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M2B+ Controller

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for the M2B+
Controller. The M2B+ Controller is available for use with several models of temperature
control units (TCUs). A separate manual describes operation, installation, and maintenance
instructions for the TCU itself.

Chapter 2: Functional Description

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Summary of Contents for M2B+

Page 1: ...___ _________________________ _________________________ _________________________ _________________________ _________________________ 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 2007 All rights reserved Chapter 1 Safety 1 of 65 ...

Page 2: ...t The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list In addition to the equipment itself y...

Page 3: ... Menu 16 2 7 Passwords and Security 17 CHAPTER 3 INSTALLATION 19 3 1 Location 19 3 2 Electrical Connections 19 CHAPTER 4 BASIC OPERATION 21 4 1 Turning the Power On 21 4 2 Starting and Stopping Water TCUs 22 Starting the Unit Local 22 Stopping the Unit 22 Starting the Unit Remote 22 4 3 Starting and Stopping Hot Oil TCUs 23 Starting the Unit Local 23 Stopping the Unit 23 Starting the Unit Remote 2...

Page 4: ...9 Using the Elapsed Time Meter 38 5 10 Programming Ramp Soak 39 Controlling Ramp Soak 41 Monitoring Ramp Soak 41 5 11 Setting the Approach Rate 42 5 12 Level Input Operation Water Units 42 5 13 Adjusting the LCD Display Contrast 42 5 14 Adjusting the Auto Shutdown Temperature Setpoint 42 5 15 Calibrating the T C RTD and V Inputs 43 5 16 Accessing the Debug Menu 45 5 17 Reloading Factory Defaults 4...

Page 5: ...uts 57 System Inputs 57 Optional Analog Output Modules 57 7 2 Menu Structure 58 7 3 Control Board Layout 64 7 4 DAC Board Layout Optional 64 7 5 Technical Assistance 65 Parts Department 65 Service Department 65 Sales Department 65 Contract Department 65 Chapter 1 Safety 5 of 65 ...

Page 6: ...n for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common pr...

Page 7: ...in excess of 500 psi 3 447 5 kPa 34 47 bars DO NOT CUT INTO THE REFRIGERATION SYSTEM This must be performed by a qualified service technician only Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long rec...

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Page 9: ...eration installation and maintenance instructions for the M2B Controller The M2B Controller is available for use with several models of temperature control units TCUs A separate manual describes operation installation and maintenance instructions for the TCU itself Chapter 2 Functional Description 9 of 65 ...

Page 10: ...ithms to automatically tune the system to heat or cool the fluid as required by the process The M2B has a Liquid Crystal Display LCD that provides all operational status and programming menus The controller includes self diagnostics to check hardware functions All diagnostic information is displayed in the second line of the Liquid Crystal Display The M2B is panel mounted and has a membrane keypad...

Page 11: ... and low water level Cascade control with remote input sensor Triac outputs for heating and cooling Crash Quick cool feature Alarm outputs for temperature absolute and deviation low or high flow with optional flow meter open temperature sensor low water pressure pump failure over temperature contactor weld high and low water level for pump tank units Analog setpoint temperature input current or vo...

Page 12: ... character liquid crystal display LCD will show operational status alarms and programming menus 1st Line The first line of the LCD continuously displays the To Process temperature 2nd Line The second line of the LCD continuously displays the Setpoint temperature 3rd Line The third line of the LCD continuously displays the From Process temperature the delta temperature of the To Process and the Fro...

Page 13: ... display when a High Alarm condition occurs 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 stat...

Page 14: ... key is pressed before going to the next previous item or Setup mode is terminated Used in conjunction with the INDEX key at power on to enter into the Factory mode Tune If no Autotune operation is in progress this button starts an Autotune operation If an Autotune operation is in progress pressing this button will immediately stop the Autotune operation While the Autotune is running the Autotune ...

Page 15: ... F 65 5 o C for a water unit and 250 o F 121 o C for an Oil unit The message Vent Time MANUAL will be displayed while the key is held down Alarm Silence Turns off the Alarm 1 Output The cause of the alarm will continue to appear in LCD until the fault is cleared Used to immediately terminate any of the three Setup modes without having to cycle through to the end of the menu items Note that the cur...

Page 16: ...e setup menus by scrolling through the menu to its end or by pressing the Alarm Silence button The controller will automatically exit the setup menu if no buttons have been pressed for more than one minute Primary Menu The Primary menu includes all non critical parameters for standard operation including but not limited to standby mode mold temperature alarm trip points ramp soak settings and high...

Page 17: ... Press the Enter button The LCD screen will display the current security level 3 Use the Up or Down buttons to change the value in the display line to the password of the new desired security level 4 Press the Enter button to select this new security level and retain the value in EEPROM The display will change from the password value to the selected security level for that password Level Password ...

