RMG Gas Line Module User’s Guidedownloads.watlowsemi.com/RMG/Watlow RMG Manual.pdf · RMG Gas...

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RMG Gas Line Module User’s Guide

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1241 Bundy Boulevard, Winona, Minnesota USA 55987Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507, http://www.watlow.com

Aug 2016Rev 1.0

http://www.watlow.com/

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RMG Gas Line Controller Basics

The Watlow RMG is a 4 channel gas line heater controller that provides then features:

• Switch up to 3 amps of heater current per channel.

• Switches DC or rectified AC

• The 4 channels are phase staggered by 90º to minimize overlap of conduction times.

• High fidelity detection of load current, voltage, resistance and power.

• Startup sequence to check heaters before full operation

• Programmable warning and shutdown levels for detected current, heater resistance, leakage to ground.

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RMG Gas Line Module

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This module can contain 2 cards:

• RMG the gas line heater controller

• Modulates heater outputs

• Senses heater current, resistance and leakage

• RMUH – Ultra High Density TC

• Senses control TCs

• Senses over-temp TCs

• Limits over temp with a mechanical relay

• Provides control loops if RMZ EtherCAT is not present


RMG Model Number

RMGV-NNLLCCTAZZ

• V is voltage

• L=Low 20 to 40

• H=High 85 to 337VDC (not available as of 2016)

• NN is number of control TC inputs

• LL is number of over temperature TC inputs

• CC is number of control loops

• T is number of outputs

• A is reserved

• ZZ is locked firmware


Device Interfaces

USB Port

Power

Power to Heaters

Over Temp Relay

TC Inputs

Power on C Connector 98 and 99 24V AC/DC

Cards: RMG RMUH


Mounting


Mounting (2)


Controller Power Connections

Connect controller power of 24 V (ac) or (dc) power to pins 98 and 99. If dc is used then 98 is preferred for positive(+). This supply needs to be Class 2 or SELV.

This C connector is supplied with the device.

Split Rail Communications

CZ, CX, CY are the communications connection between modules. They are passed on the back plane between module. If some modules need to be mounted remotely, Split Rail, then these connections need to be run between modules. A shielded twisted pair is recommended for this RS-485 network.

Power Connections


Terminal Blocks


Pinouts


Gas Line Connections on RMGRMGP1 Power In is the power input that will feed the 4 heaters.

This is rated for 9A at 36 V(dc) feeding 3 of the 4 heaters fully on simultaneously. The dot is pin 1. The high voltage option is not available yet.

P1 Power In connector from Samtec:Receptacle: IMS5-03-02Contacts: CC46L-1416-01-LCrimp Tool: CAT-HT-246-1416-11

P2 Outputs is the output to all 4 heaters. These are 36 V(dc) and 3 amps each. The dot is pin 1.

P2 Heater connectors from Samtec:Receptacle: IPBD-04-D-KContacts: CC69L-1620-01-T-SPCrimp Tool: CAT-HT-169-1620-11

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Sensor Connections on RMUH cardService Port is a USB mini connector that provides access from PC software such as Composer and Dashboard from Watlow.

P3 is the thermocouple connector. It provides up to 18 thermocouple inputs. Pin is marked with the dot.

P3 TC connector from Samtec:Receptacle: ISD2-20-D-MContacts: CC81L-2426-01-LCrimp Tool: CAT-HT-281-2430-11

These input support TC types J,K,T,E,N,R,S,B,F

P5 (Global Alarm) is a Supervisor Relay rated at 1 A resistive 30 V (ac or dc). This is an aggregate of all configured Limits. It is only closed if all limits are in the Safe state. Pin 1 is marked with a dot.

P5 Relay connector from Samtec:Receptacle: IPBD-02-D-KContacts: CC69L-2024-01-T-SPCrimp Tool: CAT-HT-169-2024-11

RMUH


Setting Addresses

RMGRMUH

Use a small screwdriver to

set a unique address for each card.

1 to F(15) through the slot in the case.

This must be unique in the system

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System Topology

Heater Array

Heater Array

Heater Array

Heater Array

Controller

DC or

Rectified

Power

Sense

Sense

Sense

Sense


Internal Logic

Controller

Heater

Heater

Heater

Heater

Heater

State

Machine

Communications

interface to Master

and output

modules

Heater

Alarms

Heater

Alarms

Heater

Alarms

Heater

Alarms

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Startup Sequence

IDLE 1

VETTING 2

RUNNING 5

STANDBY 3

Power On

STARTUP

FAULT 4

RUNNING

FAULT 6

Pending

Request is RUN

Pending Request is

STARTUP or RUN

Pending Request is

STARTUP or RUN

and line voltage is

present

Fault occurs in

matching Fault Mask

Fault occurs in

matching Fault

Mask

Faults

Cleared

OUTPUT=Loop Power

OUTPUT=OFF

OUTPUT=OFF

OUTPUT=OFF

OUTPUT=PULSE

OUTPUT=OFF


Run ManagementUser Requested State

• This can be set by the system at anytime to drive towards the requested state

Startup State• This injects a desired state on power-up

Actual State• This value indicated the actual state of the system

All channels have the same state.

