MCI/2 Measurement and Control Interface User Manual
Contents
1. 30 MOUNTING THE 32 292 IN OV ER gege 32 29 OTHER FEATURES PLANNED FOR IHE FUTURE wivsesssiicecscesnssnsnscixssexcantonsncnntonssnnaucsssxeavtenvmennteeseoss 32 05 INTERFACE EE 33 danntech PROCESS INSTRUMENTATION Page 3 of 41 Version 1 0 September 2005 1 What is Included with your 2 User Manual Power Cable RS232 Interface Cable 05089 to 25089 USB Interface Cable RS232 Interface Cable RJ45 to 05089 MCI 2 CD 1 2 CD Contents 1 1 Applications MCI application details HTML MCI applications PDFs 1 2 Brochures Various related product brochures 1 3 2 User Manual PDF version of this user manual in high resolution and low resolution formats 1 4 MCI Logger Logging and graphical display program for use with the MCI 2 Generalised data logging program which allows the MCI 2 to be used to log and display graphically up to eight analogue inputs Excel compatible data file 1 5 RMF Utils General Danntech Remote Magic and Modbus communications test program for sending and Comms Open Port receiving Danntech RMF Communications or cn Pat Modbus commands Baudrate 13200 Useful for preliminary testing and verifying that the communications ports and connections are working correctly2. danntech PROCESS INSTRUMENTATION Page 26 of 41 Version 1 0 September 2005 24 Auxiliary I O Connectors DS _ DOUT DOUT2_ DOUT DOUT4 DOUTS DOUT6 DOUT7 DOUT8 eg Sa COM2 COM2 DATA C2 RS232 C2 RS232 TXQ ___ ___84 D 5 6 8 10 11 12 13 14 15 16 17 18 R3 po 21 22 23 24 25 26 27 28 29 30 31 32 33 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 BS len H See cT Pate DES sity 0 LD24 LD2 55 2 LD3T 3 LD32 ___ LDX3 LD34 LD35 __ SLED WLED AED CABU ce a eS SW3 4 SW4 6 5 RM ____ 4__ _ A REU EN LU ea N ee 4 12 1615 eo 1 e 2 Bed 5 5 5 Fd FS 9 1 lt 27 41 25 Technical Specifications Analogue Inputs Eight analogue inputs Sixteen bit resolution 10 Hz input filter Non isolated with common zero volt connection Link selectable current or voltage options to 20 mA or 4 to 20 mA with 100 input resistance 0 to 10 V with 470 input resistance Input zero and full scale adjustment manually by means of rotary select switch and zero and full scale b
3. 1 6 Spreadsheets Excel Worksheet with Command and Register Details 1 7 USB Drivers Drivers for Win 2000 Win XP and Win 98 danntech PROCESS INSTRUMENTATION Page 4 of 41 Version 1 0 September 2005 2 Introduction to the 2 The Measurement and Control Interface MCI provides a powerful interface for doing process control data acquisition and logging In its basic form the MCI is a dumb device i e it must be used with a controller of some sort typically a PC but could be a PLC or any other controlling device RS232 5485 and USB interfaces are provided for connecting to the MCI Applications which may require several data acquisition or control points up to 32 can be can multi dropped on one pair of twisted wires at a distance of up to 1 000 metres Customized applications can be developed using Visual Basic Delphi and C An Active X Control is also available for the Remote Magic Family Interface which allows direct use with Microsoft Excel Visual Basic C or any other Windows program which supports Active X The MCI is useful in any laboratory where simple logging or control is required using a personal computer In this case the user can write a program to do exactly the job required Larger applications can be developed using more that one MCI spread over 1 000 metres with the two wire RS485 interface which allows the location of the hardware close to the process Com
4. l1 NENNEN l1 4000 NE ME NEN 7 9 40065 NEN ERE 1 1 a 60030 60030 60031 60032 60033 60034 60035 60036 60037 60045 60059 60060 60062 60064 60067 60069 60073 60075 60101 60106 60108 Delivery Configuration Digital Output Power up Word Relay 1 Pulse Value Power up Setting Relay 2 Pulse Value Power up Setting Relay 3 Pulse Value Setting 00 Relay 4 Pulse Value Power up Setting Open Collector Output 1 Pulse Value Power up Setting Open Collector Output 2 Pulse Value Power up Setting 00 Open Collector Output 3 Pulse Value Power up Setting i Open Collector Output 4 Pulse Value Power up Setting Solid State Relay 1 Pulse Value Power up Setting Solid State Relay 2 Pulse Value Power up Setting Counter Timebase Value n x 100 mSecs Counter Mode Power up Value Counter Timebase Power up Value LED Output Power Up Word Digital Output Toggle Control Power up Control Word LED Flash Control Register Power up Control Word PWM Mode Power up Value PWM Output 1 Duty Cycle Power up Value 65535 PWM Output 2 Duty Cycle Power up Value 65535 Analogue Output Power up Value 0 Auxiliary LED Buzzer Output Word Power up Word Auxiliary LED Buzzer Flash Control Register Power up Control Word
