Athena 6075 series User manual

SERIES
6075
TEMPERATURE CONTROLLERS
WITH AUTO-TUNING PID AND
PLUG-IN COMPUTER INTERFACE

Warranty Limitations
Other than those expressly stated herein,THERE ARE NO OTHER
WARRANTIES OF ANY KIND, EXPRESS OR lMPLlED, AND SPECIFI-
CALLY EXCLUDED BUT NOT BY WAY OF LlMlTATlON, ARE THE
IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE
AND MERCHANTABILITY.
IT IS UNDERSTOOD AND AGREED THE SELLER’S LIABILITY
WHETHERINCONTRACT,INTORT, UNDER ANY WARRANTY, IN
NEGLIGENCE OR OTHERWISE SHALL NOT EXCEED THE RETURN
OF THE AMOUNT OF THE PURCHASE PRICE PAID BY THE PUR-
CHASER AND UNDER NO CIRCUMSTANCES SHALL 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,
REGARDLESSOFFORM,ARISINGOUTOFTHETRANSACTIONS
OF THIS AGREEMENT MAY BE BROUGHT BY PURCHASER MORE
THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED.
SELLER’S MAXIMUM LIABILITY SHALL NOT EXCEED AND BUYER’S
REMEDY IS LIMITEDTO 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
PRlCE, AND SUCH REMEDY SHALL BE BUYER’SENTIREAND
EXCLUSIVE REMEDY.

SERIES 6075
AUTO-TUNING PID TEMPERATURECONTROLLER
CONTENTS
PAGE
SECTION 1 GENERAL INTRODUCTION . . . . . . . . . 1
1.1 GeneralDescriptionandCautions . . . . . . . . . . . . . . . . . . . . . . 1
1.2Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3ModelNumberIdentification . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 INSTALLATION INSTRUCTIONS . . . . . 5
2.1 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Locating. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Removing Unit. . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Case Dimensions. . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 OUTPUT MODULES. . . . . . . . . . . . . . . . 7
3.1ModuleDescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 4 BASIC WIRING. . . . . . . . . . . . . . . . 8
4.1 Typical Wiring Examples. . . . . . . . . . . . . . . . . . . . 8
4.2 Wiring Thermocouple and RTD Circuits. . . . . . . . . . . . . . 9
SECTION 5 OPERATION. . . . . . . . . . . . . . . . . . . 12
5.1 Front Panel Features. . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Tuning The Controller. . . . . . . . . . . . . . . . . . . . . 20
5.3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.2 Automatic PlD Tuning Procedure. . . . . . . . . . . . . . . 20
5.3.2.1 Damping
Settings. . . . . . . . . . . . . . . . . . . 20
5.3.2.2OperatingInstructions. . . . . . . . . . . . . . . . . . . . . 21
5.3.3 Manual Tuningprocedure. . . . . . . . . . . . . . . . . . . . . . 22

SECTION 6 COMMUNICATIONS . . . . . . . . . . . 26
6.1Communications Modules . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.1 RS485. . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.2
RS232C. . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.3 20 mA Current Loop. . . . . . . . . . . . . . . . . . . 27
6.2 Installing the Communications Modules. . . . . . . . . . . . . 28
6.3 Interface Examples. . . . . . . . . . . . . . . . . . . . . . 30
6.3.1ReadData. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.2 Modify(Temporary). . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3.3Modify and Store. . . . . . . . . . . . . . . . . . . . . . . . . . . .32
SECTION 7 CALIBRATION. . . . . . . . . . . . 33
7.1 Zeroand Span Adjustments. . . . . . . . . . . . . . . . . . . . . . . 33
(Factory Set)
SECTION 8 TROUBLESHOOTING. . . . . . . . . . . . 34
8.1Troubleshooting-General. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2 Troubleshooting - Communications. . . . . . . . . . . . . . . . 35
FIGURES
1.1 Ordering Code - Model Number. . . . . . . . . . . . . . . . 4
2.1
Series 6075 Dimensions. . . . . . . . . . . . . . . . . . . 6
4.1 Wiring Examples. . . . . . . . . . . . . . . . . . . . . . 8
5.1 6075 Front Panel Features. . . . . . . . . . . . . . . . . . 13
5.2
Configuration Code Chart. . . . . . . . . . . . . . . . . . . 17
5.3 Ziegler -Nichols Graph. . . . . . . . . . . . . . . . . . . . 23
6.1 Connector Pin Identification. . . . . . . . . . . . . . . . . . . . . 28
6.2 Wiring for Communications. . . . . . . . . . . . . . . . . . 29
z

