You can reach our technical support team by phoning 216.367.7000 or visiting www.ppe.
Precautions Warning Use of this equipment in a manner not specified by the manufacturer may impair protection provided by the equipment. 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. Hazardous potentials exist on components inside the mainframe and controller.
Caution If a controller shows signs of having been damaged during shipping, do not power up or install the controller. Save all packing materials and report any damage to the carrier immediately. When the controller is powered up, the output may be activated. Consider the effects on your process before powering up the controller. We recommend placing the controller in standby mode before changing tuning parameter values manually. The output is off in standby mode.
Table of Contents Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 1.2 1.3 2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 2.2 2.3 2.4 3. Prepare the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Series RMB Hot Runner Controller Instruction Manual 7. Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7.1 7.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FAQs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Series RMB Hot Runner Controller Instruction Manual 1. Introduction 1.1 About This Manual This manual contains all the information needed to set up and operate the Series RMB Hot Runner controllers. An orange LED on the front panel indicates heater on, and a red LED indicates high or low process alarm. Green LEDs signal current mode and boost action. Instructions for wiring, installing, and troubleshooting the controllers are in the manual supplied with the mainframe.
Series RMB Hot Runner Controller Instruction Manual 1.2.3 PID Control with Autotuning By default, a soft start is executed: In normal (automatic) mode each Series RMB controller uses a single TRIAC output to implement Proportional-IntegralDerivative (PID) control. Tuning is automatic. By default, the Autotune operation is executed once. If the Autotune is successful, then Autotune is disabled. You can stop the Autotune by pressing the MODE key. This does not disable the Autotune feature.
Series RMB Hot Runner Controller Instruction Manual 1.2.6.6 Ground Fault Detection Circuit 1.2.6.2 Loop Break Detection The controller monitors the input change. If the input value does not change within 999 seconds while the controller is operating in normal (automatic) mode and a “bad heater” error has not been detected (see 1.2.7.5), then the controller signals a loop break as described in 5.4 and the controller goes to manual mode with 0% output, which can then be adjusted.
Series RMB Hot Runner Controller Instruction Manual 1.3 Specifications 1.3.1 Operating Limits Ambient Temperature 32°F to 131°F (0°C to 55°C) Relative Humidity Tolerance 10 to 95% Non-Condensing Shipping Temperature –40°F to 158°F (–40°C to 70°C) Power Requirements 115 to 240 Vac 50 or 60 Hz nominal, CE compliant 1.3.2 Performance Accuracy ± 0.3% of span Setpoint Resolution 1 degree Fahrenheit Repeatability ± 0.1% of span Temperature Stability ± 0.
Series RMB Hot Runner Controller Instruction Manual 2. Operation 2.1 Front Panel RMB controllers with the optional 30 amp output TRIAC are wider than the 15 amp units (to accommodate the heat sink), but the user interface is the same.
Series RMB Hot Runner Controller Instruction Manual 2.2 What Happens When You Power Up the Controller 2.3 Operation Basics 2.3.1 See PV To see the process value: Look at the top line of the display for the PV. The top line shows the PV, unless the controller detects an error, or Autotune is active, or you are in the Pid menu. Turn on the controller by pressing the “I” end of the 16 A power switch on the front panel.
Series RMB Hot Runner Controller Instruction Manual 2.3.5 View Setpoint, Output, and Current 2.4 Manual Tuning To cycle through the lower line displays: Press the DISPLAY key repeatedly. Manual tuning is usually not necessary. By default an RMB controller Autotunes the first time it is powered up. If the Autotune is not successful, the controller will try to Autotune every time it is powered up until Autotune is successful. Autotune is then disabled automatically. • • 2.4.
Series RMB Hot Runner Controller Instruction Manual 2.4.3 Changing Tuning Parameters Values Manually At this point you can: Put the controller in standby by pressing the MODE key until the STANDBY LED is lit. 2. Access the tuning menu by pressing and holding the DISPLAY key until Pid is displayed on the top line (approximately 3 seconds). 3. Display the first parameter in the menu by pressing the MODE key.
Series RMB Hot Runner Controller Instruction Manual 3.1 Setting Switches The factory switch settings are shown below. Location of DIP Switches SW2-switch 1 – OFF for soft start only when ground fault has been detected; ON (default) for soft start every time controller is powered up. SW2-switch 2 – OFF (default) for J thermocouple input; ON for K thermocouple. SW2-switch 3 – OFF for degrees Fahrenheit; ON for degrees Celsius.
