 2 to 3. Keep leads short and use heavy gauge copper extension wires if
necessary, to minimize lead resistance. For long runs 3-wire RTD should be used and wire gauge should be
sufficient that resistance does not exceed 10 ohms.
DO NOT RUN RTD LEADS IN THE SAME CONDUIT AS POWER LINES.
If shielded RTD wire is used, terminate the shield only at the controller end, using the corner screw provided
for that purpose.
NOTE:





7
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 little 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 can often
provide optimum results.
In a bath process, the addition of a stirrer will help to eliminate lags. Since the thermocouple is basically a
point measuring device, putting more than one thermocouple in parallel will provide an average temperature
reading and produce better results in air-heated processes.
Operation
The typical control system contains the sensor, controller and the process (load). The sensor produces
a small signal proportional to the measured temperature of the process. This signal is amplified by the
controller, where it is compared with setpoint temperature. If the temperature of the sensor is below setpoint,
the output circuitry will be actuated to apply power to the process. This is indicated by means of an LED light
in the lower center of the front panel. The deviation meter will swing to the extreme left. It will remain there
until the temperature of the probe rises to within 50 °F of setpoint, and then will continue to rise to the null
point (zero degree deviation). The deviation meter accurately displays the difference between the probe’s
(process) temperature and the desired setpoint temperature.
-B - Relay Output
The “B” output is a relay rated at 7 A, 120 Vac and 5 A, 240 Vac. These contacts can be wired to provide
power to a heater within the above rating. A contactor can be operated to handle a larger load. Solenoids
can be operated to control oil or gas heaters.
The controller operates as a narrow band controller when the band adjustment is set at the narrow position.
As the band is widened, the unit becomes a time-proportioning controller, which provides close temperature
control. The percentage of the time when the relay is energized is varied by the controller to meet the load
requirements.
NOTE: To reach the plug-in module, push reset button while opening the door, and then remove two (2)
screws.
Maximum cycle time setting is 15 seconds.
-F - Current Output
Current proportional output of the -F unit is a 4 to 20 mAdc signal into 1000 ohm maximum. This output can
be used to drive power controllers, motor positioners or electropneumatic actuators.
-S - Pulsed Voltage Output
This output is similar to the -F output with the exception of a pulsed time base rather than a fully proportional
current output signal. This output is designed to drive solid state contactors.
-T - Solid State Output
The -T output unit has a solid state relay with SPST contacts rated at 1 A, 120/240 Vac (10 A inrush
maximum). These contacts can be wired to provide power to a heater within the above ratings, and a
contactor can be added to handle larger loads. Solenoids can be operated to control oil or gas heaters.

8
Layout of the front panel is shown below. To reach the adjustments, swing the top of the door forward and
down. The proportional band adjustment is on the right side and sets the gain of the controller. The offset
(manual reset) adjustment is on the left and corrects for offsets from the setpoint temperature. The output
indication (LED) can be seen through a window in the door.
Units ordered with Option A (3-Mode PID) will not have a manual reset adjustment. Instead, these units
have an automatic rate adjustment and reset selector switch on the internal 3-mode board.
Front Panel
Layout
Figure 4. Wiring for Relay Normally Open Alarm Output
Figure 5a. Bottom board illustration Figure 5b: Output Function Switch Chart
NOTE:





Output Function
Switches
—Switch No. 4 in “ON” position is for “B” or “T” outputs when driving mechanical devices such as
contactors.
—Switch No. 4 in “OFF” position is for “T”, “F”, or “S” outputs when driving devices that can withstand rapid
cycling, such as solid state devices , solenoids, etc.
Figure 5. Output Function Switch Chart

