MC100 Pump Control Module User's Manual (Profibus DP)
Contents
1. 15 14 13 12 1 10 9 8 7 6 1 0 0 0 5 4 2 1 0 0 0 0 N4 N3 N2 Ni NO Setting the number in DW10 and the PS bit in DW11 will read the string i DW12 25 status Example In the following Control means data from the PLC to the MC100 and Status means data from MC100 to the PLC Request the FMB version as text Step 1 Set the request bit for text string bit 15 and the text number in DW10 Control 15 is 14 13 12 11 10 9 8 6 5 4 3 2 1 1 0 0 0 0 0 0 0 0 1 0 0 0 Step 2 Receive the text string in DW 12 to 21 Status MC100 FBM Ver x yy z MC100 Users Manual Profibus DP rev 4 Rev 4 Page 31 of 40 MARLOW Users Manual Mc100 8 Alarm and warnings 8 1 Alarms handling When MC100 is in Alarm state the only possible action is to reset the alarm Only applies if the alarm causes are removed otherwise the alarm will re appear at the next attempt Alarms are cleared one by one starting top down meaning lowest number first 8 1 1 Module alarms Alarm no Alarm description Action 0 No pending alarms No pumps connected during 1 power up Check connections power to pumps Connection to one or more 2 pumps lost Check connections power to missing pump 3 Connected pumps not equal to Configuration changed Investigation or new last time initialization mu2. MARLOW Flexicon User s Manual Mc100 MC100 Pump Control Module User s Manual Profibus DP MC100 Users Manual Profibus DP rev 4 Rev 3 Page 1 of 40 Users Manual MARLOW MC100 CONTENTS 1 pity ero 0 03g rs resem reese OPP eee aPeeP ED SPSS Ae PE Oe er ene eee ee ree eee eee 4 1 1 Terms usedin this TIAN All secs ceeccccscecicpcncsaccecescesdecatedatetosedbeatesaeeaeee epee saeeetaae doe aareteeedeiect 4 1 2 PRGCAMTION Saurana E A a a Ee E seu E EOE 4 2 General description of MOOG wsciscts seceestcererescssxestieleccsduaverdeesbucdecarsvarescutenctatacedesnetuedgenauadesas 5 2 1 I costes te ne ce tae ne ersene seee een wees eee cae cee etn ees 5 2 2 Introduction amp design puUrposSe seme seam Beemer re eer ere enn ane er eee ree een 5 2 2 1 How it works Technical description of Operation c ccccceeeeeeeeeeeeneeeeeeeeeeeeeeeeeneeeeeeeeeeteeeea 5 2 3 Flexicon pumps used in multi filling system short GESCTiPtiON cceeeeeeeeeeeetteeeeeeeeeeeeees 6 2 4 How to operate the dispenser PUMPS eeeeeetcceeee eee eeeeeeeeaeaeeeeeeeeeeeaaaaaaaeaeeeeeeeneeensaaaeeeenees 7 2 5 Communication on the Profibus feet crete cares aylucata mente weudnd ctanertaneettinde dna rtdeucidvedatnertacneias 7 3 Technical specifications siecein ccetonsesinadrectancunsincedcresdannersieiescpontcencisnnidtenbiecemnieieinecimnctentietnneins 8 3 1 Dimensions ceran cee eee eee a e ee 8 3 2 S
3. Bit 10 in DW10 Control 15 14 13 12 11 10 3 8 7 6 5 4 3 2 1 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 Step 5 Check P3 Bit 10 in DW10 Status 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 Step5b If required check the new value for the speed in DW15 Status 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 1 0 0 1 0 1 1 0 0 Step 6 Clear P3 Bit 10 in DW10 Control 15 14 13 12 ilil 10 9 8 m 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Step 7 Check Clear P3 Bit 10 in DW10 Status 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 The cyclic data can be read in DW10 22 and will always have the selected active pump in DW10 LSB when NOT getting strings MC100 Users Manual Profibus DP rev 4 Rev 4 Page 29 of 40 WATSON MARLOW Users Manual MC100 7 3 2 New calibration value to pump 3 In the following Control means data from the PLC to the MC100 and Status means data from MC100 to the PLC A new calibration value 10 034 g is send for pump 3 Step 1 Set pump no 3 in MC100 Control Word Control 15 14 13 12 11 10 9 8 ti 6 5 4 3 2 1 0 RENEE Pt fofot1 Step 2 Set 0 in DW10 Control 15 14 13 12 11 10 9 8 i 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 Step 3 Place calibration value in DW20 21 First the calibration value has to be converted into an integer
4. Connector for Power Supply Connector for Fieldbus 3 4 Mounting 3 4 1 Choosing a place to mount the MC100 The MC100 must be mounted in an environment that adheres to the specifications in 3 2 The MC100 must be protected from the following conditions Rain and moistures Corrosive gasses Dust or metallic particles in the air Physical shock or vibration Magnetic noise e g welding machines power devices etc On the left side of the module is a dipswitch se 3 1 which should be accessible MC100 Users Manual Profibus DP rev 4 Rev 4 Page 11 of 40 WATSON Users Manual MARLOW MC100 4 Wiring MC100 Frontplate comm _ Busy g g Genii DiD Con 2 i 1 o O 2 o O O p O O Con 3 Con 4 Connectors Indicators Switches Con1 FlexNet Connector Connect with ae ue PHOENIX PHOENIX 3 DATA O MC 0 5 3 G 2 5THT FK MC 0 5 3 ST 2 5 The FlexNet connector should be connected to the corresponding terminals on all the pumps establishing a multidrop network and the last pump should be terminated with a 120 ohm resistor between DATA and DATA Use 0 25 0 35 mm2 wires twisted or screened Terminal tubes must be minimum 8 mm long Con2 Power Supply Connector Connect with 1 24V IN PHOENIX PHOENIX 2 OV IN MC 0 5 4 G 2 5THT FK MC 0 5 3 ST
5. requlatiOmS csc2cc 2 cancssesgeeneteseeevedes cc letieccathelenesthelesceebebesenseeeceneuct 36 10 3 The WEEE SVS tet sissgiase init ccrdeetsnets iE E E E E E EEEE EEA ENEE A RENEE 36 11 APPENOIX Ireen e a E E ree ee ere eee a eres 37 12 APPNO 2 iere E eee eee ee eee ee ee ee ee 38 121 WO TADS S esner R T E EE S T 38 12 2 Volume Speed and acceleration 2 5c eseesi arses codecs deartehedacantacaspdeteivassesidnatlaliasticuadenes 39 1221 PDI2 ensen shia E E E 39 12 22 PD22 aeoiee EE REE RE A EEEE EE A RERE ARE E ER EE 39 1223 ODIO e e a a a e ee ee 39 13 Declaration of Conformity ccccciecchcrctmacressancencicencieesnendseneraccneiscencmeasuacveeciendsnstnaierenuieemenceneee 40 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 3 of 40 ss Users Manual Mc100 1 Introduction 1 1 Terms used in this manual Fieldbus DeviceNet Profibus Fieldbus interface module Anybus Compact Com Module from HMS Industrial Networks AB Filling system a MC100 and up to 16 pumps Pump Any Watson Marlow Flexicon pump communicating on FlexNet PDxx GDxx DDxx WMF Watson Marlow Flexicon 1 2 Precautions This manual should be read thoroughly before using the MC100 It is strongly advised that no wiring is connected or disconnected on the MC100 while power supply is turned ON MC100 Users Manual Profibus DP rev 4 Rev 4 Page 4 of 40 os Users Manual Mc100 2 General description of MC100 2 1 Overvi
