Sterlco M2B Owner's Manual

Rev. A
Dear Valued Customer,
On behalf of Sterling, we would like to express our gratitude and appreciation for choosing us as
your supplier. We would also like to take this opportunity to introduce you to our complete offering
of quality auxiliary equipment and services available for the process industries.
Full line of water and hot oil temperature control systems available in
standard and custom configurations.
Air- and water-cooled chillers available in portable and central styles.
Cooling tower systems, with full engineering capabilities.
Granulators, shredders, and size reduction systems. Available with
vacuum take away and special hopper configurations.
Robotics, sprue pickers, and downstream automation. Custom end of
arm tooling.
Quality OEM remanufacturing and updating of Sterlco water and hot oil
temperature control units and components.
To obtain further information about any of these products, please feel free to call Sterling at either
1-800-783-7835 or 414-354-0970.
CONGRATULATIONS!
You are the proud owner of a Sterlco® Temperature Control System, the finest, most dependable
unit available in todays market. Your Sterlco unit represents over 40 years of proven field service.
We, at Sterling, are dedicated to manufacturing a temperature control unit that is second to none.
Built by skilled craftsmen with the most modern and precise machinery available today. The
simplicity of design and compactness engineered into the unit result in less maintenance and
less floor space.
The Sterlco High Temperature Control Unit, designed and tested over a period of many years,
represents one of the most significant advances ever in the field of self-contained, closed
systems, portable units for heating natural or synthetic fluid and circulating it at controlled
temperatures through molds, rolls, or jackets of processing equipment.
This Owner’s Manual is intended to provide a complete overview of the unit and to give you stepby-step guidelines for the safe operation, care and service of your unit. We recommend that you
thoroughly read this manual before initial start-up.
These standard units may have many variations of optional features added to them, relative to
the customer’s application or specific desires. The illustrations used are to help you identify
certain parts by names and to understand our explanations, which will assist you later on in the
Troubleshooting sections.
Units are warranted against defects in materials and workmanship for a minimum of one year
from date of shipment. Any Sterlco unit which has been used contrary to specific operation
instructions or materially altered, will not be covered by this warranty. Final determination of
defects must be made at Sterling Inc.
By following the instructions in this manual and treating your equipment with care and respect
due any precision equipment, you will be rewarded with years of uninterrupted, trouble free
service.
Sterlco equipment must be attended while in use.
2
Table of Contents
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . 5
M2B Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Quick Start Instructions for the M2B Controller . . . . . . . . . . . 7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Input Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Normal Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auto Vent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ramp/Soak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Basic Theory of Operation Ramp/Soak . . . . . . . . . . . . . 14
Sample Ramp/Soak Program . . . . . . . . . . . . . . . . . . . . . 17
Starting Ramp/Soak . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retransmission of Process Variable . . . . . . . . . . . . . . . .
Second Set Point Input . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Thermocouple Monitor . . . . . . . . . . . . . . . . . . .
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPI Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
21
21
21
21
24
Diagnostic Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fault Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High Temperature Oil Reconfiguration . . . . . . . . . . . . . . . . . 27
Field Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Audit Temperature Inputs . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Appendix A-Menu Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix B-Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Appendix C-Control Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Appendix D-Blank Ramp/Soak Profile . . . . . . . . . . . . . . . . . . . . 43
Appendix E-Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3
Customer Service
Your unit was engineered and carefully assembled to give you excellent
quality and years of trouble-free operation. If an unknown condition occurs,
Sterlco has a well trained customer service group to assist you. We suggest
the following for quick service.
Sterling Inc.
The customer Service Group is available from 7 a.m. to 6 p.m. (CST),
Monday through Friday. The numbers to call are:
(800) 783-7835
(414) 354-0970
Fax (414) 354-6421
Before you call, be sure to do the following:
1. Refer to the Troubleshooting section of this manual.
2. Be sure to have this manual in front of you when you call.
3. Write down the symptoms or problem that you are experiencing.
4. Have your unit’s model number and serial number available when you
call.
Sterling Return Goods Authorization (RGA)
In order to better serve our customer’s needs, we ask that before returning
material or equipment of any kind, for any reason, that you call Sterling at
1-800-783-7835 for a return goods authorization number (RGA). This is a
mandatory policy to help us identify returned goods, the reason for their
return, and to help Sterlco expedite their processing. Failure to obtain this
RGA number and mark it on the goods may result in their immediate return
at your cost without being processed.
We thank you for your cooperation and understanding.
Heat transfer fluids must be drained and identified prior to
shipment.
Please record your model identification number here for future reference.
Refer to the description on Page 6 for more information.
601
4
00521
Conventions Used in This Manual
Sterling, Inc. - Parent company of Sterlco®, Ball & Jewell®, and Sterltech®.
Sterlco - Manufacturer of water and oil temperature control systems, and
water chiller systems.
BOLD CAP letters indicate a key on the M2B keypad.
“
” text indicates the characters that are displayed on the LED
windows. This manual shows the digital text as all caps, however, the actual
readouts are a combination of caps and lower case letters.
CAUTION: A warning intended to prevent physical harm to the operator or
equipment.
Note: Information to add clarity to the text.
The following illustration provides a reference for the side-bar illustrations:
∆
S
is used to denote what is
currently visable in the
SETPOINT display.
P
is used to denote what is
currently visable in the
PROCESS display.
and
are used to denote a process variable.
5
M2B Microprocessor Controller
Introduction
The M2B is a microprocessor based process controller designed for
exclusive use with the Sterlco Temperature Control Units. The M2B
monitors and maintains the temperature of the fluid in any given process to
a selected set point using a unique proportional integral derivative (PID)
auto-tuning program. The controller employs PID algorithms and fuzzy logic
to automatically tune the system to heat or cool the fluid as required by the
process.
The M2B has LED displays for set point and process temperatures.
Controller status lights are provided for the following functions: cool, heater
high/low, run, flow, return and delivery temperatures, and temperature
differential.
The controller includes self-diagnostics to check hardware functions.
Diagnostic lights are provided for the following functions: low fluid pressure,
safety thermo, high/low alarms, delivery and return probes, and motor fail.
The M2B is panel mounted and has a membrane keypad with tactile feedback. When properly installed with a sealing gasket, the M2B is safe for
water washdown.
P3
LOW HEAT
VENT
LOW HEAT
P4
IN
PURGE
+
COOL
-
+
- HEAT
PURGE
VENT
HI HEAT
LOW
HEAT
COOL
ALARM
PUMP
L2
L1 OUT
L1 CTLR
Soldered
Ribbon
Cable
P10
SSR
ONLY
1
2
3
4
5
6
7
8
9
10
11
12
HIGH HEAT
B
P9
CONTROL
POWER
SELECT.
Flow
Input
+5V
SSR or
4-20MA PLUG
IN MODULES
EXT INT
K
GRD
P2
ALARM
Safety
Thermo
2nd
Setpoint
Press
Switch
COOL
HIGH HEAT
P8
PUMP
P7
P6
COOL
Phase
Relay
A
P5
G
P10
P7
P11
White
Return
RTD
P9
P6
D
RS485/RS232
PLUG IN
P8
MODULE
E
PROCESS OUTPUT/REMOTE S.P.
PLUG IN MODULE
A2
T/C
Lowest Level Board contains Serial Label - lower left.
Figure-1
6
+
RMT SP +
PV OUT
DATA +
DATA -
H
Black
Thermocouple
Red
Delivery
RTD
Quick Start Instructions for the M2B Controller
The quick start instructions can only be used provided the M2B is properly
installed and wired.
Turn unit on - The “SETPOINT” and “PROCESS” LED displays will read
“
“.
∆
Wait 3 sec. - The LED displays will read ““ and “
“
Wait 3 sec. - The LED displays will read ““and “
“ where ““
equals the current process temperature.
ON
S
P
3 sec.
3 sec.
S
P
1 to 5
min.
S
P
S
P
Wait 1 to 5 min. for Vent sequence. - The LED displays will read ““
and “
“ ““ equals the process setpoint. ““ equals the current
process temperature.
The process is now running. The setpoint may now be adjusted for your
installation. Press SETPOINT. Use ARROW to adjust.
RUN
Model Identification
To determine the options that are included with the M2B, use the following
configurator. The character “X” represents an option that is included.
