You can reach our technical

support team by phoning

216.367.7000 or visiting
www.ppe.com

II
Precautions

Use of this equipment in a manner not specified by the

Warning 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. Always disconnect AC power to the mainframe
when servicing the controllers or the mainframe.

Because these temperature controls or associated equipment

may not always fail safe, an approved temperature and/or
pressure safety control should be used for safe operation.

The controller power switch must be in the “OFF” position before

you put a controller into an energized mainframe, or remove a
controller from an energized mainframe.

Turn off power to the controller before cleaning the exterior of

the controller.

Failure to observe these precautions can result in exposure to a

potentially lethal shock hazard.

Changing DIP switch and jumper settings, and all wiring should
be done by an experienced technician. The controller and wiring
should be installed in accordance with national and local
electrical codes. To avoid serious personal injury and damage to
equipment, follow all warnings and cautions provided in the
manual supplied with the mainframe.

Littlefuse® is a registered trademark of Littlefuse, Inc.

Bussmann® is a registered trademark of Cooper Industries, Inc.

III
 If a controller shows signs of having been damaged during
Caution 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.

Do not locate this instrument where it may be subjected to

excessive shock, vibration, dirt, moisture, oil, or other liquids.

This is a Class A product. In domestic environments this product

may cause radio interference in which case the user may be
required to take adequate measures.

Specified operating ambient temperature 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 into a grounded metal housing. EMC testing was
conducted with a load of 1 amp and setpoint of 400°F.

EMC directive (89/336/EEC)

EN 50081-1 (1992 edition)
EN 50082-1 (1992 edition)
Low Voltage Directive (73/23/EEC)
EN 61010-1 (1992 edition, Amendments 1, 2, 3, 4 and 11)

IV
 Table of Contents
Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Features and Benefits of RMB Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 What Happens When You Power Up the Controller . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Operation Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Manual Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Setting Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Factory Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Setup and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Prepare the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Install the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Apply Power to the Mainframe and Controller . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Adjust the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Wait for the Controller to Tune Itself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Error Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Summary of Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3 Ground Fault in Controller Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Loop Break in Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.5 Open Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.6 Reversed Thermocouple Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.7 Heater Current Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.8 Autotune Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Cleaning the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Replacing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Unit Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

i
 Series RMB Hot Runner Controller Instruction Manual

7. Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 FAQs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

ii
 Series RMB Hot Runner Controller Instruction Manual

1. Introduction
1.1 About This Manual
This manual contains all the information An orange LED on the front panel
needed to set up and operate the Series indicates heater on, and a red LED
RMB Hot Runner controllers. indicates high or low process alarm.
Instructions for wiring, installing, and Green LEDs signal current mode and
troubleshooting the controllers are in the boost action.
manual supplied with the mainframe. Front panel keys make it easy to change
mode, change setpoint (normal mode),
1.2 Features and Benefits output % (manual mode), and to activate
of RMB Controllers the boost. You can also use the front
panel to change tuning parameter values.
1.2.1 Introduction
RMB controllers with the optional 30 amp
The Series RMB Hot Runner controllers output TRIAC are wider than the 15 amp
offer many advanced features designed units (to accommodate the heat sink), but
to increase productivity and ensure fast, the user interface is the same.
accurate, and repeatable mode
temperature control. Each unit is Detailed instructions for using the front
designed to control one temperature panel are in Section 2.
zone based on input from a J or K
thermocouple. The controllers are set at
the factory for J thermocouple input. To
use a K thermocouple, change a switch-
setting; see 3.4.
1.2.2 Convenient User Interface
RMB controllers are equipped with a bright
two-line LED display that is easy to read
over wide viewing angles.
The process value is displayed on the top
line (three digits).
The lower line (four digits) displays your
choice of setpoint (normal mode), output
percentage (normal and manual), and
output current to the closest tenth of an
amp (normal and manual).

