Athena Controls 16C Series User manual
16C
2
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.
As you look through this manual, you will notice
blue italicized text
appearing with, or adjacent to, the 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 (+1) 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 Inputs including Thermocouple, RTD, Current or Voltage
Process Control via On/Off Through Full PID Operation
Autotuning - Heat or Cool
Eight-Segment Ramp/Soak to prevent thermal shock
On/Off Output with Adjustable Hysteresis and Deadband to maintain tight process control
Field-Configurable Process or Deviation Alarms
Bumpless, Auto-Manual Transfer
NEMA 4X Front Panel, “Watertight”
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.
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.
E66598 Temperature Indicating and
Regulating Equipment.
E66598 Temperature Indicating and
Regulating Equipment.
3
Installation 4
Dimensions and Mounting 4
Wiring 5
Wiring for Options 6
Output Types 12
Operation 13
Front Panel Controls 13
Power On 13
Security Levels 16
Operating Modes 16
Menu System Overview 17
Parameter/Menu Descriptions 1 9
Input Menu 1 9
Temperature Input 20
Process (Linear) Input 21
Display Menu 22
Output Menu 23
Control Menu 24
PID Output and Control Menus 25
On/Off Output and Control Menus 26
Alarm Menu 28
Ramp and Soak Menu 30
Supervisor Menu 32
Calibration Menu 33
Options Menu 34
Communications Menu 35
Contact / Digital Input Menu 36
Auxiliary Output Menu 37
Autotune Damping 38
AutoTuning 38
Manual Tuning 40
Operation in Manual Mode 41
Error Codes 4 2
Technical Specifications 4 3
Recalibration Procedures 4 5
Glossary 4 6
FAQs 48
Default Parameters/Process Parameters 5 0
Warranty/Repairs 5 1
DATE DESCRIPTION REVISION
TITLE
DWG
DATE SCALE DRAWN CHECKED
Model 16C Operation Manual
900M503U01
11/22/2019 A
4
Measurements between centerlines of panel cutouts are the minimum recommended.
C
LC
L
C
L
C
L
2.850” (72.4 mm)
2.150” (54.6 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.
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 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.
Figure 1. Recommended Panel Layout for Multiple Controllers
5
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
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 5. Thermocouple Input Wiring
Note: For 2-Wire RTD
Jumper 8 & 10
The Series C accepts input from 2- or 3-wire, 100 ohm platinum resistance temperaure 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 lead resistance. For long runs, 3-wire RTDs
should be used.
Figure 6. RTD Wiring
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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.
Figure 7. Process and Linear Input Wiring
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
This optional hardware module provides two alarm drive outputs. LED indicators A1 and A2 are used to
indicate alarm conditions as configured in the Alarm Menu.
Option Description:
Option 10: Dual alarm, N.O.
Option 22: Dual alarm, N.C. (Note: NC only when power is applied to unit; otherwise NO)
Load Limits:
Max. Load Current 1 A rms
Min. Load Current 0.5 mA rms
Power Factor Range 0.2 to 1.0 (can drive small motors, solenoids, valves, and contactors)
Max. Surge Current
Non-repeating for 1 second 7.5 A
Max. I2T for fusing (0.01 sec) 4.5 amp-squared seconds (1 A - ABC1 typical fuse)
Figure 10. Wiring for Dual Alarm Outputs
7
Option Description: Dual open collectors, NPN, isolated, with clamping diode
Recommended operating conditions:
Supply Voltage Pins 13 & 14; 200 working Vdc max. (Never exceed 300 Vdc)
Collector Current 50 mA max.
Specifications:
Saturation Voltage 0.3 Vdc min., 1.2 V max.
Collector-Emitter Breakdown 300 V min.
Isolation Isolation 300 volts ac/dc output-to-output or output-to-controller
Figure 11. Wiring for Dual Open Collector Alarms
Option Description: Dual 24 V outputs with clamping diodes
Pins 13 & 7 are connected internally
Source current is limited to 25 mA (1000 ohm resistor)
Open circuit voltage is 25 volts
Isolation: Isolation 300 volts ac/dc either output to instrument
Figure 12. Wiring for Dual 24V dc Alarm Outputs
8
Option Description:
NO (Normally open) relay contact is closed when either alarm is active. Jumpers on the board can be
removed to activate the output for a single alarm only:
JP1 - Alarm A1
JP2 - Alarm A2
The relay life is greater than 100,000 operations at 5 operations per second switching full load.
*Connect load and supply voltage per the following table:
*
*
Option Description: Provides a one-to-one connection between the controller and an RS-232 port.
Computers, PLCs, or dumb terminals may be used to set and access controller data.
Figure 13. Wiring for Relay Normally Open Alarm Output
Figure 14. Wiring for RS-232 Communications
Load Type 5 Amp Voltage Limit
Resistive DC 30 Vdc
Inductive DC (L/R = 7ms) 20 Vdc
Resistive AC 250 Vac
Inductive AC (pF = 0.4) 150 Vac
Motor, AC, 1/6 hp 250 Vac
Tungsten Lamp, 360 W 120 Vac
9
Option Description: Provides one-to-many communications.
If run exceeds 1000 ft., terminate the controller furthest from the computer by connecting a 120-ohm, 1/4-
watt resistor between terminals 13 and 14.
*Converter is supplied with a wallplug-mount power transformer.
Figure 15. Wiring for RS-485 Communications
Option Description:
Dual function board (functions unrelated)
a. Output alarm is energized when either A1 or A2 is active.
b. Digital input controls Remote Standby, Ramp-Soak Run/Hold, OR Second Setpoint Select.
Option 40: Active when switch closed.
Option 41: Active when switch open.
Option 42: Active when 5 V input present
Load Limits:
Max. Load Current: 1 A rms
Min. Load Current: 0.5 mA rms
Power Factor Range: 0.2 to 1.0 (can drive small motors, solenoids, valves, and contactors)
Max. Surge Current, Non-Repeating for 1 second: 7.5 A
Max. I2T for fusing (0.01 sec): 4.5 amp-squared secs (1A - ABC1 typical fuse)
Figure 9. Wiring for Contact/Digital Input with Alarm
10
Option Description:
The Setpoint Variable or Process Variable is transmitted to a remote device (chart recorders, indicators, data
recorders, computers, process controllers, etc.) with 1 of 4 different interfaces:
Option 60: 4-20 mA
Option 61: 1-5 V
Option 62: 0-20 mA
Option 63: 0-5 V
The output signal is scalable in the Auxiliary Output Menu. Multiple remote indicators may be driven by the
controller. However, current and voltage outputs cannot be used simultaneously.
For current (mA) options, the remote indicators are connected in series. The sum of the input resistance for
all remote indicators must be less than 400 ohms. For voltage options, the remote indicators are connected
in parallel.
The sum of the currents for all remote indicators must be less than 10 mA.
Figure 18. Wiring for Auxilliary Output
Option Description:
The transducer excitation option provides power to remote transducers. The transducer outputs, in turn,
provide a signal to the controller input which can be scaled in the appropriate engineering units.
Option 50: 10 Vdc
Option 51: 12 Vdc
Option 52: 15 Vdc
Option 53: 5 Vdc
All options will provide at least 20 mA. The transducer circuitry is thermally protected from short circuits.
Figure 16. Wiring for Transducer Excitation
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