601
= STD
R = Rebuilt
X
00521
X
Base
Special Options
= STD
1="J" T/C
2=Flow
3=RAMP/SOAK (Null)
4=Process Input
4-20 MA S.P. & P.V. XMIT
5=2 Stage Set Point (Null)
6=4-20 Heat Out
7=4-20 Cool Out
X
X
XXX
030 (30 gpm)
075 (75 gpm)
Temp Limit
0 - 250 F
1 - 180 F
2 - 200 F
3 - 450 F
4 - 300 F
5 - 400 F
6 - 550 F
7 - 650 F
8 - Chiller
Options
0 - STD.
1 - RS485 SPI
2 - RS485 GEN
3 - 4-20 Heat Out
4 - 4-20 Cool Out
5 - 4-20 Heat/Cool
6 - RS232 GEN.
7 - Process Input
4-20 MA S.P. & P.V. XMIT
7
Installation
Environment
Mount the instrument in a location that will not be subject to excessive
temperature, shock or vibration. All models are designed for mounting in an
enclosed panel.
When properly mounted in an enclosed panel using a gasket at the
panel/controller interface, the keypad can be washed down with water. Do
not use high pressure fluids.
Microprocessor based instruments require a “clean” source of power that is
steady and free of noise. Electrical noise may be caused by line faults,
power switching, motors, motor controllers, or power controllers containing
SCR devices. Without a clean source, any microprocessor is prone to
failure.
Electrical
CAUTION: Electrical noise is created by devices that are connected to
a controls output load circuit. Field coils from contactors or solenoids
are a common source of electrical noise. These conditions may
interfere with the operation of the M2B controller.
If your power source is not from a clean line, your system can be protected
by installing a Line Filter.
Where external contactors or solenoids are used with relay output
instruments, an R/C Snubber Network should be used. The snubber installs
easily directly across the field coil terminals of the relay or solenoid.
Do not run thermocouples, RTD’s or other class 2 wiring in the same
conduit or area as power leads. Maintain separation between wiring of
sensors, process signals and other power and control wiring.
Security
Passwords are used to prevent access to critical menus. Four levels of
security are provided. The display shows the current security level. Security
levels are changed by changing the password value using the UP and
DOWN arrow keys and pressing the ENTER key. Refer to the password
table below for the correct value to enter for the security level desired. The
SEC menu item security level may be viewed or changed at any time
regardless of the present security level.
For example, to set the access level to ” ”, at the SEC menu item press the
UP arrow key until the upper display shows the password, 101. Press the
ENTER key. The display will blink, and return with the level value, ””, in the
Process display.
8
Menu
Security Level
Status
Displayed Value
When Viewed
Password Value To
Enter
Home
Secondary
Secure
Locked
Locked
Locked
1
110
Home
Secondary
Secure
Unlocked
Locked
Locked
2
101
Home
Secondary
Secure
Unlocked
Unlocked
Locked
3
011
Home
Secondary
Secure
Unlocked
Unlocked
Unlocked
4
111
Interface Panel
∆
Figure-2
Note: Depressing the DISPLAY keypad, the function LED will stay on for
thirty (30) seconds, then revert to the default delivery display.
Indicator Lights
Status Lights
• RUN - Flashes while controller is auto-tuning. Glows steady during
normal operation.
• HI HEAT - Fluid heaters are on Hi to rapidly raise the fluid temperature.
• LO HEAT - Fluid heaters are at 50%.
• COOL - Fluid temperature is above setpoint and is being cooled.
9
Display
• DELIVERY - The process display is showing the temperature of the
outgoing fluid.
• RETURN - The process display is showing the temperature of the
incoming fluid.
• ∆T - The process display is showing the difference between delivery
and return temperatures.
• FLOW - The process display is showing the flow of the fluid in GPM or
LPM. Must have optional flow sensor.
Alarms
• FLUID PRESSURE - Fluid pressure low. Unit shuts down and will
resume operation when pressure is restored (disabled in oil units).
• SAFETY THERMO - Over temperature fault. Heater outputs are
disabled. Pump continues to operate and the “cool” solenoid is
energized. This is a fatal fault which requires the main power to be
disconnected to reset the M2B.
• HI/LO ALARM - The alarms can be set individually via the keypads. The
HI deviation is +200 oF (+93.3 oC) above the setpoint. The LOW
deviation is -100 oF(-37.7 oC) below the setpoint. Oil temperature
control unit alarms are set to “” as default and must be activated
through the keypad if needed. The alarm settings can be changed to
absolute, “
” in the secondary menu. Alarms reset automatically.
• PROBE FAIL - A temperature sensing probe has failed. A delivery probe
fail will display “” in the display. Failure of the return probe will
display “”. The alarm will reset when the probe is replaced.
• MOTOR FAIL - Improper pump rotation, motor out of phase or thermal
overload. This is a fatal fault which requires the main power to be
disconnected to reset the M2B (water units only).
Input Keypad
Depressing any program keypad (SETPOINT, HI ALARM, LO ALARM)
displays the stored value and allows the parameters to be adjusted. The
following programmable features are allowed by the M2B.
• PROGRAM SETPOINT - Depress and hold the SET POINT keypad and
either the UP or DOWN arrow to increase or decrease the set point
display.
• PROGRAM HI ALARM - Depress and hold the HI ALARM and either
the UP or DOWN arrows to set the alarm high limit. To disable the
function, set the limit out of range or go into the secondary menu by
depressing the UP and ENTER keys together. Use the index key to
access the “
” function. Use the UP or DOWN key to select “
”.
Depress ENTER to accept the function change.
Note: The controller will automatically program a high alarm of +200 oF
(+93.3 oC) above set point and -100 oF (-73.3 oC) below setpoint.
10
• DISPLAY - Depressing the DISPLAY keypad scrolls through the display
menu. Each depression indexes to the next available function. The
display function will return to delivery temperature after thirty (30)
seconds.
• UP ARROW - Increments a value, continued pressing will cause the
value to gradually increment at a faster rate.
• DOWN ARROW - Decrements a value, continued pressing will cause
the value to decrement at a faster rate.
• ENTER - Used only in conjunction with the home menu (index pad) or
the secondary and secure menus. Pressing ENTER stores the value or
the item changed. If not pressed, the previously stored value or item will
be retained.
• INDEX - Pressing the INDEX key advances the display to the next menu
item. The following functions are accessible by the INDEX key (see
Appendix A for more information):
–
–
–
–
–
–
–
–
–
Tune
Fuzzy Logic
Auxiliary set point
Thermocouple Monitor
Flow Alarms
Autovent on-Off and Duration 1 to 5 min.
High/Low Heat Select
Ramp/Soak Run/Hold
Segment Time Remaining
• UP and DOWN ARROWs - Depressing the UP and DOWN arrows
simultaneously activates an optional output normally used for purge
options.
• UP and ENTER - Depressing the UP and ENTER keys simultaneously
will access the “secondary menu”. The following functions are
accessible in this menu (see Appendix A for more information):
–
–
–
–
–
–
–
–
oF/ oC
Select,
Alarm: On-Off/Lo/Hi/Hi/Lo
Event
Ramp Soak,
Loop Break On-Off
Percent Output Display
Communications I.D.
Proportional Output/Input Scaling
Depress and hold for 30 seconds to enter the secure menu. All outputs are
disabled.
CAUTION: Any changes will effect system operation.
Normal Operation Mode
Auto Vent:
Display ““ in the set point display for duration of auto vent condition 1 to
5 minutes, adjustable. The auto vent feature is deactivated on high
temperature oil units and chillers.
11
Tuning
Note: The M2B is shipped with preset tuning parameters. To quickly adapt
the M2B to your process, you may elect to tune the controller at start-up.
Read this section entirely before initiating operation.
The M2B features Fuzzy Logic. Manual tuning is not necessary.
Fuzzy Logic is a term that describes the decision process within the
controller. This controller has the programmed ability to “consider” inputs
and change process information accordingly. One analogy would be a
human trying to hit a target. The first attempt is recorded and the brain
makes continual process corrections until an acceptable tolerance is
reached.
The M2B controller also has multiple tuning conventions available to adjust
to your process. Tuning choices are:
• Self
• Manual PID Input
• Slow
•
•
Nor
Fast
These tuning methods will speed up the Fuzzy Logic process.
Self-autotuning may be considered when initial start-up is performed or the
mold and/or the process is changed.
CAUTION: The factory default for the M2B is automatic half/full heat.
If an autotune cycle is completed do not switch to low heat without
performing a new autotune cycle. Failure to autotune will result in
poor control of the process. Subsequent changes from one heat
setting to another require autotune to be run.
