Flintec MCS-64 User Manual

MCS-64

(Multi Channel System for Process Industry)

Manual MCS-6 with Modbus on Ethernet

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Example of MCS-64 with 5 channels and Profibus-Gateway

Document no. G165-Rev1-GB

www.flintec.com

Manual MCS-64

Page 1

Components of MCS-64 in overview

				Base Board
				MB 89.1
	Load Cell	LDM 88.1	RS 232
	#1	#1	Service-Port
				Fieldbus
			Gateway
	Load Cell	LDM 88.1	- Profibus	(PGM 68.1)
	#2	#2
			- CANopen (CGM 85.1)
			- Ethernet	(EGM 87.1)
		- Bus		Extension Boards
				MB 89.2
				MB 89.3
		RS485		MB 89.4
	Load Cell	LDM 88.1
	#64	#64

Components of MCS-64

All boards have the same technical features:

•Spring clips for load cell terminals in 6-wire-technique

•4 DI’s via spring clip terminal blocks

•4 DO’s via spring clip terminal blocks

Base Board MB 89.1

•Slot for one Gateway CGM 85.1 / PGM 86.1 / EGM 87.1

•2 Slots for weighing processor LDM 88.1

•RS 232 Service port

Extension Boards MB 89.2/.3/.4

• 2/4/8 Slots for weighing processor LDM 88.1

MB 89.2

MB 89.3

MB 89.4

LDM 88.1				CGM 85,1

PGM 86.1

EGM 87,1

MB 89.1

Dim 104 x 135 mm

Dim 79 x 135 mm	Dim 129 x 135 mm	Dimensions 229 x 135 mm
Page 2		Manual MCS-64 Ethernet

Weighing Processor LDM 88.1	The digital weighing processor LDM 88.1 is a load cell
	digitizing unit for precise measuring of loads in motion.
	• ± 18 bit resolution (±260 000 d)
	• Excitation 5 V DC / 50 mA
	• 2 400 Measurements/s internal,
	600 Measurements/s external

				Remote Control Output
				Start Filling Cycle
				Trigger Signal
		LDM 88.1
					Digital
					Input
					1 ... 4
					- Net	485 / 230 kBaud	binary format
	Load Cell	Low-Pass	ADC	Digital Filter	- Gros
		Filter		IIR- / FIR	- Average
					- Dose
						RS
					Digital
					Output /
					Setpoint
					1 ... 4

•mV/V calibration

•4 DI’s

•4 DO’s

•RS 485 bus, 115.2 kBaud

•Digital Filter (FIR and IIR)

•for static or dynamic weighing processes

•3 Firmware versions

LDM 88.1

LDM 88.1 Specifications

Linearity	< 0.002 % FS
Excitation	5 V DC,	load cells 100-2 000 Ohm, 6 wire technique
Analogue input range	±2.2 mV/V (bipolar)
Minimum input per vsi	0.05 μV per interval non approved
Resolution	±260 000 counts , ±18-Bit-A/D convertor
Conversion rate	2400 measurements per second intern
Digital Filter	FIR Filter 2.5 ... 19.7 Hz or IIR Filter 0.25 ... 18 Hz; programmable in 8 steps each
Calibration	software calibration and set up
Computer interface intern	RS485/RS422, full duplex, 115 200 Baud, bus capability up to 64 devices
Weighing functions	zero, gross, tare, net, filter etc.
Inputs	4 opto-isolated inputs, 10 ... 30 V DC max. 3 mA
Outputs	4 OC outputs, < 35 V DC, 500 mA
Temperature effects	on zero	5 ppm/°K typ.; max. < 10 ppm/°K
	on span	4 ppm/°K typ.; max. < 8 ppm/°K
Temperature range	–10 °C to +50 °C (operating); –30 °C to +80 °C (storage)
Enclosure	Aluminium, protection IP40
Dimensions	80 x 23 x 100 mm, with two M3 fixing screws for mounting on boards MB89.1/2/3/4
Power supply	12 ... 24 V DC ±10 %, < 60 mA,(reversed voltage, burst and ESD protected)
Power consumption	1,5 W max.
EMC	CE 73/23/EEC; 93/98/EEC and 89/336/EEC
Computer interface via Service Port MB 89.1	RS232C, 115 200 Baud
Vibration	withstands 1.0 G operational; 2.5 G non-operational