5. 39 41 43 60 59 Page 35 of 41 40050 60050 Analogue Input 3 0 to 1023 40051 60051 Analogue Input 4 0 to 1023 40052 60052 Analogue Input 5 0 to 1023 40053 60053 Analogue Input 6 0 to 1023 40054 60054 Analogue Input 7 0 to 1023 40055 60055 Analogue Input 8 0 to 1023 40056 60056 Analogue Output 0 to 1023 57 40057 60057 Analogue Output Power up Value 40058 60058 DIP switch 1 setting in binary 0 to 255 0 to 40059 60059 Counter Mode Power up Value 65535 40060 60060 Counter Timebase Power up Value 0 to 40061 60061 LED Output Word 65535 40062 60062 LED Output Power Up Word 40063 60063 Digital Output Toggle Control Word 65535 Digital Output Toggle Control Power 64 40064 60064 up Control Word 40065 60065 Counter Overflow Register 0 to 40066 60066 LED Flash Control Register 65535 LED Flash Control Register Power up to 67 40067 60067 Control Word 65535 40068 60068 PWM Mode 40069 60069 PWM Power up Value PWM Output Frequency for both 0 to 70 40070 60070 PWM outputs 65535 71 40071 60071 Value for both PWM outputs 65535 0 to 73 40073 60073 Value 65535 a Jeu gea puy cycle 6556 _ 74 40074 60074 PWM Output 2 Duty Cycle 65535 75 40075 60075 Value 65535 0 to 40076 60076 Analogue Input 1 65535 0 to 40077 60077 Analogue Input 2 65535 0 to 40078 60078 Analogue Input 3 65535 0 to 40079 60079 Analogue Input 4 6553
6. Siw Mun pee Jumper 0 to 11 V Jumper B 0 to 22 mA danntech PROCESS INSTRUMENTATION Page 19 of 41 Version 1 0 September 2005 13 Communicating with the 2 9 Way DSUB USB Female RJ45 Connector 5232 8 RS485 Connector 5232 amp 5485 2 Ap 5485 Communication with the MCI be done any of three ways 5232 5485 or USB RS232 and RS485 connections are available on the 9 way DSUB and the RJ45 connectors A two way plug in screw terminal connector is provided for RS485 connection Only one device can be connected using the RS232 or USB connections but up to 32 devices MCls or any other Danntech Remote Magic Family products can be connected using RS485 9 Way DSUB Female Connector RJ45 Female Connector On Details On MCI Details Pin Description 55 RS232RX 4 5232 5 A _____ 6 8 8 Way LP RA 9 DATA RS485 Telephone Jack OV DATA Tx Rx danntech PROCESS INSTRUMENTATION Page 20 of 41 Version 1 0 September 2005 14 Installing the USB Driver In the USB Drivers folder on the MCI 2 CD you will find two documents Windows XP Installation Guide pdf and Windows 98 Installation Guide pdf These documents have details regarding the USB driver installation When using Win XP plug in the MCI USB cable and you will be prompted to install drivers for the FT232BM which is the device used in the MCI 2 Generally
7. Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read Only Read and Write Read and Write Read and Write Read Only 101 106 108 Page 37 of 41 Using the Pulsing Features of the Digital Outputs All the digital outputs can be used in the pulse output mode In this mode the output pulse rate can be set by writing to the respective output pulse value register A specified power up pulse value can also be specified for each digital output which is accessed by the respective output pulse power up value which is stored in EERAM It is recommended that to begin with 0 is written to registers 63 and 64 to make sure that the output pulsing is initially disabled Simple on off control can be used by writing a or a 1 to the various output registers Using values other than 0 1 the other pulsing features can be used The various states are determined by writing other values to the digital outputs These are best described using a table format bit 3 enables or disables bit 2 bit 2 the new pulsing output state bit 1 enables or disables bit 1 bit 0 new output state bita bito Dems Drogen If 63 0 then simple on off If pulsin
8. 1 60091 Calibrate Value 65535 s 92 40092 60092 Value 65535 ames exeo Carma vame Le 93 40093 60093 Calibrate Value 65535 em ms 94 40094 60094 Value 65535 40095 Carma vame Le 95 40095 60095 Calibrate Value 65535 40096 60006 esso 40096 60096 Value 65535 sro exer Lei 97 40097 60097 Calibrate Value 65535 pem em ucro s 40098 60098 Value 65535 6009 Catirstevaue JL s _ 40099 60099 Calibrate Value 65535 yes yes yes yes yes yes yes yes yes yes yes yes yes yes 40100 60100 Analogue Output 0 to 4095 40101 60101 Analogue Output Power up Value 0 to 4095 0 to 40102 60102 Analogue Output Zero Offset Value 65535 Analogue Output Full Scale Multiplier 0 to 103 40103 60103 Value 65535 40104 60104 DIP switch 2 setting in binary 0 to 255 0 to 40105 60105 Aux LED Buzzer Output Word 65535 Aux LED Buzzer Output Word Power 106 40106 60106 up Word yes yes yes yes no yes Aux LED Buzzer Flash Control 0 to 107 40107 60107 Register 65535 Aux LED Buzzer Flash Control 0 to 108 40108 60108 Register Power up Control Word 65535 yes yes 0 to 40109 60109 Push Button Switch Input Word 65535 no danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 Read Only Read Only Read Only Read Only Read and Write Read and
9. 5 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 no no no no no no yes no yes yes yes no yes yes yes yes yes yes yes yes yes yes no no no no Read Only Read Only Read Only Read Only Read Only Read Only Read and Write Read Only Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read Only Read Only Read Only Read Only 57 62 65 67 69 69 71 73 75 36 41 0 to 40080 60080 Analogue Input 5 65535 0 to 40081 60081 Analogue Input 6 65535 2 O 5 0 0 to 40082 60082 Analogue Input 7 65535 0 to 40083 60083 Analogue Input 8 65535 Analogue Input 1 Zero Calibrate 0 to 84 40084 60084 Value 65535 Analogue Input 1 Full Scale 0 to 85 40085 60085 Calibrate Value 65535 2 5 O yes Analogue Input 2 Zero Calibrate 0 to 40086 60086 Value 65535 mro aer Gattrstevaue 87 40087 60087 Calibrate Value 65535 pem em s 88 40088 60088 Value 65535 Lage Carma vame esas 40089 60089 Calibrate Value 65535 exeo Vac 40090 60090 Value 65535 or amer exo Carma vame 91 4009