6. 2 5 Use 0 5 mm2 wires terminal tubes must be minimum 8 mm long MC100 Users Manual Profibus DP rev 4 Rev 4 Page 12 of 40 WATSON Users Manual MARLOW Mc100 Con3 Communication Connector Connect with 1 RS485 A 1 0 2 TxD OUT 3 RxD IN 4 N C Crossed cable to for 5 GND 9 pole SubD Male 6 NG example PC 7 CTS OUT 8 RTS IN 9 RS485 B 1 0 Fieldbus Interface Profibus DP 9 pole SubD Female B Line Positive RxD TxD RS485 Level RTS GND Bus 5V Bus output Max 10 mA A Line Negative RxD TxD RS485 Level O 00 Ni gt cn A Joo ro S A Housing Cable Shield Internally connected to protective shield MC100 Users Manual Profibus DP rev 4 Rev 4 Page 13 of 40 ss Users Manual Mc100 5 Fieldbus network node address and front plate indicators 5 1 Network node address switches S1 S2 The node address is setup on the 2 rotary switches S1 and S2 Address range 1 to 99 The address is normally set before powering up and connecting to the network for the first time but if the address is change after power up the new address will flash on P4 P5 display for 5 seconds during which it is possible to change back to the old address After the 5 seconds the MC100 will do a total factory reset and start up using the new address 5 2 P1 P
7. 22 Alarm and warning 7 2 5 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 19 of 40 ss Users Manual Mc100 7 1 2 Process control bits word 0 PLC gt MC100 Word 0 2 bytes is allocated for MC100 control bits as shown below Word 0 ib ll aBel olg 8 7 6 5 4 3 alai l B1 7 B1 6 B1 5 B1 4 B1 3 B1 2 B1 1 B1 0 BO 7 BO 6 BO 5 BO 4 BO 3 BO 2 BO 1 BO 0 B0 0 4 Sets the active pump number B0 5 7 Reserved for future use Mode bit 0 please see below Mode bit 1 please see below B1 2 4 Reserved for future use B1 5 Alarm reset will reset lowest alarm or warning number To reset more alarms warnings B1 5 must be reset to 0 and then raised to 1 again for each alarm warning B1 6 Rescan the FlexNet for pumps The FlexNet is scanned for pumps and a new table of the attached pumps are written in the MC100 NB This will result in a reset of all the attached pumps B1 7 Total reset of MC100 NB This will result in a reset of all the attached pumps to default values Modes selected by mode bit 0 and 1 MC100 working modes Mode bit0 Mode bit 1 Individual 1 0 Parallel 0 1 Serial 1 1 Na 0 0 Individual mode When selected the attached pumps are operated individually l e volumes dispense signals calibration values etc has to be sent to each pump Parallel mode Parallel
8. 29 7 3 1 New speed to pump 1 de ieceivisserorscieiinncsiexunniececcresdancnaiieedreiccenctnnietd pont iencmiaaaiesebiermneidaennze 29 7 3 2 New calibration value to pump 3 ssssssssssessssssserrnrtrsstrtrtrrnnttssttrrnrtnnttssttttntrnnnnnssrnnennnn nenene 30 8 Alarm and W MiNg Seire ner Me dissin eae eee Sete EEE 32 8 1 Alarms handling seismiese aaea EAEE A ENEE E EEEE REKE 32 8 1 1 Module alarmS eee ee ore en ee eee ere re 32 8 12 P mpalalmS erin castes cucencteccndierenoumsctioncetentexunmnetionateeeimtexansiaccisteseneiesatmasesooteenimierenstnerenenttionaes 32 8 2 Warnings handling ascctenencadcesescrirzrercadsdrasaet neneseedenceiaubcenat dxbepanidasenuietdeecesexeasnetenbedeesertaeseniure 33 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 2 of 40 Users Manual MARLOW MC100 821 2 U1 ea eS eT ae ee ee eT RE Se eee 33 9 Trouble SMOG TING eisirean roiie naan a aaa aara a a e eiaa aei EGON eai 34 9 1 Bi cei0 or 1 1 10 Peare eee me eet err aa ee eer eS eR ie eae eer ee EE ena eet ene Serene 34 9 2 Opening the MC100 for service replacement Of PCB S ccccccccccecccceececeeeeeeeeeeeeeeeeeeeeeess 35 10 Decommissioning lt ccoecstee ate adetaces sce cezttcecatesseatoncaeiemennececdeausceearanacecduawicetarsnecatauevscdeecseaceceuces 36 10 1 Advice about dismantling removal diSPOSal cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeereeeeeneaeees 36 10 2 Environmental conditions
9. in the data words Here the MC100 sends the values present in the pump after the data has been changed It should correspond to the data sent 7 2 4 Data word 11 Word 11 is reserved for special unctione 15 14 13 12 SE TEATE ETENTERENRNERN 7 2 5 Alarm and warning MC100 gt PLC The alarms and warnings are transmitted from the MC100 to the PLC in DW21 The structure is mS 14 13 12 11 10 9 8 7 3 AB7 AB6 AB5 AB4 AB3 AB2 AB1 ABO WB7 WB6 WB5 WB4 WB3 WB2 WB1 WBO The alarms are described in details in section 8 1 1 and the warnings in section 8 1 2 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 28 of 40 MARLOW Users Manual Mc100 7 3 Examples 7 3 1 New speed to pump 1 In the following Control means data from the PLC to the MC100 and Status means data from MC100 to the PLC The speed for pump 1 is set to 300 rpm Step 1 Set pump no 1 in MC100 Control Word DWO Control 15 14 13 12 11 10 9 8 m 6 5 4 3 2 1 0 Sh eee be Pt ototot Step 2 Set 0 in DW10 Control 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 Step 3 Speed value 300 rpm to pump 1 in DW15 Control 15 14 13 12 11 10 9 8 m 6 5 4 3 2 1 0 0 0 0 0 0 0 1 0 0 1 0 1 1 0 0 Step 4 Set P3
10. less than 10 VA Fuse max 1A Weight 0 5 kg MC100 Users Manual Profibus DP rev 4 Rev 4 Page 9 of 40 ee Users Manual Mc100 3 3 Unpacking and inspection of MC100 The MC100 is delivered with The MC100 Declaration of Conformity CD ROM with documentation Manual for installation programming and service of MC100 Documentation and support files for Anybus Compact Com fieldbus module Function blocks for Siemens Step7 GDS file for Siemens Step7 The latest revision of this manual and of the function blocks can be downloaded from our Internet site at wmflexicon dk Please check that all ordered items have been received and that no items were damaged during transport In case of any defects or omissions please contact WMF or your supplier immediately Please verify that the model number stated on the nameplate and the installed fieldbus connector matches your purchase order Model number on nameplate Fieldbus connector MC100 61 120 000 Profibus DP V1 3 3 1 Identifying the module MC100 module LED Comm LED Busy 8 bit switch CON 1 Flexnet connector 2 digit LED display Rotary switches CON 4 Fieldbus connector CON 2 Power supply CON 3 9 pin SUB D connector MC100 Users Manual Profibus DP rev 4 Rev 4 Page 10 of 40 ss Users Manual Mc100 3 3 2 Identifying the parts MC100 module Connector for FlexNet
11. mode requires that all pumps not disabled are of the same type i e PD12 or PD22 or GD30 In parallel mode the virtual pump 0 is used to hold common parameters for all the enabled pumps In parallel mode the common data are e Volume e Pump speed e Acceleration e Tube size e Density lf parameters are sent to a pump different from pump 0 there is MC100 Users Manual Profibus DP rev 4 Rev 4 Page 20 of 40 MARLOW Users Manual MCc100 Serial mode Na generated a warning 10 and the parameters are discarded Please note that in parallel mode the calibration is NOT a common data The pumps will still have to be calibrated individually to cope with differences in the tubes positioning of the tubes in the pump head etc The MC100 will take care of sending the parameters from pump 0 to all the connected enabled pumps If pumps of different types are not disabled in parallel serial mode before changing to serial mode Alarm 08 is generated Serial mode requires that all pumps not disabled are of the same type i e PD12 or PD22 or GD30 In serial mode the virtual pump 0 is used to hold common parameters for all the enabled pumps In serial mode the common data are e Volume e Pump speed e Acceleration e Density e Calibration Please note that in serial mode the tube size is NOT a common data When parameters are sent to the MC100 in serial mode the MC100 takes all parameters EXCEPT tube size whe