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 Series RMB Hot Runner Controller Instruction Manual

1.2.3 PID Control with By default, a soft start is executed:

Autotuning • every time the controller starts

and the process value is less than
In normal (automatic) mode each Series 200°F (93°C), and
RMB controller uses a single TRIAC
• every time the controller is
output to implement Proportional-Integral-
returned to normal (automatic)
Derivative (PID) control. Tuning is
operation and the PV is less than
automatic.
200°F (93°C).
By default, the Autotune operation is • any time a ground fault is detected;
executed once. If the Autotune is see 1.2.7.6
successful, then Autotune is disabled.
You can stop the Autotune by pressing the You can set SW2-switch 1 to OFF as
MODE key. This does not disable the described in Section 3 to cause the
Autotune feature. If Autotune operation is controller to execute a soft start only in
set to “once”, then the controller attempts response to detection of a ground fault
to perform the Autotune operation each interruption. More information about the
time the controller is powered up, until a start up sequence is in 2.2.
successful Autotune is completed.
1.2.5 Boost Function
You can disable Autotune entirely or
Every Series RMB Hot Runner controller
enable it for every power up. To change
supports a boost function that is activated
the Autotune setting, use the Pid menu.
when you press the BOOST key. For the
You can also use the Pid menu to change
next 15 seconds (or until you press the
the proportion band and rate manually;
BOOST key again, whichever is sooner),
see 2.4.
20% more power is added to the controller
1.2.4 CompuStep™ Soft Start output (100% output maximum).
for Heater Bake Out 1.2.6 Process Protection
All Series RMB Hot Runner controllers Features
support the CompuStep soft start feature
to extend the life of the heaters and the 1.2.6.1 Deviation Alarms
molds. The soft start allows slow
dissipation of moisture in heaters by Each Series RMB Hot Runner controller
gradually applying power to the heaters. supports two deviation alarms. If the
process value falls below the setpoint
When a soft start is executed, phase angle minus 30°F (17°C), or if the process
firing starts at 5% output power and steps value exceeds the setpoint plus 30°F
up the output 5% every 30 seconds. (17°C), the red ALARM LED on the front
The soft start lasts five minutes or until panel of the controller lights. The alarm
the process temperature reaches status indicator remains lit as long as the
200°F (93°C). process value deviates from the setpoint
The green NORMAL LED flashes during by at least 30°F (17°C).
soft start in normal (auto) mode. You can
stop the soft start by pressing the MODE
key.

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 Series RMB Hot Runner Controller Instruction Manual

1.2.6.2 Loop Break Detection 1.2.6.6 Ground Fault Detection

The controller monitors the input change. Circuit
If the input value does not change within
999 seconds while the controller is An RMB controller can detect ground
operating in normal (automatic) mode and faults in the controller output. When a
a “bad heater” error has not been detected ground fault is detected, the controller
(see 1.2.7.5), then the controller signals a attempts to perform a normal soft start, if
loop break as described in 5.4 and the the process value is less than or equal to
controller goes to manual mode with 0% 200°F (93°C).
output, which can then be adjusted. The controller performs the soft start up to
three times if necessary. If the ground
1.2.6.3 Sensor Error Monitoring fault is detected again after the soft start
The controller can detect a reversed has been executed three times, the
sensor or open sensor. The controller controller signals a “hard” ground fault;
action when a sensor problem is detected see 5.2.
depends on the type of error and the
mode of the controller; see 5.4 and 5.5 for
1.2.7 Ease of Setup
details. DIP switches make it easy to change the
input type and unit of measure. The
1.2.6.4 Heater Current defaults are J thermocouple, with degrees
Monitoring Fahrenheit for North America and degrees
Celsius for other shipping destinations.
The present current output to the heater,
expressed to the closest tenth of an amp, The controller tunes itself automatically.
is always displayable in the lower line. However, you can use the controller’s
Cycle through the available lower line front panel to change the proportional
display items using the DISPLAY key. band and rate manually; see 2.4.

1.2.6.5 Output Interruption

Check
An RMB controller constantly checks
heater current readings to ensure that
they correlate with output activity. If a
TRIAC short or bad heater is detected, the
output failure interruption relay breaks the
connection between the controller’s
TRIAC output and the heater. An error
message is also displayed; see 5.6.

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 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 ± 0.5% of full scale over the ambient range of 32°F to
131°F (0°C to 55°C)
Thermocouple Cold-End Tracking automatic, better than 0.02°F per °F
(0.01°C per °C)
Noise Rejection Common Mode > 100 dB, Series Mode > 70 dB
Process Sampling Rate 10 Hz (100 ms)

1.3.3 Connections and Mounting

The Series RMB controllers are designed for installation in a Hot Runner
mainframe (or other compatible mainframe). Removal of an RMB controller
from the mainframe requires removal of a locking pin (standard controllers) or
locking screw (CE-compliant controllers).