10. 53 100 represent the analogue input values 0 to 1023 and the second line can be broken down as follows danntech PROCESS INSTRUMENTATION Page 39 of 41 Version 1 0 September 2005 0 the echo of the device address 135 the command echoed with the highest bit set i e 128 added to the original command sent to the 48 the echo of the starting register address 4217 the checksum of the first line values 4400 the checksum of the second line values If the MCI detects a discrepancy between the calculated checksum and the transmitted checksum then the command 15 ignored The master must then time out and take appropriate action If the master does not receive the correct reply it must assume that the command was not received by the slave Command 8 Identify Attached This command allows the control module to quickly identify all modules attached to the RS485 interface The command structure is the same as before i e address command register data checksum Where the address the register and the data values are ignored so any values can be sent and the checksum is calculated as usual In response to this command each attached MCI replies after a delay of its address 10 mSec This ensures that within 450 mSecs all the modules attached are identified maximum of 32 modules The various attached modules would reply with the following address device part number code checksum Where the address is the repl
11. Analogue Inputs all 0 to 10 V Analogue Output 0 to 10 5 V and 0 to 22 5 mA Digital Inputs all 0 to 30 VDC Counter Input 0 to 30 VDC Auxiliary analogue outputs lout1 and lout2 0 to 22 mA approximate danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 Page 30 of 41 Address 1 SW2 1 ON comms be either 5232 RS485 USB The delivery configuration address and communications speed are indicated on the side of the MCI 2 danntech PROCESS INSTRUMENTATION Page 31 41 Version 1 0 September 2005 27 Mounting 2 Distance between mounting hole centres 272 x 152 mm with maximum 4 mm shank diameter screw or M6 bolt 28 Input Power The 2 is normally configured for 230 VAC unless otherwise clearly marked otherwise The soldered wire links of J22 must be changed for 115 VAC operation The input mains supply has a protection fuse mains filter and surge protection The fuse recommended is 20 x 5 mm 3 A slow blow 230 VAC Mains Fuse 20 x 5mm Slow Blow 29 Other Features Planned for the Future 29 1 Internal GSM modem 29 2 Stand alone data logging and GSM modem connection 29 3 Second serial port for connection to additional serial communication devices 29 4 128 x 64 LCD display 29 5 24 12 VDC powered 29 6 Low power option for battery powered data logging 29 7 Compact DIN mounting version danntech PROCESS INSTRUMENTAT
12. Control System Cheese Factory Cleaning Cycle and Pasteurizer Monitoring 2MW DC Furnace Monitoring o Bacterial Growth Control System o Mini Cell Test System o Motor Current Monitoring System We can also write customised firmware for the MCI 2 to suit your application where several units are required and the cost benefit can be realised A once off firmware charge based on the time required implementing your unique functions and then a standard cost thereafter 4 Educational Possibilities Computer Skills IT Educators Practical Programming Now you can teach or learn how to develop more than passive programming and computer skills We have a simple powerful and practical PC interface which enables the student to actually switch things on and off measure voltages or currents count events and detect switch closures The Measurement and Control Interface adds a very practical and immediately rewarding programming experience Using any of our software interfaces which are easy to understand students can quickly explore the power of using programs to perform practical and useful functions We have several practical add ons such as Floor mat switch Passive infra red sensor Magnetic switches Push button switches Proximity sensors danntech PROCESS INSTRUMENTATION Page 7 of 41 Version 1 0 September 2005 Temperature sensor Level switch Water flow valve Motor and speed co
13. D and Buzzer outputs Bit buzzer Bit 1 SLED Bit 2 WLED Auxiliary LED Buzzer Flash Control Register Power up Control Word Bit 3 ALED 0 no flash 1 flash enabled Fifteen plus three LEDs are available to the user these can be switched on or off or made to flash when switched on or off Each LED can be configured to flash or not and then when switched on or off will either remain on or flash Label areas are provided for each LED so that they can be labelled to suit the application There is also a buzzer available inside the MCI which can be controlled All the input and output states are also indicated using the row of green LEDs All of the LED outputs not isolated and switch inputs are also made available on the Auxiliary connectors for advanced users and future digital output expansion PROCESS INSTRUMENTATION Version 1 0 September 2005 Page 12 of 41 Each LED has power up setting as well as power up flash control setting 9 Physical Connections Counter Input Din 4 Din 1 Ding 5 Dout 8 6 Dout 3 Dout 1 DOTTED POSITION WHEN RELAY 0 VDC 0 VDC Li Li Li 24 24 1 A L 3 4 AAA A ee Me C Sch EE Hee ENS 4 2 Ls e LC 9 24 RJA
