rmg gas line module user’s guide

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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

Manual Part Number0600-0105-0000Rev ASept 2017

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 the following 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


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 24 to 26V DC Nominal

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

• NN is number of control TC inputs (00-18)

• LL is number of over temperature TC inputs (00-18)

• CC is number of control loops (00-18)

• T is number of outputs (0-4)

• A is reserved

• ZZ is locked firmware

Note: Limits Inputs + Control Inputs <= 18


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


Safety Information


Mounting


Mounting (2)


Controller Power Connections

Connect controller power of 24 V 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 36V (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 36V (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

Caution: Remove all power sources from the device and system before accessing the switches.

Attention: Retirez toutes les sources d'énergie de l'appareil et le système électrique avant d'accéder aux commutateurs.

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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 holds off requesting a transitioning to “Run” until line voltage is present.

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Power Sources for DC / FET


0

100

200

300

400

500

600

700

3 phase rectified

0

50

100

150

200

250

300

350

Rectified Single Phase

0

10

20

30

40

50

60

Pure DCUsing a FET for power switching means more flexible switching times and lower power dissipation. It also limits the system to positive polarities only. A simple full wave bridge will create a positive-only supply.


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

• Digital Signal Processor 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.


Setting Limits for Leakage

100k max = Open Resistance to Supply (ohms)RMG Setting =

% shorted to +-V36V Supply

Leakage Current mA

100000 500 99.5 72.000

100000 1000 99 36.000

100000 10000 90 3.600

100000 20000 80 1.800

100000 30000 70 1.200

100000 40000 60 0.900

100000 50000 50 0.720

100000 60000 40 0.600

100000 70000 30 0.514

100000 90000 10 0.400

100000 99700 0.3 0.361

100000 99900 0.1 0.360


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 staggered 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 enabled as an indication, a fault, or both.

• Indicating alarm are observed in the status field.

• Faults cause the channels to shutdown (no 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 enabled 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


RMUH Thermocouple SpecificationsTC Type Temperature Range Accuracy Noise (p-p)

Type K -200 to 1372°C +-2.5°C +-0.08 °C

Type J -210 to 1200°C +-2.5°C +-0.07 °C

Type T -250 to 400°C +-2.5°C +-0.09 °C

Type E -200 to 1000°C +-2.5°C +-0.06 °C

Type N -200 to 1300°C +-2.5°C +-0.13 °C

Type R 0 to 1768°C +-2.5°C +-0.62 °C

Type S 0 to 1768°C +-2.5°C +-0.62 °C

Type B 400 to 1820°C +-2.5°C +-0.83 °C


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 up to 3A each

Low Voltage 24 to 36 VDC nominal

High Voltage 85 to 336 VDC (future option)

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

TC accuracy +- 1.0C *Pending Qualification

Limit Relay 5A at 240 VAC

RS485 Standard Bus

USB Device

Communication Protocols via RMZEtherCAT ETG.5003.2060 Compliant

Watlow Standard Bus

DeviceNet


Real-Time Clock and Battery

Real-Time ClockAvailable if the device has the data logging

The real-time clock provides the timestamp

Accuracy (typical): +/- 30ppm at 25°C

+30 ppm / -100 ppm over -20°C to 60°C

Battery Backup for ClockRayovac 3V (BR1225) lithium

The battery is only available on model with Real-Time Clock

Typical battery life is three cumulative years without power applied to device at 25°C

Recycle the battery properly

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FM Approval



Declaration of ConformityEZ Zone Series RM

WATLOW Electric Manufacturing Company ISO 9001since 1996.

