MC100 Pump Control Module User's Manual (Profibus DP)
Contents
1. power up 2 Connection to one or more Ch ok eck connections power to missing pump pumps lost 3 Connected pumps not equal to Configuration changed Investigation or new last time initialization must be done 4 Attempt to access not connected pump 5 Reverse direction not available Pump aa Bit ee Direction 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 oe No Alarm string available because module not working 10 Disable Enabl fail Attempt to Disable or Re enable pumps has failed in the current mode 41 Pump run length to long Setting volume or calibration has resulted in to long fill length 12 Reserved 13 Reserved 14 Reserved 15 Reserved 16 Reserved 17 Reserved NN FB module not Ready 8 Internal MC100 module check possible replacement of module 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 Profibus OM 1 01 EN doc Rev 1 01 Page 23 of 30 OS 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 the phrase individual pumps means real2. OS 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 Internal error during initialization Steady state see trouble shooting S8 Factory Reset to default S 9 __ Factory Reset to default 5 3 2 Network address After initialization the display is showing the network node address 5 3 3 Alarm and 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 used to do a factory reset function Reset state Dipswitch Action Description 0 All OFF None Normal runtime state 1 All O
3. MARLOW Flexicon User s Manual MC100 MC100 Pump Control Module User s Manual Profibus DP MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 1 of 30 Users Manual Ww ee MC100 CONTENTS 1 Introduccion sonas oa 4 1 1 Abbreviations in this Manual cccccccccccccecccececeeceeeeceeeeaeceaeeeaeeeaeeeaecaaeseaaecaaeeaaesaaeeaaeeaaeaaaeess 4 1 2 A NN 4 1 3 REPEFENCES cece cecccec cece ccececeeecececeecececceecneeccnecececeaaenaaecaaeaaaecaaecaaesaaaaaaaeaaaeaaaeacaeaaaeeaaansaaeeeeeeseess 4 2 General description Of MC100 oocccccocccococonononnno ccoo nr 5 2 1 COVE VIG W A a ees 5 2 2 Introduction amp design PULPOSE ccccccecccececceecceeeeeeeceeeeeeccceeeeeeeaeceaaecaaesaaeceaeseaaesauesaaeeaaeeaaeaas 5 2 2 1 How it works Technical description Of Operation cccccceeceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeerees 5 3 Technical Specifications ccccecccceccceecceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneteas 6 3 1 DIMENSIONS sciseccscsnestearssasndsnecusienteasuthenegastdbeqasssuabscnsssidieosee spar hessadh Sauaasensaasuibbadaaes danazoayleseescen ect 6 3 2 Specifications iii eri er a a 7 3 3 Unpacking and inspection Of MC100 oococcncnnncnnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 8 3 3 1 Identifying the M OdUlS circa a 8 3 3 2 Identifying the parts cin 9 3 4 POV e A O a aa Ea
4. connected pumps and pump O 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 fo Calibration attempt for individual 8 Common calibration in parallel pump calibrate pump 0 only 9 Individual calibration in serial Calibration attempt for Pump 0 calibrate pumps individually MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 24 of 30 OS 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 Display is flashing AL 01 when applying power to the module indication that the MC100 cannot find any pumps connected Solution 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 it s necessary to turn power OFF and ON again Problem Display is flashing AL
5. 7 3 2 1 0 0 0 0 1 Step 2 Set 0 in DW10 15 14 13 12 11 10 9 8 7 3 2 1 0 0 0 0 0 0 Step 3 Speed value 300 rpm to pump 1 in DW15 15 14 13 12 11 10 9 8 7 3 2 1 0 0 0 0 0 0 1 0 1 1 0 0 Step 4 Set P3 Bit 10 in DW10 control 15 14 13 12 11 10 9 8 7 3 2 1 0 0 0 0 0 1 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 3 2 1 0 0 0 0 0 1 0 0 0 0 0 0 0 Step 6 Clear P3 Bit 10 in DW10 control 15 14 13 12 11 10 9 8 7 3 2 1 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 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 0 The cyclic data can be read in DW10 25 and will always have the selected active pump in DW10 LSB when NOT getting strings MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 21 of 30 Users Manual MARLOW MC100 7 2 4 1 2 New calibration value to pump 3 Step 1 Set pump no 3 in MC100 Control Word 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 a E 5 E E E E E E 0 0 1 1 Step 2 Set 0 in DW10 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 Step 4 Set P7 Bit 14 in DW10 control 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1
