Multi-Channel System MCS-08 Technical Manual Flintec GmbH Bemannsbruch 9 74909 Meckesheim GERMANY www.flintec.com MCS-08 Technical Manual, Rev. 1.
Table of Contents: 1. SAFETY INSTRUCTIONS ...........................................................................................................................4 2. DECLARATION OF CONFORMITY ...........................................................................................................5 3. 3.1. 3.2. 3.3. 3.4. INTRODUCTION .........................................................................................................................................6 Overview ..................
12. MCS-08EN – ETHERNET GATEWAY ......................................................................................................46 12.1. Front View ..............................................................................................................................................46 12.2. Electrical Connections ............................................................................................................................47 12.3. N-Bus Addressing ..................................
1. SAFETY INSTRUCTIONS CAUTION READ this manual BEFORE operating or servicing this equipment. FOLLOW these instructions carefully. SAVE this manual for future reference. DO NOT allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment. ALWAYS DISCONNECT this equipment from the power source before cleaning or performing maintenance. CALL FLINTEC ENGINEERING for parts, information, and service. WARNING ONLY PERMIT QUALIFIED PERSONNEL TO SERVICE THIS EQUIPMENT.
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3. INTRODUCTION 3.1. Overview Type MCS-08 is a powerful and economic state-of-the-art multi channel system for static and dynamic weighing applications plus force and torque measurements. The basic measurement module is the 1-channel type MCS-08AD A/D converter which converts the analogue low level signal from a load cell or a strain gauge sensor to a digital high-resolution and high-accuracy signal. All standard weighing functions are available on this A/D converter.
E xte rn a l b u s N -b u s N -b u s Figure 3.2 – MCS-08 bus system A basic configuration of type MCS-08 Mult Channel System is shown in Figure 3.2. In this configuration the gateway module is the master of the internal N-bus and it simultaneously acts as a slave for the external bus. The gateway connects the external network with the locally installed MCS-08 hardware modules and transmits commands and responses to and from the external bus.
Gateway Modules General Internal bus system Serial interface RS232C Response time Communication with up to 8x type MCS-08AD and up to 8x type MCS-08IO and 1x type MCS-08DP 9600 baud (8, N, 1), used as service interface, communication to each connected type MCS-08AD respective type MCS-08IO respective type < 4 ms (delay after each read orMCS-08DP write command) Power supply: DC power supply 10 to 28 VDC, < 100 mA, not galvanically isolated Environment and Enclosure: Operating temperature Between -10 °C a
Display Module: Type MCS-08DP Local Display: Display Status LEDs LED red, 10.
3.4. Accessories MCS-08DP MCS-08PB MCS-08PN MCS-08MB MCS-08EN 1 1 1 1 1 2 1 2 1 1 2 1 1 2 2 1 2 1 1 1 1 1 1 MCS-08PN MCS-08MB MCS-08EN 1 1 MCS-08PB 4-pin and 5 mm pitch plug, light gray, power connector 5-pin and 3.81 mm pitch plug, light gray, N-bus connector 3-pin and 3.81 mm pitch plug, green, RS232C or RS485 7-pin and 3.81 mm pitch plug, black, for load cell cable 5-pin and 3.81 mm pitch plug, green, for digital inputs 8-pin and 3.
4. INSTALLATION PRECAUTION: Please read this manual carefully before you install the instrument. If you apply all recommendations in this chapter you will increase the reliability and long term performance of your system. 4.1. Recommendations 4.1.1. Control Cabinet Design Warning: Please follow the following warnings for designing the control cabinet which will increase the reliability of your system. The control cabinet should be designed therefor the MCS-08AD modules can operate safely.
4.2. Electrical Connections Warning: Please always remember that MCS-08AD modules are very low voltage measuring instruments. Your control cabinet design and proper installation increases the reliability and the performance of the instrument. Please do not forget that the instrument must be powered off before inserting or removing any peripheral connector. All required electrical connections should be done as described below. 4.2.1.