14. ED Flash Control Register When set to 0 the LED illuminates when switched on and doesn t flash LED Flash Control Register Power up Control Word T2 L2 T1 L1 BO4NCINOEOMNCIN LD24 002 20 10230 10240 10250 10380 10330 0340 10350 SLED Si Roues A YE RS485 Vee ov vce 10 1 2 3 4 5 6 7 OUT VOUT 1 2 NSS MENEZE AINS 1 4 RM Register Modbus Read Modbus Write 105 106 107 108 40106 40107 40108 40109 60106 60107 60108 60109 Description Auxiliary LED Buzzer Output Word Auxiliary LED Buzzer Output Word Power up Word Auxiliary LED Buzzer Flash Control Register x 3 2 1 2 11 1 7 6 5 _____ OPTO OUTS 1558255 RLY4 ____0 5 _ CNTR COUNTER IN DIN1 DIN 2 DIN 5 DIN 6 DIN 7 RELAY 1 RELAY 2 RELAY 3 RELAY 4 SSR 1 551 2 DOUT 1 pour 2 3 pour 4 pour 5 6 pour MCI 2 MEASUREMENT AND CONTROL INTERFACE PROCESS INSTRUMENTATION www danntech com Ot 1 ouT2 OQ 00 mA COM1 MS FAIL COM1 OM IRS485 MAINS USB L N E Details Bit positions for the auxiliary LE
15. ION Page 32 of 41 Version 1 0 September 2005 30 Interface Protocol When communicating with the MCI the following format must be observed address command register data checksum where character must be transmitted to signal the start of the command sequence address the MCI address as set by SW1 4 SW1 8 0 to 31 command the command 0 to 127 1 Read Configuration 2 Read Registers 3 Write Registers 4 Synchronize Digital Outputs 5 6 Read Raw Data 7 Read Bulk Data 8 9 Identify All Attached Synchronize Digital Outputs register the register number as applicable to the respective command data the data as applicable to the respective command checksum the checksum is the sum of all the values excluding the start character modulo 219 Note that the checksum is a 16 bit number which wraps around through zero should the sum exceed 65535 1 the sum of the data from the address through to data is 65537 then the checksum should be sent as 1 All values are 16 bit except for the address and command and have a range of 0 to 65535 Upon receipt of any command between 1 and 9 i e checksum matches and command is recognized the MCI will reply with a copy of the original command with the command value increased by 128 i e the most significant bit is set data is the requested data checksum is also updated to reflect the changes For commands 4 Synchronize Digi
16. MCI 2 MEASUREMENT AND CONTROL User Manual Filename um0064 doc Document Number UM0064 Date 28 September Part Number DQ MCI2 10 UE Version 1 0 Page 1 of 41 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 TABLE OF CONTENTS 1 WHAT IS INCLUDED WITH YOUR deeg 4 4 APPLICATIONS 2256 ___________ __ _ __ 4 t2 BROCHURE 4 USER MANUAL 4 d Le Bee e c 4 Eo Uli 4 SPREADSHEETS _ ____ _______ 4 USB 4 2 INTRODUCTION TO THE MODA E 5 APPECA TIONS sees oe re 6 4 EDUCATIONAL POSSIBILITIES 2 7 Se FEATURE e 8 10 7 GETTING AND RUNNING QUICKLY 1 1 11 B FRONT PANEL AND LED Ee 12 PHYSICAL CON
17. N transistors with open collector and open emitter danntech PROCESS INSTRUMENTATION Page 28 of 41 Version 1 0 September 2005 Output transistor rating 30 max and 150 mA Ic max Relay Outputs Four relay outputs Both normally open and normally closed contacts available Potential free contacts Contacts AC rated at 250 VAC at 10 Contacts DC rated at 220 VDC at1A RC series snubbing across both contacts of each relay Snubber 10 nF 630 V capacitor in series with 100 two watt resistor Locations for the addition of transorbs or MOVs if required Solid State Relay Outputs Two solid state relay outputs Rated at 240 VAC at3A Triac zero voltage switching General Robust industrial enclosure Power requirements 230 V or 115 VAC 50 60 Hz 10 at 20 VA Built in auxiliary 24 V 200 mA isolated DC supply for external devices Operating temperature 0 to 70 C Plug in screw terminal connections Maximum wire size 1 5 mm 9 way DSUB interface connection Vertical or horizontal mounting with four M5 or M6 screws for which holes are provided Dimensions 290 x 190 x 62 mm length x width x height Colour powder coated white with front panel decal 2 weight 15 3 kg Packaging white foam lined self locking cardboard box 370 x 330 x 130 mm length x width x height Weight of packaged 2 with cables and user manual is 4 danntech PROCESS INSTRUMENTATION Page 29 of 41 Version 1 0 September 2005 26
18. NEC LE 13 10 REMOVING THE COVER AND GETTING 22 2 11222222 15 1 E E 15 12 JUMPER OPTION SELECTIONS 3 na 17 13 COMMUNICATING WITH THE 2 20 14 USB DRIVER eege 21 15 COMMUNICATIONS WATCHDOG 22 22 Ib ANALOGUE KE 23 17 BIGITAL INPUTS ete a ee o eH DE EUER 24 los COUNTER INPUT ecc 24 19 ANALOGUE OUTPUTS 24 20 slip iip 24 21 4 iln Ri Quienes cocina D ete d 25 EE cy Ne EAR Pup r 25 23 PULSE WIDTH MODULATED OUTPUTS dE 26 24 deers 27 danntech PROCESS INSTRUMENTATION 2 of 41 Version 1 0 September 2005 25 TECHNICAL 28 26 DELIVERY CONFIGURATION
19. S _ z 5 lt 0 VDC Tocowws USB ore u MAINS IN RS232 RS485 230 VAC default or lout 1 Input 1 Input 5 lout Vout 9 WAY DSUB AUXILIARY 115 VAC only if MALE COMMS 24 200 msaas clearly marked Input 2 Input 6 CABLE ISOLATED POWER RS232 RS485 SUPPLY Page 13 of 41 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 MAINS MAINS OUT2 OUT1 NEUTRAL _ Bee __ __ 99959599 S II 24 VDC Wee PWM Pulse Output danntech PROCESS INSTRUMENTATION Page 14 of 41 Version 1 0 September 2005 10 Removing the Cover and Getting Inside Four quarter turn screws are used to fasten the lid 11 DIP Switches SW selects the following SW1 1 Communications speed 0 off 19 200 or 115 200 bits sec 1 on 9 600 or 57 600 bits sec SW1 2 not used SW1 3 Communications speed range 0 off low range 9 600 and 19 200 bits sec used with SW1 1 1 on high range 57 600 or 115 200 bits sec SW1 4 to SW1 8 Device address Binary with SW1 4 MSB and SW1 8 LSB SW2 selects the following SW2 1 Communications medium select always ON danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 Page 15 of 41 SW2 2 Select Danntech Remote Magic 0 off RMF Family Communicatio
