MicroMod IB-MLOPR-TUT Owner's manual

Brand: MicroMod

Model: IB-MLOPR-TUT

Type: Owner's manual

MOD 30ML Training Manual

Operation and Maintenance

Training Labs for

MOD 30ML Operation

MicroMod Automation, Inc.

The Company

MicroMod Automation is dedicated to improving customer efficiency by providing the most cost-effective, application-specific process solutions

available. We are a highly responsive, application-focused company with years of expertise in control systems design and implementation.

We are committed to teamwork, high quality manufacturing, advanced technology and unrivaled service and support.

The quality, accuracy and performance of the Company's products result from over 100 years experience, combined with a continuous

program of innovative design and development to incorporate the latest technology.

Use of Instructions

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it

must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process

system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices.

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for

any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of MicroMod

Automation, Inc.

Licensing, Trademarks and Copyrights

MOD 30 and MOD 30ML are trademarks of MicroMod Automation, Inc.

MODBUS is a trademark of Modicon Inc.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:

The relevant sections of these instructions must be read carefully before proceeding.

1. Warning Labels on containers and packages must be observed.

2. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the

information given or injury or death could result.

3. Normal safety procedures must be taken to avoid the possibility of an accident occurring when operating in conditions of high

4. pressure and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling

procedures must be used.

6. When disposing of chemicals, ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual may be obtained from the Company address on the back

cover, together with servicing and spares information.

Ì Warning. An instruction that draws attention to the risk of

injury or death.

Note. Clarification of an instruction or additional

information.

q Caution. An instruction that draws attention to the risk of

the product, process or surroundings.

i Information. Further reference for more detailed

information or technical details.

All software, including design, appearance, algorithms and source

codes, is copyrighted by MicroMod Automation, inc. and is owned by

MicroMod Automation or its suppliers.

1 - 1

1 MOD 30ML Front Face Familiarization

Lab

1.1 Foreword

Many processes involve flow control loops, whether they are in the food, pharmaceutical,

chemical, pulp & paper, mining or virtually any of the industries served by MODCELL

Multi-loop Processors. This lab is designed to help you learn the basic features of the

Application Builder, as well as how to easily demonstrate configuration of a PID loop.

1.2 Objectives

In this lab we will download a simple PID control database from a memory module to the

MOD 30ML controller and get familiarized with the controller’s front face.

Figure 1 .1.

MOD 30ML Front

Face

After completing this lab, you should know how to download a database from a memory

module to a MOD 30ML controller and operate standard PID control loop from the front

face.

1.3 Equipment Required

You need the following equipment for this lab:

1. 1 x MOD30ML

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MOD 30ML Front Face Familiarization Lab

1 - 2

2. 1 x Memory module (2010PZ10000A) marked FACEPLATE (and loaded with the

FACEPLAT.CDB file)

3. 1 x Small flat screwdriver

1.4 Instructions

1.4.1 Before you power up the instrument

Step Procedure Comments

1 Make sure the SERV/RUN switch

under the front face is set to the

RUN position

This ensures that after a download the database

will be able to run.

This switch is located behind the front panel in the

NEMA 4 option. You will need to remove the

instrument from its housing to set it.

2 Make sure the switches on the

memory module are set to READ

ONLY and NORMAL

This ensures that the database stored in the

memory module is downloaded to the instrument

during a power-up sequence.

Normal = Transfers the database contained in the

memory module to the instrument.

Module Load = Transfers the database contained

in the instrument to the memory module

3 Loosen the retaining screw and slide

the instrument from the housing

CAUTION ! Ensure that the main circuit board is

supported at all times.

4 Install the memory module With the catalogue number of the memory module

facing upwards, install the memory module onto

the connector of the main circuit board

5 Place the instrument back into the

housing and tighten the retaining

screw

You should see ******** appear for a short while,

then a flashing loop display with the tag FIC-100

and the alarm light.

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MOD 30ML Front Face Familiarization Lab

1 - 3

1.4.2 Operating the alarm page and power-up sequence

Step Procedure Comments

Press the Alarm Key

MEM MOD will appear on line 1

WRTPROT will appear on line 2

UAK and RET will appear on lines 3 and 4

UAK = Unacknowledged alarm

RET = Return to loop display (Operating)

The AUTO and MANUAL keys now function as

Acknowledge and Return keys.

