Prologic PL101 Configuration

Transcription

1 Application Note Prologic PL101 Configuration Introduction The SKF Multilog On-line System DMx is designed as a hazardous area approved device. In the design restrictions for the use in a hazardous area, no 4 to 20 ma outputs were possible. Since most Distributed Control Systems (DCS) use digital communication methods as the main interfacing method, the system is designed to use protocols like the Modbus-RTU, Profibus or similar to retrieve values and status from the SKF Multilog DMx. There are still some systems where an analog input is required. Typically, the request is for a 4 to 20 ma signal. To fulfill this request for these analog outputs, an additional mini PLC (programmable logic controller) and analog output converter can be ordered. These devices can be configured for a variety of SKF Multilog DMx configurations. The description below should be used as a guideline to set up the mini PLC type PL101 in combination with the SKF Multilog DMx. Hardware Based on the type of installation, the hardware listed below is the minimum that should be included in the offer as a minimum. This setup is minimal and should be installed in a safe environment. When used for hazardous area installations, additional barriers and certified power supplies are required. Sensors and/or eddy current probes 4 CH SKF Multilog DMx, CMMA 9910/9920 Anybus Modbus RTU Gateway, CMMA Prologic PL101 controller Prologic PL8AO converter +9 V DC Power supply, CMMA 9130 for SKF Multilog DMx +24 V DC Power Supply, CMMA 9170 for other components

2 Component overview A connection diagram is included on page 9 of this application note. Due to the flexible configuration of the SKF Multilog DMx and the variables in the customer requests for the 4 to 20 ma output, each of the components needs to be configured. The configuration of the components, the CMMA 9910 or CMMA 9920 SKF Multilog DMx, the CMMA Gateway and the Prologic PL101 each uses its own setup program. The logical flow is to configure the CMMA 9910 or CMMA 9920 SKF Multilog DMx first. Configure the CMMA Gateway as a second step and then configure PL101 as the last step in the process. Configuration SKF Multilog DMx Fast Message Independent of the DMx Manager configuration, the DCS Fast Message configuration, CFDT, determines what measurements will be sent over the SKF RS-485 communication. These 14 parameters will be available in Modbus and have to be configured with their correct detection type and full scale values. The DCS CFDT is configured using the DMx Toolbox software. This software is part of the DMx Manager installation. In the Configuration tab of the DMx Toolbox, select the DCS CFDT Setup to configure the channels. Fig. 1. DMx Toolbox DCS CFDT. Fig. 2. DMx Toolbox DCS configuration. 2

3 The DCS CFDT measurement output (15 bit signed) will be scaled to the configured full scale value. Example: Ch 1 Vibration value = 600 μm pk-pk Ch 1 Full scale = 1000 Modbus value = int{(600 / 1000) (2 15 1)} = CMMA Modbus RTU configuration A full description of the CMMA configuration is available in the CMMA _INSTALLATION_MANUAL.pdf document. In this example, only SKF Multilog DMx Device 1 is used. An extract of the typical Modbus table for SKF Multilog DMx 1 with its corresponding addresses is shown below. Extract of the typical Modbus table for DMx 1 with corresponding addresses DMx Configuration Modbus RTU Gateway Prologic PL101 Controller Full scale Data Function DMx 1 Status 1 Gateway Status 0 Status 2 Rx/Tx Counters 1 Status 3 DMx Alarm 1 2 (Hi) Status 4 DMx Alarm 2 2 (Lo) Status 5 DMx Alarm 3 3 (Hi) Status 6 DMx Alarm 4 3 (Lo) Status 7 DMx Alarm 5 4 (Hi) Load Address from Modbus with 16 bit value Shift 16-bit (or 2x bipolar 15 bit) value by 3 bits Reserved Data 1 CFDT1 - Status Reserved Data 2 CFDT2 - Control Speed Data 3 CFDT3 - User Ch 1 DC (V) 24 Data 4 CFDT4 - User Ch 2 DC (V) 24 Data 5 CFDT5 - User Ch 3 DC (V) 24 Data 6 CFDT6 - User Ch 4 DC (V) 24 Data 7 CFDT7 - User Ch 1 DC (μm) 2500 Data 8 CFDT8 - User Ch 2 DC (μm) 2500 Data 9 CFDT9 - User Ch 3 DC (μm) 2500 Data 10 CFDT10 - User Ch 4 DC (μm) 2500 Data 11 CFDT11 - User Ch 1 (μm pk-pk) 1000 Data 12 CFDT12 - User Ch 2 (μm pk-pk) 1000 Data 13 CFDT13 - User Ch 3 (μm pk-pk) 1000 Data 14 CFDT14 - User Ch 4 (μm pk-pk) 1000 Data 15 CFDT15 - User spare Data 16 CFDT16 - User Reserved Reserved Write new 12 bit value to Address Table 1 The first columns correspond with the settings of the SKF Multilog DMx DCS CFDT as discussed above. When the SKF Multilog DMx measures the value of 600 μm, the value of will be written to the CFDT12 (-User 10) position in the Gateway. The Gateway stores the information in register address 43 for this value and makes it available for other devices to read (like a PL101 PLC). If a device requests the data from Gateway register address 43, the Gateway will return the value This value, together with the SKF Multilog DMx CFDT programmed full scale, can be converted to a vibration value of 600 μm. 3