12. selected in word 0 part 1 7 2 1 13 Volume data for the pump selected in word 0 part 2 7 2 1 14 Tube used in the pump selected in word 0 7 2 1 15 Speed data for the pump selected in word 0 7 2 1 16 Acceleration data for the pump selected in word 0 7 2 1 17 Reverse data for the pump selected in word 0 7 2 1 18 Density data for the pump selected in word 0 part 1 7 2 1 19 Density data for the pump selected in word 0 part 2 7 2 1 20 Calibration data for the pump selected in word 0 part 1 7 2 1 21 Calibration data for the pump selected in word 0 part 2 7 2 1 22 Alarm and warning 7 2 5 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 18 of 40 MARLOW Users Manual Mc100 If the PLC has requested a text string Data Content Described in section word no 0 MC100 control bits 7 1 3 1 Control pump 1 and 2 7 1 5 2 Control pump 3 and 4 7 1 5 3 Control pump 5 and 6 7 1 5 4 Control pump 7 and 8 7 1 5 5 Control pump 9 and 10 7 1 5 6 Control pump 11 and 12 7 1 5 8 Control pump 13 and 14 7 1 5 9 Control pump 15 and 16 7 1 5 10 Header for word 12 to 21 7 2 3 11 For future use 7 2 4 12 Text byte 1 and 2 13 Text byte 3 and 4 14 Text byte 5 and 6 15 Text byte 7 and 8 16 Text byte 9 and 10 17 Text byte 11 and 12 18 Text byte 13 and 14 19 Text byte 15 and 16 20 Text byte 17 and 18 21 Text byte 19 and 20
13. 00 7 Operating the MC100 7 1 Process Data Exchange Cyclic data Due to limitations in the Profibus structure the data for the MC100 and the attached pumps are multiplexed as described below Data are sent to and from the MC100 on a cyclic basis in a data package of 23 data word each of 2 bytes The MC100 acknowledge by returning a package of 23 data words The communications runs continuously i e also if no parameters are changed 7 1 1 Structure of the data package sent to and received from the MC100 Data sent to the MC100 PLC gt MC100 Data Content Described in section word no 0 MC100 control bits 7 1 2 1 Control pump 1 and 2 7 1 4 2 Control pump 3 and 4 7 1 4 3 Control pump 5 and 6 7 1 4 4 Control pump 7 and 8 7 1 4 5 Control pump 9 and 10 7 1 4 6 Control pump 11 and 12 7 1 4 8 Control pump 13 and 14 7 1 4 9 Control pump 15 and 16 7 1 4 10 Header for word 12 to 21 7 2 2 11 Header for special use 7 2 4 12 Volume data for the pump selected in word 0 part 1 7 2 1 13 Volume data for the pump selected in word 0 part 2 7 2 1 14 Tube used in the pump selected in word 0 7 2 1 15 Speed data for the pump selected in word 0 7 2 1 16 Acceleration data for the pump selected in word 0 7 2 1 17 Reverse data for the pump selected in word 0 7 2 1 18 Density data for the pump selected in word 0 part 1 7 2 1 19 Density data for the pump selected in w
14. 2 LED indicators Green Continuously ON or flashing indication communication with the pumps P1 a Red Flashing indicates Lost connection to at least 1 pump or internal error Green Currently not used P2 ON indicates at least 1 pump is active Red TER l l Flashing together with P1 indicate fatal internal error in the module MC100 Users Manual Profibus DP rev 4 Rev 4 Page 14 of 40 ee Users Manual Mc100 5 3 Display P4 P5 This display is used for general indication of the start up states in the MC100 and for various other purposes 5 3 1 Start up states P4 P5 Description Note SU__ Initial start up state S U Internal communications started S 0 _ Start initialisation of the fieldbus module Short state if no errors S 1 Cyclic data now exchangeable with the network Short state if no errors S 2 _ MC100 ready and waiting for connection S 3 __ Intermediate state special network state Short state idle state S 4 Connection to network established and working Short state S 5 Internal error during initialization Steady state see trouble shooting S 7 _ nternal error during initialization Steady state see trouble shooting S8 Factory Reset to default S9__ Factory Reset to default 5 3 2 Network address After initialization the display is showing the network node address 5 3 3 Alarm and
15. 6 3 Electromagnetic compatibility EMC Part 6 3 Generic standards Emission standard for residential commercial and light industrial environments According to the provisions in the Directives 2004 108 EC On the approximation of the laws of the Member States relating to electromagnetic compatibility Signature i L yp ETE September 2009 Ringsted Denmark J rn Jeppesen Development Manager MC100 Users Manual Profibus DP rev 4 Rev 4 Page 40 of 40
16. SE AMON stane teehee a a a a a ee 9 3 3 Unpacking and inspection of MG100 vescci cceresssesscststtetessiwessaseictererenveavanthterers mwearenvandencreewrnres 10 3 3 1 Identifying the OU ccc eed teen deca caste nesta daasenan nesta edemanentGe eeececienenieineteemeet te de 10 3 3 2 Identifying the 82g ee ee ESSE EEEE EEEE Ensee eenn 11 3 4 Moning eee oi eee eee erg eee a tas 11 3 4 1 Choosing a place to mount the MC100 ccccccceceeeeeeseceeeeee teen eeeeeceaaeeeeeeeeeeeeeenaaaeeeeeeeeeneneas 11 4 WIRING E Ar EE E E E E EE E E ena taesenei donee E 12 5 Fieldbus network node address and front plate indicators ccceeeeeeeeee eee eeeeetteeeeeeeeeeeeee 14 5 1 Network node address switches 81 82 cccccccccceeeeeeeeeseneceeeeeeeeeeeesnsaaeaeeeeeeeeeeeseseaaaeeeeees 14 5 2 P VPZ EED indicators ireren E NE 14 5 3 Display PAP ca ee ee eee a re ae eee 15 53l Stant p SU MU st ca ca ee eg ec ae ee et 15 53 2 _ Network address enisinia een EA EENE EEA EEE EREA EE A NEN EENET RENEE EEA ERAEN 15 5 3 3 Alarm and warning GISDIAY s oisicesssececeeiveatecessccevacienaseonacasdacincacecnaysasdacssiatecerezasidalulaiadenensaviende 15 534 DIPSWiItON sei ea aeaea ee ee eee 15 6 Configuring the fieldbus network to the MC100 ss sssssssssserrneessseeenrrnnrsssrrnnnrnnnrsserrrnrrnnne 16 6 1 Connecting the MC100 and the pumps for the first time cccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaees 16 6 2 Configuring to the Profibus DP netwo