6. B1 4 Ready to receive acyclic ADI parameters Used with DeviceNet explicit messages B1 5 Parameter error is reset when new parameter is accepted B1 6 Ready B1 7 Alarm MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 16 of 30 MARLOW Users Manual MC100 7 1 3 Process control bits for the pumps To control each pump one byte 8 bits is dedicated as described below Minimum one word is transmitted for pump control The number of pumps connected is a parameter which is part of the configuration of the number of cyclic bytes of the network Word 8 Word 7 Word 6 Word 5 Word 4 Word 3 Word 2 Word 1 P16 P15 P14 P13 P12 P11 P10 P9 P8 P7 P6 P5 P4 P3 P2 P1 Bit mapping in each command byte 7 6 5 4 2 1 0 Direction a n RESET PUMP DISP START ar 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 the START bit to start dispenses If removed during a dispense the pump stops immediately Bit2 PUMP2 Starts pump running continuously with the set speed Bit 3 Reserved for future use Bit 4 RESET To be used with future pumps Bit 5 Disable pump in parallel and serial mode Bit6 Direction 1 0
7. Stating that pumps numbered 1 4 are detected lowest number is 1 and highest number is 4 totalling 4 pumps 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 correct wired If all is OK then continue to configure the Profibus master according to the guidelines from HMS se below 6 2 Configuring to the Profibus DP network The description is on 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 the newest verison can be downloaded from http www hms se products products asp PID 3218ProductType Anybus CompactCom On the CDrom is also GDS files MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 14 of 30 OS Users Manual MC100 7 Operating the MC100 7 1 Process Data Exchange Cyclic data The cyclic data consists of control bits and status bits There is a distinction between MC100 control status bits and pumps control status bits When connected to the Fieldbus network the MC100 will always transmit and receive 1 word for the MC100 function and minimum 1 word for the pumps even if only 1 pump is connected there will still be allocated 1 word where the highest 8 bits will be empty 7 1 1 Process control bits for MC100 There is allocated one word 2 bytes for MC100 control bits as shown below Word 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 B
8. be send to the MC100 as 12345678 or Floating point value 1 2 must be send to the MC100 as 120000 In the PLC or HMI there must be a conversion to this format i e multiply with 100000 if the input is in floating point format Likewise if reading for example volume from the MC100 then divide the value with 100000 to display it as a floating point The tube size setting is a number from 1 10 as the maximum number of tubes in a pump is 10 the actual tubes sizes available for the pump can be found in appendix 1 7 2 2 Description of parameter multiplexing in DW12 21 DW10 The header describing the contents of DW12 21 DW11 Reserved for future use DW12 21 Holds pump parameters and other miscellaneous information depending on DW10 DW22 Holds Alarm Warning numbers 5 These parameters can also be exchanged using DPV 1 Class 2 acyclic data exchange MSAC2 contact Watson Marlow Flexicon description if necessary MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 19 of 30 WATSON Users Manual MARLOW MC100 7 2 3 Control Data Words PLC gt MC100 DW 10 15 14 13 12 11 10 9 8 m 6 5 4 3 2 1 0 PS P7 P6 P5 P4 P3 P2 P1 N4 N3 N2 N1 NO N4 0 DW12 21 Comments 0 Not Used 1 Request for MC100 FBM Version 2 Application Name 3 Pump version For the active pump in DWO 4 Alarm text strings Text strings for th