Manual MCS-64 Ethernet

Page 3

Contents

Part A: Modbus on Ethernet.........................................................................................			pages 6 - 13
Part B: Commands......................................................................................................			pages 14 - 35
Part C: MCS-64 Components and Configuration........................................................			pages 36 - 45
1.	Introduction...........................................................................................................................			6
	1.1.	Identification and Scope ................................................................................................		6
	1.2.	Purpose .........................................................................................................................		6
2.	System Design......................................................................................................................			6
	2.1	General..........................................................................................................................		6
	2.2	Backplane handling .......................................................................................................		6
	2.3	Ethernet Gateway..........................................................................................................		7
	2.3.1	IP Settings .................................................................................................................		7
	2.3.2	The Modbus port .......................................................................................................		7
	2.3.3 The ASCII entry port..................................................................................................			7
3	Ethernet Gateway Profile .....................................................................................................			8
	3.1	The Modbus Objects .....................................................................................................		8
	3.2	Communication Profile ..................................................................................................		8
4	Modbus Mapping ..................................................................................................................			9
	4.1	Modbus Register Map Overview ...................................................................................		9
	4.1.1	Gateway Register Map ..............................................................................................		9
	4.1.2	LDM Register Map...................................................................................................		10
5	COMMANDS ........................................................................................................................			14
	5.1	System diagnosis – ID, IV, IS ......................................................................................		15
	5.2	Calibration Commands – CE, CM, CI, DS, DP, CZ, CG AZ, AG, ZT, FD, CS.............		16
	5.3	Motion detection Commands – NR, NT.......................................................................		20
	5.4	Filter setting Commands – FM, FL, UR .......................................................................		21
	5.5	Set Zero/Tare and Reset Zero/Tare Commands – SZ, RZ, ST, RT ............................		23
	5.6	Output Commands – GG, GN, GT, GS .......................................................................		25
	5.7	Setpoint Commands - Sn, Hn, An ...............................................................................		26
	5.8	Trigger Commands – SD, MT, GA, TE, TR, TL...........................................................		28
	5.9	Trigger Special Commands– RW, TT, TS, DT, TW, TI, HT.........................................		31
	5.10	Save calibration, setup and setpoint parameters Commands – CS, WP, SS .............		34
	5.11	Filling Commands – PD1 to PD21, DI, SC, AC, GD, DT, SD ......................................		35
	5.12	Loss in Weight Commands – PL1 to PL5, LC, LI, GF, GR, GM, SL...........................		35
	5.13	Speed Estimation Multi-Channel System MCS-64 ......................................................		35

Page 4

Manual MSC-64: Modbus on Ethernet

6 MCS-64 Components and Configuration..........................................................................		36
6.1	Base Board MB 89.1 for 1 Gateway and 2 LDM 88.x..................................................	36
6.2	Extension Board MB 89.2 for 2 LDM 88.x ...................................................................	37
6.3	Extension Board MB 89.3 for 4 LDM 88.x ...................................................................	38
6.4	Extension Board MB 89.4 for 8 LDM 88.x ...................................................................	39
6.5	Address setup guide extension boards for 1 – 16 channels........................................	40
6.6	Address setup guide extension boards for up to 32 channels.....................................	41
6.7	Example Check Weigher Wiring..................................................................................	42
6.8	Example Liquid Filling Wiring ......................................................................................	43
6.9	LDM 88.1 – Digital Input / Digital Output - ...................................................................	44
6.10	Firmware Versions.......................................................................................................	45
6.11	DOP software for Windows 2000/XP...........................................................................	45

Manual MCS-64: Modbus on Ethernet

Page 5

1. INTRODUCTION

1.1.Identification and Scope

This document describes the system design for the Modbus on Ethernet (EGM 87.1) and up to 64 Load Cell Digitizing Modules (LDM88.x) using the Flintec backplane system. It describes the functionality of the backplane, the protocol used on the backplane and the Modbus mapping used to access the LDM88 modules via the EGM87 Gateway.