9
Configuring
Output Function
Switches
There is a switch assembly on the bottom board (see bottom board illustration). This four-position switch
regulates cycle time and output selection. It is factory-configured for the plug- in output ordered. Check the
output function chart to make sure the configuration is correct for your application.
Switches 1&2: These switches act together to select either proportional current output or one of the time
proportioning cycle times. (See the output function switch chart.) Use longest times to get
best relay life expectancy. If meter shows temperature swings following each “on” cycle,
select a faster time to reduce “ripple.”
Switch 3: Selects either on/off or proportional action. “On” provides proportional action. “Off”
provides on/off action.
Switch 4: Selects output for either mechanical or solid state relays.
: Provides slow proportional times for mechanical relays
  : Provides 20 mAdc when used with the “F” module or fast time proportioning
times when used with “S” or “T” modules
Proportional
Band
Adjustments
For All Outputs
The proportional band adjustment widens or narrows the band over which proportional action occurs. Too
narrow a band can cause the temperature to swing about the setpoint. This can be seen on the deviation
meter. Too wide a band can cause an error between the setpoint and the actual temperature (droop error) as
measured at the sensor.
Proper setting of this adjustment is the point where the temperature swings just stop. When adjusting the
proportional band control, do so in small increments, allowing time between each adjustment for the process
to stabilize.
Turning the adjustment in a clockwise direction widens the proportional band and should reduce swings to
straight line control with most processes.
Offset
(Manual Reset)
Adjustment
After the proportional band is set, the process temperature may stabilize at a point other than the setpoint,
high or low, as shown on the display. This can be corrected with the offset (manual reset) adjustment.
If the deviation meter indicates a low temperature, turn the offset (manual reset) adjustment clockwise (+
direction) until the display is correct.
Turn the offset (manual reset) adjustment counter-clockwise (- direction) for high temperature as indicated by
the display.
For applications requiring multiple setpoints over wide temperature spans, some automatic droop
compensation can be achieved by cutting jumper “A” (See bottom board diagram for location, Figure 5).
NOTE:





Deadband
Adjustments
An adjustable 0 to 5 degree deadband can be accessed by setting switch #3 to off and cutting the jumper
next to the manual reset pot.(See Figure 5.) The band can be adjusted using the proportional band
adjustment.
NOTE:




10
Some preventive maintenance steps on the controllers are:
1. Keep the controller fairly clean, and protect it from dirt, oil, and corrosion. An optional dust cover is
available for use in hostile environments.
2. Periodically recheck all electrical connections
Installation
The Series 4000 is available with optional plug-in PID. To install this option in the field, simply plug the
3-mode card into the connector located next to the output module socket and then cut jumpers (2) labeled
M (see bottom board drawing for location, Figure 5).
How to Set 3 Mode (PID) Action
3-Mode (PID) action automatically corrects for errors in proportionally controlled processes.
1. For slow processes, move the switch located on the 3-mode board to slow (S), proportional band
wide, and go to step 4; otherwise:
2. Set the switch to the fast position (F) for very fast and/or low mass processes. Use the middle
position for most others as a first try.
3. Set the proportional band located on the front panel to full wide (270 degrees clockwise).
4. Plug controller in. Turn your process on.
5. Observe warm-up. If it takes the process too long to reach the setpoint, make the switch setting
faster. If, on the other hand, it overshoots the setpoint by an amount that is not acceptable, a
slower switch setting should be tried.
6. Turn proportional band pot 1/4 turn toward narrow (counter-clockwise). Process could begin to
oscillate again. If it doesn’t, proceed to step 7. If it oscillates, back up 1/8 turn clockwise.
7. Tighten proportional band by turning the pot counter-clockwise. Observe the process. If oscillation
continues, widen back by 1/8 turn. Continue until the process stabilizes.
Maintenance

Optional 3 Mode
(PID)
NOTE:


























How To Set
The Auxilliary
Output
(Optional)
Deviation Type: B, C or D
The Deviation auxiliary output is triggered when the temperature deviates from the main setpoint by a preset
amount. Units can be ordered with high, low or common high/low trip points.
Full Scale Type: E
The full scale auxiliary output is triggered when temperature goes above its setting. The setting can be
placed anywhere within the span of the unit.
Setting
To set either type or auxiliary output press and hold the “read” switch to the left. The display will indicate the
present setting. Adjust set II to the desired trip point in either actual or deviation degress, whichever applies.
The output on terminals 5, 6, and 7 will be energized when the auxiliary setting is exceeded.