Initiate Autotuning:
∆
The controller will evaluate the process and select the P, I, D and Fuzzy
Logic values. To maintain control:
1. Turn the control power switch to ON.
2. Press SETPOINT.
3. Use UP/DOWN arrows to adjust setpoint.
4. Allow completion of Autovent (“” in set point display).
ON
5. Press INDEX keypad until “” appears in the display.
S
6. Press UP/DOWN arrows until “
” appears in the display.
S
Autovent
7. Press ENTER.
S
P
8. The Run Lamp will flash during the entire Autotune process.
S
P
9. Press INDEX keypad until “” and “
” appear in the displays. Use
the UP/DOWN arrows to select “” to cancel the tune.
S
P
S
Autotune
Finished
RUN
12
10. Press ENTER.
Do not attempt to reprogram the M2B or depress any keypads while the
“RUN” LED is flashing, as this will cancel the autotuning process.
For best Autotune results, start with a stabilized process temperature (no
rapid rises or drops in temperature).
Manual Tuning Procedure (Zeigler-Nichols PID Method):
S
This tuning method may be used if the spread between ambient
temperature and process operating temperature is small. For best results,
the use of a recording device is required when tuning with this method:
P
1. Disable the cooling output. Set “” in the scure menu to “”.
S
P
S
P
S
P
S
P
S
P
S
P
2. Set the reset (integral), the rate (derivative), and the fuzzy intensity
(FPC) to zero. Set the proportional band (PBH) to 100.
3. Adjust setpoint to the desired value.
4. While monitoring the process temperature or recording device,
decrease the proportional value by repeatedly halving the value until a
small, sustained temperature oscillation is observed. Measure the
period of one cycle of oscillation ”T”.
5. Divide the period of oscillation ”T” by eight, the resulting number is the
correct rate, “” time in seconds. Multiply this number by four. This is
the correct reset “
” time in seconds.
T
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
6. Multiply the bandwidth value ”T” by 1.66, enter this as the new
proportional “” value.
7. Reset the cool output “” to “”.
8. Reset the fuzzy intensity “ ” to 50.
13
Manual Proportional Integral Derivative (PID):
Allows the operator to manually input P, I and D parameters into the
controller. These parameters are fixed as long as the controller is in this
mode.
Slo, Nor, or Fast:
Heat/Cool PID quick tune pre-determined parameters. Selectable through
the keypad. See table below for Reference Settings.
Reference Settings For Manual PID Input
Index
Slow Response
System
Medium Response
System
Fast Response
System
Air
Cooled
Water
Cooled
Air
Cooled
Water
Cooled
Air
Cooled
Water
Cooled
Pb1
Heating Band
12
12
8
8
6
6
Pb2
Cooling Band
12
20
8
12
6
10
db
DeadBand
0
0
0
0
0
0
rES Reset
20.0
15.0
7.0
5.0
3.0
2.0
rtE
Rate
1.67
1.25
0.58
0.42
0.25
0.17
Ramp/Soak
The controller is provided with a 16 segment, front programmable
Ramp/Soak feature. Unused alarms can be programmed as a segment.
Caution: Do not operate the auto-tune while a ramp/soak
function is operating.
Ramp/Soak is one of the many features that add process programming
capabilities to the M2B controller. This section will deal only with the
Ramp/Soak programming operation.
Basic Theory Of
Operation Ramp/Soak
The M2B controller is user friendly. It offers an easy way to program a ramp.
Instead of requiring the operator to calculate an approach rate, the M2B
does the calculation automatically. The operator needs to program the
target set point and the time desired to reach that set point. When the ramp
segment is executed by the controller, it calculates the ramp required to
reach the process temperature from starting set point to the programmed
set point in the time allowed.
Dwells (or soaks) are ramp segments with target set point equal to starting
process temperature. This allows for multistage ramps without wasting
intermediate soak steps.
IMPORTANT! Test any program for best results before running production
material.
14
Caution: Make sure to run auto-tune before operating Ramp/Soak
because Ramp functions will interfere with the operation of auto-tune.
Ramp/Soak Set Up
∆
S
P
S
P
S
S
Before programming Ramp/Soak, evaluate your program on paper. To
program Ramp/Soak function, enter the secondary menu (pressing UP and
ENTER keys simultaneously).
•
•
•
•
•
•
•
•
•
•
•
•
Press INDEX key repeatedly until “!” appears.
Use the ARROW keys to change to ““(if it is on).
Press ENTER.
Press INDEX once, “
” should appear.
Use the ARROW keys to change to “” (if it is off).
Press ENTER.
Press INDEX. “
” should appear.
Skip this parameter for now, and press INDEX once more. “
” will
appear.
Use the ARROW keys to select time base (seconds or minutes).
Press ENTER.
Press the INDEX key until “"#” appears.
From this point, pressing INDEX will display the following items in the
following order:
“"#
"#”, “"
"
”, “""
""” and “"”---“$#”, “$
”---“#”, “
”---“!#
!#”,
“!
!
”
Alarms 1 and 2 display only if they are programmed as an event.
To eliminate repetition, each item will be described once.
S
S
S
S
S
S
Through 16 points
15
∆
S
P
S
P
S
P
S
P
S
P
Through 16 points
RUN
16
• For the first ramp, set “"#“ to the required time. This value is in time
units from 0 to 999 (seconds or minutes).
• Press ENTER.
• Press INDEX, set “"
” to target set point for the first ramp. The units
of this value are the same as normal set point (SP1).
• Press ENTER.
• If alarm 1 is programmed as an event, then “""” will appear when
INDEX is pressed. If alarm 1 is required for this segment, set “""” for
ON, if not, set for OFF.
• If alarms 1 or 2 are not programmed as an event, the “""” and “"”
will not appear. If “""
""” or “"” are set to ON, alarm 1 or 2 will be
active for the period of “"#” and “"”.
• Set the segment times (“"#”---”!#
!#”), segment set points (“"
”--”!
!
”), event alarms (“""
""”---”"%”), if they exist.
• For the segments that are not used, set the segment times to 0, and
segment set points to the same value as the last active set point.
• Event alarms may be set as necessary.
• END is the last menu item for the Ramp/Soak function. END determines
what the controller does when the program has ended.
• To set the program to repeat, select (“”).
• If (“”) is selected, it is important to allow the process to return to the
same condition that existed when the program first started.
• To hold last set point (“!
!
”), select (“”).
• Turn off outputs at end of program, select (“&”)
• Press ENTER to accept your choice.
Sample Ramp Soak Program
Segment Prompt
Function
Time (Min.)
1TI
1st Event
1
1SP
2TI
50
2nd Event
2
3rd Event
2
2SP
3TI
150
3SP
4TI
150
4th Event
2
4SP
5TI
100
5th Event
1
5SP
6TI
Setpoint oF
100
6th Event
2
7TI
Un-Used
0
7SP
Hold Last Setpoint
↓
Un-Used
GTI
Un-Used
6SP
50
50
0
GSP
50
END
Stay at present set pt. (gSP)
HLd
END
Turn off outputs at end of program
Oof
END
Repeat program at 1TI
Lop
17
The following flow chart diagrams the sample Ramp/Soak procedure.
Enter the secondary menu. Follow the “Ramp/Soak setup” steps to reach S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
Set the remaining points, 8-9
and A-G to zero
S
P
S
P
S
P
S
P
S
P
or
S
P
S
P
S
S
P
P
or
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
This program is now ready to run. See Starting Ramp/Soak.
18
Starting Ramp/Soak
∆
S
Return to Normal
P
• To run the program, enter the secondary menu and set the “” menu
item to “”.
• Press ENTER.
• Return to normal display by pressing SET POINT key or waiting for the
display to time out.
• Press INDEX key once, “'!
'!” will appear.
• Use the ARROW keys to change to “(” (if it is “”).
• Press ENTER. The primary menu will change depending on the setting
of “
” menu item in the secondary menu. If “
” is off, there is no
change. If “
” is set to on, the primary menu has three additional
information items added after “'!” appears:
• “"” displays remaining time in the current segment
• “"#” displays total time of active segment
• “"
” displays the segment set point (“"
”---”!
!
”).
To exit primary menu, press SET POINT key.
S
P
STA
OFF No Change
ON
S
P
S
P
S
P
Remaining
Time
Total Time
of Segment
Segment
Set Point
19
Options
Remote Set Point
Installation
If the serial number date of the M2B is before 1/99 and the M2B controller
was not factory equipped with a remote set point card, the controller must
be configured to activate the option when field installed.