9. gt RS485 B 1 0 Con4 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 CO N Od 01 BA Go RO gt Housing Cable Shield Internally connected to protective shield MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 11 of 30 OS 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 where it is possible to change back to the old address After 5 seconds the MC100 will do a total factory reset and start up using the new address 5 2 P1 P2 LED indicators Green Continuously ON or flashing indication communication with the pumps Red Flashing indicates Lost connection to at least 1 pump or internal error Green Currently not used P2 Red ON indicates at least 1 pump is active Flashing together with P1 indicate fatal internal error in the module P1 MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 12 of 30
10. nn nccccnnn 27 10 3 A A A dae la ieeh suebiadehe 27 MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 2 of 30 WATSON MARLOW Users Manual MC100 11 Appendik iii A AA A 28 12 A 29 PAS A eaa di iaaa Eaei an eai ea aia dnain iee niania aa 29 13 Declaration of Conformity seeesstocececcaletsenicn dts cetineartleucisdtdetdlauedenatatchdtedsoransddant denis dica doi 30 MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 3 of 30 OS Users Manual MC100 1 Introduction 1 1 Abbreviations in this manual Fieldbus DeviceNet Profibus CANOpen etc Fieldbus interface module Anybus Compact Com Module from HMS Filling system System consisting of an MC100 and from 1 to 16 pumps Pumps All Watson Marlow Flexicon pumps types that communicates on Flexnet 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 connect or disconnect on the MC100 while power supply is turned ON The MC100 must mounted in an environment that adheres to EN 60204 1 2006 4 4 3 6 The MC100 must not to be used in explosion hazardous environments 1 3 References EN 60204 1 2006 MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 4 of 30 OS Users Manual MC100 2 General description of MC100 2 1 Overview MC100 is a Pump control module capable of controlling up to 16 WMF Pumps The basic function is to rece
11. 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 O 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 Profibus OM 1 01 EN doc Rev 1 01 Page 28 of 30 OS 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 CON DD WB WIN 0 5 12 1 1 2 PD22 Tube Number Inner Diameter mm 1 3 0 2 5 0 3 6 5 4 8 0 5 10 0 6 12 5 12 1 1 3 GD30 Tube Number Inner Diameter mm 1 1 0 pseudo number MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 29 of 30 OS 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 Y Flexicon a s denmark Modell Mmao O Serial No XXXX XXXX Supply 24VDC Year 2009 C Made in Denmark To which this dec
12. the PUMPS ooooooocccconcconcconcnoncnnnnnnonononononnnnnnnnonononnnonnnnnnnnnnnnnnnnnnnnnnas 17 7 1 4 Process status bits from the pUMPS oooooooooococoncnonononnncononononononnnnnnnnnnnnn nono nonnnnnnonnnnnnnnrnnnrnnnnnnns 18 7 2 Operation Parameters Parameter Specifications oooocooooniccniccniconinnnncnncccincnncn 19 7 2 1 List of basic parameterS oooococnnccnoncccccoccconnnonnno ono nn 19 7 2 2 Description of parameter multiplexing in DW 12 21 ooooooonooonnconcconononcnnncnoncnnnnnnonnnnnnnonnnonnnnnnnos 19 7 2 3 Control Data Words PLC gt MOTO x ccce tisnsttce clades aus iaaiditeedtyandsvebdedescartdeeesdabetdanctlatsiantantheas 20 7 2 4 Status words from parameters transfer MC100 gt PLC 00 eee tree eee eeennaeeeeeeeeeeeeeeea 20 8 Alim and WEA METS sosa laa 23 8 1 Alarms VARNA oc a Sica o ga ace acme eaaenceee ees 23 8 1 1 A EREEREER E A E E EAEE EEA 23 8 2 aca A ia aide E Sinde 24 el o 24 9 A aaan iaaa AA AAAA AAEE aie 25 9 1 rouble shootings e rere en a Aa E E aE ere 25 9 2 Opening the MC100 for service replacement of PCB S ccceeceeeeceeeeeeeeeeeteeeeeeeeeeeeeeeeees 26 10 DECOMMISSIONING sxictfcrceceveastncraniccardetarstuelscuterenesucuseestiecatiicce ia 27 10 1 Advice about dismantling removal diSPOSAl cece eeeeeee teeter eee eeeaaaeeeeeeeeeeeeeneneeneeeeees 27 10 2 Environmental conditions regulatiONS oooooocccccnnnnnncccononcnnnnnnnnnnnnnnnncnnnncnnnnnnnnnnnnn