17. al Mode and then sending the calibration value through the use of DW10 and DW20 21 The parameters are sent to the individual Pump number after setting the pump number by the MC100 control bits 2 Parallel Parallel filling is used in a multi head filling system in which a number of bottles are changed in each cycle and filled at the same time This gives a very high capacity The number of Pumps and the number of bottles changed at each cycle should be identical If more Pumps are connected to the MC100 they can if they are of the same type work synchronously with the same set of parameters In parallel mode only parameters in Pump 0 will be used i e all Pumps use same volume tube size speed etc Calibration must be carried out for the individual Pumps by first selecting the pump number via MC100 control bits as in Individual Mode and then sending the calibration value through the use of DW20 21 3 Serial Serial filling is used to boost the overall capacity in a semi or fully automated system by using each Pump to fill part of the total volume Similar to parallel filling Pump 0 is used for setting parameters for all connected pumps with the exception of Function 2 for tube diameter For setting tube diameter select the Pump number by the MC100 control bits as in Individual Mode and then send the tube number using DW10 and DW14 In this way the last Pump may for instance fill a smaller part of the total volume than the other P
18. as batteries electrolytic capacitors and printed circuit boards Further information is available on our web site www flexicon dk 10 3 The WEEE system WEEE stands for Waste Electrical and Electronic Equipment and the term is used commonly throughout the EU for waste from electrical and electronic equipment EEE The WEEE Directive stipulates common EU regulations on treatment of WEEE The rules are based on consideration for the environment and they aim at limiting the amount of WEEE we have to dispose of The objective is on the one hand to encourage producers to manufacture environmentally friendly products and on the other to increase reuse recycling and other forms of recovery The WEEE rules provide for producer responsibility which means that producers and importers of electrical products must organise and finance take back and treatment of WEEE and report information to a producer register WEEE pictogram MC100 Users Manual Profibus DP rev 4 Rev 4 Page 36 of 40 ee Users Manual Mc100 11 Appendix 1 Operating modes for MC100 1 Individual Individual filling means that each Pump has its own operating parameters and that fills calibration and pumping will not be synchronized with any other connected Pump In theory this means that the MC12 can control up to 16 Pumps concurrently Calibration is carried out by first selecting the pump number via MC100 control bits as in Individu
19. as described earlier 10 034 100 000 1003400 Then the value is placed in DW20 and DW21 where the LSB is DW20 bit 0 and MSB is DW21 bit 15 DW 20 Control 15 14 13 12 11 10 9 8 y 6 5 4 3 2 1 0 0 1 0 0 1 1 1 1 1 0 0 0 1 0 0 0 DW21 Control 15 14 13 12 iliil 10 9 8 m 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 Step 4 Set P7 Bit 14 in DW10 Control 15 14 13 12 11 10 9 8 7 6 5 3 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 Step 5 Check P7 Bit 14 in DW10 Status 15 14 13 12 11 10 9 8 Y 6 5 3 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 Step 5b If requested check the new calibration value for the pump DW 20 Status 15 14 13 12 11 10 9 8 7 6 5 3 1 0 0 1 0 0 1 1 1 1 1 0 0 1 0 0 DW21 Statu 15 14 13 12 11 10 9 8 7 6 5 3 1 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 Step 6 Clear P7 Bit 14 in DW10 control 15 14 13 12 ilil 10 9 8 m 6 5 3 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Step 7 Check Clear P7 Bit 14 in DW10 Status 15 14 13 12 11 10 9 8 7 6 5 3 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 30 of 40 ss Users Manual MC100 7 3 2 1 1 Reading strings Set the request bit for receiving text strings in DW10 bit 15 and the required text number in DW10 bit 0 4 3
20. ase see the manual for the pumps attached During production a regularly re calibration may be necessary e g for each 1 000 filling depending on the product to be filled This can be done on the fly For details on how to send and receive data from the MC100 please see section 7 2 5 Communication on the Profibus The communication between the MC100 and the PLC system for the filling line runs continuously Changes in status of the pumps and commands to the MC100 and attached pumps are communicated when required To send new data to the MC100 and the attached pumps the data are sent using a 23 data words telegram The details of this telegram are described in section 7 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 7 of 40 ss Users Manual MC100 3 Technical specifications 3 1 Dimensions MC100 Users Manual Profibus DP rev 4 Rev 4 Page 8 of 40 ss Users Manual Mc100 3 2 Specifications Fieldbus Profibus DP V1 Pumps Up to 16 pumps can be connected to and controlled by one MC100 The pumps must be able communicate with MC100 via FlexNet protocol Material and surface treatment Mounting box made from aluminium All aluminium parts anodised conductive Environmental Ingress protection according to IP30 NEMA 1 enclosure Mounting MC100 is to be mounted on DIN rail size 35 Power supply Supply 24 VDC 10 Power consumption
21. ate that the pump is active either dispensing or pumping 0 the pump is idle Bit2 Tube Br Tube bridge bit 1 tube bridge on 0 tube bridge off Please note that due to security reasons the pump cannot run if the tube bridge is off This is controlled by the pump controller Bit3 Dispense Dispense bit 1 dispense mode Bit4 Pump Pump bit 1 pump mode Bit 5 DONE 4 Is set when pump goes from dispensing to idle reset by a new START bit Bit 6 Direction Handshake for bit B5 from command byte O normal 1 reverse direction Bit 7 ALARM See Chapter 7 3 2 1 1 for further information 4 The DONE bit can be necessary to use if there is very short filling times where the BUSY signal is not detected because of transmission times on the fieldbus network MC100 Users Manual Profibus DP rev 4 Rev 4 Page 24 of 40 Users Manual MARLOW MC100 7 2 Operation Parameters Parameter specifications The section describes parameter exchange between MC100 and PLC5 7 2 1 List of basic parameters Parameter Description Data type Range Default DW 1 Volume Double integer 1000 999990000 10000000 12 13 2 Tube Integer 1 10 6 14 3 Speed Integer 30 600 100 15 4 Acceleration Integer 1 200 10 16 5 Reverse Integer 0 5 0 17 6 Density Double integer 50000 200000 100000 18 19 7 Calibration value Double integer 50 200 of Volume meee 20 21 Please note that to allow the MC100 t
22. e HyperTerminal Set the communication parameters to 9600 baud 8 bits even parity and 1 stop bit When applying power to the MC100 it will identify itself by printing the line MC100 MFSC Ver x yy x yy is the current version The MC100 will then try to identify all connected pumps on the Flexnet the LED indicator X1 will flicker and finally be steady green If for example 4 pumps holding address 1 2 3 and 4 are detected the following line will be shown Pumps 123 4 144 In this example pumps numbered 1 4 are detected lowest number is 1 and highest number is 4 and there are 4 pumps connected If the 2 line is not printed and the MC12 has an alarm indication ALO1 or ALO2 flashing it must be investigated if the FlexNet is correctly wired If everything is OK you continue to configure the Profibus master according to the guidelines from HMS please see below 6 2 Configuring to the Profibus DP network The description how to configure the MC100 for Profibus DP V1 using Siemens Step7 PLC is described in the HMS document PROFIBUS Slave Step7 2 1 pdf You find this document on the CD supplied with the MC100 The newest version of the document can be downloaded from http www hms se products products asp PID 321 amp Productl ype Anybus CompactCom You find the GDS files on the CD supplied with the MC100 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 16 of 40 MARLOW Users Manual Mc1