Series RMB Hot Runner Controller Instruction Manual 4. Setup and Installation 4.1 Prepare the Controller Unpack the RMB controller. 2. Inspect the controller for damage. 3. When the controller is powered up, all segments of the display and all LEDs light briefly, and then the firmware version number is displayed. Make sure the power switch on the front of the controller is set to off (O). If a controller shows signs of having been damaged during shipping, do not install or power up the controller.
Series RMB Hot Runner Controller Instruction Manual The display reverts to the normal mode operating display: PV on top line, SP on lower line. The proportional band and rate values calculated by the controller during the Autotune have been saved. (The integral (reset) action for PID control is always set to five times the rate value in an RMB controller.) Autotune is disabled. (If the Autotune is not successful, output goes to 0%, and you will see an error code; see 5.8.
Series RMB Hot Runner Controller Instruction Manual Displayed Code or Message Error Condition Operator Action Err 0249 Err 0303 Calibration value corrupted. Cycle power to clear the message. Note the error code and call for service. EEPROM write failure occurred. Cycle power to clear the message. Try again to save a Pid menu parameter value. If the message recurs and persists, the EEPROM may be worn out. Call for service.
Series RMB Hot Runner Controller Instruction Manual 5.3 Ground Fault in Controller Output Wiring The controller remains in this alarm and output off state until you cycle power to the controller. The RMB controller detects ground faults in the controller output wiring by monitoring the current to ground. If the current to ground is 55 mA or higher, the controller attempts to perform a normal soft start if the process value is less than or equal to 200°F (93°C).
Series RMB Hot Runner Controller Instruction Manual 5.7 Heater Current Monitoring The present current output to the heater, expressed to the closest tenth of an amp, is always displayable in the lower line. Cycle through the available lower line display items using the DISPLAY key. The controller constantly checks heater current readings to ensure that they correlate with output activity.
Series RMB Hot Runner Controller Instruction Manual 6. Maintenance 6.1 Introduction This section contains instructions for cleaning the front panel of the controller and instructions for replacing the fuses. Except for fuses, the controller contains no user-serviceable parts. Warning Do not attempt to clean any part of a controller other than the front panel.
Series RMB Hot Runner Controller Instruction Manual 3. Use a cotton cloth to gently and sparingly apply isopropyl alcohol to the front panel of the controller. Do not use cleaning solutions or other solvents. Use of anything other than isopropyl alcohol can result in damage to the controller. 4. Allow the controller to air-dry thoroughly. Do not use a heater or compressed air to dry the unit. 5. Inspect all surfaces to make sure that they are completely dry. 6.
Series RMB Hot Runner Controller Instruction Manual 7. Frequently Asked Questions 7.1 Introduction Before you call for technical support, please look at this section to see if your question is covered here. If you do call for technical assistance, be ready to supply the following information: • • • • complete model number of controller (and firmware version if known) symptoms of the problem unusual events, if any, that preceded the problem remedies you have already tried 7.2 FAQs 7.2.
Series RMB Hot Runner Controller Instruction Manual Index G A alarms, 2, 5, 6 At.OP parameter, 6, 7, 11 automatic mode. See normal mode Autotune, 2, 6, 7, 10 Autotune errors, 12, 14 Autotune Operation parameter, 6, 7, 11 gFI error message, 13 ground fault detection, 3, 13 H HEAT LED, 5, 6 heater conversion error, 12 heater current display, 7 heater current monitoring, 3 HT.
Series RMB Hot Runner Controller Instruction Manual N S NORMAL LED, 5 normal mode, 2 SafeChange feature, 9, 17 safety information, I, 15 sensor error, 3 sensor type, switch setting for, 3, 17 setpoint, 5, 7 soft start, 2, 3 span calibration, 17 STANDBY LED, 5 switch settings, 3, 9, 10, 17 O open sensor, 13 Out Shrt error message, 14 output bad, 3, 14 output displayed, 7 output for control, 2, 6 output in manual mode, 7 output state on power up, 6 output TRIAC short error, 3, 14 T tC oPn error message,
Series RMB Hot Runner Controller Instruction Manual Two-Year Limited 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, INCORPORATED IS TO REPLACE OR REPAIR THIS EQUIPMENT AT ITS FACTORY, PROVIDED THAT IT IS RETURNED WITH TRANSPORTATION PREPAID WITHIN TWO (2) YEARS OF ITS PURCHASE.
Series RMB Hot Runner Controller Instruction Manual Notes 21
Plastic Process Equipment, Inc. 8303 Corporate Park Drive Macedonia, OH 44056 1.800.321.0562 • 216.367.7000 FAX: 216.367.7022 • www.ppe.