13. 0 0 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 7 6 5 4 3 2 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Step 6 Clear P7 Bit 14 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 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 4 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7 2 4 1 3 Reading strings 15 14 13 12 11 10 9 1 0 0 0 0 0 0 0 s N4 N3 N2 N1 NO N o a S w N o Setting the number in DW10 and the PS bit in DW11 will read the string i DW12 25 status Example 15 14 13 12 11 10 9 8 il 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 1 MC100 FBM Ver x yy z MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 22 of 30 WATSON 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 Alarms Alarm no Alarm description Action 0 No pending alarms 1 No pumps connected during Check connections power to pumps
14. 03 when applying power to the module Solution 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 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 Important The cyclic bytes exchanged with fieldbus master scanner will now reflect the current configuration If this configuration is different from setting in the Master scanner it will not be possible to connect to the scanner Problem 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 Solution 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 but after a factory reset focus must be moved to the pumps where probably one or more pump
15. 1 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 B0 0 4 Sets the active pump number B0 4 7 Reserved for future use B1 0 Mode bit 0 B1 1 Mode bit 1 MC100 working modes 1 Mode bit 0 Mode bit 1 Individuel q1 0 Parallel o 4 Seriel q 4 B1 2 4 Reserved for future use B1 5 Alarm reset will reset lowest number alarm or warning B1 6 Rescan for pumps resulting in new values for connected pumps B1 7 Total reset of MC100 including loading the default values to connected pumps 1 See Appendix 1 for description of the working modes MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 15 of 30 OS Users Manual MC100 7 1 2 Process status bits from MC100 Status bits cyclic process data For MC100 status one word 2 bytes is dedicated as scheduled below 15 14 13 12 11 10 9 8 7 4 2 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 Active pump number B0 4 7 Reserved for future use B1 0 Mode status bit 0 B1 1 Mode status bit 1 MC100 mode status Mode status bit 0 Mode status bit 1 Individuel q o Parallel o 4 Seriel q 4q B1 2 3 Reserved for future use
16. 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 Profibus OM 1 01 EN doc Rev 1 01 Page 17 of 30 WATSON MARLOW Users Manual MC100 7 1 4 Process status bits from the pumps To retrieve status from each pump one byte 8 bits is dedicated as described below Minimum one word is received with status from the pumps The number of pumps connected is a parameter which is part of the configuration of the number of cyclic bytes of the network The MC100 will always automatically send the number of bytes for the connected pumps after a factory reset to defaults Word 8 Word 7 Word 6 Word 5 Word 4 Word 3 Word 2 Word 1 P16 P15 P14 P13 P12 P11 P10 P9 P8 P7 P6 P5 P4 P3 P2 P1 Bit mapping in the status byte 7 6 5 4 3 2 1 0 ALARM Direction DONE Pump Dispense Tube Br BUSY READY Bit 0 READY Pump is ready self check is OK Bit 1 BUSY 1 Indicate that the pump is active either dispensing or pumping 0 pump is idle Bit 2 Tube Br Tube bridge bit 1 tube bridge on 0 tube bridge off Bit 3 Dispense Dispense bit 1 dispense mode Bit 4 Pump Pump bit 1 pump
17. FF 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 The factory reset can be necessary to do before trying to connect to fieldbus network During the factory reset initialization the MC100 determines how many and what pump types are connected on the Flexnet see 6 x x MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 13 of 30 OS 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 with 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 example 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 will be 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 are detected the following line will be Pumps 1234 144