23. e pump type and the tube size 12 2 1 PD12 Volume range 0 01 to 9999 9 ml NB remember the conversion to integer Speed range using tube 1 2 7 and 8 30 to 600 rpm Speed range using tube 3 30 to 500 rpm Speed range using tube 4 to 6 30 to 400 rpm Acceleration using tube 1 2 7 and 8 1 to 200 rpm s Acceleration range using tube 3 1 to 150 rpm s Acceleration using tube size 4 to 6 1 to 100 rpm s 12 2 2 PD22 Volume range 10 to 9999 ml NB remember the conversion to integer Speed range 30 to 250 rpm Acceleration range 1 to 250 rpm s 12 2 3 GD30 Volume range 10 to 9999 ml NB remember the conversion to integer Speed range 30 to 750 rpm Acceleration range 1 to 100 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 39 of 40 ss Users Manual Mc100 13 Declaration of Conformity We Watson Marlow Flexicon Frejasvej 2 6 DK 4100 Ringsted Declare on our sole responsibility that the product Pump control module MC100 Model 91 120 000 91 121 000 M7 Flexicon a s denmark Model MC100 Serial No __XXXXXXXX Supply ae eae Year 2009 C Made in Denmark To which this declaration relates is in conformity with the following standard s EN55022 Information technology equipment Radio disturbance characteristics Limits and methods of measurement EN61000 6 2 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments EN61000
24. ed Acceleration The range is 1 to 200 rpm s depending on the pump and the tube selected Reverse back sucking Is a figure between 1 and 10 defining a short reverse pumping to prevent dripping after the dispensing Tube The pumps hold a tube table of up to 10 tubes which can be read from the pumps The tubes are depending on the pump type Thus the pump table can be down loaded from the pump software via the MC100 Volume The volume the pump has to dispense at each filling Please also see serial and parallel mode below Density The density g cm for the product to be filled Used when calculating the calibration value Calibration The net weight filled during dispensing When a new volume is defined for a pump it will dispense approximately 70 80 of this volume until calibrated The calibration is normally done by tare weighing a vial filling it and weighing it again to calculate the net filling weight The net weight filled is sent to the MC100 The MC 100 then calculates the dispensing data and sends it to the pump in question Please see the manual for the pump for further details When more than 1 pump is connected to the MC100 it is possible to operate the filling system MC 100 with pumps in 3 different operating modes Individual parallel and serial mode Individual mode All the different types of WM Flexicon pumps can be connected and run independently for all parameters Parallel mode This mode requires
25. ew MC100 is a pump control module for controlling up to 16 WMF Pumps The basic function is e to receive filling data from the filling line control system through an industrial fieldbus e based on data received from the filling line control system to calculate operating values for the pumps e to transmit data to the pumps connected to the MC 100 via FlexNet e to receive data from the pumps connected to the MC 100 via FlexNet e to transmit the pump data to the filling line control system MC100 constitutes together with WMF pumps a filling system designed for incorporation into a larger filling line as described below Filling system pete ee ee a Se See er eee p e ee ems 7 N Recipe ae Commands Filling line control system MC100 kE incl storing of recipe and A HMI x Y Actual Wi ree og a parameter Status Product toe seca O Achieved fill amount 2 2 Introduction amp design purpose The MC100 is a small module for mounting inside the control cabinet of the filling line It is designed with the purpose of integrating Watson Marlow Flexicon pumps into a filling line 2 2 1 How it works Technical description of operation Via the fieldbus the MC100 receives operating data from and sending data to the control system for the filling line The data are divided in three types e General data for the pump system e Set up data for each pump e Operation data for eac
26. h pump The MC100 sets up the pump system according to the data received from the control system for the filling line All control and status signals for the individual pumps connected to the MC100 are sent to the MC100 via the fieldbus The dispensing can also be controlled via hardwired signals Please see the manual for the pumps for more details regarding the hardwired signals MC100 Users Manual Profibus DP rev 4 Rev 4 Page 5 of 40 ee Users Manual MCc100 The MC100 cannot store data such as recipes and historical data These data must be stores in the control system for the filling line and be transmitted to the pump system when needed 2 3 Flexicon pumps used in multi filling system short description The Watson Marlow Flexicon multi filling system consists of up to 16 filling dispensers pumps connected via a fieldbus to a MC controller The dispensers can be peristaltic dispenser pumps PD12 and PD22 and gear dispenser pumps GD30 The MC controller can be either a MC12 controller with integrated keyboard and display to enter data and control the dispensing or MC100 for integration in control systems This manual describes the MC100 controller The pumps are used for dispensing accurate doses of liquid into vials For this purpose there are a number of parameters which are used to control the pump Speed The range for the dispensing speed is 30 to 600 rom depending on the pump and the tube select
27. he MC100 cannot find any pumps connected First check if power is applied to the pump s and they are ON then check cabling and connectors for faults To check if problem has been solved its necessary to turn power OFF and ON again Display is flashing AL 03 when applying power to the module First check if all the pump s has power applied and are indicating power ON If this is OK then the MC100 has stored a different configuration and must be reconfigured using the factory default configuration Make a factory reset to default by following the steps below 1 Locate the dipswitches on the right side of the cabinet turn dipswitch 8 ON 2 Turn power ON to the module which now starts up with the Alarm but shortly after starts the reset sequence and starts up again without the alarm 03 3 Turn power OFF and turn dipswitch 8 back to OFF 4 Turn power ON again and confirm that the alarm is still removed Alternative Use the Node address switch to do a factory reset see section 5 1 Display is shoving S 2 As a follow up on the configuration problem above this will be the display when the master scanner has a different configuration of the number of cyclic bytes 1 If this is the initial configuration please use section 6 Configuring the fieldbus network to the MC100 and the supplied documentation and files on the CD rom to setup the network 2 If this situation occurs after the system has been running normally bu