∆
S
P
S
P
S
P
S
P
• Turn the control power off, cycle control power on.
• During self test, hold the INDEX and ENTER keys until display shows
prom version number.
• Release the keys and the display will show the prom version across
both displays.
• Depress the INDEX key until “” “
” appears.
• If ”
” is flashing, the remote set point is disabled.
• If the “
” is steady, the remote set point is enabled.
• Press ENTER to change status.
• Press INDEX twice.
• Display “)” “”.
• Press the UP arrow to display “ ”.
• Press ENTER.
P
Operation
The M2B is capable of an analog remote set point input. The operator can
toggle the set point from local to remote input via the following sequence.
S
P
RUN
P
• Depress the UP and ENTER keys simultaneously.
• Depress the INDEX key to scroll through the menu until “
” appears
in the left display.
• Depress the UP or DOWN keys to select remote set point “” or “”.
• Depress the ENTER key to accept the selection.
Note: The M2B analog input is a 0-20mA current input. If a 4 to 20mA input
is required, the low limit “” must be scaled using the following
calculation:
y = mx+b
where y = “
”
m = high limit - 0/analog high-analog low
x = analog high limit (20mA)
b = “”
“
* is Set Stop Limit High
“
* is Set Stop Limit Low
20
For Example: 250 oF = (250oF/20Ma - 4 mA) 20mA + b
-62.5 = b (”
”)
Retransmission Of
Process Variable
The M2B is capable of re-transmitting the process output “'” or the set
point input “
” via a 0-20mA analog signal. If a 4 to 20mA output is
desired, follow the scaling calculation outlined in the remote set point
section. Insert the low and high values for “” and “
”.
Second Set Point
Input
The M2B is provided with a secondary set point “
” pre-programmed for
0 oF (-17.7 oC), but is adjustable. When an external switch contact is closed,
the controller will switch to this set point and will display “” . This will
occur when SP2 is set to 0 oF and the actual setpoint is any other value.
The controller will revert to “
” when the contact is released and unit
returns to run mode.
Flow Meter
The M2B is capable of displaying and alarming process flow in gallons per
minute (GPM) or liters per minute (LPM), via a factory installed flow sensor.
The M2B is capable of accepting numerous flow sensors.
Note: Please contact the factory if the flow readout oscillates or appears
erratic for evaluation, calibration, and installation instructions.
The M2B is equipped with a software activated digital filter. The filter is
adjustable from 0-100, the larger the number the greater the signal
dampening. Consult the factory for further information and access.
Remote
Thermocouple
Monitor
Monitors type “J” thermocouple input. Depress INDEX key until “)”
appears. Temperature is displayed in process display window. See Figure-1
for location.
Communications
The Sterling M2B controller can communicate with a host machine via a
half or full duplex RS232 or RS485 communication link.
P
S
S
RUN
S
• Press and hold the UP and ENTER keys to access the secondary
menu.
• Use the INDEX key until “+” appears.
• Use the UP or DOWN keys to select “ ” or “”.
• Depress ENTER to accept your selection.
• INDEX to “” to select the controller address “1 to 3FF”.
• Depress ENTER to accept your selection.
Note: All data is sent and received in the ASCII hex character format, using
10 bits: 1 Start bit, 8 data bits, no parity and 1 Stop bit.
Any changes in the communication protocol should be made by qualified
technicians.
Host will be used to describe the computer operating as the originator of
communications. Instrument will be used to describe the process
control(2) using this protocol. In the following examples, only Host and
Instrument will be used.
21
1. The “L” (ASCII 4C hex) is used as a filter character in the examples below.
The filter characters are specific. The filter character changes according
to the Instrument’s address.
(ASCII 4C hex) = Instrument addresses 01 through FF
(ASCII 4F hex) = Instrument addresses 101 through 1FF
(ASCII 56 hex) = Instrument addresses 201 through 2FF
(ASCII 43 hex) = Instrument addresses 301 through 3FF
Addresses 00h, 200h and 300h should not be used. These are for
Factory Service use only.
2. The checksum generated by the Host is obtained by adding all ASCII
characters in hex, excluding the <stx>, filter character, and the <etx>.
Only the lowest 8 bits are used. The checksum is inserted into the
message between the data field and the <etx>.
Example: Host checksum calculation
32h
0100h
<stx> L
<addr>
02
33 32 30 31 30 30
4C
<---data--->
26h
<cksm>
32 36
<etx>
03
<----------cksm-------->
33+32+30+31+30+30 = 126h (use only the low byte)
3. The checksum generated by the Instrument is obtained by adding all
ASCII characters in hex, excluding the <stx> and the <ack>. Only the
lowest 8 bits are used. The checksum is inserted between the data field
and the <ack>. Note that the filter character is included in the checksum
calculation by Instrument.
Example: Instrument checksum calculation
32h
0100h
<stx> L
<addr>
02
33 32 30 31 30 30 31 35
4C
<---data--->
26h
<cksm> <ack>
44 38 06
<-------------------cksm------------------->
4C+33+32+30+31+30+30 +31+35 = 1D8h (use only the low byte)
4. Checksums are generated for all Host commands
5. Checksums are generated for all normal Instrument responses. A
checksum is not sent when errors are reported to the Host.
22
Command And Response Example Notations
1. [nu]: “not used” at present time, (for future expansion). Undefined data,
data returned should not be used.
2. <Data>: These are ASCII characters shown in Hex notation. The upper
case alpha character set is used for values A through F. (ASCII 46h - F,
ASCII 33h - 3). Lower case is not used.
ASCII in hex
ASCII Control Character
<stx>
<etx>
<ack>
L
00N
100N
200H
02
03
06
4C
Description
Start of Text
End of Text
Acknowledgment
Filter Character
Process Variable Value
Read Set Point Value
Write Set Point Value
Error Messages Reported
Example:Checksum error detected by Instrument at address 32
Instrument responds to Host’s last command with Error message
<stx>
02
L
4C
<addr>
N
<error code>
32h
N
02h
33 32
4E
30
32
<ack>
06
(Note the absence of Checksum)
N - ASCII character (4Eh) used to denote Error Present
Table Of Error Messages Possible From Instrument
<error code>
00 - Not used.
01 = Undefined command. Command not within acceptable range.
02 = Check-sum error on received data from Host.
03 = Command not performed by Instrument (option not enabled,
restricted
read/write menu, check message)
04 = Illegal ASCII characters received in command. Instrument
accepts only ASCII characters 0 through 9. A through F and a
through f in data field.
05 = Data field error. Not enough, too many, or improper positioning of
characters in data field.
06 = Undefined command. Command not within acceptable range.
23
07 = Not used.
08, 09 = Hardware fault. Return to Factory for service.
10 = Undefined command. Command not within acceptable range.
SPI Protocol
The Society of the Plastics Industry (SPI) communication protocol specifies
a connection management Protocol, a packetized communication format,
and communication error mechanisms passing commands and data
between a host computer and a slave. A host computer initiates all
communications. The protocol used corresponds to the 3.01 version of the
SPI communication protocol specification dated October, 1990. The data is
transmitted via a multidrop EIA-485 (half-duplex) hookup. The character
format required is 1 start bit, 8 data bits, no parity and 1 stop bit.
The M2B controller will support a number of commands that will allow the
host computer to retrieve status and assign set points. The commands
correspond to a mold temperature controller device.
Commands
Descriptions
(CMDl)
(CMD2)
(20H)
(20H)
Echo poll — Controller integrity command. Return the 4 bytes of ASCII
assigned by the Echo Select command in an open format.
(21H)
Echo Select — Controller integrity command. Supplies 4 bytes of ASCII in
an open format that is to be returned when an Echo Poll command is
received.
(22H)
Version poll — Returns a version number (AABB = 0101) as 4 bytes of ASCII
in an open format where:
AA = SPI assigned version level
BB = Vendor assigned version level
(30H)
Set point poll — Returns the current process set point value in numeric
format.
(31H)
Set point select — Assigns a value to the process set point in numeric
format.
(32H)
Alarm, high temperature deviation poll —Return the high temperature
deviation set point value in numeric format. This value when added to the
process set point gives the temperature at which a high alarm will occur.
(33H)
Alarm, high temperature deviation select —Assigns a value to the high
temperature deviation set point in numeric format.
(34H)
Alarm, low temperature deviation poll —Returns the low temperature
deviation set point value in numeric format. This value when subtracted
from the process set point gives the temperature at which a low alarm will
occur.
