Operation and Installation Manual Advanced & M2B+ Microprocessor Controller Part Number: 882.12046.
Write Down Your Serial Numbers Here For Future Reference: We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No. © Copyright 2010 All rights reserved.
Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. ALL returns are to be shipped prepaid.
Table of Contents Chapter 1: Safety ......................................................................... 8 1-1 1-2 1-3 How to Use This Manual ...................................................................................................... 8 Warnings and Precautions ..................................................................................................... 9 Responsibility .......................................................................................
Chapter 5: Advanced Operation .............................................. 29 5-1 5-2 Using the Analog Remote Input .......................................................................................... 29 Retransmission Analog Signal ............................................................................................ 30 Setting the Analog Signal Source to FLOW .............................................................................................
Chapter 7: Appendix ................................................................ 58 7-1 Electrical Specifications ...................................................................................................... 58 Temperature Sensor Inputs ...................................................................................................................... 59 Flow Sensor Inputs ..................................................................................................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. The Functional Description section outlines models covered, standard features, and optional features.
1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: § Follow all SAFETY CODES. § Wear SAFETY GLASSES and WORK GLOVES.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for the Advanced and M2B+ controller. The Advanced and M2B+ are available for use with several models of temperature control units (TCUs). A separate manual describes operation, installation, and maintenance instructions for the TCU itself.
2-3 Standard Features • PID Control for both heating and cooling • 4 line x 20 character LCD Display Screen • Setpoint, To Process, From Process, and DT displays • System status • Password protection • Selectable sensor types (Type K, J, & T thermocouples; 100 ohm and 1000 ohm RTDs) • Autovent sequence (adjustable from 1 to 10 minutes) • Sixteen segment Ramp/Soak program • Start, stop, vent, and alarm silence switches • D.C.
2-5 Panel Layout and Keypad See Figure 1 on page 15 for an illustration of the control panel and its buttons. The LCD backlight lights up whenever any key is pressed. The backlight turns off after five minutes if no other key activity occurs. LED Indicator Lights The Advanced and M2B+ controller has one LED that will light up to indicate the control process has been started. This LED is located inside the Start button of the controller’s front panel.
Low Alarm Indicator. Appears in the LCD display when a Low Alarm condition occurs. ‘From Process’ Temp Indicator. Appears in the LCD display when the temperature display is showing the ‘To Process’ temperature. Delta Temp Indicator. Appears in the LCD display when the temperature display is showing temperature differential. High Heat Output Indicator. Displays status in the LCD display when full power heat output is applied. Low Heat Output Indicator.
Keypad Four keys, ‘Index’, ‘Up’, ‘Down’, and ‘Enter’ are used primarily to gain access to the menu structure and modify the controller’s parameters and features. The remaining six keys are used to direct the controller to start or stop a process. Button Index Up Down Enter Tune Run/Hold Start Stop 14 of 68 Function • Used to advance to one of the three setup menus. • Used to advance to the next menu item when in a setup mode.
Button Vent Alarm Silence Function • When the system is first powered-on and the “Power Available - System Off” message is displayed, pressing the VENT key will turn on the Vent Output for a period of 8 seconds. The message “VENT” will be displayed during this period. • When the system is running, pressing the VENT key shall manually turn on the Vent Output for as long as the key is held down, provided the ‘To Process’ temperature is o o o o below 150 F (65.
2-6 Menu Structure The parameter menu structure is organized into three basic menus: Primary, Secondary, and Secure. To access the menus, press the Index button until the menu label appears in the second line of the LCD display. Additional menus display when an option is selected; however, the options are non-functional unless the appropriate menu option or option board has been installed. See the Menu Parameter Tables in the Appendix of this manual for more information.
2-7 Passwords and Security The controller provides four levels of security. Depending on the security level, some or all of the setup menus may be locked. The security level must be changed in order to unlock these menus. The current security level is displayed in the lower right corner of the menu display. The default security level is 3. Security levels are changed by changing the password value using the Up and Down buttons and pressing the Enter button.