GENERALINTRODUCTION
SECTION 1
1.1
General Description and Cautions
AthenaControls, Inc. is proud of the Series 6075 which you will now use It
hasbeenmanufacturedtoour exacting productionstandards,andpacked
for maximum protection in shipment You will get years of reliable service
fromtheunitiftheinformationinthemanualisfollowedregardinglocation,
adjustments,andgeneraloperation.
CAUTlON
High Voltage and High Temperature can cause injury and are a
FireHazard.Pleasereadallinstructions,haveonlyskilledprofes-
sionals wire the unit, and use an approved temperature and/or
pressure safety control. Even the best components can be
damaged or may not failsafe.
WarningNotes:
1. "B" Outputforresistanceloadonly.
2. Anopen thermocouplewill disablethe INDEXfunction.
3.
Note also that in units utilizing only heating output the cooling gain
should be set by user to the equivalent heating gain. The inverse IS
also true.
4. A unique algorithm in the Model 6075 prevents continual buildup of
oscillationdue to grosslymisadjusted rate/reset (-rt-) or gain. When
thisoccurstheunit will control at somepoint higherorlower thanset
point outsidetheproportionalband.Ifthisoccurs -rt- wasprobablyset
too low and/or gain set too high.
5.
-rt- sets Rate (Derivative) and Reset (Integral) action. The number dis-
playedistheRatetimeinseconds.ThisistrackedbytheResettimein
seconds (1:6 ratio).

SECTION 2 INSTALLATION INSTRUCTIONS
2.1 Unpacking
Unpack the instrument and inspect for shipping damage. Report any
damage to the carrier immediitely.
2.2 Locating
Select a location for the controller where it will not be subject to excessive
shock vibration, dirt moisture or oil. The ambient temperature of the area
shouldbebetween 32º and131 ºF (A model DC-15 dust,oilandwater resis-
tantcoverisavailabletoprotectfromharshenvironments.)
2.3 Mounting
Mountthecontroller intoa92 mm (3 5/8”) squarecutoutSeefigureforthe
cutout and case dimensions. The plug-in controller does not have to be
removedfromitshousingformounting.Removetwoscrewsthatholdthe
mountingslides andthenremove theslides. Insertcase fromfrontpanel
and re-install thetwoslidesandtwoscrews.Donotover-tightenscrews.The
lengthoftheslidesmustbereducedifthecontrolleristobemountedinan
extrathick panel. Ifthecontrollerhasbeenunpluggedfromitshousing,the
topofthehousingcan bedeterminedbecause itfeatures theserialtag.
2.4
Removing Unit
The 6075 can be removed from its housing by pulling firmly on the black
front bezel. If a communication port is connected, it should be removed
first

SECTION 3 OUTPUT MODULES
3.1 Module Description
The Athena 6075 offers 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
7A/5A relay (at 120/240 Vac) is used for driving resis-
tive heaters. NOTE:
Do not use this output module with mechanical
contactors
because they generate an excessive EMI field which can interfere
with the
6075’s microprocessor, Instead, we recommend “T’
output modules for this application
Module Type
F: This 4-20mA output module can deliver full output to loads
having an input impedance of 500 Ohms or less. The cycle time setting
must be ZERO for smooth current output.
Module Type S: Similar to
F. but pulsed 20 Vdc output 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.
“F’ & “S” MODULE NOTE:
A push-on terminal is utilized as a return for ground currents of
the
milliamp source. It is connected internally by the mating lug
on the circuit board. To avoid ground loops, drive floating
(ungrounded) loads.
Module Type T: This solid state relay is capable of 1 amp at 120/240 Vac. It is
zero voltage switched and
optically isolated from the drive signal. With it
resistive loads up to
I20 watts at I20 Vac and 240 watts at 240 Vac may be