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Page 19: ... 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 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 ...

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Page 21: ...ameter is enabled the following messages about Option Cards can be displayed Re Transmit Detected Cool Analog Detected Heat Analog Detected Serial Comm Detected None Installed 6 The LED segments turn off 7 The LCD backlight turns off 8 The LCD displays Power Available System OFF At this point a Manual Vent Operation can be initializeed for 8 seconds by pressing the Vent button The unit is now in a...

Page 22: ...ts 7 The LCD displays SHUTDOWN Cool Down 8 The setpoint changes to 150º F 9 The Heat Outputs will turn off 10 The Cool Output will turn on 11 The system waits for the process temperature to drop down to 150º F Note Shutdown temperature is adjustable from 90 F to 180 F See Section 5 14 for procedure 12 At 150º F the LCD displays SHUTTING DOWN 13 All outputs immediately turn off 14 The system re cyc...

Page 23: ...owing sequence of events 9 The LCD displays SHUTDOWN Cool Down 10 The setpoint changes to 150ºF 11 The Heat Outputs will turn off 12 The Cool Output will turn on 13 The system waits for the process temperature to drop down to 150ºF Note Shutdown temperature is adjustable from 908F to 1808F See Section 5 14 for procedure 14 At 150ºF the LCD displays SHUTTING DOWN 15 All outputs immediately turn off...

Page 24: ...ler is automatic half full heat for water units and full heat for oil units 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 The Tune button is used to toggle the autotune process If no autotune operation is...

Page 25: ...on 4 In the Primary Menu change the Reset Time and Rate Time OFF and change the Prop Band Heat to 100 5 Adjust setpoint to the desired value 6 While monitoring the process temperature or recording device decease 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 7 Divide the period of o...

Page 26: ...he 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 If the manufacturer supplies the probe the controller is preconfigured and the user needs to set up the controller as local or remote input Use the following procedure to monitor the process from the remote probe...

Page 27: ...splay CNTL depress enter The controller is now set for cascade control Scroll to the menu MOLD SENSOR type Press the up arrow to display RTD This is the setting for a 100 ohm RTD for the remote probe For 1K ohm select RTD1K Continue to scroll through the menu until the control goes back to the run menu Or wait one minute without touching a key The controller will return to the run mode automatical...

Page 28: ...and Down buttons to set the cycle time to the desired time 6 Press the Enter button to save the cycle time 7 Press the Alarm Silence button to return to Running mode 4 8 Using Crash Cool The Crash Cool feature allows the user to quickly cool the process down Once Crash Cool is turned on the setpoint is automatically adjusted to 0ºF and the cooling valve is opened Oil TCUs not equipped with the opt...

Page 29: ...button 7 Press the Index button one time to access the Remote Signal parameter 8 Press the Enter button 9 Use the Up and Down buttons to change the range of the analog input 10 Press the Enter button 11 Press the Alarm Silence button to return to Running mode From the factory the remote setpoint temperature range is set up to be the same as the range of the controller Water 0 F to 250 F Oil 0 F to...

Page 30: ...ess the Secondary menu 3 Press the Enter button 4 Press the Index button until the display reads Analog Out Process Signal Type 5 Use the Up and Down buttons to change the value 6 Press the Enter button to accept the value 7 Press the Index button until the display reads Process Outlow 8 Use the Up and Down buttons to change the low limit value 9 Press the Enter button to accept the value 10 Press...

Page 31: ... button 14 Press the Index button until the display reads Remote Input 15 Use the Up and Down buttons to select OFF 16 Press the Enter button to accept the value 17 Press the Alarm Silence button to return to Running mode Using Analog Output for Heating and Cooling 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 control a modula...

Page 32: ...he scaling factor to the K factor pulses per gallon provided by the sensor manufacturer If the K factor isn t known use the GPM flow rate and frequency A factor GPM Hz K factor 60 sec A factor 14 Press the Enter button to accept the value 15 Press the Alarm Silence button to return to Running mode At this point the controller should display the flow as FL X X The user can now set up as many as two...

Page 33: ...re to set up the temperature alarm to be either an absolute alarm or a deviation alarm 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 Alarm1 Cfg 4 Press the Enter button 5 Press the Up and Down buttons to select the alarm type low high hilo or evnt 6 Press the Enter button 7 Press the Index button one time t...

Page 34: ...orrect the condition and start the controller to clear the fault There are no menu items that affect this function Low Pressure This alarm occurs when the controller loses the signal from the pressure switch In water units this alarm immediately disables the pump motor heat and cool outputs In the water unit this alarm is not critical and will automatically reset the controller once the pressure s...