1.3.4 Inputs
Thermocouple J or K
Supported Sensor Range 32 to 999°F (0 to 537°C)

1.3.5 Output
TRIAC, 15 amps at 120/240 Vac (30 amp optional), driven by optically isolated
interface circuit. Protected with a pair of 15 amp (or one 30 amp) field-
replaceable fuses. Instructions for replacing the fuses are in 6.3. Replacement
fuses must be Type F fast-acting 250 Vac fuses rated at 15 amps (or 30 amps).
A 15 amp (120/240 Vac) relay (30 amp optional) interrupts power to the heater if
the controller detects shorting of the TRIAC output or other system failures.
A ground fault detection circuit is also standard.

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 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.

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 Series RMB Hot Runner Controller Instruction Manual

2.2 What Happens When 2.3 Operation Basics

You Power Up the
2.3.1 See PV
Controller
To see the process value: Look at the
Turn on the controller by pressing the “I” top line of the display for the PV. The top
end of the 16 A power switch on the front line shows the PV, unless the controller
panel. When an RMB controller is detects an error, or Autotune is active, or
powered up, it lights all segments of the you are in the Pid menu.
display briefly, then displays its firmware
level. 1 2.3.2 See if Output is On
The sequence of controller actions that To see if the output is on: Look at the
follow and the state of the controller output HEAT LED. It is on when the output is on.
depend on:
2.3.3 Monitor for Alarms
• SW2-switch 1 setting–If SW2-switch
1 is ON (the default), the controller To watch for process alarms: Look at
does a CompuStep soft start if the the red ALARM LED. If the process value
process value is less than or equal to falls 30°F (17°C) below the setpoint or
200°F (93°C). If SW2-switch 1 is increases to 30°F (17°C) above the set-
OFF, the controller does not do a soft point, the ALARM LED lights. It stays lit as
start at power up. long as the PV deviates from the setpoint
by at least 30°F (17°C).
• PId (PID control) menu’s At.OP
(Autotune operation) parameter 2.3.4 Change Mode
value–If the value of At.OP the
To change the mode: Press MODE
default oncE (once) or EnA (always
repeatedly until the LED lights for the
enabled), Autotune is attempted.
mode you want. The modes are:
You can stop soft start and Autotune by
• normal (closed loop control) –
pressing the MODE key repeatedly.
Controller uses the input value to cal
culate the output needed to maintain
the setpoint shown on the lower line.
• manual (open loop control) –
Controller output is the percent
shown on the lower line. Input is
ignored. Transfer from normal to
manual is “bumpless” when the
process value is within 9°F (5°C)
of the setpoint.
• standby – Standby output 0P
(zero percent) is on the lower line.

1
It is a good idea to make a note of the
firmware version number. If you phone for
technical support, you will be asked for this
version information, as well as for the
complete model number of the controller in
question.

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 Series RMB Hot Runner Controller Instruction Manual

2.3.5 View Setpoint, Output, 2.4 Manual Tuning

and Current 2.4.1 Usually Not Needed
To cycle through the lower line Manual tuning is usually not necessary.
displays: Press the DISPLAY key By default an RMB controller Autotunes
repeatedly. the first time it is powered up. If the
• In normal mode you can cycle Autotune is not successful, the controller
through the setpoint, output will try to Autotune every time it is powered
percent (with P), and heater up until Autotune is successful. Autotune
current to the closest tenth of an is then disabled automatically.
amp (with A).
• In manual mode you can switch
2.4.2 PID Control
between output percent (with P) With PID control the device modulates
and heater current to the closest output power by adjusting the output
tenth of an amp (with A). power percentage within a proportional
band. Power is proportionally reduced as
2.3.6 Change Setpoint or the process temperature gets closer to the
Output setpoint temperature.
To change the setpoint (normal mode) The derivative action affects the output
or output (manual mode): Press based on the rate of change of the
DISPLAY until the setpoint or manual process value.
▼
mode output is on display. Press the or
You can use the Pid menu to change the
▼ key until the displayed value has been
Pb (proportional band) and rAtE
changed to the new value you want.
(derivative) values.
The output current value and normal mode
The integral action (reset) affects the out-
output percentage are read-only.
put based on the duration of the process
2.3.7 Start Boost value’s variation from the setpoint. In the
Series RMC Hot Runner controllers, the
To start the boost: Press the BOOST integral (reset) action is always equal to
key. The LED above the BOOST key five times the derivative (rate) action.
lights. For the next 15 seconds (or until You can also use the Pid menu to
you press the BOOST key again, change the setting of the At.OP (Autotune
whichever is sooner), 20% is added to the operation) parameter, which determines
controller output (100% output maximum). when Autotuning is attempted.