StandardThermocouples
I.SA. Type
Materials
Color Code
J Iron-Constantant (I/C)
White( + ) Red( - )
K Chromel-Alumel
Yellow( + ) Red( - )
T
Copper-Constanan
Blue( + ) Red( - )
Platinum-Platinum 13%Rhodium -
Platinum-Platinum 10% Rhodium
-
Wiring RTD Circuits
6275 units are designed for 100 Ohm Platinum RTD’s 2-wire RTD’s are
connectedtoterminals 1 and 2witha jumperconnecting 2to 3.Keepleads
shortand useheavygauge copper extensionwiresifnecessary,tominimize
leadresistance. For longruns 3-wire RTDshould beusedandwiregauge
shouldbesufficientthatresistancedoesnotexceed10Ohms.Anerrorof
0.2ºF will result for each additional 10 Ohms Per lead
DO NOT RUN RTD LEADS IN IN THE SAME CONDUIT AS POWER LINES.
IfshieldedRTDwireisused,terminatetheshieldonlyatthecontrollerend,
usingthe comerscrew providedforthatpurpose.
NOTE RTDs tend to beshock sensitive andrequire extracarein handling
and installation.
THERMOCOUPLE PLACEMENT (or RTD)
Proper thermocouple placement can eliminate many problems in the sys-
tem. The probe should be placed so that it can detect any temperature
change with minimal thermal lag. In a process that requires fairly constant
heatoutput,the probeshouldbeplaced closetothe heater.Inprocesses
whereheatdemandisvariable,theprobeshouldbeclosetotheworkarea.
Some experimenting with probe location is often needed to find its
optimum Position.
A WORD ON ELECTRICAL NOISE
Microprocessor are essentially small computers. As such they can
randomlybe interferredwithbylargeelectrical spikes,even withelaborate
10
R
S

watchdogcircuitsandfilteringbuiltintotheunitContactsandcoilsmustbe
suppressed!Onevery effective filteris a .1 ufd/600V capacitor in series with a
100Ohm, 1/2 watt(min.)resistor.Thisnetworkmustbeputonallcontacts,
especiallyacrosshardcontactsthatareswitchingcoilsandacrossthecoils
themselves. The filter should be placed as close to the noise source as
Possible i.e. right on a contactors coiletc.
Otherrecommendedpracticesinclude:
* Runsensorwiresseparately,shieldifpossibleandgroundonlyoneend
oftheshield.
* Install .01 ufd/100V or greater capacitors from each sensor terminal to
caseground(the greenscrew).
* Connect each unit’s ground (the green case screw) directly to the machine
(ground). Do not connect it to the panel Paint and corrosion can cause
poor signal transmission Do not connect ground wires in series from
unit to unit Ground wires must be connected from each unit directly
to ground
* Make sure the machine is connected to earth ground Do not assume
it is.
11

SECTION 5 OPERATION
5.1 Front Panel Features
TouchKeyandIndicationOperationLayout
1.
2.
3.
4.
5.
6.
7.
Process Temperature or Parameter code is viewed on the upper
display.
SetPointorParametersettingisviewedonthelowerdisplay.DegreesF
andCisalsodisplayed.
Set Point Key: Allows user to return to set point
ENTER/TUNE Key: Enters a selected value into nonvolatile memory.
AlsoinitiatesAuto-Tuningwhenused inthecorrectsequence.
UpandDownKeys:Raisesandlowerssettingrespectively.2Stepscan
rate:Slow and Faster(after 5seconds).
Index Key: Selects Parameters to be addressed
STAND-BY/CANCEL Key: Disables outputs. Unit is put in idle mode.
LEDabove switch lights in STAND-BY mode. STAND-BY is also used
as the position from which AUTO-TUNE is accessed. If the key is
pressedduringAuto-Tuningtheunit will cancel the Auto-Tuning pro-
cedure and return to the STAND-BY mode.
8. Receive(RX) and transmit (TX)lights:Indicateasignalispresentatthe
communication port tights only momentarily
9. Heat (HT)a nd CooI (CT) Output Lighk Lights when output drive signal
is present
10. Alarm Lights (A1 and A2): Lights when unit is in alarm. (programmable
Hi,Low,processordeviation.)
12