(40H)
Status process poll —Returns the status of the process as 16 flag bits in
open format. The following bits are supported. The rest are set to 0.
Bit 0 — Processing
Bit 1 — Alarm, System
Bit 2 — Alarm, Process
24
Bit 3 — Alarm, Machine
Bit 4 — Alarm, High Temperature
Bit 5 — Alarm, Low Temperature
Bit 7 — Alarm, Low Pressure
Bit 9— Alarm, Low Flow
(42H)
Status, machine 1 poll — Returns the status of the machine as 16 flag bits
in open format. The following bits are supported. The rest are set to 0.
Bit 0 — Processing
Bit 1 — Alarm, System
Bit 2 — Alarm, Process
Bit 3 — Alarm, Machine
Bit 4 — Alarm, High Temperature
Bit 5 — Alarm, Low Temperature
Bit 7 — Alarm, Low Pressure
Bit 14 — Alarm, Phase Reversed or Lost
(44H)
Status, machine 2 poll — Returns the status of the machine as 16 flag bits
in open format. The following bits are supported. The rest are set to 0.
Bit 0 — Processing
Bit 1 — Alarm, System
Bit 2 — Alarm, Process
Bit 3 — Alarm, Machine
Bit 4 — Fault, Sensor, Delivery
Bit 5 — Fault, Sensor, Return
(48H)
Mode, Machine Poll — Returns the current status of temperature control
unit if the machine is On (1) or Off(0).
(49H)
Mode, Machine Select — Commands the temperature control unit to turn
On (1) or Off (0)
Bit 0— Machine On/Off
Bit 1 — Alarm Acknowledge
(70H)
Temperature, to process poll — Returns the delivery temperature in numeric
format.
(72H)
Temperature, from process poll — Returns the return temperature in
numeric format.
25
Diagnostic Error
Messages
DISPLAY
DESCRIPTION
ACTION REQUIRED
Flashing
“”
Ambient temperature out
of range
Reduce ambient temperature
at controller, consult factory.
Flashing*
“”
Controller Ram violated,
static discharge.
Controller must be reset to
factory defaults. Consult
factory for causes.
Steady
“”
Delivery probe fail.
Check probe connection or
replace probe.
Steady
“”
Return probe fail.
Check probe connection or
replace probe.
Steady
4-20 mA input failed
“+” “)-”
Check polarity.
* Prior to Jan 1999 this was a flashing “”.
Fault Reset Procedure
Reset Flashing “”
• Enter Secure 4 menu by pressing UP and ENTER simultaneously for 3
seconds.
• INDEX to “”
• UP arrow until “+++” right display, press ENTER.
• INDEX to “$)” left display, press ENTER, 9 flashes.
• UP arrow until “,,” in right display.
• Press DOWN and ENTER together to accept.
• Display will flash “”, then “” steady.
• Press SET POINT to exit to run.
∆
S
P
S
P
Reload Factory Default
RUN
S
RUN
26
P
S
P
S
P
• Cycle control power to system Off and On.
• While M2B controller is performing the self test, simultaneously depress
the INDEX and ENTER keypads together.
• Index until “&” and “ ” appears in the display.
• Press the DOWN and ENTER keypads simultaneously to accept the
factory default. Both displays will flash “&&” then “ “indicating reboot is complete.
• The controller will automatically return to the run mode.
CAUTION: The M2B controller automatically defaults to a 250 oF (121.1 oC)
set-stop limit, water temperature control unit (TCU) configuration. All
special configurations. i.e. 4-20 MA scaling, will be lost. Please record
menu variables before performing a factory default. If you have an oil TCU,
the controller must be re-configured for a high temperature 550 oF
(287.7 oC) set-stop limit.
High Temperature Oil
Re-configuration
∆
S
P
S
• Depress and hold the UP and ENTER keypads simultaneously for five
(5) seconds to enter the secure menu.
• “
” will appear in the left display and “.” will appear in the right
display.
• Depress the INDEX keypad until “)
)” appears in the left display and
“” appears in the right display.
• Depress the UP arrow until “” appears in the right display.
• Depress the DOWN and ENTER keypads simultaneously to enter the
parameter.
• Both the displays will flash “&&” then “ “ indicating the re-boot is
complete.
• Depress the SET POINT keypad for short cut to the run mode, or, wait
thirty (30) seconds for auto exit to run mode.
P
P
S
P
S
P
RUN
27
Field Calibration
All Sterlco controllers are pre-calibrated at the factory. Due to the design of
our input circuitry, the factory calibration should be valid for the life of the
instrument. In the event recalibration is warranted, Sterlco recommends
verifying input calibration specifications every twelve (12) months. Follow
the calibration procedures outlined in your controller manual.
Audit Temperature
Inputs
To audit the temperature probes for accuracy the following procedure
should be followed:
Materials supplied by user
1. Input Signal testing
a. Millivolt Runup (MVR) with an output impedance of 100 ohms or
less. Accuracy should be ± 1% or better.
b. Resistance decade box (RD) with an accuracy of ± 1% or better.
c. Frequency counter with an accuracy of ± 1% or better (0 to 2.5K mm.
range).
d. Frequency generator capable of 50 to 200 Hz.
∆
2. 4-1/2 Digit Digital Multimeter (DVM) with an accuracy of ± 0.05% or
better.
P
3. Ambient Temperature Indicator with an accuracy of ± 0.05% or better.
No
S
P
4. Assortment of test leads.
Procedure
Yes
1. Power up Instrument and allow the M2B to warm up for 1 hour.
S
P
S
P
S
P
P
Attach decade box
To Accept
P
2. Hold the ENTER and UP Arrow keys for 5 seconds. The Menu will enter
the SECURE MENU. The displays will read “
” and “.”. If not, set the
right display to “"""
"""’, and press ENTER. The right display should blink
and return to “.”. Press the INDEX key until you see “” and change
it from “” to “” and press ENTER. INDEX to “)#
)#” and change it
from “” to “” and press ENTER.
3. Press the INDEX key until you reach “”. Use the UP and DOWN
arrow keys until “+++“shows in the right display. Press ENTER, and the
two left digits of the left display will read “)” (See Figure-3).
This is CAL 0. Place the RTD connector into slot D (see Figure-4).
Adjust the decade box to 99.114 ohms. The calibration value of the M2B
should be between 18CA to 22CF (in hexadecimal - see Table 1). Press
the ENTER and DOWN arrow keys if the value is within the acceptable
range.
Calibration Value (Hexadecimal, 0-9, A-F)
Calibration #
To Accept
Repeat for 2c, 3c, 4c, 5c,
6c, 7c, 8c, 9c, ac, bc
RUN
28
Figure-3
4. Use the UP arrow key to go to CAL 1 (“")”). Adjust the input to 2351.38
ohms. Make sure the calibration value is within the acceptable range
(See Table 1) and press the ENTER and DOWN arrow keys
simultaneously to accept.
5. Press the UP arrow key to go to CAL 2 (“)”). Move the RTD connector
from D to E (See Figure-4) and adjust the Input down to 99.114 ohms.
Make sure the calibration value is within the acceptable range (See
Table 1) and press the ENTER and DOWN arrow keys simultaneously
to accept.
6. Press the UP arrow key to go to CAL 3 (“/)”). Adjust the input to
2351.38 ohms. Make sure the calibration value is within the acceptable
range (see Table 1) and press the ENTER and DOWN arrow keys
simultaneously to accept.
K
A
P8
P7
A2
RJC
C
D
E
Flow Input
H
Figure-4
7. Press the UP arrow key to go to CAL 4 (“.)”). Place the millivolt
connection into connector C (see Figure-4). Adjust your millivolt signal
to 4.663 mV. Make sure the calibration value is within the acceptable
range (see Table 1) and press the ENTER and DOWN arrow keys
simultaneously to accept. Repeat this step for Cal 5 (“0)”), adjust the
input for 73.953mV.
8. Press the UP arrow key to go to Cal 6 (“1)”). Place the wires for the
remote setpoint input into the last 2 terminals of connector A2. See
Figure-4. (+ to terminal 3 and - to terminal 4). Adjust your input to 1.224
mA. Make sure the calibration value is within the acceptable range (see
Table 1) and press the ENTER and DOWN arrow keys simultaneously
to accept.
9. Press the UP arrow key to go to CAL 7 (“,)”). Adjust the remote
setpoint input to 19.721 mA. Make sure the calibration value is within
the acceptable range (see Table 1) and press ENTER and DOWN arrow
keys simultaneously to accept.