Page 35: ...or overload trip If any of these occur the heat cool and pump motor outputs are disabled Turn the unit off and then on again to reset the fault Safety Thermostat Alarm This critical factory set alarm occurs when the thermostat sensor opens on a high temperature condition For both water and oil TCUs the heater output is disabled but the pump and cooling outputs are still active For water TCUs the c...

Page 36: ...ce button to return to Running mode 8 Press the Index button to access the Primary menu 9 Press the Enter button 10 Press the Index button until the display reads Aux Set Point 11 Press the Enter button 12 Use the Up and Down buttons to change the value The range is between the SetPtLoLimit and the SetPtHiLimit in the Secure menu 13 Press the Enter button to accept the change 14 Press the Alarm Si...

Page 37: ...pt the change 6 Press the Alarm Silence button to return to Running mode 5 8 Setting the Temperature Display Precision The controller is factory set to display the temperature and all related settings as an integer The user has the ability to change the display precision to tenths of a degree Use the following procedure to change the display precision 1 Press the Index button two times to access t...

Page 38: ...Alarm Silence button to return to Running mode Use the following procedure to view the elapsed time meter 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 ElapsedTime 4 Press the Alarm Silence button to return to Running mode Use the following procedure to reset the elapsed time meter 1 Press the Index button thr...

Page 39: ... 2 for sample ramp soak program Dwells or soaks are ramp segments with target setpoint equal to starting process temperature This allows for multistage ramps without wasting intermediate soak steps Note Before programming Ramp Soak evaluate your program on paper Test any program for best results before running production material Caution Make sure to run auto tune before operating Ramp soak becaus...

Page 40: ... 2 Press the Enter button 3 Use the Up and Down buttons to change the length of time for Segment 1 4 Press the Enter button to save the segment time for Segment 1 5 Press the Index button one time to access the Seg 1 SetPoint parameter 6 Press the Enter button 7 Use the Up and Down arrows to set the desired setpoint at the end of Segment 1 8 Press the Enter button to save the setpoint for Segment1...

Page 41: ...will control at that value for as long as the Hold state continues Press the RUN HOLD button again to toggle the ramp soak operation back into the ramp soak Run state While the Ramp Soak operation is running there are two ways to abort the operation Hold down the RUN HOLD key for 3 seconds In the Secondary Menu set the Prog Ramp Soak parameter to OFF Monitoring Ramp Soak If the Status of Prog para...

Page 42: ...tem will continue to function without interruption If a low level condition exists for more than three seconds the pump cooling and heating outputs are disabled while the fill solenoid re fills the tank The controller has a Water Fill Timer which can be set in the Secondary menu The timer can be set to OFF or from 1 to 180 minutes When it is set to off there is no time limit for the fill solenoid ...

Page 43: ...ave the value Calibrating the Thermocouple Input T C Note This thermocouple calibration procedure requires a J T C reference source to calibrate this analog input circuit Once the circuit is calibrated either a Type J or a Type K thermocouple can be selected for operation 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 calibrati...

Page 44: ...adjust the values if needed to compensate for any interaction that may occur between the two parameters Calibrating the Analog Input V Note This analog input calibration procedure uses a Voltage source for this analog input circuit Once the circuit is calibrated the JMP4 jumper can be changed for a Milliamp or Voltage input source for operation 1 Put a jumper on pins 2 and 3 of JMP4 on the main PC...

Page 45: ... of commands between the host and the slave controllers If one of the characters isn t flashing it is not communicating 8 Return to the Debug program and turn it off after the troubleshooting task is complete Use the following procedure to troubleshoot flow sensor input errors 1 Press the Index button three times to access the Secure menu 2 Press the Enter button 3 Press the Index button until the...

Page 46: ...displays will flash the words OFF and ON indicating reboot is complete 5 Restart the controller to automatically return to Running mode TCUs will default to a 250ºF 121 1ºC set stop limit For 550ºF 287 7ºC applications the controller must be reset for a high heat configuration Use the following procedure to configure the TCU for high heat applications 1 Press the Index button until the Secure Menu...

Page 47: ...00 or 19 2KB Secondary Menu Comm Local RMT RMT enables serial communication Port Address Operator selection of the address to use is from a menu parameter selection of 1H to 3E7H Note For MODBUS configuration this address setting must be set between 1 and 247 0x00Hex to 0xF7Hex The default value for this parameter is 1H The SPI DEVID specified in the SPI Protocol Specification field is set by this...

Page 48: ...s the diagnostic function 08 08 subfunction 00 00 to perform a loopback test When a loopback test is performed the MODBUS master sends a message to a controller and the controller sends the same message back to the master No changes are made to the controller database as a result of processing the command If the master does not receive a reply it is time to troubleshoot the network or the controll...