4.2.3. Digital I/O Connection MCS-08IO modules have the digital I/O connectors on the module‟s front. The I/O connection diagram is shown in figure 4.5. The outputs are potential-free contacts (1A @ 250 VAC, 30 V DC) and the inputs are opto-isolated (12…30 V DC). M C S -0 8 IO m o d u le Figure 4.5 – Digital I/O connection 4.2.4.
5. SETUP PRECAUTION: Please read this manual carefully before energizing the system. Perform the commissioning according the procedure given in chapter 4.3. Only trained person are allowed for commissioning, checking, cleaning and servicing of the instrument. The interference of untrained person may cause some unwanted damages or injures. MCS-08 systems are setup and calibrated by the xFace software supplied with the instrument.
5.3. N-Bus Addressing First define the number of MCS-08AD modules and MCS-08IO modules in the GSD configuration. Figure 5.3 – xFace GSD configuration Figure 5.
5.4. Gateway Setup Depending on their interface structure gateways have an interface parameter which has to be set up BEFORE the external communication bus can be started. The gateway setup is done in the gateway tab. Details on the gateway parameters and their descriptions can be found in the corresponding gateway chapter. Figure 5.
Scale Selection: Click the „Left‟ or „Right‟ arrow to select the current MCS-08AD module A/D Converter Parameters: This block allows the user to setup the A/D Converter‟s parameter related to the operation mode. Refer to chapter 5.5.
Auto Zero Tracking AZT automatically re-adjusts the scale to zero for compensating defined small deviations around the center of zero. AZT only works within the defined zeroing range and stops working if this range is left.To avoid unwanted zeroing this parameter should be disabled or carefully set up in applications like silo weighing, tank weighing and automatic weighing applications (Not available in Count Mode).
Weighing Mode: Force Mode: Unipolar weight data in calibrated weighing unit will be transmitted. This mode is compatible to OIML R76 and EN 45501. Bipolar or unipolar force measurement data in calibrated force unit will be transmitted. Select the scale operation mode and the polarity. Then click the “Write to Instrument” button to save your mode selection. The default calibration of MCS-08AD modules is Count Mode and 10 mV unipolar input signal range.
button. The [WAIT] message appears on the virtual display during the zero adjustment. Approximately 5 seconds later the zero adjustment will be finalized. Note: Zero adjustment is also performed over the bus interface. Refer to the data structure of the related bus interface. Span Adjustment If your scale has a span drift, you may perform a span adjustment only.
5.7. Digital I/O Test Figure 5.10 – MCS-08IO Status Input / Output Test: This block allows the user to check I/O status. The I/O test button is used to test outputs as seen in this figure. The active MCS-08IO modules are shown with their own N-Bus address block. You can follow the input and the output status and you can switch the outputs. The I/O test property is very useful for checking the output states. Warning: Please be careful to avoid damaging your process during the output test. 5.8.
4. Now change the address number on the Gateway Module by pressing the gateway switch (YELLOW) until it reached an address you want to use for an MCS08AD or MCS08IO module. 5. To assign the selected address number to an A/D Converter or Digital I/O module press the setup switch on the selected module (BLUE). Please note: The MCS08 allows up to 8 A/D and 8 I/O in one system. A/Ds and I/Os use the same address range (0 to 7).
5.10. Modbus Data Structure (for MCS-08MB + MCS-08EN only) EXPLANATION Attention: For hardware connection details, please refer to the related hardware descriptions in chapter 9 (respective chapter 12 for MCS-08EN gateway). The Modbus slave address is defined in the Modbus RTU Setup in chapter 9.4. Function code „0x03‟ and function code „0x10‟ are supported. In the two word registers the data is stored to the registers in big-endian format.