28. lings after entering a new volume will be approximately 70 80 of the requested filling volume Hereafter a new calibration must be made Please note that if the calibration value is outside the limits below 50 or above 200 of the volume a warning is generated and the calibration value is ignored When transmitting and receiving the value for calibration please note the conversion to integer as described above Please consult the manual for the actual pump type for a more detailed description of the parameters MC100 Users Manual Profibus DP rev 4 Rev 4 Page 26 of 40 Users Manual MARLOW MC100 7 2 2 Control Data Word data word 10 PLC gt MC100 DW 10 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 PS P7 P6 EZ P3 P2 P1 TEHET N3 RON OND N4 0 DW 12 21 Comments 0 Not Used 1 Request for MC100 FBM Version 2 Application Name 3 Pump version For the active pump selected in DWO 4 Alarm text strings Text string for the pending alarm 5 Warning text strings Text string for the pending warning 6 Reserved 7 Reserved 8 Reserved 9 Reserved 10 Tiibe Gbb irade pump Tube table consisting of 10 bytes with tube diameters amp N4 0 Selects the parameters type to be received in DW 12 21 if text string is requested P7 1 is set if the corresponding parameter has a new value to be send to the active pump selected in DWO P1 A
29. n sent to pump 0 and ONLY the tube size when sent to a pump number different from 0 In serial mode the filling volume is divided to the enabled pumps based on the individual tube sizes The MC100 do a calculation so the distance the pumps runs are the same independent of the tube size l e if the tube sizes are different in the enabled pumps the filling volumes from these pumps will also be different If the enabled pumps are using the same tube size the filling volume will be divided equally between the pumps Calibrations for all the pumps are carried out by calibrating pump 0 If pumps of different types are not disabled in parallel serial mode before changing to serial mode Alarm 08 is generated If operation mode 0 is selected nothing will be changed in the setup MC100 Users Manual Profibus DP rev 4 Rev 4 Page 21 of 40 ee Users Manual Mc100 7 1 3 Process status bits MC100 gt PLC As acknowledgment of receiving word 0 the MC returns word 0 with 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 B1 7 B1 6 B1 5 B1 4 B1 3 B1 2 B1 1 B1 0 BO 7 BO 6 BO 5 BO 4 BO 3 BO 2 BO 1 BO O BO 0 4 Active pump number BO 5 7 Reserved for future use B1 0 Mode status bit 0 please see above B1 1 Mode status bit 1 please see above B1 2 3 Reserved for future use B1 4 Ready to receive acyclic parameter transfer B1 5 Parameter error is reset when new
30. new value for the volume is set in word 12 and 13 is ready to be retrieved by the MC100 P2 A new value for the tube size is set in word 14 is ready to be retrieved by the MC100 P3 A new value for the speed is set in word 15 is ready to be retrieved by the MC100 P4 A new value for the acceleration is set in word 16 is ready to be retrieved by the MC100 P5 A new value for reverse is set in word 17 and is ready to be retrieved by the MC100 P6 A new value for density is set in word 18 and 19 and is ready to be retrieved by the MC100 P7 A new value for calibration is set in word 20 and 21 and is ready to be retrieved by the MC100 You can send more parameters to a pump in one data package e g when sending a new recipe PS is set to request a test string in DW12 to 21 The data is selected in N4 NO as described above Please remember to reset the flags when the data has been received by the MC100 6 Tube diameter is an integer value with a hidden decimal point e g 16 equals 1 6 mm ID MC100 Users Manual Profibus DP rev 4 Rev 4 Page 27 of 40 ee Users Manual Mc100 7 2 3 Status words from parameters transfer MC100 gt PLC DW 10 15 14 13 9 8 7 6 5 4 3 2 i 0 PS P7 P6 P4 P3 P2 P1 0 0 0 0 0 P7 1 and PS are handshake for parameter bit s in Control DW 10 The bits are set by the MC100 when the information is received and used Please also check the acknowledgements
31. o be used with PLC s without capability to use floating point data the values in parameter 1 6 and 7 volume density and calibration is converted into double integer values The MC100 will handle the double integer as a floating point value with a fixed decimal point with 5 decimals As a consequence of the above the PLC program must multiply the values for volume density and calibration by 100 000 before sending the value to the MC100 Examples Floating point value 123 45678 must be send to the MC100 as 12345678 Floating point value 1 2 must be send to the MC100 as 120000 The parameters above are Volume The volume to be dispensed at each filling Please note that to avoid overfilling the first dispense before calibrating will be approximately 80 of the requested filling Tube The tube number 1 to 10 used selected from the tube table The tube table is specific for the pump type and can be downloaded from the pump controller please see next section The tube table for each pump type is found in appendix 2 in this manual Speed The revolutions per minute of the pump If the product is foaming the revolutions may have to be lowered The speed range is 30 to 600 however the upper value is dependent on the pump type and the selected tube size Please see the details in appendix 2 Acceleration A number indicating the ramp up and down when starting stopping the dispensing The range is 1 to 200 rpm s The upper value is dependent on
32. ord 0 part 2 7 2 1 20 Calibration data for the pump selected in word 0 part 1 7 2 1 21 Calibration data for the pump selected in word 0 part 2 7 2 1 22 Na The data package will always consist of the control words for all possible pumps word 1 to 9 please see above regardless of the number of pumps attached to the MC100 The control for pumps which are not present will be ignored The data are sent with the lowers number first i e from data word 0 to data word 22 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 17 of 40 MARLOW Users Manual MCc100 When the above data package is received by the MC100 it acknowledges by returning a new data package MC100 gt PLC The structure of the returned data package is different if the return data are requested as a data communication or a text string This is selected in data word 10 as described in section 7 2 2 If the PLC has requested a data communication Data Content Described in section word no 0 MC100 control bits 7 1 3 1 Control pump 1 and 2 7 1 5 2 Control pump 3 and 4 7 1 5 3 Control pump 5 and 6 7 1 5 4 Control pump 7 and 8 7 1 5 5 Control pump 9 and 10 7 1 5 6 Control pump 11 and 12 7 1 5 8 Control pump 13 and 14 7 1 5 9 Control pump 15 and 16 7 1 5 10 Header for word 12 to 21 7 2 3 11 For future use 7 2 4 12 Volume data for the pump