Advanced Microprocessor Controller Chapter 3: Installation 3-1 Location 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.
Chapter 4: Basic Operation 4-1 Turning the Power On When AC power is first applied to the unit, the following sequence of events will occur: 1. 2. 3. 4. 5. The LCD backlight lights up. The LCD displays dashes: LEDs have all segments on. The LCD displays the PROM Rev/Date. The LCD displays “SelfTest in Progress.
4-2 Starting and Stopping Water TCUs Starting the Unit (Local) Press the Start button to begin the following sequence of events: 1. 2. 3. 4. The green LED inside the Start button lights up. The LCD backlight lights up. The Pump Output turns on. The LCD displays the setpoint value, process temperature, return temperature, and delta temperature. 5. If the Auto Vent Cycle parameter is enabled, the Vent Output turns on, and the LCD displays “Vent Time = mm:ss.” 6.
4-3 Starting and Stopping Hot Oil TCUs Starting the Unit (Local) Press the Start button to begin the following sequence of events: 1. 2. 3. 4. 5. 6. 7. 8. The green LED inside the Start button lights up. The LCD backlight lights up. The Pump Output turns on. The LCD displays the setpoint value, process temperature, return temperature, and delta temperature.
button is released, at which time the 30-second time-out will restart. After 30-seconds, the system will recycle to the “Power Available/System OFF” state. Starting the Unit (Remote) REMOTE START option is similar to the water process sequence. Closure of pins 5 and 6 of header J6 initiates the start sequence. The display flashes MODE IS OFF, PRESS START TO RUN. THE VENT/FILL timer counts down from 10 minutes.
Manual Tuning (Zeigler-Nichols PID Method) This tuning method may be used if the spread between ambient temperature and process operating temperature is small. For best results, use a recording device when tuning with this method. 1. Disable the cooling valve by removing the output signal to the device. For solenoid valves, remove plug from the solenoid. For modulating valves, remove the J7 plug located on the back of the controller. 2. Press the Index button one time to access the Primary Menu. 3.
Using a Remote Input Probe for Monitoring The Remote Probe Input can be used for two different functions: To control or monitor the temperature of a process outside of the temperature control loop. To set up this feature you must have access to the Secure Menu. See Section 2-6 on page 16 to review accessing the Secure Menu. This option can be purchased with or without the manufacturer supplying the actual temperature-sensing device.
4-6 Setting Up Cascade Control The controller is provided with an internal cascade control feature. Cascade control is used to enable a process having multiple lags to be controlled with the fastest possible response to process disturbances. The system uses a remote control probe in the downstream process and a local delivery and return probe in the TCU.
4-7 Adjusting the Automatic Venting Timer When the Auto Vent Cycle Timer is set, the controller will open the venting valve for the set time at the startup of the unit. The Auto Venting Timer can be turned off, or it can be set to a specified time period. For water TCUs, Auto Vent can be set between 1 and 10 minutes. For hot oil TCUs, the vent time can be set between 1 and 60 minutes. TCUs are programmed at the factory to Auto Vent for 1 minute for water units and 10 minutes for oil units.
Chapter 5: Advanced Operation 5-1 Using the Analog Remote Input This feature is typically setup at the factory, but can be installed as a retrofit in the field. It is used to accept a remote analog setpoint value or flow value. If the analog signal is set up for remote setpoint input, the Up and Down arrow keys are locked out for changing the setpoint at the controller. The analog signal can be configured to be 0-20 mA, 4-20 mA, 0-5 VDC, 15 VDC, 0-10 VDC, or 2-10 VDC via jumper 4 and menu selection.
5-2 Retransmission Analog Signal This feature is typically set up at the factory, but it can also be installed as a retrofit in the field. It is used to transmit an analog signal for process temperature, setpoint temperature, and flow. The analog signal can be configured to be 0-20mA, 4-20mA, 0-5VDC, 1-5VDC, 010VDC, and 2-10VDC. The Process Output Low and High values must match the high and low limits of the controller setup in the Secure menu.