Requesting a state on 1 channels will set the other channels to the same value since the system is managed from a central state machine.

The state machine does not being the requested run until the line voltage is present.


Sensed Heater Voltage and Current

Sensed Targets

Voltage and Current

• Sensed simultaneously over 100ms at

5kHz at 24-bit

• Periodic points are determined to bracket

good readings

• DSP calculates RMS values

Current Limits can be set

for high and low trip points.

Voltage is a reference

value.

Accuracy• Voltage• Current

+/- 1 mV

+/- 1 mA 10mA min load

Wattage

• Calculated from V * I * %Duty Cycle

Wattage is a reference

value


Sensed Resistance Values

Sensed Targets

Resistance

• Calculated from V/I

Expected Resistance

Difference from Expected (user entered)

Actual Baseline Resistance

Difference from Baselined value

(captured and saved when triggered by

user)

Accuracy• Sensed Resistance • Resolves to 1 ohm out of 1000 ohms

• Add margin for trip limits to be

tolerance of system dither


Sensed Heater Ground Leakage

Sensed Targets

Leakage to Earth• Connected the center earth pin on the power

connector to gas line earth. Earth

• The pin is reference from support V+ to V- by a divider network.

Leakage Limit are set as %

of rail voltage.

• The reference point will shift relative to the rails if the heater network gets shorted to the gas lines.

A value of 1% with a 32V

rail would be a 320mV

swing.


Power Limiting

The outputs may be power limited to keep conduction times less than 100%.

This can limit the energy to the heaters for safety.

The 4 outputs are stagger 25% to minimize simultaneous conduction.

Only one output will be on at a time if the power is limited to 25% on all channels. This can lengthen time to set point.

The output cycle times default to 1 second with the outputs duty cycling at that rate.


Warnings and Faults

• The alarms have high and low trip levels. Each alarm can be enables as an indication or a fault or both.

• Indicating alarm are observed in the status field.

• Faults cause the channels to shutdown (not output power) in the fault condition.

• These are the available alarms

• Heater Current

• Heater Resistance relative to expected (matches spec)

• Heater Resistance relative to Baseline (tighter)

• Ground shift as a result of heater leakage to earth

• Open Heater

• Shorted Heater

• Shorted Heater is a hardware comparator for > 25A. Dead shorts will trip this within 200ns.


Fault and Warning Masks

• The alarms have high and low trip levels. Each alarm can be enables as an indication or a fault or both.

0x0001 Shorted Output Fault Enable

0x0002 Open Output Fault Enable

0x0004 Leakage Fault Enable

0x0008 Heater Current Level Fault Enabled

0x0010 Heater Resistance Shift from Baseline Fault Enabled

0x0020 Heater Resistance off expected by %

0x0040 Switching Device Over-Temp Fault Enabled


Setup via EtherCAT Interface

Setup in the 0x4002 objectsMap to module via 0x4000 objects


Operate via EtherCAT Interface

Run-Time Control in the 0x3000 objectsMonitor in the 0x2000 objects

These parameters can be mapped to User Tx PDO

These parameters can be mapped to User Rx PDO


Setup via USB and Dashboard


Operate and Monitor via USB and Dashboard


RMUH Setup via USB

TC Input Setup Control Loop Setup


RMUH Limit Setup via USBOver-Temp Input Setup

To configure the limit for each input

• Set the Sensor Type in the Temperature Input settings

• Set the Sides (High, Low, or Both)• Set Point High and Set Point Low as appropriate• Set the Hysteresis if needed• Clear Request to 1 to reset the limit

• The State shows if the limit is in a limit condition

• The relay P5 on the front of the device will close only when all 4 limits are in the SAFE condition.

The number of limits available is defined in the part number.

Example: RMGL-0504054AAA

This model number has 4 limits. They will be instances 6,7,8,9 since input 1-5 are control loops.


Troubleshooting

Faults occurring when not expected.

• Verify Fault Enable mask• Check limit trip points• Verify power is enabled to the heater

Faults not indicating

• Verify Warning Enable mask is set correctly

Values not reading

• Verify EtherCAT mapping


System Specifications

EnvironmentUnit ambient ratings -18 to 65°C 0 to 90% RH non-condensing

IP Code (IP20)

RMG CardAmbient Temperature Rating (Electronics): -18 to 65 C

Heater current 4 channels at 3A

Low Voltage 20 to 40 VDC

High Voltage 85 to 336 VDC

RMUH CardAmbient Temperature Rating (Electronics): -18 to 65 C

TC accuracy +- 1.0C *Pending Qualification

Limit Relay 5A 240 VAC

RS485 Standard Bus

USB Device

Communication Protocols via RMZEtherCAT ETG.5003.2060 Compliant

Watlow Standard Bus

DeviceNet


CE Declaration

RMG Gas Line Module User’s Guidedownloads.watlowsemi.com/RMG/Watlow RMG Manual.pdf · RMG Gas...

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