29
10. Press the UP arrow key to go to CAL 8 (“)”). The left display should
read between 5400 and 6400 (hexadecimal).
11. Press the UP arrow key to go to CAP 9 (“$)”). Press the ENTER key.
The right display will blink. Observe the temperature from the Ambient
Temperature Indicator. Press the UP and DOWN arrow keys until you
reach the ambient temperature. Press the ENTER and DOWN arrow
keys to retain (display will blink to indicate value is accepted).
12. Press the UP arrow key to go to CAL A (“)”). Place load (1.5K ohm
resistor) into terminals 1 and 3 of connector K, see Figure-4. Connect
frequency generator and frequency counter across the load. Adjust the
input to 50 Hz (41 Hz for 75 GPM). Make sure the calibration value is
within the acceptable range (see Table 1) and press the ENTER and
DOWN arrow keys simultaneously to accept.
13. Press the UP arrow key to go to CAL B (“)”). Now adjust the input to
200 Hz (131.5 Hz for 75 GPM). Make sure the calibration value is within
the acceptable range (see Table 1) and press the ENTER and DOWN
arrow keys simultaneously to accept. Press the INDEX key to exit. The
calibration is now complete.
Table-1
30
Input Type
Cal. #
Input Value
Calibration Value
RTD
0
99.114 ohms
18CA to 22CF
RTD
1
2351.38 ohms
8759 to B228
RTD
2
99.114 ohms
18CA to 33CF
RTD
3
2351.38 ohms
8759 to B228
TC
4
4.663 mV
18CA to 22CF
TC
5
73.953 mV
8759 to B228
Remote Input
6
1.224 mA
18CA to 22CF
Remote Input
7
19.721 mA
8759 to B228
Ambient
8
Ambient
5400 to 6400
Ambient
9
Flow (30 GPM)
A
50 Hz
18CA to 36D9
Flow (30 GPM)
B
200 Hz
6d48 to 9816
Flow (75 GPM)
A
41 Hz
Flow (75 GPM)
B
137.5 Hz
Ambient Temperature
Electrical Specifications
Temperature Inputs
T/C’s J, K, E, (Remote Sensing Only)
Input Type
Range
J:
-100 to 1600 oF (-73 to 871 oC)
K:
-200 to 2500 oF (-129 to 1371 oC)
E:
-100 to 1800 oF (-73 to 982 oC)
Impedance 3 Meg ohms min.
Ω/ oC Range -328 to 1607 oF (-200 to 875 oC)
RTD’s Pt1000 din 0.00385 Ω/Ω
Source current 200 µA
Flow Input
Min. sig. 100 mV peak to peak
Impedance 100k min.
20 to 250 Hz.
128 GPM (485 lpm) max.
Temperature/Flow input resolution
Low gain 2.1 uV
Signal Inputs (0.5mA @ 5Vdc Sense)
Phase Relay
Safety Thermo
Low Pressure
Remote Set point Current: 0-20mA across 600OHM
Max., isolated to 500Vac
Outputs
Relay: SPST, 1A @ 250 Vac resistive; 1A @ 250 Vac inductive
Pilot Duty Rating: 125VA
Hi/Lo Heat, Cool, Alarm, Purge, Pump, Vent (adjustable off to 5 min.)
SSR: 1A@250Vac, isolated to 1500 Vac
Hi/Lo Heat, Cool
Current: 0 to 20 mA across 600 ohms max., isolated to 500 Vac
Heat, Cool, Process Output
Communications: RS232, RS485, Half and Full Duplex
RS 485SPI Half Duplex Only
Accuracy Temperature
±0.25% of span ± least significant digit
Temperature Stability
4uV / oC typical, 8 uV / oC maximum
Common Mode Rejection
140 db minimum at 60 Hz.
Approvals
Ambient Temperature Range
14 to 131 oF(-10 to 55 oC)
0 to 90% up to 40 oC non-condensing,
0 to 50% at 55 oC non-condensing
31
Supply Requirements
100 to 240 Vac, nominal, +10 to -15%, 50 to 400 Hz, single phase
132 to 240 Vdc, nominal, +10 to -20%
Power Consumption
5VA maximum
DC Supply: +5V @ 30mA
General Specifications
Dimensions
Front Panel 5 1/2 x 9 inches (13.97 x 22.86 cm)
Depth 3 3/4 in. (8.89 cm)
Weight
20 oz. (622 g)
Displays and Indicators
(2) 3-Digit Red Displays 0.56” (1.42 cm)
Red LED’s for alarm functions
Pressure, Thermo, Hi/Lo Temp, Probe Fail, Motor
Green LED’s for status and display indication
Run, Hi/Lo Heat, Cool, Delivery, Return, Delta, Flow
Connectors
PCB Interconnects
T and B Jumpers
System Connectors
WAGO 231 Series or equal
Communication and Current Output Connectors
WAGO Screw Pressure Plate
32
Appendix A
Hard Keys
Set Point
Process
Heat Low
Heat
High
175
SP1
###
Main Set Pt.
175
ALO
###
Alarm Low
-100
AHI
###
Alarm High
200
Home (Index Keys)
Set Point
Process
SYS
On/OFF
Prg
run/HLd
Heat Low
System On or Off (Standby)
note 1
Heat
High
On
Programmer Run/Hold
ti
###
note 3
Program Segment Time remaining
#ti
###
note 3
Program Segment Time
#SP
###
note 3
Program Segment Set Point
tun
Tune choice
SLF
PID
PID
3
3
Self Tuning
Lrn
YES/No
dFa
Damping factor 1=less, 7 = more
OFF, 1 to 7
ratio rate to reset
Pid
Start Learn
Manual PID tuning
PbH
1 to 5000
Proportional Band 1 (deg or counts)
14
14
PbC
1 to 5000
Proportional Band 2 (deg or counts)
20
10
rES
0 to 999.9
Reset time in sec
1.5
1.5
OFS
0 to 99.9
Manual reset value in percent
OFF
OFF
rtE
0 to 99.99
Rate time in minutes
0.05
0.05
SLO
Slow response process
nor
Normal response process
FAS
Fast response process
FPC
0 to 100
Fuzzy intensity in percent 0 = off
Impact fuzzy logic has on process
50
50
Fbd
1 to 400
Fuzzy Band in deg. or counts = to PBH
14
14
FrC
0 to 99.9
Fuzzy rate of change in deg. or counts per
second
2.5
2.5
0
0
PEA
###
Peak PV, ENTER to reset to present PV
UAL
###
Valley PV, ENTER to reset to present PV
2SP
###
Auxiliary Set Pt.
tc
###
Note 4
T/C Monitor Temp
FAL
0 to 100
Note 4
Flow Alarm Low
0
0
FAH
0 to 100
Note 4
Flow Alarm High
100
100
AUt
OFF, 1 to 5
Auto vent cycle OFF, 1 to 5 min.
1.0
OFF
HiH
On/OFF/AUt
High Heat On/ Off/Auto
AUt
AUt
33
Secondary Menu (Up and Enter Keys)
Set Point
Process
Heat Low
Heat
High
F
F
OFF
OFF
dE
dE
Unt
F/C
Degrees F or C
AL1
OFF/Lo/Hi/HL/Eut
Alarm (Off, Low, High, Hi.Lo, Event)
A1t
AbS/dE
Absolute or Deviation to SP1
A1r
OnF/HOL *
Alarm Reset, auto reset/manual reset
OnF
OnF
A1i
On/Off
Power Interrupt
OFF
OFF
A1H
On/OFF
Power inhibit, suspend alarm until PV enters
non-alarm condition
On
On
A1S
CLS/OPE
Contact Closed/Open @ Alarm
CLS
CLS
A1L
O on/oFF
Lamp (on/off) contact closed
Oon
Oon
A1b
On/OFF
Alarm on Loop Break
OFF
OFF
Prg
On/OFF
Programmer ON/OFF (ramp/soak)
OFF
OFF
SEt
On/OFF
Prog, values available for viewing &
changing
OFF
OFF
StA
On/OFF
note 2
Status of Prog. in Home Position
OFF
OFF
SEC
1 S/6OS
note 2
Prog. time base (1 or 60 sec.)
1-S
1-S
#ti
0 to 9999
note 2
Segment time
0
0
#SP
####
note 2
Segment Set Pt.