20. TATION Page 22 of 41 Version 1 0 September 2005 16 Analogue Inputs For 0 10 Input Jn 1 A Jn 2 out Jn 3 out 220K ES1 For 4 20 Input J1 2 R1 9 R1 10 BE 82K ES1 4 7 ES R1 8 R1 12 For 0 20m Input 2 5Vb ERE Jil 680K 251 100 51 Jn 2 out y 2 U1 1 Jn 3 out i 3 LM358 R14 lR1 1 2 XB1 1 7 270K 27K 330nF 1 5KE15CA 7 ES1 ES1 50CSA V Calibration SW2 4 used for manual input calibration control OFF normal operation ON analogue input calibration When manual calibration is selected the rotary switch SW3 selects the channel being calibrated SW4 sets the zero and SW5 the full scale input values Inject the value you wish to have as zero for the input being calibrated allow a few seconds to stabilize and then press the Zero button Then inject the value you wish to have as the full scale value and after a few seconds press the Set Full Scale button This sets up the value Set Zero Ain 1 2 5Vk 1 3 1 1 R1 13 D 40 Set Full Analogue Scale Select A read back from the analogue input as 0 the zero value and 65535 for the full scale value The LED near the CPU will flash three times when calibration measurements successful This same procedure can be done using the calibrate command and registers 84 through 99 for s
21. bits danntech PROCESS INSTRUMENTATION Page 8 of 41 Version 1 0 September 2005 derived from the PWM outputs 0 to 22 mA Oto11V e Auxiliary 24 V 200 mA isolated DC supply for external devices e Eighteen user controllable front panel LEDs with flashing capability e LED status indication of all digital inputs digital and relay outputs on front panel e Communications fail relay LED indication and relay output 120 VAC 10 A 240 VAC 6 A 24 VDC 10 A e Interface serial RS232 RS485 and USB optically isolated from the internal circuitry e 230 VAC powered also 115 VAC by changing internal link e Robust industrial enclosure e Plug in screw terminal connections e Backward software compatibility with older version Physical compatibility with older version same mounting screws and same plug in connections danntech PROCESS INSTRUMENTATION Page 9 of 41 Version 1 0 September 2005 6 Safety 5 VAC un Earth connect safety Neutral danger only authorised person may connect _Live danger only authorised person may connect danntech PROCESS INSTRUMENTATION Page 10 of 41 Version 1 0 September 2005 7 Getting Up and Running Quickly The quickest to get Up and RMF Utils Version 1 4 Iof xs running is to find the communications cable that you want to use the DSUB 0000 0000 0000 oooo oooo 1 T RS232 the RJ45 serial or the USB connection cables If
22. data returns the data requested Command 6 Read Raw Data Returns the unscaled or uncalibrated data read from the analogue inputs Command 7 Read Bulk Data Allows the user to read blocks of data instead of single data values The command structure is the same as before i e address command register data checksum where command is the allocated command number 7 Now instead of simply sending all the registers back to the control module the MCI will now send a range of registers These registers are specified by a start address contained in the register parameter and an end address stored in the data portion of the command string Having received the command the module will transmit the registers in a single stream of values separated by commas and terminated with a CR LF combination After the stream of data the original command 15 echoed to the host with the command value updated as normal 128 added to the command value The data returned in the echoed command however is the checksum of the block transfer data This echoed command will be ended with the standard checksum validating the echoed command and its data Thus with the MCI at address 0 to obtain the analogue input values with 9 32 V applied to inputs 1 to 4 and 0 988 V applied to inputs 5 to 8 the following command could be used 20 7 48 55 110 953 952 963 952 99 99 99 100 0 135 48 4217 4400 Where the first line 9
23. e Registers Read and Write Registers Commands 2 and 3 EN 2 read register Allows access to the all the input current output values and the DIP switch settings 3 write register Allows writing to the all the output registers Read 0 02 Value RM Register Reg from Power up Description _____ Reg Description Range EERAM RM Mode Register 0001 no Read Ony 0 to 1 no Read Only 0 to 1 no Read Ony 0 to 1 no Read Only 000255 Read Only Read and bit 0 of reg 40006 60006 Relay 1 0 off 1 on 010 1 yes Write 17 Read and bit 1 of reg 7 40007 60007 Relay 2 0 off 1 on 010 1 yes Write 17 Kai Read bit 0 of reg 40008 60008 Relay 3 0 off 1 on 010 1 yes Write 17 40009 60009 Relay 4 0 off 1 on 010 1 yes Read and bit 0 of reg danntech PROCESS INSTRUMENTATION Page 34 of 41 Version 1 0 September 2005 0 1 et opooupussozot 1o 001 s ama 0 41 001 eeng ow _ Solid State Relay 2 0 off 1 on 40010 60010 Opto Output 1 0 1 on 12 13 14 0 to 40018 60018 Relay 1 Pulse Value 65535 Solid State Relay 1 Pulse Value 26 0 to 27 40027 60027 Solid State Relay 2 Pulse Value 65535 28 to 37 ti Digital Output Power up registers PWM Output Frequency for both 38 40038 60038 PWM outputs PWM Output Freq