Setting the Analog Signal Source to FLOW If the analog signal source is set to “FLOW,” follow steps 1 through 15 on page 30, and then complete the following procedure: 1. 2. 3. 4. Press the Index button until the display reads “Remote Input.” Use the Up and Down buttons to change the value to “FLOW.” Press the Enter button to accept the value. Press the Index button until the display reads “Remote Signal.” Do not alter this value; use the default setting. 5.
5-3 Using the Flow Monitor The controller is set up to accept a pulsed or current input from a flow sensor. The controller translates the pulse or current into either gpm (gallons per minute) or lpm (liters per minute). If the flow sensor is of the pulsed variety, it is connected to block J1 on the main controller board. For analog signal sensors, see Section Chapter 5: on page 29. Use the following procedure to set up a pulsed flow sensor: 1. 2. 3. 4. 5. 6. 7. 8. 9.
5-4 Programming the Alarms The controller is set up to monitor both critical and non-critical operations within the process. Based on the severity of the condition, the controller will alarm and perform a specific function based on the type of unit being controlled. If an alarm is tripped, the LCD display will flash the backlight and if an audible alarm is present, turn it on. Below is a brief explanation of each of the eight areas that the controller monitors and how to set them up.
Flow Alarm This alarm is used to monitor the flow rate input from either a pulse or analog style flow meter. Once the Flow Monitor is turned on (in the Secure Menu; Flow Monitor = PUL or CUR) either a low flow alarm or high flow alarm or both can be set up. Use the following procedure to set up the Flow Alarm: 1. Press the Index button one time to access the Primary menu. 2. Press the Enter button. 3. Press the Index button until the display reads “Flow Alarm Low.” 4. Press the Enter button. 5.
Low Fluid Level Alarm This factory-set alarm occurs when the low level switch is in a closed condition. This is not a critical alarm and will reset once the condition is cleared. For water TCUs the Low Level alarm disables the heater and the pump motor outputs. For oil TCUs it disables the heater output. There are no menus that affect this alarm. High Fluid Level Alarm This factory-set alarm occurs when the high level switch is in a closed condition. This alarm is only applicable for water TCUs.
5-5 Using the Second Setpoint Function With this function, the user can send the controller a dry contact closed signal to activate the second setpoint. Opening the dry contact causes the controller to revert to the primary setpoint. To reinitiate the second setpoint, the switch must be closed again. Use the following procedure to enable the second setpoint function: 1. Press the Index button three times to access the Secure menu. 2. Press the Enter button. 3.
5-7 Changing the Temperature Display Units The controller is set up to display the temperature, and all related temperature settings, in either degrees Fahrenheit or degrees Celsius. Use the following procedure to change the display units: 1. 2. 3. 4. 5. 6. 5-8 Press the Index button two times to access the Secondary menu. Press the Enter button. Press the Index button one time to access the “Degrees (F/C)” parameter. Use the Up and Down buttons to change the value.
5-9 Using the Elapsed Time Meter The controller is equipped with an elapsed time meter that keeps track of the time that the pump motor has run in hours. The meter is enabled or reset in the Secure menu and viewed in the Primary menu. Use the following procedure to enable the elapsed time meter: 1. Press the Index button three times to access the Secure menu. 2. Press the Enter button. 3. Press the Index button until the display reads “ElapsedTimeMode.” 4.
5-10 Programming Ramp/Soak The controller has a 16-segment, front-face programmable Ramp/Soak feature. Unused alarms can be programmed as a segment. Do not attempt to auto-tune the controller during a ramp/soak program. The Tune button will not function during this process. Instead of requiring the operator to calculate an approach rate, the controller does the calculation automatically. The operator needs to program the target setpoint and the time desired to reach that setpoint.