18. a 9 3 4 1 Choosing a place to mount the MC100 ccsiccisiutccccserssssssincrepinentthonasesnawbarddeastabieaiaeedcelesatenterseces 9 4 A eae cbs E cose a a aaa aieas 10 5 Fieldbus network node address and front plate indicators coccccccccccccccccnccnnnnnncnnnnnnnnnno 12 5 1 Network node address switches 81 82 oooooooncoonccoccconcconcnnoncnonnnoncnonnnonnnnnnnonnnnnnnnnnnnnnnnnnnnnnnns 12 5 2 P1 P2 LED indicators secie aE AE a Erie iE eE ie dien end a aeiaai 12 5 3 Bispla y PAIF S iene ea e eea a A A a A a eE aa A Aa A aA ES 13 539 1 Start AAA a a a a E aa a a Maes 13 9 32 Network address eerren ro a IN a 13 5 3 3 Alarm and warning Splice ai 13 5 3 4 DipSWilCh ona yeu REE REEERE A A EA EEEE ENERE 13 6 Configuring the fieldbus network to the MC100 ccceceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaaeeeeeeeeeeeeaea 14 6 1 Connecting the MC100 and the pumps for the first time 0 cece eceee cece cess eeeeeeeeeeeeeeeeeeees 14 6 2 Configuring to the Profibus DP Me WOM icc sidincecetrcrnsssitrracedsanatdncrsmnetienceatcentsenadsecedeartianaaaacone 14 7 Operating the I aes foes sh oh cane ion AE A NEA E T E EEEa 15 7 1 Process Data Exchange Cyclic data iii ns 15 7 1 1 Process control bits for MC100 ooooooooooconcconocoonccnncnononononononnnnonnnnnn nono nnnnnnrnnnnnnnnnnnnnnnnn nan nnnnnnas 15 7 1 2 Process status bits from MC 1D ooooooncoocccococonooooco nono nononnnnnnnnonnnn nono 16 7 1 3 Process control bits for
19. anual for installation programming and service of MC100 Documentation and support files for Anybus CompactCom fieldbus module 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 Fielbus connector MC100 61 120 000 Profibus DP V1 3 3 1 Identifying the module MC100 module LED Online 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 Profibus OM 1 01 EN doc Rev 1 01 Page 8 of 30 OS Users Manual MC100 3 3 2 Identifying the parts MC100 module Connector for Flexnet 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 Be sure that the MC100 is also protected from the following conditions Rain and moistures Corrosive gasses Dust or metallic particles in the air Physical shock or vibration Magnetic noise Examples welding machines power devices etc On the left side of the module is
20. ary FlexNet communication protocol All control signals and status signals from the pumps are available through the fieldbus interface but start and status signals can be sent to received directly from the individual pump by 24V signals MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 5 of 30 OS Users Manual MC100 MC100 holds no recipes historical data or audit trail only current runtime parameters for the filling system is stored internally 3 Technical specifications 3 1 Dimensions 124 MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 6 of 30 MARLOW Users Manual MC100 3 2 Specifications Fieldbus Profibus DP V1 Pumps Max 16 pumps can be connected and controlled 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 EN 60204 1 2006 Mounting MC100 is to be mounted on DIN rail size 35 Power supply Supply 24 VDC 10 Power consumption less than 10 VA Fuse max 1A Weight 0 5 kg MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 7 of 30 OS Users Manual MC100 3 3 Unpacking and inspection of MC100 With the shipment of MC100 you should receive The MC100 Declaration of Conformity CD rom with documentation M
21. e pending alarm 5 Warning text strings Text strings for the pending warning 6 Reserved 7 Reserved 8 Reserved 9 Reserved Tube table consisting of 10 bytes with tube 10 Tube table for active pump f 9 y diameters 6 N4 0 Selects the parameters type to be received in DW 12 21 P7 1 is set if the corresponding parameter has a new value to be send to the active pump DWO PS is set to retrieve text strings or additional information 7 2 4 Status words from parameters transfer MC100 gt PLC DW 10 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 PS P7 P6 P5 P4 P3 P2 P1 0 0 0 0 0 P7 1 and PS are handshake for parameter bit s in Control DW 10 Word 11 is reserved for future use 15 14 13 12 11 10 9 6 Tube diameter is an integer value with a hidden decimal point for example 16 equals 1 6 mm ID MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 20 of 30 WATSON Users Manual MARLOW MC100 7 2 4 1 Examples 7 2 4 1 1 New Speed to pump 1 Step 1 Set pump no 1 in MC100 Control Word 15 14 13 12 11 10 9 8