Zeroing MCS-08AD [1] at register 41063. Request: 01, 10, 04, 26, 00, 01, 02, 00, 01, 25, 56 Answer: 01, 10, 04, 26, 00, 01, E1, 32 MCS-08AD [1] is zeroed. Taring MCS-08AD [0] at register 41062. Request: 01, 10, 04, 25, 00, 01, 02, 00, 02, 65, 64 Answer: 01, 10, 04, 25, 00, 01, 11, 32 MCS-08AD [0] is tared. Taring MCS-08AD [1] at register 41063. Request: 01, 10, 04, 26, 00, 01, 02, 00, 02, 65, 57 Answer: 01, 10, 04, 26, 00, 01, E1, 32 MCS-08AD [1] is tared. Zero Calibration of MX08 AD [0].
Address R/W Word Command 40010* R/W 1 40011* R/W 2 40013* R 1 40014* R/W 1 40015* R/W 1 40016* R/W 1 N-bus address *Starting register address Definition 0 None 188 Adjust Zero Calibration Calibration Adjust Span Calibration (First load 40011 with span test 220 weight value) Span Calibration Value 1 Ready for calibration D0 .. D7 3 Zero calibration in process Calibration Process 4 Span calibration in process Status 9 Error (Refer to D8 ...
Address R/W Word Command 41001 R 1 41002 R 1 41003 R 1 41004 41005 1 R 1 Description D10 00: No module found at address [5] D11 01: Module at address [5] is active System Status of D12 00: No module found at address [6] MCS-08AD and D13 01: Module at address [6] is active MCS-08DP D14 00: No module found at address [7] D15 01: Module at address [7] is active 00 = Module at address [0] not found D0 01 = Module at address [0] is active IO [0] 10 = reserved D1 11 = reserved 00 = Module at addre
Address 41006 41008 41010 41012 41013 41015 41017 41019 41020 41022 41024 41026 41027 41029 41031 41033 41034 41036 41038 41040 41041 41043 41045 41047 41048 41050 41052 41054 41055 41057 41059 41061 R/W R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R Word 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 41062 R/W 1 41063 41064 41065 41066 41067 41068 41069 41070 R/W R/W R/W R/W R/W R/W R/W 1 1 1 1 1 1 1 1 41071 R/W 1 41072 41073 41074 41075 41076 41077 R/W R/W R/W
Address 41078 41079 41080 41081 41083 41084 41086 41087 41089 41090 41092 41093 41095 41096 41098 41099 41101 41102 41104 R/W R/W R R R R R R R R R R R R R R R R Word 1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 41105 R 1 41106 R 1 41107 41109 41111 41113 41115 41117 41119 41121 R R R R R R R R 2 2 2 2 2 2 2 2 Command Description MCS-08 IO [7] I/O Control Not in use MCS-08 AD [0] Status MCS-08 AD [0] Indicated Weight MCS-08 AD [1] Status MCS-08 AD [1] Indicated Weight MCS-08 AD [2] Status MCS-08 AD [2]
5.11. Profibus and ProfiNet Data Structure (for MCS-08Px only) MCS-08Px Output to PLC Input D31 D30 st Bit no.
th Bit no.