Page 49: ...0003 4006 34 343 Return Temp ºC 4 R 0004 4008 0 999 Flow Value 5 R W 0005 4010 0 1 System Standby Heat cool 6 R W 0006 4012 0 1 Temp Units 7 R W 0007 4014 34 343 Setpoint 1 ºC 8 R W 0008 4016 34 343 Setpoint 2 ºC 9 R W 0009 4018 34 343 Alarm 1 Low ºC 10 R W 0010 4020 34 343 Alarm 1 High ºC 11 R W 0011 4022 1 343 Prop Band Heat ºC 12 R W 0012 4024 1 343 Prop Band Cool ºC 13 R W 0013 4026 0 999 Rese...

Page 50: ... Reply The controller reply will consist of the following data 01 MODBUS unit ID 03 MODBUS command read holding registers 0F high byte of first register to read A2 low byte of first register to read 0FA2 4002 decimal 00 high byte of number registers to read 02 low byte of number of registers to read 2 16 bit registers are read in a single command to get all of a 32 bit floating point register 66 l...

Page 51: ...n level 30H Setpoint poll Returns the current process setpoint value in numeric format 31H Setpoint select Assigns a value to the process setpoint in numeric format 32H Alarm high temperature deviation poll Return the high temperature deviation setpoint value in numeric format This value when added to the process setpoint gives the temperature at which a high alarm will occur 33H Alarm high temper...

Page 52: ...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 O 49H Mode Machine Select Commands the temperature control unit to turn On 1 or Off D Bit 0 Machine On Off Bit 1 Alarm Acknowledge 70H Temperature to process poll Returns the delivery temperature in numeric format 72H Tempe...

Page 53: ...ture is higher than Setpoint Alarm trip point incorrect set Change the value of the high or low tripping point for the alarm See 5 4 on page 33 Remote input is not enabled Remote input is incorrectly configured Change the value for Remote Input in the Secondary Menu to SETP Setpoint will not change with a change of Remote Analog Setpoint value or setpoint displays 0 Remote Signal value is incorrec...

Page 54: ...D for MODBUS RTU or SPI Incorrect address selected Change the parameter Comm Addr Hex in the Secure Menu to a unique address in hexadecimal This parameter will depend on the type of protocol being used See debug menu on page Error Bookmark not defined Controller does communicate with remote host computer Incorrect communications speed The parameter Comm Baud Rate in the Secure menu must equal the ...

Page 55: ... Alarm Input Detected Alarm Major Fault Alarm1 2 SensorRange This Indicates Sensor Over range or beyond range of the unit Alarm Major Fault Alarm1 2 Sensor Open This Indicates Delivery Return or Remote Sensor Open or Not Connected to the input connector Alarm Major Fault Alarm1 2 WeldContact This Indicates Heater Weld Contact Input Detected Alarm Major Fault Alarm1 2 Pump Fail This Indicates Pump ...

Page 56: ... mm Terminal Connector Alarm Outputs Mechanical relay Type 2 Outputs 1A 120VAC INDUCTIVE Alarm 1 tied to incoming AC Alarm 2 contacts only no applied power External System Outputs SCR Triac Type 120Vac 1A continuously 60 C for all output loads Snubbers to be applied externally by customer there will be no board mounted snubbers System Output Variables Pump Vent Heater High Low Cool Aux Purge Alarm...

Page 57: ...125Hz 0 5Vdc pulsed JMP5 pins 2 3 HI Resolution 15 250Hz 80mV 1 6Vpp sine JMP5 pins 1 2 8 125Hz 0 5Vdc pulsed JMP5 pins 2 3 HI System Inputs Type Dry Contact 0 5mA 5 Vdc Sense CLASS 2 System Input Variables Pressure Low Level Phase Detection 2 Switches In Series 2nd Setpoint Remote Start Safety Thermostat Weld Contact Detect High Level System Dry Contact Input Ground Common Grounding Analog Input ...

Page 58: ...w Prog End PressLevel Inp Flow Alarm High Alarm 2 Low Auto Vent Cycle Alarm 2 High PressLevel Crash Cool Alarm 2 DeadBnd Pressure Timer High Heat AntiRst Windup SP2 RmtStart ElapsedTime PerCent Output HighLevel Inp Comm Add Hex Loop Break Time Weld Cont Inp Analog Output Sensor Type Process OutLow MoldSensorType Process OutHigh Input Fault Timer Process Out Src Out1 Type Heat Output Out2 Type Cool...

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Page 64: ...M2B Controller 7 2 Control Board Layout 7 3 DAC Board Layout Optional 64 of 65 Chapter 7 Appendix ...

Page 65: ...ustomer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products www acscustomerservice com Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST Fax 262 641 8653 Our products are sold by a world wide network...

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