0
0
#A1
On/OFF
note 2
Alarm 1 Event
OFF
OFF
#A2
On/OFF
note 2
Alarm 2 Event
OFF
OFF
End
Hld/Oof/LoP/SPt
note 2
Programmer End (Hold, Off, Loop, SP)
OFF
OFF
A2L
###
Alarm 2 Low
A2H
###
Alarm 2 High
Ato
On/OFF
Auto/Man
OFF
OFF
rUP
On/OFF
Anti-Reset windup
OFF
OFF
Pct
On/OFF
Percent Output in SV display
OFF
OFF
LPb
OFF, 1 to 9999
Loop Break time in sec.
OFF
OFF
POL
###
Process Output Low
0
0
POH
###
Process Output High
250
550
POS
InP/SP1
Process Output Source
InP
InP
rSL
###
4 mA = -62.5
0 mA = 0
20 mA = 250
rSH
###
250
rSP
On/OFF
Remote Set Pt On/OFF
OFF
OFF
L-r
LOC/rE
Comm Local/ Remote
LOC
LOC
Add
1 to 3FF
Comm Address Viewable Only
32
32
Remote Set Pt. Low
0
0
Remote Set Pt High
250
550
* manual reset by simultaneously pressing index & down keys for 5 seconds.
34
Secure Menu (Up and Enter - 5 seconds)
Set Point
Oil Temp.
Water
Control
Temp.
Unit
Control
Heat
Unit
High
Heat Low
Process
SEC
####
Security Code
FnC
HL/HH/L
Function (Lo/Hi heat Chiller)
Sto
0 to 100
Self Tune Offset Percent
InC
-500 to +500
Input Correction
Fil
OFF, 1 to 99
digital
Filter value 0=off (electrical noise)
Second Set Pt (COOLING)
4
4
HL
HL
0
0
0
0
OFF
OFF
0
0
SP2
###
Pd2
On/OFF
Link the I and D terms to PB2
ON
ON
Art
OFF, 1 to 99.99
Approach Rate outside PB1
OFF
OFF
tci
On/OFF
T/C Monitor On/OFF
OFF
OFF
FLO
On/OFF
Flow Monitor On/OFF
OFF
OFF
FCY
###
Flow in FREQ.
FSL
0 to 100
Flow Scale Low @ 25 Hz (CAL.)
6
6
FSH
0 to 255
Flow Scale High @ 225 Hz (CAL)
30
30
FLF
0 to 100
Flow Filter
2
2
SAF
On/OFF
Safety Thermo On/OFF
ON
ON
PrS
On/OFF
Pressure Input On/OFF
ON
ON
InP
J-/CA-/E-
T/C Input Type (J, K, E)
J
J
Int
OFF,0.1 to 540.0
Input Fault Timer (min.)
OFF
OFF
20
20
15
15
OFF
OFF
Output 1 type
OnF
On/OFF
S1d
Ot1
#PuL
####
On/OFF differential
1 to 80t
Time proportioning cycle rate in sec.
1 to 7
Pulse curve value 1 = linear, 7 = most nonlinear
PrP
Voltage/Current proportional output
Output 2 type
OnF
ON/Off
S2d
Ot2
#PuL
####
On/Off differential
1 to 80
Time proportioning cycle rate in sec.
1 to 7
Pulse curve value 1 = linear, 7 = most nonlinear
PrP
Voltage/Current proportional output
SEn
OFF<1 to 4000
Sensor rate of change (cnts or deg. per sec)
SCL
DEFAULTED
Scale low
0
0
SCH
DEFAULTED
Scale high
250
550
SPL
min - SCL
Set Pt. low limit
0
0
SPH
max- SCH
Set Pt. high limit
250
550
S1S
dir/rE
Direct or Reverse Acting
rE
rE
S1L
0 to 90
Output 1 low limit
0
0
S1H
10 to 102
Output 1 high limit
100
100
35
Set Point
S1C
Oil Temp.
Water
Control
Temp.
Unit
Control
Heat
Unit
High
Heat Low
Process
O on/off
Oon
Oon
S2t
AbS/dE
Absolute of Deviation to SP1
dE
dE
S2S
dir/rE
Direct or Reverse Acting
dir
dir
S2L
0 to 90
Output 1 low limit
0
0
S2H
10 to 102
Output 1 high limit
100
100
S2C
O on/oFF
Lamp (on/off) contact closed
Oon
Oon
AL2
OFF/Lo/Hi/HL/Eut
Alarm (Off. Low, High, Hi/Lo, Event)
OFF
OFF
A2t
AbS/dE
Absolute or Deviation to SP1
dE
dE
A2r
OnF/HOL
Alarm Reset (On/Off, Hold)
OnF
OnF
A2i
On/OFF
Power Interrupt
OFF
OFF
A2H
On/OFF
Power Inhibit
On
On
A2S
CLS/OPE
Contact Closed/Open @ Alarm
CLS
CLS
A2C
O on/oFF
Lamp (on/off) contact closed
Oon
Oon
A2b
On/OFF
Alarm on Loop Break
OFF
OFF
Add
1 to 3FF
Note 4
Comm Address Hexadecimal (992/3)
nAt
OFF, 1 to 99
Note 4
No activity Timer Minutes
Bau
300-19.2 K
Note 4
Comm baud rate
Note 1: Only present when Pro = On
Note 2: Only present when SEt = On
Note 3: Only present when StA = On
Note 4: Only present when the option is active
36
Lamp (on/off) contact closed
32
32
OFF
OFF
9.6
9.6
Appendix B
Mounting
The M2B requires a hole in the panel measuring 8 1/2 inches (21.59 cm) by
4 1/2 in. (11.43 cm) high (see Figure-5). Four mounting holes are spaced
7 in. (17.78 cm) horizontally, and 5 in. (12.7 cm) vertically in a rectangular
layout. The mounting holes are 1/4 in. (6.35 mm) diameter and the bolts are
size 10 or equivalent.
1/4" (6.35 mm) dia.
5"
(12.7 cm)
4 1/2"
(11.43 cm)
8 1/2" (21.59 cm)
7" (17.78 cm)
Figure-5 Mounting Dimensions.
37
Appendix C
Control Modes:
On-Off:
Action takes place if any deviation from set point occurs. The output is either
full on or full off depending on the direction of deviation. Because the on-off
controller can cause rapid cycling around the set point, hysteresis (dead
band) is built in to suppress fast control action.
Temp
P.B. too small
S.P.
P.V.
TIME
Proportional:
Referred to as “P” or GAIN.
The controller switches the output based on the difference between the set
point value and the process variable, and controls the output proportional
to the deviation. This proportional action is active within a zone around the
set point called the proportional band. The output becomes gradually
smaller as the process variable nears the set point. Note that the process
seldom reached the set point, but stabilizes at some deviation offset.
Temp
TIME
Integral:
P.B.
S.P.
P.V.
OFFSET
Referred to as “I” or RESET.
Expressed by integral time in seconds, the purpose of the integral action is
to automatically compensate for any offset due to proportional action. The
integral moves or resets the proportional band up or down to obtain set
point. It is not intended to correct for process disturbances.
Temp
PB SHIFTED UP
TIME
38
P.B.
S.P.
P.V.
OFFSET
Derivative:
Referred to as “D” or RATE.
Expressed as derivative time in seconds. The controller measures the rate
of process increase or decrease and moves the proportional band to
minimize overshoot. The change in the output is directly proportional to the
rate of change in the process value.
Temp
P.B.
S.P.
TIME
Anti-Reset Windup:
Direct/Reverse
Action:
This function inhibits the integral action until the process variable is within
the proportional band, thus reducing overshoot on start-up.
Direct action is used for cooling applications. The output of the controller
increases with respect to an increase in the process value.
Reverse action is used for heating applications. The output of the controller
decreases with respect to an increase in the process value.
Output
100%
(HEAT)
P.B.
P.V.
0%
(COOL)
P.B.
P.V.
S.P.
TIME
39
Adjustments:
Proportional
1) The lower the gain value (large proportional band), the less reactive the
output becomes.
Temp
P.B. too large
S.P.
P.V.
OFFSET
TIME
2) The larger the gain value (small proportional band) over responsive
output, can lead to oscillation.
Temp
P.B. too small
S.P.
P.V.
TIME
A proportional band which is correct approaches the set point as fast as
possible while minimizing overshoot.
If a faster response is desired and process overshoot is not a problem,
increase the gain value (over-damped system). If overshoot can’t be
tolerated, decrease the gain value (under-damped system.)
Integral
Integral action eliminates offset by adding to or subtracting from the output
of the proportional action alone.