1.2.Purpose

The purpose of this document is to specify functionality and performance of the Gateway and the Load Cell Digitizing Modules (LDM88) with the available firmware versions (standard 88.183, filling 88.184, loss in weight 88.185).

2. SYSTEM DESIGN

2.1 General

This software connects an Ethernet network to the local backplane modules. The Gateway transports commands and responses from and to the Ethernet.

Ethernet

LDM and other IO

Up to 64 modules per backplane

Ethernet

Ethernet

ADAPTOR

ADAPTOR

BACKPLANE

Figure 1- ETHERNET Gateway in context

2.2 Backplane handling

The Gateway translates Modbus requests to local backplane requests and local backplane responses to Modbus responses. The Modbus is currently fixed to port 502 using an UDP/IP connection. Multiple register access through the Ethernet will produce multiple accesses on the local backplane. The PLC response timeout must allow 3.125 ms for each register access required.

However reading registers 2000 or 2004 will cache register 2060 also allowing the PLC to acquire the corresponding qualifier to the weight values.

Page 6

Manual MSC-64: Modbus on Ethernet

2.3 Ethernet Gateway

The Ethernet Gateway is using a 10/100baseT on RJ45 connection (IEEE 802.3u standard). The Gateway is essentially a server waiting for a node to connect to one of its services.

Application stacks:

	Modbus Application Layer		Setup
Port 502		Port 502	Port 23
MBAP		MBAP	-
TCP		UDP	TCP
IP		IP	IP
802.3		802.3	802.3

System stacks:

(echo / ping)	(Dynamic IP addr.)	(Address Resolution)
ICMP	DHCP	-
IP	IP	ARP
802.3	802.3	802.3

2.3.1 IP Settings

The IP address is set by connecting a terminal program (e.g. HyperTerm) to the DB9 service port on the MB 89.1 Base board. After the system is powered up it is possible to communicate with the Ethernet Gateway Module (EGM). After openening the gateway with command "OP 64" it is possible to set and/or examine the gateway settings with the address command:

Command

op64	opens serial communication to the gateway
ai 192.168.1.29	sets the gateway’s IP address to “192.168.1.29”
ai	selects a dynamic IP address (DHCP) for the gateway
a	reads current MAC address and IP address of the gateway

Example: op64 OK

a mac=00:50:C2:70:50:62 ip= DHCP

2.3.2 The Modbus port

[Port 502, TCP/IP (Modbus) or UDP/IP (Modbus)]

The Modbus is a simple Master-Slave connection; the master asks and the slave answers. Modbus over TCP or UDP is just another way of transporting Modbus communication. One of the registers will be used to define a streaming port. When a client connects to this user-defined port the gateway will scan the backplane and transmit the LDM data on a regular basis.

See Chapter 3 “Ethernet Gateway Profile” below.

2.3.3 The ASCII entry port

[Port 23, TCP/IP (Telnet)]

This entry is for simple setup and diagnostic use. It works as if you were connected to the service port except it goes through the Ethernet. The HyperTerm program in Windows can access the gateway in this manner. Refer to LDM 88.1 commands, see chapter 5.

Manual MCS-64: Modbus on Ethernet

Page 7

3 ETHERNET GATEWAY PROFILE

3.1 The Modbus Objects

All parameters and result data can be accessed in this way. Please note that many of the registers in the 2000 – 20FF range require a local backplane access cycle per register. Reading multiple registers in this range may produce a very long response time.

Below is the preliminary Modbus Map.

3.2 Communication Profile

The parameters which are critical for communication are determined in the communication profile. This includes the data for manufacturer's product nomenclature, for identification, or the parameters for object mapping.

Abbreviations used in the tables:

R	= read only
R/W	= read / write
W	= write only (read will not be regarded as an error, but returns undefined results)
UI16	= Unsigned16 (single register)
UI32	= Unsigned32 (register pair)
Int16	= Signed16 (single register)
Int32	= Signed32 (register pair)
Float	= 32 bit IEEE754 floating point (register pair)

Page 8

Manual MSC-64: Modbus on Ethernet

4 MODBUS MAPPING

The MBAP header “Unit Identifier” field is used to select a module in the backplane. Address 0 (zero) is reserved for broadcast. Address 1 to 64 is then used for direct communication with any LDM in the backplane using registers in the range 2000-2FFF (hex). Access to the gateway should use address 0xFF (255 dec) and registers in the range 3000-3FFF(hex).