33. parameter is accepted B1 6 Ready B1 7 Alarm Note B1 4 in the MC100 control bits is used as a READY BUSY bit for explicit parameter transfer The data bit will go low when accepting an explicit parameter transfer and will go high again when the data is processed thereby enabling a new transfer This handshake mechanism MUST be respected otherwise data will be lost 1 1 Normally only used in DeviceNet versions of the MC100 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 22 of 40 Ss Users Manual Mc100 7 1 4 Process control bits for the pumps word 1 to 9 PLC gt MC100 For each pump address 1 to 16 one byte is dedicated for control bits l e one data word holds the control bits for two pumps Regardless of the number of pumps attached to the MC100 all pump control words has to be sent The data for pumps not available are ignored Word 8 Word 7 Word 6 Word 5 Word 4 Word 3 Word 2 Word 1 P16 P15 P14 P13 P12 P11 P10 P9 Ps P7 P6 P5 P4 P3 P2 P1 Bit mapping in each command byte P1 to P16 Ti 6 5 4 3 2 1 0 Direction Pisablein Reger PUMP DISP START Par Serial BitO START Starta single Dispense cycle when the Pump is set in Dispense mode Bit 1 This bit must be cleared upon receiving the BUSY bit in the status byte for the pump see below Bit 1 DISP Sets the pump in dispense mode and thereby enables
34. rk 2 2i 2 cictisicticidilin dui die ieee 16 7 Operating the MG TOO s sirena kea E E E A ENARE E REAREA 17 7 1 Process Data Exchange Cyclic data wcccicccicceteciveesctieccasseetentectatenesivedeentedctoeesteateceitzencemtenise 17 7 1 1 Structure of the data package sent to and received from the MC100 c sseeeeeeeeeeeeeee 17 7 1 2 Process control bits word 0 PLC gt MC100 cccceeeeeeeee rete eeeenneee eter ee eteeeeneeeeeeeeeeeteee 20 7 1 3 Process status bits MC100 PLC cccspessea cia cts ceticeidsyeiscaieneinists Sanit dase 22 7 1 4 Process control bits for the pumps word 1 to 9 PLC gt MC100 eee ceeeteeeeeeeee ete 23 7 1 5 Process status bits from the pumps word 1 to 9 MC100 gt PLO eeeeeree eee 24 7 2 Operation Parameters Parameter specifications cece eeeeeneeeeeeeeeeeeeeeeeneeeeeeeeeeeeeneaaees 25 7 2 1 List of basic parameters o ccciecai icra crtcerenwstcea shes Gestencinxtimedtieeierene ne wieinnetne nani ecmeeiaies 25 7 2 2 Control Data Word data word 10 PLC gt MC100 cece eeetetee eee ee eteeeenneeeeeeeeeetenee 27 7 2 3 Status words from parameters transfer MC100 gt PLC 0 eeeeeeeeeeeeeeeeee eee eeeeetnneeeeeeeeeeteeee 28 T24 Data word TI esinin nar EE A NEE AEA EEEE EE A NEA EEEE EEA RENEE EEA EAEE 28 7 2 5 Alarm and warning MC100 gt PLO sssessssssssrrsressssseerrnrnsssrrrrnrrnntrssetrnrrnnnnrssernnennnnnenent 28 7 3 Examples eaea a a a a a E
35. st be done 4 Attempt to access not connected pump SPD i Pump command Bit 5 Direction 5 Reverse direction not available set for one direction pump 6 Unstable FlexNet Check pumps 7 7 FRAM storage failure Restart or Reset 8 Mode change not completed Changing mode was not possible check pump check pumps versions if change was to parallel or serial mode 9 a e a A No Alarm string available because module not working CompactCom Module 10 Reserved 11 Run length limit Run less than 5 or more than 16777215 steps 12 17 Reserved NN FB module not Ready 8 Internal MC100 module check possible replacement of module 8 1 2 Pump alarms 20 Dispense not finished Dispensing has stopped before finishing 21 Tube bridge off at dispense start Dispensing or pumping cannot start 22 Tube bridge off while dispensing Dispense not finished 23 Tube bridge off at pumping start Trying to start pumping with tube bridge off 24 Tube bridge off while pumping Removing tube bridge while pumping 7 Expected to be implemented in a later version 8 Alarm is only displayed with the 2 LED s on MFSC module both flashes RED MC100 Users Manual Profibus DP rev 4 Rev 4 Page 32 of 40 WATSON MARLOW Users Manual MC100 8 2 Warnings handling All warnings are cleared automatically when data within limits are received via FB or with clear bit MC100 command B1 4 In warning 08 13 by
36. t after a factory reset focus must be moved to the pumps where probably one or more pumps is not communicating on the FlexNet Use the description in 6 1 Connecting the MC100 and the pumps for the first time to control the number of pumps that are detected on the FlexNet When the problem is solved and the correct pumps corresponding to the correct configuration is verified it will be necessary to do a factory reset again MC100 Users Manual Profibus DP rev 4 Rev 4 Page 34 of 40 ee Users Manual Flexicon Mc100 9 2 Opening the MC100 for service replacement of PCB s 1 Power OFF for the 24V to the Module 2 Remove all cables attached the MC100 3 To access the 2 circuit boards remove the front cover by removing the 4 countersunk pozidrive screws and the front cover will come off The 2 PCB s are connected with a ribboncable and has to be pulled out together for service on either one MC100 Users Manual Profibus DP rev 4 Rev 4 Page 35 of 40 ss Users Manual Mc100 10 Decommissioning 10 1 Advice about dismantling removal disposal Disconnect all services prior to dismantling the MC100 Disconnect all connections to other equipment 10 2 Environmental conditions regulations A MC100 is subject to the WEEE system and may not be disposed using normal refuse collection The machine must be collected and disposed separately as it contains electrical components such
37. that all enabled pump are of the same type i e all PD12 all PD22 or all GD30 Different pump types can be connected to the MC 100 but only pumps of the same type can be enabled and operated together in parallel mode MC100 Users Manual Profibus DP rev 4 Rev 4 Page 6 of 40 ss Users Manual MCc100 In parallel mode a virtual pump pump no 0 is be used to hold common parameters for all the enabled pumps However the pumps will still have to be calibrated individually Serial mode This mode requires that all enabled pump are of the same type i e all PD12 all PD22 or all GD30 Different pump type can be connected to the MC 100 but only pumps of the same type can be enabled and operated together in parallel mode All pump data except tube sizes are stored in the virtual pump pump no 0 The filling volume is divided to the pumps based on the tube sizes Calibration for all the pumps is done by calibrating the virtual pump 0 2 4 How to operate the dispenser pumps Before a new filling is started the parameters for this filling is loaded to the pumps from the filling system The data are loaded to the pumps either individually or as common data depending on the operating mode please see above Initially the pumps need to be primed i e the product has to be filled into the tubes and nozzles of the filling system Hereafter the pumps must be calibrated For details of priming and calibrating ple