5.2 Basic Series 6075 Setup
1. The 6075 has dual-input ranges which allow selection of one of two
ranges and T/C types, by simply moving the position of the internal
jumper.
Tosetunittoproperrange,removeunit fromcaseandposition jumperon
top board. Front position is range A, rear position is range B, grouped s
offered.
A = 01F No Jumper = 26F A = 33F A = 22F No Jumper = 22C
B = 02F B = 32F B = 26C
Consult Serial Tag for actual range and sensor type ordered. Ranges
are defined in Section 1.3, Model Number Identification.
The Series 6075 is shipped from the factory with the following settings:
SP = 100 CG = 30 Id = 01
A1 = 105 CC = 05 (F=00) bd = 02
A2 = 95 cd = 08 cL = Range dependent
rt = 00 AT = 00 cH = Range dependent
HG = 30 cF = 08 (05 for ºC ranges)
HC = 05 (F=00) ct ct = 00
14

2. . RangeofAdjustments(Parameters)
All parametersareaccessed bypressingtheINDEXkey. They are listed
in the order they are displayed when the lNDEX key is pressed.
Thefront panelof the Model6075 containsa lowerdisplay of5 digits
whichdisplaysthesetpointtemperature,the otherparametervalues
anddegreesForC.Theupperdisplayconsistsof4digitswhichdisplay
the process value or the parameter abbreviations; e.g. -A1- identifies
Alarm 1. As the INDEX key is pressed the second column abbreviations
appear in the upper display. To the right of the ENTER Key is an EXIT
Key labelled ‘SET POINT’ which allows the user to EXIT parameters 2
thru 16 back to parameter # 1 (set point). After changing a value the
ENTERKeymustbepressed.Thisentersthenewvalueinmemory.Ifit
is not pressed and power is removed, the last value entered for that
parameter will be set up for that parameter.
DlSPLAYED
NUMBER CODE PARAMETER
RANGE
0 ProcessTemperature Zero to span of
unit (ºF or ºC)
1
SetPoint
Zero to span of
unit (ºF or ºC)
2 -A1- Alarm One
Zero to span of
unit (ºF or ºC)
3
-A2-
Alarm Two Zero to span of
unit (ºF or ºC)
4
-rt- Rate/Reset (1:6 ratio) 0 to 255 Seconds
5
-HG-
6
-HC-
7
-CG-
8 -CC-
9 cd-
Heat Gain
HeatCycleTime
Cool Gain
CoolCycleTime
AccessCode
(See Note 6)
(See Note 2)
0 to 120 Seconds
(See Note 7)
0 to 400
(See Note 2)
0 to 120 Seconds
(See Note 7)
0 to 255
(See Note 3)
15
-
-
1 to 400

Locally Adjustable only (Not by Remote Keyboard)
10
-At-
Auto-Tune Damping
0=Low, 1 =normal,
2=High
11 -cF- Configuration 0 to15
(See Note 4)
12xx -ct-
CoolingType
0-Oil ornone,
1 -Air, 2-Water
13 -Id-
Unit ID CODE 0 to 99
(See Note 5)
14
-bd-
BaudRates
300(0),600( 1)
1200(2), 2400(3)
15 -cL- Calibration, Low ±3% Span
(ZERO)
(°F/ºC)
16
-cH-
Calibration, High
±3% Span
(SPAN)
(ºF/ºC)
xx Not on RTD units
When setting up the unit for the first time, push the “STAND BY" key
(LEDabovebuttonison),andtheunitwillbeplacedintoanidlecondi-
tion.Outputsandalarmswillbeoff.Oncompletionof inital setup, push
the key again (LED off) for normal operation.
press the INDEX key until parameter #9 (-cd-) appears in the process
displayarea.
a. Set 14 in lower display to gain access to configuration code, by
pressing the up or down arrow and then pressing the ENTER key.
press the INDEX key until parameter #11 (-cF-) appearsintheprocess
displayarea.
a. Refer to the configuration code chart and select a number that
representsthedesiredconfigurationofthealarmsanddisplay units
e.g., #06 = ºF, Deviation Alarms Alarm 1=Low Acting, Alarm
2=High Acting.
b. Set this number into the lower display, using the keys
c. press the ENTER key.
16 Note: Changing temperature scale requires re-setting of all points.
3.
4.
5.