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 Series RMB Hot Runner Controller Instruction Manual

2.4.3 Changing Tuning At this point you can:

Parameters Values • change the value of the newly dis
▼
Manually played parameter with the and
▼ keys, or
To change a tuning parameter value
manually: • if you like the current value of the
parameter on display, you can press
1. Put the controller in standby by the MODE key to leave the displayed
pressing the MODE key until the value unchanged and go on through
STANDBY LED is lit. the parameters in the menu, or
2. Access the tuning menu by pressing • exit the Pid menu by pressing and
and holding the DISPLAY key until holding the DISPLAY key until the
Pid is displayed on the top line normal operating display returns to
(approximately 3 seconds). view, and then press MODE to return
3. Display the first parameter in the to normal mode.
menu by pressing the MODE key. If you do not press any key, eventually you
The second line of the display will will be timed out of the Pid menu. The
show Pb (proportional band), the controller will revert to the operational
name of the first parameter in the display that was in view before you
menu, alternating with the current entered the menu. The value that was on
value. display when you were timed out of the
Pid alternating Pid menu will be saved to the controller’s
database automatically.
pb with 24
4. If this is not the parameter you want 2.4.4 Pid Menu Parameters
to change, press MODE repeatedly Pb (proportional band) – Valid range is 0.1
until you see the parameter you want. to 999°F (0 to 537°C). Default is 24°F
▼
5. Use the ▼ and keys to change a (13°C).
numeric value or scroll through the rAtE (derivative) – The valid range is 0.0
choices. to 999 seconds. Default is 7 seconds.
6. When the desired choice or numeric At.OP (Autotune operation) – Choices are:
value is on display, press the MODE
key once. The displayed choice or d IS Autotune disabled
value will be written to the controller’s oncE Autotune once at next power up,
database. The next parameter in the then disable if Autotune was
menu (or the first parameter if you successful.
were at the end of the menu) will be
displayed. EnA Autotune enabled every time
controller is powered up.

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 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.
Default depends on shipping destination:
OFF for North America
ON for all other destinations.
SW2-switch 5 – OFF (default) for normal
operation; ON to load default parameter
values the next time controller is powered
up.
SW2-switch 8 – OFF – Normal
ON – Loop Break Disabled
SW2-switch 4 is used only at the factory.
SW2-switches 6, 7, and 8 are not used.
Leave them off.

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 Series RMB Hot Runner Controller Instruction Manual

4. Setup and Installation

4.1 Prepare the Controller 3. Set the power switch on the front of
1. Unpack the RMB controller. the controller to on (I).

2. Inspect the controller for damage. When the controller is powered up, all
segments of the display and all LEDs light
3. Make sure the power switch on the briefly, and then the firmware version
front of the controller is set to off (O). number is displayed.
If a controller shows signs of having been
damaged during shipping, do not install or 4.4 Adjust the Setpoint
power up the controller. Save all packing When the controller is powered up, it will
materials and report any damage to the automatically do a CompuStep soft start
carrier immediately. for heater bake out if the process value is
4.2 Install the Controller below 200°F. (PV is on the top line of the
display. SP is on the lower line.) During
This guide assumes that the mainframe the soft start the NORMAL LED flashes.
has already been wired as described in
During the soft start (which lasts five
the installation manual supplied with the
minutes or until the PV is 200°F),
mainframe.
adjust the setpoint to a value that is
1. Make sure the plunger in center of representative of the setpoint you expect
the locking pin is pulled out (or to use when the controller is in service. 2
loosen the locking screw). ▼
To adjust the setpoint press the or
2. With the controller and mainframe ▼ key.
power switches set to off (O), align
the RMB controller’s printed circuit 4.5 Wait for the Controller
board with the guide channels in a to Tune Itself
slot in the Hot Runner mainframe.
New RMB controllers are set to do a soft
3. Slide the controller into the main start every time they are powered up (if
frame until the RMB connectors are the PV is less than 200°F), and then to do
firmly seated in the backplane of an Autotune operation each time the
the mainframe. controller is powered up until a successful
4. Lock the controller into the frame by Autotune is completed.
pressing in the plunger on the locking If you are setting up a new process,
pin (or tighten the locking screw). Autotune all the RMB controllers in the
process simultaneously, so that interac-
4.3 Apply Power to the
tions between zones during tuning
Mainframe and Controller
When the controller is powered up, the 2
If the PV is greater than 200°F, then the
output may be activated. controller will skip the soft start, and will
Autotune as soon as you power up the con-
1. Before powering up the controller, troller the first time. However, the tuning will
consider the effects on your process not be valid, because you have not yet
entered the appropriate setpoint for your
if the output is activated. Take site- process. Press MODE once to interrupt the
specific precautions. Autotune. With the controller in normal
mode (NORMAL LED lit), adjust the set-
2. Turn on the power to the mainframe. point, and then cycle power to start
Autotune again with a valid setpoint.