24. g is enabled then will set output OFF until the next state changed as defined by the pulse settings If 63 0 then simple on off If pulsing is enabled then will set output ON until the next state changed as defined by the pulse settings Leaves pulse state unchanged sets output OFF Same effect as writing O Leaves pulse state unchanged sets output ON Same effect as writing 1 No effect No effect effect as writing 0 effect as writing 1 Disable pulsing and leave output in its current state Disable pulsing and leave output in its current state Disable pulsing and set output OFF Disable pulsing and set output ON Enable pulsing and leave output in its current state Enable pulsing and leave output in its current state Enable pulsing and set output OFF initially Note that register 63 can be used to enable or disable pulsing on all of the digital outputs all together Register 64 simply defines weather the various digital outputs will have the pulsing feature enable or disabled at power up This value is stored in EERAM danntech PROCESS INSTRUMENTATION Page 38 of 41 Version 1 0 September 2005 Command 4 Read Write Registers Calibrate analogue inputs and outputs Command 5 Read Run Time Returns the approximate length of time the MCI has been running since the last power up register address of the register to be read 0 seconds 1 minutes 2 hours 3 days
25. igned equipment We can write specialized software to suit your application PROCESS CONTROL Level control PID loops temperature control system monitoring and logging EDUCATION Waveform generation introductory computer control PID and ON OFF control system design very low frequency synthesis easy to use I O platform for projects full PC source code for integration into new applications e Galvanic isolation of plant signals from the controller Remote monitoring of a mixture of analogue and digital signals e Simple remote control using the various inputs and outputs he concentration of a mixture of plant signals down to a pair of wires up to 1 000 metres long to minimise plant wiring thereby reducing the cost e The distant switching of equipment without the need to run mains wiring e The ability to provide a mixture of remote analogue measurement and control outputs on any network systems implemented using the Measurement and Control Interface details on the MCI 2 CD or www danntech com website o Electroplating Control System o Leach Plant Control System o Crystallization Plant Control o Irrigation Multi Acid pH Control System danntech PROCESS INSTRUMENTATION Page 6 of 41 Version 1 0 September 2005 Distributed Ammonia Gas Monitoring System o Stack Gas Monitoring System Automated Dilution of Hydrochloric Acid o Galvanostatic Potentiostatic Measurement Control System o Fabric Dying
26. in 0 20 B ou Page 17 of 41 SEES 23 ula 02a LJ ES E Rie ag m eg dis 7 c m T Kn jr ETT d Fe E em amp CU See BNET e M d ep Digital Inputs Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Digital Input 5 Digital Input 6 Digital Input 7 Digital Input 8 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 0 12 17 012v s m o 012v m 0 12 0 12V 0 30 J412 n 0 42V _ J13 in ou 0 12 0 30V n ow 0 12 015 n ot FEEN E ey 009 Page 18 of 41 418 47 19 DIN2 1 16 DIN 3 CIN J20 DIN 4 720 198 De Jumper IN 0 to 12 V er Qe lt 2 QOO 14 Jumper OUT 0 to 30 V J12 DIN 5 J5 J6 J17 J19 2420 DING dw CIN DIN2 DIN3 DIN4 Jumper IN 0 to 12 V Jumper OUT 0 to 30 V 121 Counter Input 0 2 0 30V aman 16 in Aan lout2 J13 2 Auxiliary Analogue Outputs our Io T V 0 22 mA hour
27. ituations where access to the MCI 2 is difficult danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 Page 23 of 41 17 Digital Inputs Links IN for SV input OUT for 24V R57 R69 CN12 gt 05 1 s 2 DINT amp 3 08 4 DINOV 5 18 Counter Input 5 15K 1 3K3 ES1 13 CIN _ CHA 241 e E ee e 71 n e n2 wo 19 Analogue Outputs 20 Relay Outputs 15 D11 D12 D13 R4107 7P ES1 100K ES1 0258 10K 51 R103 R104 SEN 10 1K0 ES1 10K ES1 ES1 MC33174A S 5 D MC33174A S Xp 9 R101 R105 Wg IS 2K7 100nF 1 5KE15CA ES 100nF ES1 50CSA 50 5 re Ovf ovt d ovf d Est VRS J 25 0 1 XB2 MN MC33174A S 1 5KE15CA V e WEE Ove Ovf danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 1 CN21 5 IOUT IOUT L3 vou lt YOUT 4 4 Way Hdr AOUT V Ovf Page 24 of 41 RL1A _CN14_ 3 Way 10 RL1 630 10 21 Solid State Relay Outputs U16 SSR OUT 1 CN18 5561 _55 1 _4 Way SSR OUT 2 02 003 2A 230 22 TLP523 4 DIP16 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 _ RELAY OUT 1 Page 25 of 41 23 Pulse Width Modulated Outputs 4N35 DIP6 4 Way
28. most MCI 2 users will require the second driver type which is the virtual COM port VCP driver The VCP drivers emulate a standard PC COM port These can be communicated with in the same manner as any other COM port on the PC Under Windows XP the Found New Hardware Wizard should be used to install devices when they are connected to the PC for the first time as this is the recommended procedure for reliable device operation You need to install the drivers found on the MCI 2 CD in the USB Drivers folder danntech PROCESS INSTRUMENTATION Page 21 of 41 Version 1 0 September 2005 15 Communications Watchdog The MCI 2 has a serial communications watchdog which provides a way of making sure that the 2 and the controller keep working correctly Each time the MCI 2 responds to a command transmits the internal watchdog is reset While the watchdog is reset periodically the red COMMS FAIL LED remains off and the COMMS FAIL relay remains closed When the 2 stops transmitting for whatever reason for a preset period of time then the watchdog times out and the red COMMS FAIL LED comes on and the COMMS FAIL relay opens The trimpot adjustment when fully anti clockwise produces a watchdog timeout of 1 second fully clockwise produces a watchdog timeout of around 20 seconds Watchdog Timeout Adjust LED off when comms on when 2 stops transmitting NEUTRAL LIVE danntech PROCESS INSTRUMEN