2. Press the Auto key next to

UAK.

Line 3 will change to ACT (Active) indicating that

the alarm is still present. The flashing red alarm

lamp indicates that other alarms are still

unacknowledged.

Press the Alarm Key

INST, PWR UP will appear on lines 1 and 2

UAK and RET will appear on lines 3 and 4

UAK = Unacknowledged alarm

RET = Return to loop display (Operating)

4. Press the Auto key next to

UAK.

Line 3 will change to CLR (clear) indicating that the

alarm is no longer present, but the flashing red

alarm lamp indicates that other alarms are still

present.

Press the Alarm key.

INST, PWR DOWN will appear on lines 1 and 2

UAK and RET will appear on lines 3 and 4

6. Press the Auto key next to

UAK.

Line 3 will change to CLR (clear) indicating that the

alarm is no longer present, but the flashing red

alarm lamp indicates that other alarms are still

present.

Press the Alarm key.

PROCESS LOW will appear on line 1

The actual process value appears on line 6

UAK and RET will appear on lines 3 and 4

Advantage: Alarm displays provide complete information, not just codes

8. Press the Auto key next to

UAK.

Line 3 will change to ACT (Active) indicating that

the alarm is still present. The flashing red alarm

lamp will change to constant illumination. This

indicates that all alarms have been acknowledged

and one or more is still active

9. Press the R/L key next to RET

(return)

The display will return to the FIC-100 operating

display.

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MOD 30ML Front Face Familiarization Lab

1 - 4

 Note: Active Diagnostics

An unacknowledged diagnostic condition is always indicated by flashing of the alarm

LED. The indication may also include a flashing display and a beep signal depending on

configuration. A dedicated alarm display provides information on all active diagnostics.

An example of the display with control key information is shown in the next figure. When

the alarm light indicates an alarm condition, press the alarm key to access the alarm

displays. Pressing the key repeatedly scrolls through a series of displays covering all

unacknowledged alarms and acknowledged alarms that are still active. Unacknowledged

diagnostics are always displayed first in the viewing sequence. See IB-1800R-OPR,

Section 3 for more information.

Figure 1 .2.

MOD 30ML Alarm

Abbreviated diagnostic message.

[UAK] indicates that the alarm is active and has not been

acknowledged. Press the ‘A' key to acknowledge the alarm. If

alarm is still active [ACT] appears. If alarm is no longer active

[CLR] appears, and this display is deleted upon exit. [RET]

indicates that the R/L key can be pressed to return to the

runtime displays.

[7] is the Diagnostic event code number.

[AOUT] [2] indicates the block type and number.

Use the block type and event code number to locate a

description of the diagnostic event in IB-23M601 Section 7.3.

For example, code 7 for the [AOUT] block indicates an AOUT

(module) error because the output circuit has reported an

output-too-high or output-too-low error.

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MOD 30ML Front Face Familiarization Lab

1 - 5

1.4.3 Operating the Loop display

Left Bar will display the Process variable

Middle Bar will display the setpoint

Right Bar will display the control output

Line 1 will display the loop tag = FIC-100

Line 2 will display the process input and units = 0.00 GPM

Line 3 will display the control mode = MAN (manual)

Line 4 will display the setpoint mode = LOC (local)

Line 5 will indicate what value is displayed on line 6 = OP (output)

Up/Down arrows indicate that the value on line 6 = /

can be manually altered

Line 6 will display the value indicated by line 5 = 0.00 %

1.4.4 Operating the Auto/Manual key

Step Procedure Comments

Press the Auto key You will notice that line 3 changes to AUT and the

UP/DOWN arrows disappear indicating that manual

manipulation of the output is not possible.

2. Press the Manual key.

You will notice that line 3 changes to MAN and the

UP/DOWN arrows reappear indicating that manual

manipulation of the output is possible.

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MOD 30ML Front Face Familiarization Lab

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1.4.5 Operating the Ramp keys

Objective: To manually set the control output to a value of 24.8%. During the following

procedure, if the time between key strokes is greater then 10 seconds, then the display will

automatically change back to the operating loop display. If this is the case, simply press

either the UP or DOWN key and select the character you wish to change using the FST

and SLO keys.