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 Series RMB Hot Runner Controller Instruction Manual

parallel the interactions expected while the The display reverts to the normal mode
controllers are in use. operating display: PV on top line, SP on
lower line. The proportional band and rate
If you need to stop the Autotune, press the
values calculated by the controller during
MODE key until the controller is in
the Autotune have been saved. (The
standby. (When you are ready to
integral (reset) action for PID control is
Autotune, cycle the power to the
always set to five times the rate value in
controller.)
an RMB controller.) Autotune is disabled.
If you are installing a single replacement (If the Autotune is not successful, output
controller, let the Autotune proceed without goes to 0%, and you will see an error
interruption. During Autotune, the process code; see 5.8.)
value alternates with tun.
RMB controllers do not require calibration.
At the conclusion of a successful
The controller is ready to use.
Autotune, the flashing tun disappears.

5. Error Messages and Codes

5.1 Introduction 5.2 Summary of Error
Usually the controller displays the process Codes
variable on the top line and the setpoint on If the controller detects a problem, the
the lower line of the display. You can see highest priority error will be displayed.
other values on the lower line by pressing The possible errors and suggested
the DISPLAY key. operator actions in response are
However, when the controller detects a summarized below.
problem with the input or output, or with its When one of these error codes is dis-
own operation, messages and codes are played, the output is 0%. In the case of
displayed to alert you to conditions that the Out SHrt (output short) and bAd Htr
require your immediate attention. (bad heater) errors, the output failure relay
interrupts the output.

Displayed Code Error Condition Operator Action

or Message
Highest Priority – Controller has detected a problem with its own operation. All errors of this type
shut down controller activity (except for display of error message).
Err PROM checksum error Cycle power to clear the message.
0100 Note the error code and call for service.
Err RAM error Cycle power to clear the message.
0101 Note the error code and call for service.
Err Default Pid menu parameter Cycle power to clear the message.
0202 values were loaded Because the At.OP (Autotune
automatically, because the operation) value will be set to “once”,
controller found corrupted the controller will tune itself.
values stored on the EEPROM.
(This message is not displayed
when you use SW2-switch 5 to
set the default values
intentionally.)

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 Series RMB Hot Runner Controller Instruction Manual

Displayed Code Error Condition Operator Action

or Message

Err Calibration value corrupted. Cycle power to clear the message.

0249 Note the error code and call for service.
Err EEPROM write failure occurred. Cycle power to clear the message.
0303 Try again to save a Pid menu
parameter value. If the message
recurs and persists, the EEPROM
may be worn out. Call for service.
Err The controller could not Cycle power to clear the message.
2436 determine whether the power Check the line frequency. If it is OK,
frequency is 50 Hz or 60 Hz. but the message recurs and persists,
call for service.
Err Interrupt-related problem Cycle power to clear the message.
3923 occurred. If the message recurs and persists,
throu9h call for service.
3543
High Priority – PV is displayed on top line, unless an input error (medium priority) occurs
simultaneously. In that case, the top line is blank; no valid PV is available. If two high priority error
states are detected, the one ranked highest will be displayed on the lower line (see numbers below).
1) 9FI Hard ground fault detected
(see 5.2).
2) bAd Htr Heater problem detected
(see 5.7).
3) Out SHrt Output is off, but current flow is Turn off controller. Fix the problem.
detected (see 5.7). Turn on the controller.
4) LPbr PV has not increased at least
1% of supported sensor span in
999 seconds (loop break time;
see 5.4).
5) Ht.rd Err Heater conversion error occurred. Cycle power to clear the message.
Call for service.
Medium Priority – SV is displayed on lower line. These conditions cannot occur simultaneously.
tC oPn Thermocouple is open (see 5.5). If the condition is fixed, the message
will clear automatically. To clear the
message manually, cycle the power.
tC rEu Thermocouple leads are
reversed (see 5.6).
Low Priority – SV is displayed on lower line. Output goes to 0%. Only one Autotune error will be
displayed.
tun Er3 Autotune error; see 5.8 for details.
tun Er5
tun Er8
tun Er9

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 Series RMB Hot Runner Controller Instruction Manual