Currently implemented function codes are:	Access
03	Read Holding Registers
04	Read Input Registers
06	Write Single Register
16	Write Multiple Registers
Used exception codes are:	Meaning
01	Illegal or unkown function code
02	Illegal data address or no response from LDM

4.1Modbus Register Map Overview

Register	Type	Size	Access Function
2000 – 2FFF				Selected LDM
3000 – 30FF				Gateway

4.1.1 Gateway Register Map

Register	Type	Size	Access	Function
3000	Int16	1	R/W	LDM selector [0..63]
3001	Int16	1	R/W	LDM multiple register selector.
3002	Int16	1	R/W	LDM multiple register mode
3003 – 300F	-	-			(reserved)
3005	Int16	1	R/W		Auto-Scan Control/Status
					Bit:
					15	10	9	2	1
					+------------+--------+-----+
					| Last scan	| unused | R/S |
					+------------+--------+-----+
3006	Int16	1	R/W	Auto-Scan Port (IP port no.)
3007	Int32	2	R/W		Auto-Scan Interval (ms)
3009 – 30FF					(reserved)
3100 – 31FF			R/W	Multiple register access across multiple LDM modules.
3200 – 32FF	Float	2+2+1	R	Multiple read of LDM packets
3300 – 33FF	Integer	2+2+1	R	Multiple read of LDM packets

Manual MCS-64: Modbus on Ethernet

Page 9

4.1.2 LDM Register Map

The register map for each LDM.

LDM overview

Register		Type	Size	Access	Function
2000	– 201F	Float	08 * 2	R/W	Data in Float Format
2020	– 205F	Int32	16 * 2	R/W	Data in Integer Format
2060	– 207F	Int16	08 * 1	RW	Control/Status functions
2080	– 20FF				(reserved)
2100	– 2FFF	-	-	R/W	Parameter pages

Data in Float Format

Register	Type	Size	Access	Data in Float Format
2000	Float	2	R	Gross weight
2002	Float	2	R	Net Weight
2004	Float	2	R/W	Tare
2006	Float	2	R	Dosed weight
2008	Float	2	R	Average weight

Data in Integer Format

Register	Type	Size	Access	Data in Integer Format
2020	Int32	2	R	Gross weight
2022	Int32	2	R	Net Weight
2024	Int32	2	R/W	Tare
2026	Int32	2	R	Dosed weight
2028	Int32	2	R	Average weight
202A	Int32	2	R	A/D sample
202C	Int32	2	R	Device ID
202E	Int32	2	R	FW Version
2030	Int32	2	R	Device Status
2032	Int32	2	R	ADC Reference

Control/Status Functions

Register	Type	Size	Access	Control/Status functions
2060	Int16	1	R	Measurement Qualifier Values:
				$0001 - Under range
				$0002 - Over range
				$0004 - Not within Zero range (not yet implemented, zero)
				$0008 - Exactly zero
				$0010 - No motion, still stand, steady state
				$0020 - Tare set
				$0040 - Preset tare (0=tare is measured, 1=tare is set by user)
				$0080 - Invalid weighing (wire-break, A/D ref. out of range)
				$0100 - Set-point 0 (source>limit)
				$0200 - Set-point 1
				$0400 - Set-point 2
				$0800 - Set-point 3
				$1000	- Filling in progress
				$2000	- Filling has completed
				$4000	- Average ready
				$8000	- Cold start

