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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
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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
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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
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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
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Mounting
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Mounting (2)
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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
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Terminal Blocks
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Pinouts
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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
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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
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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
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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.
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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
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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
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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.
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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.
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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.
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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
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Setup via EtherCAT Interface
Setup in the 0x4002 objectsMap to module via 0x4000 objects
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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
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Setup via USB and Dashboard
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Operate and Monitor via USB and Dashboard
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RMUH Setup via USB
TC Input Setup Control Loop Setup
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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.
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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
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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
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CE Declaration