Sterlco M2B Owner's Manual
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Sterlco M2B Owner's Manual

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Rev. A

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March 1, 2025

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Summary of Contents for Sterlco M2B

  • Page 1        Rev. A...
  • Page 2 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...
  • Page 3 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.

  • Page 4: Table Of Contents

    Conventions Used in This Manual ......5 M2B Microprocessor Controller ......6 Introduction .

  • Page 5: 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.

  • Page 6: 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. ...

  • Page 7: M2B Microprocessor Controller

    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 feed- back. When properly installed with a sealing gasket, the M2B is safe for water washdown.

  • Page 8: Quick Start Instructions For The M2B Controller

    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        ∆...

  • Page 9: Installation

    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.

  • Page 10: Interface Panel

    Security Level Displayed Value Password Value To Menu Status When Viewed Enter Home Locked Secondary Locked Secure Locked Home Unlocked Secondary Locked Secure Locked Home Unlocked Secondary Unlocked Secure Locked Home Unlocked Secondary Unlocked Secure Unlocked 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.

  • Page 11: Input Keypad

    • 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.

  • Page 12: Normal Operation Mode

    • 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.

  • Page 13: Tuning

    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.

  • Page 14: Manual Tuning

    Manual Tuning Procedure (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, the use of a recording device is required when tuning with this method:         1.

  • Page 15: Ramp/Soak

    M2B controller. This section will deal only with the Ramp/Soak programming operation. Basic Theory Of 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 Operation Ramp/Soak does the calculation automatically.
  • Page 16 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 Before programming Ramp/Soak, evaluate your program on paper. To ∆ program Ramp/Soak function, enter the secondary menu (pressing UP and ENTER keys simultaneously).
  • Page 17 "# "# "# "# • 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 “ ”...

  • Page 18: Sample Ramp/Soak Program

    Sample Ramp Soak Program Segment Prompt Function Time (Min.) Setpoint 1st Event 2nd Event 3rd Event 4th Event 5th Event 6th Event Un-Used Hold Last Setpoint ↓ Un-Used Un-Used Stay at present set pt. (gSP) Turn off outputs at end of program Repeat program at 1TI...
  • Page 19 The following flow chart diagrams the sample Ramp/Soak procedure.  Enter the secondary menu. Follow the “Ramp/Soak setup” steps to reach Set the remaining points, 8-9 and A-G to zero This program is now ready to run. See Starting Ramp/Soak.

  • Page 20: Starting Ramp/Soak

    Starting Ramp/Soak • 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.

  • Page 21: Options

    ”. • 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 “...

  • Page 22: Retransmission Of Process Variable

    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.
  • Page 23 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.
  • Page 24 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).

  • Page 25: Spi Protocol

    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.
  • Page 26 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.

  • Page 27: Diagnostic Error Messages

    • Press SET POINT to exit to run. Reload Factory Default • 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 “...

  • Page 28: High Temperature Oil Reconfiguration

    CAUTION: The M2B controller automatically defaults to a 250 F (121.1 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 (287.7...

  • Page 29: Field Calibration

    3. Ambient Temperature Indicator with an accuracy of ± 0.05% or better. 4. Assortment of test leads. Procedure 1. Power up Instrument and allow the M2B to warm up for 1 hour. 2. Hold the ENTER and UP Arrow keys for 5 seconds. The Menu will enter     .
  • Page 30 " " " " ) ) ) ) 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.
  • Page 31     ) ) ) ) 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 (“ ”).

  • Page 32: Electrical Specifications

    Electrical Specifications Temperature Inputs T/C’s J, K, E, (Remote Sensing Only) Input Type Range -100 to 1600 F (-73 to 871 -200 to 2500 F (-129 to 1371 -100 to 1800 F (-73 to 982 Impedance 3 Meg ohms min. RTD’s Pt1000 din 0.00385 Ω...

  • Page 33: General Specifications

    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.

  • Page 34: Appendix A-Menu Selections

    Appendix A Hard Keys Heat Set Point Process Heat Low High Main Set Pt. Alarm Low -100 Alarm High Home (Index Keys) Heat Set Point Process Heat Low High On/OFF System On or Off (Standby) run/HLd note 1 Programmer Run/Hold note 3 Program Segment Time remaining note 3...
  • Page 35 Secondary Menu (Up and Enter Keys) Heat Set Point Process Heat Low High Degrees F or C OFF/Lo/Hi/HL/Eut Alarm (Off, Low, High, Hi.Lo, Event) AbS/dE Absolute or Deviation to SP1 OnF/HOL * Alarm Reset, auto reset/manual reset On/Off Power Interrupt Power inhibit, suspend alarm until PV enters On/OFF non-alarm condition...
  • Page 36 Secure Menu (Up and Enter - 5 seconds) Water Oil Temp. Temp. Control Set Point Process Control Unit Unit Heat Heat Low High #### Security Code HL/HH/L Function (Lo/Hi heat Chiller) 0 to 100 Self Tune Offset Percent -500 to +500 Input Correction OFF, 1 to 99 digital...
  • Page 37 Water Oil Temp. Temp. Control Set Point Process Control Unit Unit Heat Heat Low High O on/off Lamp (on/off) contact closed AbS/dE Absolute of Deviation to SP1 dir/rE Direct or Reverse Acting 0 to 90 Output 1 low limit 10 to 102 Output 1 high limit O on/oFF Lamp (on/off) contact closed...

  • Page 38: Appendix B-Mounting

    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.

  • Page 39: Appendix C-Control Modes

    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.
  • Page 40 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.
  • Page 41 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.
  • Page 42 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...
  • Page 43 PID COMPONENTS REACTING TO A LOAD CHANGE LOAD S.P. TEMP P.V. PROPORTIONAL S.P. OUTPUT INTEGRAL S.P. OUTPUT DERIVATIVE S.P. OUTPUT RESULTANT PID S.P. OUTPUT TIME...

  • Page 44: Appendix D-Blank Ramp/Soak Profile

    Appendix D Drawing a Ramp/Soak 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 Profile record of your program and will assist you when entering the set point data. Prompt Function Segment...

  • Page 45: Appendix E-Glossary Of Terms

    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.
  • Page 46 Deadband 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. Derivative (Rate) Adjusts the controller gain quickly in response to load changes. Derivative Action Is normally used to give a fast response to changes in process value and to improve process stability.
  • Page 47 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.
  • Page 48 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.

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