5.3 Ground Fault in The controller remains in this alarm and

output off state until you cycle power to
Controller Output Wiring the controller.
The RMB controller detects ground faults
in the controller output wiring by
5.5 Open Thermocouple
monitoring the current to ground. If the If the controller detects an open sensor:
current to ground is 55 mA or higher, the
• the red ALARM LED lights (all other
controller attempts to perform a normal
LEDs off), and
soft start if the process value is less than
or equal to 200°F (93°C). The standard • the upper display alternates tC and
CompuStep soft start described in 1.2 is oPn (open sensor), and
executed. In this special case, the soft
• the appropriate output action is taken,
start will be executed up to three times. If
depending on control mode:
the ground fault is still detected, the
controller considers this a “hard” ground • if the controller is in normal (auto)
fault. mode, the output goes to 0% for
approximately one second, and then
If a ground fault is detected when the
the controller uses a calculated out
process value is greater than 200°F
put value, based on stored output
(93°C), the controller considers it a “hard”
values that have successfully
ground fault immediately.
maintained the current setpoint for
When a hard ground fault is detected, the your process in the past
controller:
• if the controller is in manual mode,
• interrupts the signal to its own output, the output remains at the percent in
in effect “turning off” the output, and use when the open sensor was
detected
• an error message 9FI is displayed on
the lower line, and The controller remains in this alarm and
failsafe state until the condition clears or
• the red ALARM LED lights (all other
you cycle power to the controller.
LEDs off).
Following the interrupt in response to a 5.6 Reversed Thermocouple
“hard” ground fault, the controller’s output Leads
remains off until you cycle power to the
controller. If the controller detects a reversed sensor:

5.4 Loop Break in Sensor • the controller output goes to 0%, and

Wiring • the red ALARM LED lights (all other

LEDs off), and
If the input value does not change at least
1% of supported sensor span (9.67°F or • the upper display alternates tC and
5.37°C) within 999 seconds while the rEu (reversed sensor).
controller output is on, and a “bad heater” The controller remains in this alarm and
error has not been detected (see 5.6), output off state until the condition clears or
then: you cycle power to the controller.
• the controller output goes to 0%, and
• the red ALARM LED lights (all
other LEDs off), and
• the message LPbr is displayed on the
lower line.

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 Series RMB Hot Runner Controller Instruction Manual

5.7 Heater Current • controller processing stops, and

Monitoring • the red ALARM LED lights (all other

The present current output to the heater, LEDs off), and
expressed to the closest tenth of an amp, • an alarm message is displayed on
is always displayable in the lower line. the lower line:
Cycle through the available lower line
display items using the DISPLAY key. • if a short was detected, Out
The controller constantly checks heater alternates with SHrt
current readings to ensure that they • if a heater problem is detected, bAd
correlate with output activity. alternates with Htr
• If the output is off and a current flow The controller remains in this halted state
greater than 0.1 amp is detected, until you cycle power to the controller.
then the controller posts a “TRIAC
short” error. 5.8 Autotune Errors
• If the output is on, but no controller At the conclusion of an unsuccessful
current output flow is detected, then Autotune, you will see Er plus a one-digit
the processor posts a “bad heater” error code (alternating with tun). If the
error. (This condition is checked only Autotune is not successfully completed,
if no loop break has been detected the Autotune feature is not disabled
while the controller is in normal (auto) automatically.
mode, and the PV is not within the
An Autotune error code is displayed until
proportional band.)
you press the MODE key. If the Autotune
If either of these error conditions is operation is terminated by the controller
detected: because of an error condition, the
• the output failure interruption relay controller output goes to 0%.
breaks the connection between the
controller’s TRIAC output and the
heater, and

Autotune Errors
Error Code Description
Er3 Setpoint is higher than the process value. Look at the setpoint.
If it is realistic for your process, then check the thermocouple
leads; maybe they are reversed.
Er5 There is not enough difference between initial PV and the
setpoint. For Autotune to work, the difference must be at least
9°F (5°C).
Er8 The startup curve (change in PV) was not acceptable to the
Autotune algorithm. This could be caused by a process upset
that occurred during tuning. Try Autotuning again when the
process is stable. If the error recurs, your process is not
suitable for Autotuning. Use manual tuning; see 2.4.
Er9 The Autotuning timed out, because the process was
unresponsive (or extremely slow). Your process is not suitable
for Autotuning. Use manual tuning; see 2.4.

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 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.