1241 Bundy Blvd.

Winona, MN 55987 USA

Model Numbers: Access Models – RMA (A, F or S) – A (A, 2, 3, 5 or 6) (A or B) (A, B, U, Y or D) – AA (XX)Control Models – RMC (#) – (A, B, U, D, E, F, G, H, J, K, L, M, N, P, R, S, T, Y or Z) (A, R, P or #) (A, B, U, D, E, F, G, H, J, K, L, M, N, P, R, S, T Y or Z) (A, R, P or #) (A, B, U, D, E, F, G, H, J, K, L, M, N, P, R, S, T, Y or Z) (A, R, P or #) (A, B, U, D, E, F, G, H, J, K, L, M, N, P, R, S, T, Y, Z or C) –(A or F) (A or 1)(XX)Expansion Models – RME (A, F, R or S) – (A, C, J, F, L, K or T) (A, C, F, L, J or T) (A, J, C, F, L, K or T) (A, C, F, L or T) – A (A or 1)(XX)Fiber Optic Models – RMFA – (A or 1 to 8) (A or T) AA – A A (XX)High Density Models – RMH (A, F or S) – (1, 2 or T) (A, 1, 2 or T) (A, 1, 2, J, F, L, C or T) (A, 1, 2, J, F, L, C or T) – A (A or 1) (XX)Limit1 Models – RML (A, F or S) – (5 or 6) (A, 5 or 6) (A, 5, 6, J or C) (J or B) – A (A or 1) (XX)Scanner Models – RMS (A, F or S) – (R, P or T) (A, R, P or T) (A, R, P, J, C, D, F, L or T) (A, R, P, J, C, B, F, L or T) – A (A or 1) (XX)EtherCat Models – RMZ4 – (AA or 00 to 48) (AA or 00 to 04) – (A or B2) A (XX)Line Heating Models RMG (L) – (AA or 00 to 18)(AA or 00 to 18)(AA or 00 to 18) – (AA or 00 to 08) A (XX)Ultra-High Density Input Models – RMUH – (AA or 00 to 36)(AA or 00 to 36) – (AA or 00 to 36) (XX)# = Any number 0 to 9, XX = Any two letters or number combinations.

Classification: Temperature control, Installation Category II, Pollution degree 2Voltage and Frequency: SELV 24 to 28 V ac 50/60 Hz or dc Power Consumption: RMA, RMG and RMUH models 4 Watts, any other RM model 7 WattsEnvironmental Rating: IP20

Declares that the following Series RM (Rail Mount) products:

1Have not been evaluated for safety limit applications. Is considered an independent monitor device.

Meet the essential requirements of the following European Union Directives by using the relevant standards show below to indicate compliance.

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Declaration of Conformity (2)


EN 61326-1:2013 Electrical equipment for measurement, control and laboratory use – EMC requirements, Industrial Immunity, Class A Emissions (Not for use in a Class B environment without additional filtering).

IEC 61000-4-2:2008 Electrostatic discharge immunityIEC 61000-4-3:2007 +A1/2008, A2/2010

Radiated, radio-frequency electromagnetic field immunity, 10 V/m 80 MHz to 1 GHz 3 V/m 1.4 GHz to 2.7 GHz

IEC 61000-4-4:2012 Electrical fast-transient / burst immunityIEC 61000-4-5:2014 Surge immunityIEC 61000-4-6:2013 + Corrigendum 2015

Immunity to conducted disturbances induced by radio-frequency fields

IEC 61000-4-11:2004 + Interpretation 2010

Voltage dips, short interruptions and voltage variations immunity

EN 61000-3-2:2014 Limits for harmonic current emissions for equipment ≤ 16 Amps per phaseEN 61000-3-33:2013 Voltage fluctuations and flicker ≤ 16 Amps per phaseSEMI F47-0812 Specification for semiconductor sag immunity Figure R1-1

2014/30/EU Electromagnetic Compatibility Directive

3NOTE: To comply with flicker requirements cycle time may need to be up to 160 seconds if load current is at 15A, or the maximum source impedance

needs to be < 0.13. Control power input of RM models complies with 61000-3-3 requirements.

EN 61010-1:2010 Safety Requirements of electrical equipment for measurement, control and laboratory use. Part 1: General requirements

2014/35/EU Low-Voltage Directive

Compliant with 2011/65/EU RoHS Directive

Per 2012/19/EU W.E.E.E Directive Please Recycle Properly

EN 300 328 V 1.8.1 Wideband transmission systems; data transmission equipment operating in the 2.4 GHz ISM band and using wideband modulation techniques. Covering essential requirements under article 3.2 of the R&TTE directive.

EN 301 489-1 V 1.9.2 EMC standard for radio equipment and services; Part 1: Common technical requirementsEN 301 489-17 Part 17: Specific condition for 2.4 GHz wideband transmission systems.EN 60950-1:2006 +A11/2009, A1/2010

Information Technology Equipment - Safety

21999/5/EC Radio and Telecommunication Terminal Equipment DirectiveOnly applies to Bluetooth Module equipped version Model RMZ4-XXXX-BXXX (X = any letter or number)

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Declaration of Conformity (3)


Joe Millanes Winona, Minnesota, USAName of Authorized Representative Place of Issue

Director of Operations September 2016Title of Authorized Representative Date of Issue

Signature of Authorized Representative

rmg gas line module user’s guide

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