1) Short integral time means the controller corrects for offset quickly. If too
short, the controller would react before the effects of previous output
shifts, due to dead time or lag, are complete, could cause oscillation.
Temp
"I" is too short
P.B.
S.P.
TIME
40
2) Long integral time means the controller corrects for offset over a long
time. If the integral time is too long, the offset will remain inactive,
causing slow response or sluggish control.
Temp
P.V.
"I" is too long
P.V.
S.P.
TIME
Derivative:
Derivative time is the amount of anticipatory action needed to return a
process back to set point. In the case of a process upset, proportional only
or proportional-integral action alone can’t react fast enough in returning a
process back to set point without overshoot. Derivative action corrects for
disturbances, providing sudden shifts in output which opposes the process
disturbance.
Temp
DERIVATIVE ACTION
(RATE)
S.P.
P.V.
RATE TIME
TIME
1) A short derivative time means little derivative action. If the derivative is
too short, the controller would not react quickly to process disturbances
and may not attain set point.
2) A long derivative time means more derivative action. If the derivative
time is too large, the controller would react too dramatically to process
disturbances creating rapid process oscillation (alternating heat and
cool continuously).
41
PID COMPONENTS REACTING TO A LOAD CHANGE
TEMP
S.P.
P.V.
LOAD
OUTPUT
S.P.
PROPORTIONAL
OUTPUT
OUTPUT
INTEGRAL
S.P.
DERIVATIVE
S.P.
OUTPUT
TIME
42
S.P.
RESULTANT PID
Appendix D
Drawing a Ramp/Soak
Profile
Draw your ramp/soak profile on the record sheet below and fill in the
associated information in the table below. This will give you a permanent
record of your program and will assist you when entering the set point data.
Prompt
Function
Prompt
Function
Segment
STRT SEG
Start Seg.
Segment
Value
SEG7RAMP
Ramp Time
7
END SEG
End Seg.
SEG8 SP
Soak SP
8
RECYCLES
Number of
Recycles
SEG8TIME
Soak Time
8
SOAK DEV
Deviation
Value
SEG9RAMP
Ramp Time
9
SEG1RAMP
Ramp Time
1
SG10 SP
Soak SP
10
SEG2 SP
Soak SP
2
SG10 TIME
Soak Time
10
SEG2TIME
Soak Time
2
SG11 RAMP
Ramp Time
11
SEG3RAMP
Ramp Time
3
SG12 SP
Soak SP
12
SEG4 SP
Soak SP
4
SG12 TIME
Soak Time
12
SEG4TIME
Soak Time
4
STATE
Program
Controller
State
SEG5RAMP
Ramp Time
5
PROG END
Controller
Status
SEG6 SP
Soak SP
6
RAMP UNIT
Engr. Unit for
Ramp
SEG6TIME
Soak Time
6
Value
43
Appendix E
Glossary of Terms
Alarm
A condition that exists if the process variable exceeds internally stored
alarm setpoints. Those setpoints can be:
Alarm Inhibit
Prevents low setpoint alarm activation during cold startup applications.
Auto/Manual
Alternative control conditions that can be selected within the controller.
Manual - An open loop condition, in which the power to the process is
manually set and not influenced by the sensor.
Auto-A closed loop condition, in which the power to the process is
automatically computed and set by the sensor output relative to the
setpoint.
44
Bias
Allows the operator to compensate for any difference between sensor
temperature and the point to be measured. The process display and
setpoint will be offset by the value entered in the Bias parameter in the input
menu. Example: Desired temperature is 150 degrees. Sensor is adjacent to
heater and reads 50 degrees higher than the actual process temperature.
Enter bias of -50. Enter setpoint of 150. Process will display 150 even
though sensor will be measuring 200 degrees.
Cycle Time
The period of time in which the controller’s output completes an on-off cycle
(proportional output type only). Example: Output type = mechanical relay;
cycle time = 10 seconds; Output power = 50%; controller output = 5
seconds closed, 5 seconds open.
Deadband
Derivative (Rate)
Derivative Action
In on/off temperature control, it is the band above or below the setpoint
where there is no output action, It has the effect of moving the apparent
setpoint.
Adjusts the controller gain quickly in response to load changes.
Is normally used to give a fast response to changes in process value and to
improve process stability. Alternatively derivative action may be configured
to act on the error signal which is useful in ramping applications.
Direct Action
Control action such that the output increases as the process value
increases.
Failsafe State
Designates the percentage of power output that the controller defaults to
after it detects a loop break condition and after the loop break time has
elapsed.
Filter (in Display
Menu)
Filtering (in Input
Menu)
Hysteresis
Changes the filtering speed for the process value display only. It does not
affect control. This parameter is mainly used to slow down the flickering of
the display when the decimal position chosen is greater than zero.
Sets the time period over which the process value is averaged.
In on/off temperature control, hysteresis represents the band where the
output changes state from deactivated to activated. It prevents chattering
around the setpoint and prevents rapid output cycling.
Hold
The freezing of a running program, in time, for the duration of the condition.
Integral (Automatic
Reset)
Slowly adjusts the position of the proportional band (range of power output)
to eliminate offset error.
Local/Remote
Alternative selections of the working setpoint. Either a value stored within
the controller (local) or an analog signal brought into the controllers rear
terminal (remote).
Loop Break
A condition where the input is not changing or responding properly to the
output action. This could be caused by a thermocouple or input failure, or a
heater or load failure.
Loop Break Time
The time interval from when the controller detects a loop break condition
and the initiation of the failsafe state.
Manual Reset
An adjustment that moves the proportional band up or down by a fixed
percentage so that more or less power is applied at setpoint. It is used to
eliminate offset error.
45
On/Off Output Type
In a heating application, the controller applies 100% output power if the
process temperature is below the setpoint and 0% at the setpoint. For a
cooling application, the controller applies 100% output power if the process
temperature is above the setpoint and 0% output power at the setpoint.
There are only two output states: fully on and fully off.
Applications for On/Off Control: 1. When temperature oscillation is
acceptable. 2. When constant cycling of mechanical devices is prohibited
(compressors, blowers, etc.). 3. Under-powered processes.
Output Low Limit %
Prohibits the controller’s output from going below the specified percentage.
Output High Limit %
Prohibits the controller’s output from going above the specified percentage.
Output Relay
Relays that are normally driven by the alarm output condition but can, as an
alternative, be driven by segments of the program.
PID Output Type
(Proportional Integral-Derivative)
The controller modulates output power by adjusting the output power
percentage within a proportional band. Power is proportionally reduced as
the process temperature gets closer to the setpoint temperature. PID
control helps reduce overshoot on start-up, enhances stability, and
compensates for process lag. The PID parameters are automatically
calculated for a particular application during the autotune process.
Applications for PID Control: 1. Where process temperature lags exist. 2.
When load changes are present. 3. When overshoot is prohibited. 4. When
very accurate control is required.
Program
Proportional Action
Proportional Band
The lower the gain value (large proportional band) the less reactive the
output becomes proportionally to the error between setpoint and process
value. The proportional band is the range of process value over which this
linear gain action occurs before the output saturates at maximum or
minimum. This is often expressed as a percentage of the instrument span.
The gain of the instrument varies inversely as the proportional band
increases. (see Manual Reset)
The band (expressed in degrees of temperature) in which the controller
modulates its power percentage.
Ramp
One segment of a program where the controller setpoint moves from one
level to another linearly during a fixed period of time.
Reset
An action which returns a completed or running program to the start
condition, i.e. controlling SP1, SP2, or remote SP.
Reverse Action
Run
46
A preset profile of the controller setpoint made up of ramps and soaks,
together with the sequence of state of the output relays.
Control action such that the output decreases as the process value
increases.
An action which starts a program running or restarts it from a hold condition.
Self Tune
A facility which, when enabled, performs a number of ‘on’ and ‘off’
sequences of the controller output measuring the influence this has on the
measured value. From these results the value of proportional ban, integral
time and derivative time plus, under certain circumstances, cut back low,
cut back high, heat cycle, cool cycle time and relative cool gain, for optimum
control, are calculated and written into the commissioning mnemonics.
Soak
A time entered into a program during which the setpoint remains constant.
Temperature Lag
The product of thermal resistance and thermal capacity. Also defined as
delay of the transmission of heat from the controlled element to the sensor
caused by thermal mass of the process material and/or process container,
or the distance between the control element and the sensor.
Upper Setpoint Limit
Prohibits users from adjusting the setpoint higher than the selected value.
47
48
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