ACS 601.86861.00 Operation And Instruction Manual
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ACS 601.86861.00 Operation And Instruction Manual

Advanced microprocessor controller
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M2C Advanced Microprocessor Controller
OPERATION AND INSTRUCTION MANUAL
TC120 – 601.86861.00
Part Number: 682.98769.00
Revision: 7/29/18

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  • Page 1 M2C Advanced Microprocessor Controller OPERATION AND INSTRUCTION MANUAL TC120 – 601.86861.00 Part Number: 682.98769.00 Revision: 7/29/18...
  • Page 2 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No. ____________ © Copyright 2018 All rights reserved. M2C Advanced 682.98769.00 •...
  • Page 3 Shipping Info 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.

  • Page 4: Table Of Contents

    Table of Contents CHAPTER 1: SAFETY ..............7 How to Use This Manual .................... 7 Safety Symbols Used in this Manual ..............7 General Safety Regulations ..................8 Responsibility ......................8 Warnings and Precautions ..................9 CHAPTER 2: FUNCTIONAL DESCRIPTION ......11 Models Covered in This Manual ................
  • Page 5 CHAPTER 5: ADVANCED OPERATION ......... 25 5-1 Using the Analog Remote Input ..................25 5-2 Retransmission Analog Signal ..................26 Setting the Analog Signal Source to FLOW .............27 Using Analog Output for Heating and Cooling ............27 5-3 Using the Flow Monitor ....................28 5-4 Programming the Alarms ....................
  • Page 6 Electrical Specifications ................... 61 Temperature Sensor Inputs ..................61 Flow Sensor Inputs ....................62 System Inputs ......................62 Optional Analog Output Modules ................62 Drawings and Diagrams................... 62 Technical Assistance ....................69 M2C Advanced 682.98769.00 • 8/24/18...

  • Page 7: Chapter 1: Safety

    Chapter 1: Safety How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your machine. 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.

  • Page 8: General Safety Regulations

    General Safety Regulations These regulations should be read, understood and periodically reviewed by all personnel involved in any way with this machine. Never operate or remove any machine components that are secured by mechanical fasteners unless the motor is electrically locked out and all moving parts are motionless. Do not circumvent the safety interlocks.

  • Page 9: Warnings And Precautions

    Figure 1: Safety Tags and Warning Labels Hazard Alert Description/Explanation Preventative Maintenance Symbol Electricity Hazard. The controller operates on single phase power and the electrical Every six months inspect all electrical enclosure is supplied with 3-phase electrical connections for secure attachment. power.
  • Page 10  ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the machine before performing any service.  SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and electrical safety interlocks ensure the safety of personnel. They should never be tampered with or removed for ANY reason. They should be checked frequently by a qualified mechanic for proper operation.

  • Page 11: Chapter 2: Functional Description

    Chapter 2: Functional Description Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for the M2C Advanced controller. The M2C Advanced 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.

  • Page 12: Panel Layout And Keypad

    • RS-485 SPI communications 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.

  • Page 13: Keypad

    High Alarm Indicator. Appears in the LCD 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’...
  • Page 14 • 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” message is displayed on the LCD in place of the normal “Running”...

  • Page 15: Menu Structure

    Figure 1: Panel Layout System Status Display Displays status of various system functions Setpoint Value Display Process Variable Display including from Process Constantly displays fluid Constantly displays to fluid temperature, flow, Process fluid temperature. temperature setpoint alarms, etc. Enter Button Press to accept entry.

  • Page 16: Secondary Menu

    Secondary Menu The Secondary menu includes all non-critical parameters for optional equipment including but not limited to degrees F/C, Alarm parameters, ramp/soak segments, remote setpoint scaling, communication setup, and retransmission scaling. Secure Menu The Secure menu includes all critical parameters for setting up the controller including but not limited to controller function, select either Water TCU or Oil TCU default values, flow meter on/off, remote control probe on/off, pressure switch, high and low level, safety thermostat on/off, output parameters, and scale limits.

  • Page 17: Chapter 3: Installation

    Chapter 3: Installation Electrical Connections 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.

  • Page 18: Chapter 4: Operation

    Chapter 4: Operation Turning the Power On When AC power is first applied to the unit, the following sequence of events will occur: 1. The LCD backlight lights up. 2. The LCD displays dashes: LEDs have all segments on. 3. The LCD displays the PROM Rev/Date. 4.

  • Page 19: Starting And Stopping Hot Oil Tcus

    9. The Heat Outputs will turn off. 10. The Cool Output will turn on. º 11. The system waits for the process temperature to drop down to 150 Shutdown temperature is adjustable from 90 ° F to 180 ° F. See Section 5-14 for procedure.

  • Page 20: Starting The Unit (Remote)

    15. All outputs immediately turn off. 16. The system re-cycles to the “Power Available/System OFF” state. Pressing the Stop button a second time while the controller is in the “SHUTDOWN [Cool Down]” mode will abort this cool down operation and the system will immediately go into the “SHUTTING DOWN” phase of the operation.

  • Page 21: Manual Tuning (Zeigler-Nichols Pid Method)

    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.

  • Page 22: Setting Up Cascade Control

    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: 1. Press the Menu button three times to access the Secure menu. 2. Press the Enter button. 3.