D7 D6 D5 D4 D3 D2 D1 D0 Error Codes 0000 1001 Calibration Errors 0000 0010 Span calibration in progress 0000 0011 0010 0010 MCS-08IO [x] MCS-08IO [0] MCS-08IO [1] MCS-08IO [2] MCS-08IO [3] MCS-08IO [4] MCS-08IO [5] MCS-08IO [6] MCS-08IO [7] Byte st +1 Byte nd +2 Byte rd +3 Byte th +4 Byte th +5 Byte th +6 Byte th +7 Byte th +8 Byte D7 D6 Zero calibration in progress System ready for calibration D5 D4 D3 Input 4 Input 4 Input 4 Input 4 Input 4 Input 4 Input 4 Input 4 D2 Input 3 Input 3 Input 3
2nd Dword (W) MCS08 AD [0]* D31 D30 D29 D28 D27 D27 D25 D24 D23 D22 D21 D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D29 D28 D27 D27 D25 D24 D23 D22 D21 3 Dword (W) D15 D14 D13 D12 D11 D10 Not in use *Register address for D5 D4 D3 D2 D1 D0 MCS-08IO [x] MCS-08IO [0] MCS-08IO [1] MCS-08IO [2] MCS-08IO [3] MCS-08IO [4] MCS-08IO [5] MCS-08IO [6] MCS-08IO [7] D16 D0 D20 D19 D18 D17 D16 D4 D3 D0 Not In Use st D10 D9 D8 D7 D6 D19 D18 D17 D3 D2 D1 Next Dword defines the usage of this Dword D31 D30 Bit
6. MCS-08AD – A/D CONVERTER MODULE MCS-08AD modules are state-of-the-art strain gauge load cell signal digitizers. These modules are used for any type of process weighing and force measurement including tank and silo weighing, dynamic weighing, check weighing, filling, tension /compression force measurement etc. 6.1. Front View There are 3 status LEDs on the front panel which indicate the operational module status (Refer to table 6.1).
6.2. Electrical Connections Load Cell Connection See chapter 4.2.2 Power Supply Connection See chapter 4.2.1 6.3. Setup and Calibration MCS-08AD modules are set up and calibrated by xFace. The A/D Converter settings are very important for a good weighing performance. Please refer to chapter 5.3. MCS-08 Technical Manual, Rev. 1.
7. MCS-08DP – DISPLAY MODULE The MCS-08DP module is a display unit for the MCS-08 system. The weight/force or count data and stable, zero, net information of one MCS-08AD module can be displayed. All installed MCS-08AD modules on the NBus are indicated with their N-Bus address information. Two keys on the front panel are used for selecting the A/D Converter module to display the weight or count data. 7.1.
8. MCS-08IO – DIGITAL I/O MODULE The MCS-08IO module has 4 opto-isolated digital inputs and 4 potential-free relay outputs. All I/O control is done over the external bus system or the xFace software. Please refer to the data structure of the related gateway module for the available input and output commands. For example, with a Profibus gateway all input and output conditions are by Profibus commands. 8.1.
9. MCS-08MB – MODBUS RTU GATEWAY The MCS-08MB gateway module integrates up to 8 pcs. MCS-08AD A/D Converter modules and up to 8 pcs. MCS-08IO Digital I/O modules to an external Modbus RTU bus. The MCS-08MB gateway module communicates with other MCS-08 modules via the internal N-bus and responses to the PLC via Modbus RTU. 9.1. Front View There are 3 status LEDs on the front panel which indicate the operational module status (Refer to table 9.1).
9.2. Electrical Connections RS232C and RS-485 connections are shown in figure 9.2. Figure 9.
Figure 9.3 – MCS-08MB gateway setup You will see the Modbus setup in this tab. Data Format Modbus RTU Baud Rate One of the following baudrate will be selected for the RS-485 communication port. 1200 19200 2400 38400 4800 57600 9600 (default setting) Data Length and Parity The data length and parity can be selected as 8 None 1 (default), 7 Odd 1 or 7 Even 1. RS485 Address Data Format Modbus RTU: The Modbus slave address range is 01 (default) to 31.
10. MCS-08PB – PROFIBUS GATEWAY The MCS-08PB gateway module integrates up to 8 pcs. MCS-08AD A/D Converter modules and up to 8 pcs. MCS-08IO Digital I/O modules to an external Profibus network. The MCS-08PB gateway module communicates with other MCS-08 modules via the internal N-bus and responses to the PLC via Profibus DP. The GSD file is available on a CD which is supplied together with the instrument. 10.1.
ST Status LED State Off Green Flashing Green Red Indication No power or not initialized Initialized Initialized, diagnostic event(s) present Exception error Comment No power or profibus module is in initializing Diagnostic is active There is an exception error OP Operation Mode LED State Off Green Flashing Green Flashing Red (2x) Indication Not on-line / No power On-line, data exchange On-line, clear PROFIBUS configuration error Comment Check power and cable Check GSD file configuration. 10.2.