38. the pump type and the selected tube size Reverse A number indicating the reversing of the pump after dispensing to avoid dripping of the product between dispensing The reverse is a number in the range 0 to 10 The physical reversing is dependent on the pump type For a PD12 the value 10 gives reverse rotation where for a PD22 the value 10 gives a full reverse rotation Density The density of the product to use when calibrating When calibrating the 5 These parameters can also be exchanged using DPV1 Class 2 acyclic data exchange MSAC2 contact Watson Marlow Flexicon for a description if necessary MC100 Users Manual Profibus DP rev 4 Rev 4 Page 25 of 40 ss Users Manual Mc100 weight of the filled amount of the product is entered If the product has a density other than 1 the MC100 has to take that into the calculation of the pump data for filling to convert to volume The density must be in the range 0 5 to 2 0 g cm Please note the conversion to integer as described above Calibration value The weight of the product in g filled found by subtracting the weight of the vial from the total weight of the filled vial When receiving the weight MC100 calculates new pump parameters for the actual pump and send it to the pump controller The pump will use the new setting from the first dispensing after having received the new data If the volume is changed the calibration is reset To avoid overfilling the fil
39. the START bit to start dispenses If removed during dispensing the pump stops immediately Bit 2 PUMP2 Starts pump running continuously with the set speed Bit 3 Reserved for future use Bit4 RESET Tobe used with future pumps Bit 5 Disable pump in parallel and serial mode If set high the pump will ignore dispense and pump bites Bit 6 Direction 1 0 Backwards Normal pump and dispense direction Bit 7 Reserved for future use 2 The DISP bit has higher priority and must be cleared before setting the PUMP bit 3 Available for pumps able to handle this function GD30 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 23 of 40 MARLOW Users Manual Mc100 7 1 5 Process status bits from the pumps word 1 to 9 MC100 gt PLC For each pump address 1 to 16 one byte is dedicated for status bits l e one data word holds the status bits for two pumps Regardless of the number of pumps attached to the MC100 all pump control words has to be sent The data for pumps not available are ignored Word 8 Word 7 Word 6 Word 5 Word 4 Word 3 Word 2 P16 P15 P14 Pi P12 P11 Word 1 P10 P9 P8 P7 P6 P5 P4 P3 P2 P1 Bit mapping in each status byte P1 to P16 7 6 5 4 3 2 1 0 ALARM Direction DONE Pump Dispense Tube Br BUSY READY BitO READY Pump is ready self check is Ok Bit 1 BUSY 1 Indic
40. the phrase individual pumps means real connected pumps and pump 0 means the pseudo pump which holds common parameters in parallel and serial mode 8 2 1 Warnings Warning no Warning description Action 0 No pending warnings 1 Fill volume out of range 2 Tube number is not in table 3 Speed setting is out of range Attempt to set parameter that is 4 Acceleration setting is out of range outside limits 5 Reverse setting is out of range Set new parameter 6 Density setting is out of range 7 Calibration is out of range 8 Common calibration in parallel ie eae a i 9 Individual calibration in serial Vallprallon antompr tor ingividual pump calibrate pump 0 only Set parameters via pump 0 nahan S fetve common pump or clear warning 11 Attempt to calibrate pump 0 fictive common Clear by calibrating physical pump in individual mode connected pumps 1 to 15 MC100 Users Manual Profibus DP rev 4 Rev 4 Page 33 of 40 ee Users Manual MC100 9 Trouble shooting 9 1 Trouble shooting Different kind of problems can cause machine stop errors etc Most trouble shooting will be based on the information from the front plate indicators and display and the Alarm list information see 8 1 1 Examples Problem Solution Problem Solution Problem Solution Display is flashing AL 01 when applying power to the module indication that t
41. umps in the system This is done by applying a smaller tube in the last Pump When all Pumps have been programmed the MC100 will automatically calculate which part of the total volume the individual Pumps should fill so that they are completed simultaneously This gives the best capacity Calibration is also carried out in Pump 0 as the system perceives the whole system as one single Pump l e selecting pump number 0 via MC100 control bits as in Individual Mode and then sending the calibration value through the use of DW10 and DW20 21 see example in section MC100 Users Manual Profibus DP rev 4 Rev 4 Page 37 of 40 ee Users Manual Mc100 12 Appendix 2 12 1 Tube tables 12 1 1 1 PD12 Tube Number Inner Diameter mm 1 0 8 1 6 3 2 4 8 6 0 8 0 1 2 COIN DMB Ww Ny 0 5 Tube number 1 to 6 is valid for all versions of PD12 where the tube number 7 and 8 only is valid for PD12 B PD12 from after date 12 1 1 2 PD22 Tube Number Inner Diameter mm 1 3 0 5 0 6 5 8 0 10 0 HD WM HB Ww rN 12 5 12 1 1 3 GD30 Tube Number Inner Diameter mm 1 1 0 pseudo number MC100 Users Manual Profibus DP rev 4 Rev 4 Page 38 of 40 Users Manual MARLOW MC100 12 2 Volume Speed and acceleration The range for speed and acceleration is dependent on th
42. warning display The node address is replaced by a flashing AL and the alarm number XX when and alarm is present see 8 1 1 Alarms Er and the warning number XX when a warning recoverable alarm is present see 8 1 2 warnings 5 3 4 Dipswitch The dipswitch on the right side of the MC100 module can be used to do a factory reset function Reset state Dipswitch Action Description 0 All OFF None Normal runtime state 1 All OFF Remove power to MC100 MC100 starts up and reaches init state 2 2 SW 8ON_ Apply power to MC100 And the restart again initializing to factory defaults and starts up 3 SW 8ON_ Remove power to MC100 4 SW 8 OFF Apply power to MC100 MC100 starts up normally It can be necessary to do a factory reset before connecting the fieldbus network During the factory reset initialization the MC100 determines the number and types of pumps connected on the Flexnet Please see section 6 x x MC100 Users Manual Profibus DP rev 4 Rev 4 Page 15 of 40 ee Users Manual Mc100 6 Configuring the fieldbus network to the MC100 6 1 Connecting the MC100 and the pumps for the first time Make sure all pumps have been giving a unique address and all the pumps have been powered up The FlexNet is connected to the MC100 and to the pumps in a multidrop network Connect SubD connector X3 to a PC using a NULL modem cable Start a terminal program on the PC for exampl
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