  • Page 23: Adjusting The Automatic Venting Timer

    mode automatically. • The remote probe input is wired to Header J5, pins 3 and 4 on the back of the controller. The remote probe is factory defaulted for a Type J T/C input. Move the jumper “JMP2” to pins 1 and 2 for a RTD input. •...
  • Page 24 5. Use the Up and Down buttons to set the “Crash Cool” parameter to “ON.” 6. Press the Enter button to begin crash cooling. The setpoint will change to 0, and the cool output will turn on. 7. Press the Alarm Silence button to return to Running mode. M2C Advanced 682.98769.00 •...

  • Page 25: Chapter 5: Advanced Operation

    An optical isolator is recommended for these instances and ACS Group offers this as an option when it is known that a PLC will be generating the analog signal.

  • Page 26: Retransmission Analog Signal

    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, 0- 10VDC, and 2-10VDC.

  • Page 27: Setting The Analog Signal Source To Flow

    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. Press the Menu button until the display reads “Remote Input.” 2.

  • Page 28: Using The Flow Monitor

    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 m i nute). If the flow sensor is of the pulsed variety, it is connected to block J1 on the main controller board.

  • Page 29: Programming The Alarms

    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.

  • Page 30: Flow Alarm

    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.

  • Page 31: Low Fluid Level Alarm

    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.

  • Page 32: Using The Second Setpoint Function

    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.

  • Page 33: Using The Elapsed Time Meter

    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 Menu button two times to access the Secondary menu. 2.

  • Page 34: Programming Ramp/Soak

    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.

  • Page 35: Starting Ramp/Soak Programming

    Use the following procedure to program the Ramp/Soak functions: Starting Ramp/Soak Programming: 1. Press the Menu button two times to access the Secondary menu. 2. Press the Enter button. 3. Press the Menu button until the display reads “Prog Ramp/Soak.” 4.

  • Page 36: Controlling Ramp/Soak

    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.

  • Page 37: Level Input Operation (Water Units)

    5-12 Level Input Operation (Water Units) All level inputs have a three-second input suppression timer to prevent false input signals caused by turbulent fluid. The level input has a menu selection for CONTROL or ALARM in the Secure menu. When the machine is started, the controller will determine if a high- or low-level condition is present.

  • Page 38: Calibrating The T/C, Rtd, And V Inputs

    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.

  • Page 39: Calibrating The Thermocouple Input (T/C)

    Calibrating the Thermocouple Input (T/C) 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.

  • Page 40: Calibrating The Rtd Input

    Calibrating the RTD Input 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.

  • Page 41: Accessing The Debug Menu

    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. Press the Menu button three times to access the Secure menu. 2.

  • Page 42: Reloading Factory Defaults

    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.”...

  • Page 43: Serial Communications Operation

    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.
  • Page 44 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. So that a MODBUS master can read and write the controller parameters, setpoints, and status values in an Athena Temperature controller, the Athena implementation of the MODBUS protocol supports the following function codes: function 03 ($03) This function is used to read to one or more contiguous “holding registers”...
  • Page 45 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. All data conversion such as rounding, integer float, Etc, is transparent and handled by the controllers, since internal variables data type can be different for the MODBUS data exchange types.
  • Page 46 MODBUS Function 03 Request. The format for a function 03 request is shown below. Device Function Code Register Address Number Of Words Address To Read 1 byte 1 byte containing $03 MODBUS Function 03 Request Example. Suppose you want to Read Delivery Temperature in Float 32 Bit IEEE Format, which has registers address of "4002"...

  • Page 47: Spi Protocol

    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.
  • Page 48 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...

  • Page 49: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, circuit breakers turned off, and with the machine tagged as out of service. The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated.

  • Page 50: Operating Mode And Error Display Messages

    The status of the program has Either Press the Run/Hold been stopped. button on the face of the controller or change the value of “Prog Ramp/Soak” in the Secondary Menu to ON. Ramp/Soak program does not The segment setpoint is Change the value of “Seg # transition to desired setpoint.

  • Page 51: Chapter 7: Appendix

    Chapter 7: Appendix Customer Satisfaction Warranty Program The terms and conditions of the warranty set forth are for one (1) year from the original date of purchase by the original purchaser. The manufacturer warrants to the original purchaser the product and/or goods to which this disclaimer is attached, and manufactured by us, to be free from defects in material and workmanship under normal use and service.

  • Page 52: Electrical Specifications

    Electrical Specifications General Dimensions 5.5” X 9” X 4” (140 x 230 x 100) Range of the Unit -45°F to 650°F (-42.7°C to 343°C) Normal Operating Environment Operating Temperature Range 0° C to 40° C (LCD Display up-to 50° C) (-32°F to 104°F, display up to 122°F) Humidity 0 to 95% RH (Non condensing)

  • Page 53: Flow Sensor Inputs

    Temperature Stability 4 uV/° C TYPICAL,5 uV/° C MAX Flow Sensor Inputs Ranges 15-250Hz@80mV-1.6Vpp (sine) JMP5, pins 1-2 8-125Hz, 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...
  • Page 54 DelivRate Time Status of Prog Approach Rate Cool Ratio Prog Time Base Sensor Monitor Mold Prop. Band Seg # Time Flow Monitor Mold Reset Time Seg # SetPoint Flow Constant B Mold Rate Time Seg # A1 Event Flow Constant K Aux Set Point Seg # A2 Event Flow Filter...
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  • Page 60: Technical Assistance

    Technical Assistance PARTS SUPPORT ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service. 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.

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