Page 10

Manual MSC-64: Modbus on Ethernet

2061	Int16	1	R/W		Bit commands. Functions regardless of the setting of the LDM
					selector register.
					Bit 1:	Reset Zero (RZ)
					Bit 2:	Set Zero (SZ)
					Bit 3:	Reset Tare (RT)
					Bit 4:	Set Tare (ST)
					Bit 5 – 7: unused
					Bit 8 –15: LDM#
					Write a “1” to activate function, reads as “1” until command done
2062	Int16	1	R/W		Trigger: Functions regardless of the setting of the LDM selector
					register.
					Write the LDM number to trig LDM;
					Write the LDM number + 80h(128 dec) to cancel measurements
					(LDM 88.183 only)
2063	Int16	1	R/W		Parameter page select. Valid values= [0..4].
					General parameter values
					Calibration parameter values
					Filling parameter values
					Check weigher parameter values
					Mass flow parameter values
2064	Int16	1	R/W		TAC access, see calibration page.
2065	Int16	1	R/W		START	/		ABORT	filling	process.
					Writing a Non-zero value starts filling process.
					Writing a zero ABORTS filling process.
2066	Int16	1	R/W		EEPROM functions:
					Bit 1:	Save analogue parameters (AS)
					Bit 2:	Save calibration (CS); TAC protected
					Bit 3:	Save general setup parameters (WP)
					Bit 4:	Save dosing parameters (SD)
					Bit 5:	Save setpoint parameters (SS)
					Bit 6 –14: unused
					Bit 15:	Factory default; TAC protected
2067	Int16	1	R/W		Set-point select [0..3]
2068	Int32	2	R/W		Set-point source
206A	Int32	2	R/W		Set-point hysteresis
206C	Int32	2	R/W		Set-point Value
206E	Int16	1	R		Read the dose info:
					Bit value Meaning
					$0001		Coarse valve open
					$0002		Fine valve open
					$0004		Dose program running
					$0008		Not used
					$0010		Not used
					$0020		Not used
					$0040		Tare out of range – no filling in this cycle
					$0080		Zero out of range
					$FF00		The High byte has the following interpretation:
							00= Idle
							01= Waiting for trigger(2nd trigger)
							02= Bottle on, calculating tare
							03= Pre-fill
							04= Main Filling
							05= Fine Filling
							06= In-flight delay
							07= Post fill calculations
							08= Post Filling

Manual MCS-64: Modbus on Ethernet

Page 11

Page 0 – General Parameter Values

Register	Type	Size	Access	General parameter values
2100	Int32	2	R/W	Analog action
2102	Int32	2	R/W	Analog high
2104	Int32	2	R/W	Analog low
2106	Int32	2	R/W	Filter setting
2108	Int32	2	R/W	Filter Factor
210A	Int32	2	R/W	Output status
210C	Int32	2	R/W	Input mask
210E	Int32	2	R/W	Measuring Time
2110	Int32	2	R/W	Filter mode
2112	Int32	2	R/W	No-motion range
2114	Int32	2	R/W	No-motion time
2116	Int32	2	R/W	Output mask
2118	Int32	2	R/W	Tare
211A	Int32	2	R/W	Start Delay
211C	Int32	2	R/W	Trigger Edge
211E	Int32	2	R/W	Trigger Level
2120	Int32	2	R/W	Update rate
2122	Int32	2	R/W	Zerotrack (TAC protected)
2124	Int32	2	R/W	dtime

Page 1 – Calibration Parameter Values

Register	Type	Size	Access	Calibration parameter values
2200	Int32	2	R/W	Absolute gain calibrate (32 bit Integer)
2202	Int32	2	R/W	Absolute zero calibrate (TAC protected)
2204	Int32	2	R/W	Calibrate enable
2206	Int32	2	R/W	Calibrate gain (TAC protected)
2208	Int32	2	R/W	Set calibration point B
220A	Int32	2	R/W	Set calibration point A
220C	Int32	2	R/W	Calibrate max (TAC protected)
220E	Int32	2	R/W	Calibrate min (TAC protected)
2210	Int32	2	R/W	Calibrate save (TAC protected)
2212	Int32	2	R/W	Calibrate zero (TAC protected)
2214	Int32	2	R/W	Decimal point (TAC protected)
2216	Int32	2	R/W	Display step size (TAC protect)