Do not attempt to clean any part of a controller other than the

front panel.
Warning
If you want to clean the front panel of a single controller, use the
power switch on the front of the controller to turn it off, then
remove the controller from the mainframe.
If you want to clean the front panel of several controllers, turn
off all controllers in the mainframe and turn off power to the
mainframe before cleaning the controllers while they are in the
mainframe.
While cleaning a controller’s front panel, do not allow alcohol to
enter the switch.
Allow controllers and mainframes to dry thoroughly before
restoring power. Do not use a heater or compressed air to dry
the units.
Failure to observe these precautions can result in exposure to a
potentially lethal shock hazard.
The controller power switch should be in the “OFF” position
before you put a controller into an energized mainframe, or
remove a controller from an energized mainframe. Failure to
observe these precautions can result in damage to the
connectors and printed circuit boards.

6.2 Cleaning the Front

Panel
To clean an RMB controller: loosening the locking screw), and
pulling on the handle on the front of
1. Read the safety warnings above
the controller.
before you start cleaning a controller.
Alternatively, if you plan to clean the front
2. To clean the front panel of a single
panel of several controllers, put the power
controller, put the controller power
switch of every controller in the mainframe
switch in the “OFF” position, and then
in the “OFF” position, and then turn off
remove the controller from the
power to the entire mainframe. After the
energized mainframe by pulling out
mainframe has been de-energized, you
the plunger on the locking pin (or
can clean the controllers while they are in
the mainframe.

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 Series RMB Hot Runner Controller Instruction Manual

3. Use a cotton cloth to gently and 4. Use the handle on the front of the
sparingly apply isopropyl alcohol to controller to pull it out of the
the front panel of the controller. Do mainframe.
not use cleaning solutions or other
5. Replace the fuses.
solvents. Use of anything other than
isopropyl alcohol can result in 6. Re-install the controller and return it
damage to the controller. to service.
Do not allow alcohol to enter the 6.4 Unit Repairs
power switch on the controller’s front
panel. It is recommended that units requiring
service be returned to an authorized
4. Allow the controller to air-dry service center. Before a controller is
thoroughly. Do not use a heater or returned for service, please consult the
compressed air to dry the unit. service center nearest you. In many
5. Inspect all surfaces to make sure that cases, the problem can be cleared up over
they are completely dry. the telephone. When the unit needs to be
returned, the service center will ask for a
6. When the controller is completely dry,
detailed explanation of problems
re-install it and return it to service.
encountered and a Purchase Order to
6.3 Replacing the Fuses cover any charge. This information should
also be put in the box with the unit. This
Each RMB controller with 15 amp output should expedite return of the unit to you.
contains two fuses, located on the main
printed circuit board. An RMB with 30
amp output has one fuse on the main cir-
cuit board.
To replace the fuses in an RMB
controller:
1. Make sure that you have the correct
replacement fuse.
• For RMB controller with 15 amp
output – Type F fast-acting 250
Vac fuses rated at 15 amps.
Suitable fuses are p/n
210B001U01 and Littlefuse Inc.
p/n 314015.
• For RMB controller with 30 amp
output – Type F fast-acting 250
Vac fuse rated at 30 amps.
Suitable fuses are p/n
210A009U01 and Cooper
Bussmann FWX-30A14FB.
2. Put the power switch of the controller
in the “OFF” position.
3. Pull out the plunger in the locking pin
(or loosen the locking screw).

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 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
7.2.1 How do I change from a J to a K thermocouple?
Every Series RMB controller is shipped ready to accept input from a J thermo
couple. If you plan to use a K thermocouple for input, you must set
SW2-switch 2 to ON as described in Section 3. Read the safety warnings at
the front of this manual before changing switch settings.

7.2.2 Do I have to calibrate a new controller?

No

7.2.3 Why doesn’t the displayed PV match the value on a

thermometer in the process?
Unless the thermometer and the sensor providing input to the controller are very
close to one another, their readings will not match in some applications, because
of temperature variations within the process.

7.2.4 I turned on the power; why doesn’t the controller light up?
If SafeChange is enabled, but the mainframe does not support SafeChange, the
controller will not work. Instructions for checking to see if a mainframe supports
SafeChange are in 3.2.