Use the following procedure to program the Ramp/Soak functions: Starting Ramp/Soak Programming: 1. Press the Index button two times to access the Secondary menu. 2. Press the Enter button. 3. Press the Index button until the display reads “Prog Ramp/Soak.” 4. Use the Up and Down buttons to change the parameter to “On.” 5. Press the Enter button to accept the change. 6. Press the Index button one time to access the “Prog Values” parameter. 7. Press the Enter button. 8.
Controlling Ramp/Soak The Secondary Menu parameter “Prog Ramp/Soak = “ must be set to ‘ON’ in order to control the ramp/soak operation. Press the ‘RUN/HOLD’ button on the panel to put the ramp/soak operation into the Run state. The LCD display will change from “Running” to “RAMPSOAK”. The setpoint will step to the programmed value over the programmed time period and the process will be changed accordingly. Press the ‘RUN/HOLD” button again to toggle the ramp/soak operation into the Hold state.
5-11 Setting the Approach Rate The controller is provided with a selectable up and down ramp to setpoint feature, located in the secure menu. The time base is in minutes and is adjustable from off to 99 minutes in 1 minute increments. Use the following procedure to enable the approach rate feature: 1. 2. 3. 4. 5. 6. Press the Index button three times to access the Secure menu. Press the Enter button. Press the Index button until the display reads “Approach Rate.
5-15 Calibrating the T/C, RTD, and V Inputs ACS Group will certify that all controllers are factory calibrated and the calibration parameters are electronically stored in the controller to maintain its optimum performance. Due to the design of our input circuitry, the factory calibration should be valid for the life of the instrument. ACS Group controllers are not calibrated to a traceable N.I.S.T. standard.
1. Put a jumper on pins 2 and 3 of JMP2 on the main PC board to select the T/C input type. 2. Connect the “J” thermocouple calibration source to pins 3 (+) and 4 (-) on the J5 connector on the main PC board. 3. Select the “LOCalJTC(25C)” parameter. 4. Set the “J” thermocouple low calibration source to 25ºC. Use the Up and Down buttons to change the value on the display to 25.0. 5. Press the Enter button to save the value. 6. Select the “HICalJTC(345C)” parameter. 7.
Calibrating the RTD Input 1. 2. 3. 4. 5. 6. 7. 8. 9. This RTD calibration procedure requires a 0 to 1000 ohm Decade Resistance box to calibrate this analog input circuit. Once the circuit is calibrated, either a 100 ohm RTD or a 1000 ohm RTD can be selected for operation. Put a jumper on pins 1 and 2 of JMP1 on the main PC board to select the RTD input type. Connect the Decade Resistance Box to pins 1 and 2 on the J5 connector on the main PC board. Select the “LOCalJR1k(10R)” parameter.
5-16 Accessing the Debug Menu The controller has a troubleshooting tool in the secure menu. Use this menu to assist in debugging communications errors and flow sensor input errors. Use the following procedure to troubleshoot communications errors: 1. 2. 3. 4. 5. Press the Index button three times to access the Secure menu. Press the Enter button. Press the Index button until the display reads “Debug”. Press the Enter button. Press the Up button until the top display reads “Comm.
5-17 Reloading Factory Defaults When factory default settings are reloaded, all special configurations (i.e., 4-20 ma scaling) will be lost. Please record menu variables before restoring the factory defaults. Restoring factory defaults for low-heat water TCUs can be accomplished by entering “Factory mode.” Use the following procedure to restore factory defaults: 1. 2. 3. 4. 5. TCUs will default to a 250ºF (121.1ºC) set-stop limit. For 550ºF (287.
5-18 Serial Communications Operation The controller communicates with a host machine via an RS232 or RS485 communication link when the communication option card is installed in the J8 slot on the motherboard. There are two versions of this option card; one is populated with the ICs to support RS232, and the other is populated with the ICs to support RS485. All data is sent and received in the bit data format, using 10 bits: 1 start bit, 8 data bits, no parity bits, and 1 stop bit.