Page 2 - Filing Parameter Values

Register	Type	Size	Access	Filling parameter values
2300	Int32	2	R/W	Pre-fill mode
2302	Int32	2	R/W	Correction factor for in-flight value
2304	Int32	2	R/W	Zero Check Time
2306	Int32	2	R/W	Tare delay
2308	Int32	2	R/W	Tare Average Time
230A	Int32	2	R/W	Delay after pre-fill
230C	Int32	2	R/W	Blanking time
230E	Int32	2	R/W	In-flight delay time
2310	Int32	2	R/W	Filling Weight Average Time
2312	Int32	2	R/W	Zero tolerance
2314	Int32	2	R/W	Tare reference
2316	Int32	2	R/W	Tare tolerance
2318	Int32	2	R/W	Pre-fill level
231A	Int32	2	R/W	Fine-fill weight
231C	Int32	2	R/W	Filling weight
231E	Int32	2	R/W	In-flight value

Page 12

Manual MSC-64: Modbus on Ethernet

Register	Type	Size	Access	Filling parameter values
2320	Int32	2	R/W	Secondary pre-fill level
2322	Int32	2	R/W	Timeout value in milliseconds
2324	Int32	2	R/W	Underweight post-fill time
2326	Int32	2	R/W	Tare interval
2328	Int32	2	R/W	Bag Rupture Blanking

Page 3 – Check Weigher Parameter Values

Register	Type	Size	Access	Checkweigher parameter values
2400	Int32	2	R/W	Trigger Level
2402	Int32	2	R/W	Trigger Edge
2404	Int32	2	R/W	ReTrigWindow
2406	Int32	2	R/W	ReTrigTime
2408	Int32	2	R/W	HoldTime
240A	Int32	2	R/W	TareWindow
240C	Int32	2	R/W	TareTime
240E	Int32	2	R/W	ReTrigStop
2410	Int32	2	R/W	Measuring time
2412	Int32	2	R/W	Start delay
2414	Int32	2	R/W	dTime

Page 4 - Mass Flow Parameter Values

Register	Type	Size	Access	Mass Flow parameter values
2500	Int32	2	R/W	Decimal Point
2502	Int32	2	R/W	Scale values
						d/sec	d/min	d/hour
					x1	0	1	2
					x1.000	3	4	5
					x1.000.000	6	7	8
2504	Int32	2	R/W	dTime
2506	Int32	2	R/W	dWeight
2508	Int32	2	R/W	Delay after Refill

Page 5 - Mass Flow Control Values

Register	Type	Size	Access	Mass Flow parameter values
2600	Int16	2	R/W	Flow Control
2601	Int16	2	R/W	Flow Status

Page 6 - Mass Flow Results

Register	Type	Size	Access	Mass Flow parameter values
2700	Float	2	R	Mass Flow Value
2702	Float	2	R	Mass Flow Trend
2704	Float	2	R	Total Mass

Manual MCS-64: Modbus on Ethernet

Page 13

Part B

5 COMMANDS

These pages describe the ASCII commands as they must be used by the DOP software. For each command the corresponding Modbus register and data types are shown in brackets [ ] for reference.

5.1	System diagnosis – ID, IV, IS ......................................................................................	15
5.2	Calibration Commands – CE, CM, CI, DS, DP, CZ, CG AZ, AG, ZT, FD, CS.............	16
5.3	Motion detection Commands – NR, NT.......................................................................	20
5.4	Filter setting Commands – FM, FL, UR .......................................................................	21
5.5	Set Zero/Tare and Reset Zero/Tare Commands – SZ, RZ, ST, RT ............................	23
5.6	Output Commands – GG, GN, GT, GS .......................................................................	25
5.7	Setpoint Commands - Sn, Hn, An ...............................................................................	26
5.8	Trigger Commands – SD, MT, GA, TE, TR, TL...........................................................	28
5.9	Trigger Special Commands– RW, TT, TS, DT, TW, TI, HT.........................................	31
5.10	Save calibration, setup and setpoint parameters Commands – CS, WP, SS .............	34
5.11	Filling Commands – PD1 to PD21, DI, SC, AC, GD, DT, SD ......................................	35
5.12	Loss in Weight Commands – PL1 to PL5, LC, LI, GF, GR, GM, SL...........................	35
5.13	Speed Estimation Multi-Channel System MCS-64 ......................................................	35

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Manual MSC-64: Modbus on Ethernet