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 Series RMB Hot Runner Controller Instruction Manual

Index
A G
alarms, 2, 5, 6 gFI error message, 13
At.OP parameter, 6, 7, 11 ground fault detection, 3, 13
automatic mode. See normal mode
Autotune, 2, 6, 7, 10 H
Autotune errors, 12, 14 HEAT LED, 5, 6
Autotune Operation parameter, 6, 7, 11 heater conversion error, 12
heater current display, 7
B heater current monitoring, 3
bad Htr error message, 14 HT.rd Err message, 12
boost, 5, 7
bumpless transfer, 6
I
input failure, 13
C input switch setting, 3, 17
integral action, 2, 7, 11
calibration, 11, 17 interrupt (unexpected or invalid), 12
calibration value corrupted error, 12
CE EMC compliance, II
changing setpoint or output, 7
J
checksum error, 11 J thermocouple, switch setting for, 3, 10,
cleaning controllers, 15 17
CompuStep, 2, 3 jumper setting, 9
current displayed, 3, 7
current monitoring, 3, 14 K
K thermocouple, switch setting for, 3, 10,
D 17

default switch settings, 10

default values, 11
L
derivative action, 2, 7, 11 line frequency determination error, 12
deviation alarms, 2, 5, 6 loop break, 3, 13
DISPLAY key, 5 LPbr error message, 3, 13
displays, 5, 11
M
E maintenance, 15
EEPROM write error, 12 MANUAL LED, 5
error codes, 11 manual tuning, 7
MODE key, 5
F modes of operation, 2, 6
factory default switch settings, 10
factory default values, 11
front panel, 5
fuses, 16

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 Series RMB Hot Runner Controller Instruction Manual

N S
NORMAL LED, 5 SafeChange feature, 9, 17
normal mode, 2 safety information, I, 15
sensor error, 3
O sensor type, switch setting for, 3, 17
setpoint, 5, 7
open sensor, 13 soft start, 2, 3
Out Shrt error message, 14 span calibration, 17
output bad, 3, 14 STANDBY LED, 5
output displayed, 7 switch settings, 3, 9, 10, 17
output for control, 2, 6
output in manual mode, 7
output state on power up, 6
T
output TRIAC short error, 3, 14 tC oPn error message, 13
tC rEv error message, 13
P technical support, 17
TRIAC short error message, 3, 14
part number for fuses, 16
troubleshooting, 11, 17
part number for SafeChange clip, 10
tuning, 7, 10
Pid menu, 2, 6, 7, 11, 12
powering up controller, 6
process value display, 5, 6
U
proportional band, 2, 7, 11 unit of measure switch setting, 9, 10
user interface, 5
R user-serviceable parts, 15

RAM error, 11
rate, 2, 7, 11
Z
replacing fuses, 16 zero calibration, 17
reset, 7, 11
reversed sensor, 13

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 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.
THE PURCHASER AGREES THAT ATHENA CONTROLS, INCORPORATED ASSUMES
NO LIABILITY UNDER ANY CIRCUMSTANCES FOR CONSEQUENTIAL DAMAGES
RESULTING FROM ITS USE OR FROM IMPROPER HANDLING OR PACKAGING OF
SHIPMENTS RETURNED TO THE FACTORY.
COMPONENTS WHICH WEAR OR WHICH ARE DAMAGED BY MISUSE ARE NOT
WARRANTED. THESE INCLUDE CONTACT POINTS, FUSES, ELECTROMECHANICAL
RELAYS, AND TRIACS. UNITS WHICH HAVE BEEN MODIFIED BY A CUSTOMER IN
ANY WAY ARE NOT WARRANTED.
Other than those expressly stated herein, THERE ARE NO OTHER WARRANTIES OF
ANY KIND, EXPRESS OR IMPLIED, AND SPECIFICALLY EXCLUDED BUT NOT BY WAY
OF LIMITATION, ARE THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR
PURPOSE AND MERCHANTABILITY.
IT IS UNDERSTOOD AND AGREED THE SELLER’S LIABILITY WHETHER IN
CONTRACT, IN TORT, UNDER ANY WARRANTY, IN NEGLIGENCE OR OTHERWISE
SHALL NOT EXCEED THE RETURN OF THE AMOUNT OF THE PURCHASE PRICE
PAID BY THE PURCHASER AND UNDER NO CIRCUMSTANCES SHALL SELLER 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, REGARDLESS OF FORM, ARISING OUT OF THE
TRANSACTIONS 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
LIMITED TO 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 PRICE, AND SUCH REMEDY SHALL BE BUYER’S ENTIRE AND
EXCLUSIVE REMEDY. THE SPECIFICATIONS PUT FORTH IN THIS MANUAL ARE
SUBJECT TO CHANGE WITHOUT NOTICE.

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 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.com

Part #900M212U00 RevA-05/06