22. ive filling data from the filling line control system through an industrial fieldbus and to calculate operating values for the pumps Transmit Receive those values and status through the FlexNet protocol MC100 constitutes with WMF Pumps a filling system that is designed for incorporation into a larger facility as described below Filling system Y A N Recipe Commands Filling line control system MC100 ME incl storing of recipe and A HMI N A y Actual PO AN parameter AS Status AAA AA Achieved fill amount MALO le DON 7 2 2 Introduction amp design purpose The MC100 is physically a small module intended for mounting inside the control cabinet of the filling line The MC100 is designed with the purpose of integrating Watson Marlow Flexicon pumps into a filling line The MC100 has no physical operator interface all access to the module and hence the pumps is done through the fieldbus interface module 2 2 1 How it works Technical description of operation Recipes containing parameters such as filling volume and filling speed for the requested filling are sent to the MC100 via the fieldbus communication The MC100 will based on these specifications calculate operating parameters for all the pumps and transfer these parameters to the pumps Parameters will be sent to and status retrieved from the pumps by the RS485 multidrop network using the propriet
23. laration 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 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 GE IS September 2009 Ringsted Denmark J rn Jeppesen Development Manager MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 30 of 30
24. le 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 Profibus OM 1 01 EN doc Rev 1 01 Page 27 of 30 OS 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 Individual Mode and then sending the calibration value through the use of DW10 and DW20 21 The parameters are
25. located a dipswitch se 3 1 which should be accessible MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 9 of 30 Users Manual MARLOW MC100 4 Wiring MC100 Frontplate comm O Busy B B Address Canji OO x10 x1 Con 2 ar 1 o 2 o O O f O O Con 3 Con 4 Connectors Indicators Switches Connect with Con1 Flexnet Connector eve e PHOENIX PHOENIX 3 DATA VO 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 2 5 Use 0 5 mm2 wires terminal tubes must be minimum 8 mm long MC100 Profibus OM 1 01 EN doc Rev 1 01 Page 10 of 30 MARLOW Users Manual MC100 Con3 Communication Connector Connect with RS485 A 1 0 TxD OUT RxD IN N C GND p 9 pole SubD Male Crossed cable to for NC example PC CTS OUT RTS IN 00 Nj gt 01 BA Go DO
26. mode Bit 5 DONE 4 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 2 4 1 3 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 Profibus OM 1 01 EN doc Rev 1 01 Page 18 of 30 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 20 21 S Text string Character 22 characters 20 22 The data types for parameter 1 6 and 7 are special in that this data format has been chosen in stead of floating point to be able to use the MC100 with PLC s without floating point capability The data type is a double word type where there is a hidden fixed decimal point position with 5 decimals Examples Floating point value 123 45678 must
27. s 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 Profibus OM 1 01 EN doc Rev 1 01 Page 25 of 30 OS 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 Profibus OM 1 01 EN doc Rev 1 01 Page 26 of 30 OS Users Manual MC100 10 Decommissioning 10 1 Advice about dismantling removal disposal Disconnect all services prior to dismantling the MC 100 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 as batteries electrolytic capacitors and printed circuit boards Further information is availab
28. 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 O 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 DW 14 In this way the last Pump may for instance fill a smaller part of the total volume than the other Pumps in the system This is done by applying a smaller tube in the last Pump When all Pumps have been
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