Step Procedure Comments

1. Press the UP or DOWN key The leftmost digit of line 6 starts to flash

Lines 3 and 4 (also flashing) are now displaying

FST (fast) and SLO (slow)

The AUTO and MAN keys now function as cursor

movement keys for the digits on Line 6

2. Press the AUTO key, next to FST, 3

times

The cursor is now blinking under the blank space

to the left of the output value _0.00%

Press the UP key 2 times

The output value increments to 20.00%

5. Press the MAN key , next to

SLO, 1 time

The cursor moves to the second digit to the left of

the decimal point 20.00%

Press the UP key 4 times

The character increments to a value of 4.

7. Press the MAN key , next to

SLO, 1 time

The cursor moves to the first digit to the right of the

decimal point 24.00%

Press the UP key 8 times

The character will increment to a value of 8 and the

output value is 24.80%

Press the TAG key

This will stop the flashing and change the display

back to the FIC-100 loop display. Don’t forget that

the display will automatically change after 10

seconds of no key strokes.

Advantage: The operator can set the exact desired value with no overshoot

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MOD 30ML Front Face Familiarization Lab

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1.4.6 Operating the Scroll key

Step Procedure Comments

Press the SCROLL key

Line 5 changes to display SP (Setpoint)

You can use the method described in section F - OPERATING THE RAMP KEYS to

change the value of the setpoint.

2. Press and hold the SCROLL key

The top of the display indicates TUNE

PASSWORD

FST, SLO, and ENT indicators are flashing

Arrows appear to allow changing of the numerical

tuning password on the bottom line

Press the UP key twice to

change the bottom number to 2, and

then press ENT

The tuning password for this configuration is 2.

FIC-100 appears on Line 1

GAIN appears on Line 2

The base gain value appears on Line 6. Dual

arrows   indicate the gain value may be

changed.

Press the NXT key

RESET appears on Line 2

The base reset value appears on Line 6 (RPM =

Repeats Per Minute). Dual arrows   indicate

the gain value may be changed.

Derivative is not configured for this

strategy.

Press the NXT key

ACTION appears on Line 2

The control action, REVERSE, appears on Line 6.

Dual arrows   indicate the action may be

changed.

Advantage: information which is useful during commissioning can be included on tuning

displays

Press the NXT key

PID TYPE appears on Line 2

The configured PID type, ESPO, appears on Line

6. This represents gain on Error, Standard reset,

derivative on Process, manual reset OFF.

Advantage: information which is useful during commissioning can be included on tuning

displays

Press the UP key when you

reach the EXIT TUNING display

This returns you to the FIC-100 operating display.

Training Manual

MOD 30ML Front Face Familiarization Lab

1 - 8

1.4.7 Checking the Communication setup

Objective: Determine the Modbus address and communication parameters of this

instrument

Step Procedure Comments

Press and hold the TAG key

Line 6 changes to display DEV STAT (device

status).

This is the start of the Status and Configuration

menus.

The Remote Local (R/L) and SCROLL keys now

function as “previous” PRV and “next” NXT keys.

Press the NXT (scroll) key

SETUP appears on the bottom line, with a down

arrow  indicating there are sub-menus

Press the DOWN arrow key

The top of the display indicates SETUP BI COMM

(Set up built-in communications) with a down arrow

indicating there are further sub-menus

Press the DOWN arrow key

The top of the display reads BI MSC 1 ADDRESS

(built-in Modbus serial port 1 address) and the

Modbus address for the built-in communication port

is shown on the bottom line.

Press the NXT key

The top of the display changes to BI MSC 1

BAUDRATE and the baud rate is shown on the

bottom line. Dual arrows   indicate that the

baud rate may be changed. Change the baud rate

to 38400

Press the NXT key

The top of the display changes to BI MSC 1

PARITY and the parity is shown on the bottom line.

Dual arrows   indicate that the parity may be

changed, however, for most applications you

should leave this at default of NONE.