MODBUS Protocol Every message sent from a MODBUS master to a slave on to the network contains a function code that represents the action the slave device should take in response to the message.
Modbus Accessible Parameter Mapping. The customized controller allows access to (29) controller parameters and settings, which can be accessed in Integer Mode or Floating point mode. This is accomplished with (2) Point Address ranges, allowing data exchange in either integer or floating point format, for all controller parameters and settings.
MODBUS Function 03 Request. The format for a function 03 request is shown below. Device Address 1 byte Function Code 03 1 byte containing $03 Register Address MSB LSB Number Of Words To Read MSB LSB CRC MSB LSB MODBUS Function 03 Request Example. Suppose you want to Read Delivery Temperature in Float 32 Bit IEEE Format, which has registers address of "4002" and if the controller ID is "01".
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 multi-drop EIA485 (half-duplex) hookup.
(44H) (48H) (49H) Bit 5 -Alarm, Low Temperature Bit 7 -Alarm, Low Pressure Bit 14 -Alarm, Phase Reversed or Lost 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.
Chapter 6: Troubleshooting This Troubleshooting section should be used in conjunction with the Troubleshooting section of the unit that the controller was supplied with. The problems listed below are displayed on the LCD and the action the user takes will depend on whether the alarm is critical or noncritical. Problem Process Temperature Alarm does not acknowledge when Process Temperature is lower than Setpoint Possible Cause Alarm configuration is set up incorrectly.
Problem Unit shuts down after running through Ramp/Soak program Possible Cause The Program End function is incorrectly configured. Setpoint temperature does not change when using the Up or Down Arrow keys Security password set to lockout status Controller setup in remote analog input. Buttons on the face of the controller do not function when pressed Controller does communicate with remote host computer Security password set to lockout status Controller parameters setup to in remote function.
6-1 Operating Mode and Error Display Messages Figure 5: Display Messages, Operational and Errors Message Type Normal Autotune Normal Running Normal RampSoak Alarm Alarm Alarm Alarm Display Presentation Autotuning [ ] Running [ ] Rampsoak [ ] Alarm1/2 [LoFluid LVL] Alarm1/2 [Lo Pressure] Alarm1/2 [High LEVEL] Alarm1/2 [Process] Alarm Alarm1/2 [Deviation] Alarm (Major Fault) Alarm1/2 [SafetyTherm] Alarm [Major Fault) Alarm1/2 [SensorRange] Alarm [Major Fault) Alarm1/2 [Sensor Open] Alarm (Major Fa
Chapter 7: Appendix 7-1 Electrical Specifications General Dimensions 5.5” X 9” X 4” (140 x 230 x 100) Range of the Unit -45°F to 650°F (-42.
Temperature Sensor Inputs Thermocouple Type J, K, and T ungrounded Thermocouple Types (Class 2) RTD Type 100Ω, 1000Ω RTD Type, 00385 COEF. 2 Wire (Class 2) Measurement (Full Scale) Range -40 °F to 650°F (-40°C to 343°C) Process/Setpoint Display Resolution 1° C, 1° F, 0.1° C, 0.1° F Measurement Accuracy ± 0.25% OF SPAN, ±LEAST SIGNIFICANT DIGIT Number of Sensors Measured Up-to, Three (3) Common Mode Noise Rejection 100db MINIMUM AT 60 Hz.
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Menu Structure* Primary Menu Secondary Menu Secure Menu System Monitor Temp Alarm 1 Low Alarm 1 High PrgSeg#Remain PrgSeg# Time PrgSeg# SetPt Tune Choice DelivProp Band Heat DelivProp Band Cool DelivReset Time DelivRate Time Cool Ratio Mold Prop.
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7-2 Control Board Layout 7-3 DAC Board Layout (Optional) 67 of 68
7-4 Technical Assistance Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience.