29. munications signal isolation affords protection of the controlling equipment against high industrial potentials surges and spikes Eighteen front panel LEDs can be controlled and used to indicate various things Internally the MCI comprises of two printed circuit boards The Interface Board at the bottom which has the main processor and all the plug in screw terminal connections and the Display Board mounted in the top cover with the LEDs and auxiliary connectors The MCI can be located simply on a desktop or screwed vertically to a panel For permanent mounting four holes are provided in the MCI bottom corners for bolting the MCI securely vertically or horizontally danntech PROCESS INSTRUMENTATION Page 5 of 41 Version 1 0 September 2005 3 Applications LABORATORY Controlling of experiments logging of results for analysis using other applications dynamic display of experimental results temperature profile control PRODUCT TESTING Production line quality assurance linearity measurements of input output devices logging of temperature performance monitoring of products undergoing burn in ENERGY MANAGEMENT Logging of energy consumption switching of reactive compensators warning and monitoring of maximum demand controlled load shedding timed switching TEST AND MEASUREMENT SYSTEMS Easy integration with Labview and other block diagram type programs Direct program control provides sophisticated control of purpose des
30. ns Protocol or Modbus 1 on Modbus Only SW2 4 is used Manual input calibration control 0 off normal operation 1 on analogue input calibration Ba Ka T 579 X Communications Baudrate 9 600 or 19 200 or depends on range selected 57 600 115 200 0 Communications Baudrate Range 3 low range high range Not Used Address MSB Address LSB Always ON selects 5232 RS485 and USB 3 Danntech RME or Modbus Select RMF Protocol Modbus 3 Manual Input Calibration Calibrate NotUsed L Not Used 7 danntech PROCESS INSTRUMENTATION Page 16 of 41 Version 1 0 September 2005 12 Jumper Option Selections Analogue Input 1 Analogue Input 2 Analogue Input 3 Analogue Input 4 Analogue Input 5 Analogue Input 6 Analogue Input 7 Analogue Input 8 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 2 13 420m B in in 0 20 _ B ou out 422 23 _ 0 10 V out 420m B in in _020 B ot 532 33 o in _020 B out 9492 43 _ in _020 B ou out 952 J53 _ 0 10 420 B in in _020 B ou ot n 960 J63 420m B in in 0 20 B ou ot 42 in i 020mA B ou out J82 J83 in
31. ntroller Power supply Supplied free of charge are various software examples and interface for use directly with programs such as Excel Visual Basic Delphi C and Visual C These tools gives the student practical meaning to programming and bridges the gap between a powerful programmable device the PC and the real world Say goodbye to programs which just say hello world or are contrived to try and be of practical use Our Measurement and Control Interface MCI can switch several high power devices directly measure up to eight voltage or current inputs detect the status of four switches switch any of the 15 light emitting diodes LEDs amongst other things Requires a free com port a 486 or more powerful PC will do along with the creativity to explore 5 Features Eight 16 bit analogue inputs 0 to 10 V 0 to 20 mA or 4 to 20 mA e Eight digital inputs four individually isolated four with common OV 0 to 12V or 0 to 30 V input e One high speed sixteen bit counter input 0 to 12V or 0 to 30 V input counter frequency modes Four relays 120 VAC 10 A 240 VAC 6 A 24 VDC 10 A e wo solid state relays 240 VAC 3A e Eight digital outputs four individually isolated four with common Vcc connections 40 V 100mA e wo pulse width modulated outputs 30 V 50 mA e Three analogue outputs non isolated self powered 12 bits 0 to 22 5 mA and 0 to 10 5 V two isolated externally powered 16
32. tal Outputs 7 Read Bulk Data and command 8 Identify All Attached the MCI response is a little different see later The command set and corresponding parameters are outlined below Command 1 Read Configuration Returns the data preset into the device firmware relating to the number of inputs outputs etc danntech PROCESS INSTRUMENTATION 33 41 Version 1 0 September 2005 register address of the register to read 0 Device part number code 12 for this device 1 Firmware version number in the format zzzz 10 so 10 means version 1 0 and 43 version 4 3 2 Number of digital outputs this unit has 10 3 Number of digital inputs this unit has 4 4 Number of analogue outputs this unit has 34 2 analogue output and start up register 2 digital output and start up register 20 pulse dividers and start up registers 8 PWM outputs and start up registers 2 counter value and mode 5 Number of analogue inputs this unit has 8 6 Imbedded serial number be written once and thereafter can only be read data any value when transmitted to the device usually zero contains the requested configuration data upon return The digital and analogue inputs and outputs relate to the Modbus protocol in which the digital outputs are read and write digital inputs are read only analogue inputs are read only and the analogue outputs are read and write Command 2 and 3 Read and Writ