Press the NXT key

The top of the display changes to BI MSC 1

STOPBITS and the number of stop bits is shown

on the bottom line. Dual arrows   indicate

that the number of stop bits may be changed,

however, for most applications you should leave

this at default of 1.

Press the NXT key

The top of the display changes to BI MSC 1

ENABLED. This tells you that the Modbus

communications have been enabled. This occurred

during the download.

Press the TAG key

This will return you to the beginning of the device

status displays

10. Press the TAG key again This will return you to the FIC-100 loop display

11. Record the communication information for this instrument in the next table.

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MOD 30ML Front Face Familiarization Lab

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Communication Information:

Modbus

Address

Baud Rate

Stop bits

Built-In Comm

Enabled

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MOD 30ML Front Face Familiarization Lab

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Notes:

2 - 1

2 MOD 30ML Operation Lab 2

2.1 Foreword

MOD 30ML can perform complex continuous control as well as discrete control. The

Sequencer block in the MOD 30ML can be used for executing complex batch and

sequencing control. Custom displays can be built for information and operation of the

advanced control.

2.2 Objectives

In this lab we will download a batch control strategy from the memory module to the

MOD 30ML controller and run the batch from the custom displays.

Control of a batch reactor includes sequential and continuous elements, and tight control

of the reaction temperature. Ideally, only one device is used to perform both types of

control, with a common local display interface providing complete process information.

The following demonstration will show:

• integration of automatic sequential and continuous control

• front panel display of sequence steps

• cascade control

• front panel recipe selection and entry of recipe data

• manual control of sequence steps through front panel

2.2.1 The Control System

The batch reaction is conducted according to a definite time-temperature cycle. The next

figure illustrates a typical cycle of many industrial processes.

Reactants are added to the reactor at room temperature; the reaction mass is heated to

reaction temperature; the reaction is carried out to form products; the batch is cooled; and

the reactor is emptied. Total batch time in reactors used in the manufacture of PVC or

polystyrene, for example, is approximately fourteen to eighteen hours. The progression of

the batch cycle is controlled by the sequence operation. It may sometimes be necessary

for the operators to pause, stop, or manually advance the cycle to another step.

Training Manual

MOD 30ML Operation Lab 2

2 - 2

Figure 2 .1.

Batch Temperature

Cycle

During the heat stage of the batch cycle, a cascade temperature loop is used to control

temperature. At the time the sequence enters the heating step, the setpoint of the master

controller is ramped to the reaction temperature; the master controller measures the

product temperature while the slave measures jacket temperature. At the cooling stage,

the setpoint is ramped back to the cool setpoint.

Figure 2 .2.

Batch Reactor

The MOD 30ML is performing the process simulation as well as the sequence control and

temperature cascade control. Once started, the batch cycle will progress automatically

unless it is switched to manual mode.

The following operations may be done from the front panel displays:

• Batch initialization

• Recipe selection

• Recipe parameter entry

Training Manual

MOD 30ML Operation Lab 2

2 - 3

• Manual advance of sequence

Initial Conditions:

1. Batch AUTO, OFF (Note: once the batch has been started, Line 2 will indicate

the Time in Step for each step. If the batch is put into manual mode, Line 2 will

display Manual. The “time in step” timer does not stop if the batch is put into

manual. However, if you manually advance to another step, the step timer re-

starts).

2. RECIPE 1 selected

3. Temperature setpoint LOCAL

4. Level 0.0” H2O

5. Step OFF

Training Manual

MOD 30ML Operation Lab 2

2 - 4

2.3 Instructions

2.3.1 Download Reactor database from the memory module:

Step Procedure Comments

1 Make sure the SERV/RUN switch

under the front face is set to the

RUN position

This ensures that after a download the database

will be able to run.

This switch is located behind the front panel in the

NEMA 4 option. You will need to remove the

instrument from its housing to set it.

2 Make sure the switches on the

memory module are set to READ

ONLY and NORMAL

This ensures that the database stored in the

memory module is downloaded to the instrument

during a power-up sequence.

Normal = Transfers the database contained in the

memory module to the instrument.

Module Load = Transfers the database contained

in the instrument to the memory module

3 Loosen the retaining screw and slide

the instrument from the housing

CAUTION ! Ensure that the main circuit board is

supported at all times.