Power Supply Connection: See chapter 4.2.1 10.3. N-Bus Addressing MCS-08 modules communicate to each other over the internal N-bus. The MCS-08xx gateway module is the master of the internal N-bus. All other MCS-08 modules are slaves and have to be addressed to the gateway module. The N-bus addressing can be done by using the xFace PC software (refer to chapter 5.3) or via setup switch (refer to chapter 5.8). 10.4. Profibus Setup The Profibus setup is done by the xFace software.
11. MCS-08PN – PROFINET GATEWAY The MCS-08PN gateway module integrates up to 8 pcs. MCS-08AD A/D Converter modules and up to 8 pcs. MCS-08IO Digital I/O modules to an external ProfiNet network. The MCS-08PN gateway module communicates with other MCS-08 modules via the internal N-bus and responses to the PLC via ProfiNet. The GSD file is available on a CD which is supplied together with the instrument. 11.1.
MS Module Status LED LED State Description Off No power or not initialized Green Green, 1 flash Initialized Initialized, diagnostic event(s) present Green, 2 flashes Blink Red Red, 1 flash Red, 2 flashes Red, 3 flashes Exception error Configuration error IP address error Station name error Red, 4 flashes Internal module error Comment No power or ProfiNet module is in initialization state Diagnostic is active Used by engineering tools to identify the node on the network There is an exception erro
11.3. N-Bus Addressing MCS-08 modules communicate to each other over the internal N-bus. The MCS-08xx gateway module is the master of the internal N-bus. All other MCS-08 modules are slaves and have to be addressed to the gateway module. The N-bus addressing can be done by using the xFace PC software (refer to chapter 5.3) or via setup switch (refer to chapter 5.8). 11.4. ProfiNet Setup The ProfiNet setup is done by the xFace software.
12. MCS-08EN – ETHERNET GATEWAY The MCS-08EN gateway module integrates up to 8 pcs. MCS-08AD A/D Converter modules and up to 8 pcs. MCS-08IO Digital I/O modules to an external Ethernet network. The MCS-08EN gateway module communicates with other MCS-08 modules via the internal N-bus and responses to the PLC via Ehernet. 12.1. Front View There are 3 status LEDs on the front panel which indicate the operational module status (Refer to table 12.1).
12.2. Electrical Connections Ethernet and RS-232C connections are shown in figure 12.2 to 12.4.
Power Supply Connection See chapter 4.2.1 12.3. N-Bus Addressing MCS-08 modules communicate to each other over the internal N-bus. The MCS-08xx gateway module is the master of the internal N-bus. All other MCS-08 modules are slaves and have to be addressed to the gateway module. The N-bus addressing can be done by using the xFace PC software (refer to chapter 5.3) or via setup switch (refer to chapter 5.8). 12.4. Ethernet Setup The Ethernet setup is done by the xFace software.
13. ERROR TABLE The MCS-08 modules have been designed as very reliable and virtually error free instruments. However if an error occurs do not attempt to repair the equipment before you understand what caused the error. Note the problems you have with your instrument and the error messages shown by the LEDs located on the front panel. Then try to solve the problem according to the error tables given below.
14. DIAGNOSTICS In this test menu serial interface tests (RC-232C and/or RS-485) and load cell signal analog to digital conversion and processing tests can be initiated. For entering the diagnostics mode, press the setup switch before power on and release the switch after the module is powered on. A gateway module will go into the RS-232C RXD test mode which is indicated by lighted Pwr LED and flashed Err LED as shown below.
15. FREQUENTLY ASKED QUESTIONS Question : Answer : Question : Answer : Question : Answer : Question : Answer : Question : My PC has a COM port but I cannot see any COM port in the Connection Setting menu. How can I solve that problem? Answer : Another software may be connected to that COM port. Close all applications before you start xFace. Question : Answer : My PC cannot interface with the MCS-08 system.
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