33. tor Output 1 is off the following command is used 1 9 17 1 28 The 17 is derived by setting bits 0 Relay 1 and 4 Open Collector Output 1 and the 1 is to set bit 4 in the OFF state and bit in the ON state at synchronization danntech PROCESS INSTRUMENTATION Page 41 of 41 Version 1 0 September 2005
34. uency Power up 39 40039 60039 Value for both PWM outputs 0 to 255 40040 60040 PWM Output 1 Duty Cycle 0 to 255 PWM Output 1 Duty Cycle Power up 41 40041 60041 Value 0 to 255 40042 60042 PWM Output 2 Duty Cycle 0 to 255 PWM Output Z2 Duty Cycle Power up 43 40043 60043 Value 0 to 255 Low S e ________ e 0 to 40045 60045 Counter Timebase Value 65535 0 to 40046 60046 Counter Value 65535 40047 60047 Counter Mode 40048 60048 Analogue Input 1 to 1023 40049 60049 Analogue Input 2 0 to 1023 danntech PROCESS INSTRUMENTATION Version 1 0 September 2005 yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes to 255 yes yes yes yes yes yes yes no yes no no Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read Only Read and Write Read Only Read Only 17 bit 0 of reg 17 bit 0 of reg 17 bit 0 of reg 17 bit 0 of reg 17 bit 0 of reg 17 bit 0 of reg 17 17 28 29 30 31 32 33 34 35 36 37
35. uttons or using software and the calibrate commands Digital Inputs Eight digital inputs four individually isolated four with common OV 0 to 12V or 0 to 30 V input Link selectable input voltage range options Voltage input option 0 to 12 V Vin lt 1 V digital 0 Vin gt 4 V digital 1 Input resistance 3 3 Voltage input option O to 30 V Vin 8 V digital O Vin gt 13 V digital 1 Vin max 30 V Input resistance 15 Counter Inputs One sixteen bit counter Isolated input 0 to 50 kHz Link selectable voltage or current options Voltage input option Vin lt 1 V digital 0 Vin gt 4 V digital 1 Vin max 30 V input resistance 1 Current input option lt 10 mA digital 0 lin gt 18 mA digital 1 lin max 30 mA input resistance 270 Q Analogue Output One analogue output Ten bit resolution 10 Hz output filter Non isolated with common zero volt connection Both current and voltage outputs available to 20 mA or 4 to 20 mA with 500 maximum load resistance to 10 V with 2 minimum load resistance Offset and span adjustment with multiturn trimpots PWM Outputs Two pulse width modulated outputs TTL O V to 5 V levels Easy conversion to two eight bit analogue outputs Frequency controllable from 50 Hz to 14 460 Hz in 255 steps Duty cycle controllable from 0 to 100 in 255 steps Digital Outputs Four individually isolated digital outputs Independent uncommitted NP
36. ying module address and the device part number is 12 Command 9 Synchronize Digital Outputs This command provides a means of synchronizing any of the digital outputs so that they switch on and off together It works as follows address 9 outputselect syncvalue checksum Where the address and checksum are calculated as for the other commands and outputselect aword 0 to 65535 in which the setting of the various bits determines which of the digital outputs are to be synchronized 1 Bit 1 Relay 2 Bit 2 Relay 3 Bit 3 Relay 4 Bit 4 Open Collector Output 1 Bit 5 Open Collector Output 2 Bit 6 Open Collector Output 3 Bit 7 Open Collector Output 4 Bit 8 Solid State Relay 1 Bit 9 Solid State Relay 2 danntech PROCESS INSTRUMENTATION Page 40 of 41 Version 1 0 September 2005 syncvalue word value made up with the individual bits indicate what value 0 or 1 the selected output should inherit When the MCI receives this command it analyses which outputs are to be affected as determined by the outputselect parameter and adjusts the internal counters used on each output such that they will toggle at the same time starting with set state The other outputs are not affected by this command and continue operating how they were last configured So for example using an MCI at address 1 to synchronize Relay 1 and Open Collector Output 1 so that Relay 1 is on and Open Collec
37. you plan to use the USB cable check out and install the USB drivers Comms Open Fort Close Port Comm Port 54 Baudrate 18200 ataHecerved 11301 0132 The LEDs should flash once when power is applied Now find and run the RMF select the correct communications port and 19 200 bits per second if this is the same as when delivered AutoSend Address Command E oet up up the Address Command Ew 7 2 Register Data as shown in the OF picture open the port and press the otart Send button If all is well the MCI 2 should reply as shown i e with Parion gt the reply 1 130 1 0 32 If so then all is OK If there is no reply check out all the settings and connections until a reply is received danntech PROCESS INSTRUMENTATION Page 11 of 41 Version 1 0 September 2005 8 Front Panel and LED Details RM Register Modbus Read Modbus Write 61 62 66 67 40062 40063 40067 40068 60062 60063 60067 60068 H 8 17161511 4 LD14 LD1 2 10430 10150 Description LED Output Word Bits O LD1 1 15 LED Output Power Up Word 8 0 Z LLE3M 3 I3 LLD3 4 14 11 When the corresponding bit is set then the LED m flashes at about 0 5 Hz when set on using register 61 L
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