4 Install the memory module With the catalogue number of the memory module

facing upwards, install the memory module onto

the connector of the main circuit board

5 Place the instrument back into the

housing and tighten the retaining

screw

You should see ******** appear for a short while,

then a display as shown in the next figure should

appear.

Figure 2 .3.

Batch main display

Training Manual

MOD 30ML Operation Lab 2

2 - 5

2.3.2 Scroll through the displays:

Step Activity Look For

1 The first display as shown in the

previous page is the main batch

display. This is the display where we

will start the batch. But before that,

we will scroll through the other

displays to get an overview.

Note that the batch is in AUTO mode and is not

running right now (OFF). The setpoint is in local

(LOC) mode.

2 Press the TAG key once to go to the

TIC-100 temperature control loop

display. See the next figure.

Read the temperature of the product.

Read the output. Press the SCROLL

key to show the setpoint at the

bottom.

Press the TAG key again to go to

TIC-101 control loop display. See the

next figure.

Read the process, setpoint and

output values.

Press the TAG key to go to the next

display. See the next figure.

This is the Master temperature controller.

Master temperature controller TIC-100 setpoint

100ºF.

This is the Slave temperature controller.

Slave temperature controller TIC-101 setpoint

200ºF.

Setpoint is in Remote mode (REM). Its value is

same as the output value of the TIC-100 loop.

This display shows the Flow rates of Product A and

B and also the Level value in inches.

Product A and B flow 0 GPM

Level in vessel 0.0” H2O

Figure 2 .4.

TIC-100, TIC-101

and Flow/Level

Displays

Training Manual

MOD 30ML Operation Lab 2

2 - 6

 You can display and manipulate on one instrument, all process and calculated values

associated with the process unit, including both sequence and continuous control.

2.3.3 View the Tuning displays and change the batch recipe:

3 Display tuning pages for TIC-100

and TIC-101.

First switch to the control display

(TIC-100 or TIC-101) and then hold

down Scroll key to access the tuning

display.

Tuning displays for controller algorithm type,

controller action, gain, reset

Commissioning activity can take place through

front panel of instrument.

4 Display recipe selection by returning

to main batch display and holding

down scroll key.

Enter tuning password of 1 (if

required; the tuning password from

the previous activity may still be in

effect)

Select recipe 1 using UP/DOWN

arrows and press ENT (Scroll key).

Press NXT key to view recipe

parameters

Change Recipe 1 target level to 15

inches water. See the next figure.

This is a tuning display within the main batch

display to select and change the recipe for the

batch.

Once tuning password is entered the recipe can be

scrolled between the choices of Recipe 1 and

Recipe 2

You can view and change the following

parameters: Reaction temperature setpoint entry,

Reactor level, Fill A rate, Fill B rate

Figure 2 .5.

Recipe Tuning

display

Training Manual

MOD 30ML Operation Lab 2

2 - 7

2.3.4 Run the Batch:

5 Press the TAG key to return to main

Batch display

Press AUTO key to start the batch

See the next figure.

Batch status changes to RUN

Setpoint status changes to REMOTE

Step indication on Line 6 changes to START and

then to FILL.

Figure 2 .6.

Batch main display

6 Scroll to fill display

See the next figure:

Fill A and Fill B flow rates displayed on lines 1 and

2, left and middle bar

Reactor level displayed on Line 6 and right bar

Figure 2 .7.

Batch Flow/Level

display

Training Manual

MOD 30ML Operation Lab 2

2 - 8

7 Return to main batch display and

observe step.

8 When controller has entered

HEATUP step, scroll to temperature

control displays (TIC-100 and TIC-

101)

Read the process value of TIC-100.

Refer to the next figure.

Cascade control for temperature is now active

Master controller setpoint value ramps to 111ºF.

This will also ramp to 111 def F in a couple of

minutes

Figure 2 .8.

Master

Temperature

control loop

 Note that in MOD 30Ml, continuous control is completely integrated with sequential

control without the need for an external device. Cascade with full tracking provides

tight temperature control.

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MicroMod IB-MLOPR-TUT Owner's manual

MicroMod IB-MLOPR-TUT Owner's manual

MicroMod IB-MLOPR-TUT Owner's manual

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