4 Prologic PL101/8AO The PL101 PLC is a compact controller with a combination of communication ports. The fact that the controller is programmable enables the user to program their own requirements. The Prologic I/O modules plug into each other and the module on the left plugs into the PL101. Up to eight modules can plugged together. The PL101 PLC is programmed in ladder logic. The Procon s ProSoft windows-based PC software is used to generate the ladder diagram, compile the program and then download the program to the PL101 via the Ethernet port on the front of the unit. The software can be downloaded via: Programming-Software-Version-2-0.aspx The PL101 includes a web server which enables access to internal parameters for configuration. This allows configuration of IP address, default gateway IP address and subnet mask. The web server can be accessed by most web browsers. The PL101 supports the FTP protocol, which enables the web pages to be customized if required. The PL101 is factory programmed with a default IP address of This address must be changed before the converter is added to an existing network. The web page address for viewing the setup parameters is: The web page address for configuring the converter is: The master device which is polling the PL101 must be configured with the IP address of the PL101 and with the Modbus ID of the PROLOGIC modules. The Modbus ID of the PL101 is 0 (zero). The PL8AO is an eight channel current output module. Each channel can be set to output a current in the range of 0 to 20 ma. The outputs are isolated from the logic and share a common negative terminal. The resolution is 12 bits, so writing a value to the Modbus register for each output of 0 to 4095 would give an output current of 0 to 20 ma. A value of 819 ±1 LSB will give a current output of 4 ma. ProSoft configuration Once the communication with the Configuration PC has been set up, the correct parameters can be downloaded to the PL101. In the example below, the system defaults are used as much as possible. The actual Modbus communication parameters like baud rate and parity depend on the Gateway configuration. The addresses and registers are derived from the CMMA installation manual. The PL101 will read 16 registers from the gateway (one block of 16 registers has been configured by the Fast Message data). The block of data starts at CMMA Modbus address 32 (DMx ID = 1). See fig. 5 for the configuration of the Modbus read data block. This block of data will be written to address location 401 to 416 of the PLC and then converted from 15 bit into 12 bit format, because the PL8AO module will only accept 12 bit data. This 12 bit value will be written to memory location 508 to 516, from which the PL8AO converter reads its data. The Ladder program to convert the 15 bit values to a 12 bit value is shown on the following pages. Two variants of the Ladder program are shown. The first type is the unipolar version. In this version, the 15 bit value is read and then shifted right three times to get a 12 bit number. Fig. 3. PL101 programming address. Fig. 4. PL8AO output. 4

5 Fig. 5. Modbus transfer configuration. Fig. 6. Modbus communication parameters. Fig. 7. I/O module switch settings. Fig. 8. I/O module setup. 5

6 Simple Ladder program The Ladder program is created using the PL101 Configuration program. 6

7 7

8 Special bipolar setup In case of bipolar measurements, like axial position, one additional bit is required for the polarity. Programming the PL101 is done like the above examples, except that the value has to be shifted with an extra bit (4 bits) and a value of has to be subtracted from the original Modbus value, like the next example for the first PL8AO output. 8

9 Calculation example (Also see table 1 for the Modbus-RTU table.) 16 bit = 2 16 = or as bipolar value: to Normal vibration measurement The vibration value from the previous example (600 μm) will be represented as Modbus value: int{(600 / 1000) 32767} = (decimal) or The Prologic PL8AO has a 12 bit resolution. We have to shift the above value to the right (with 3 bits) to get the most significant bits; the next value will be sent to the PL8AO: (this is 2457 on a scale of 4096). This result will be written to address 512 in the PL101 and then sent to the PL8AO, where it generates an output of: 2457 / = 13.6 ma Bipolar axial position measurement If a bipolar measurement is expected, the Prologic value has to be subtracted with 2 15 and shifted with 4 bits for the polarity and the value has to be shifted 4 bits. Assuming a value of 0.6 mm on a scale from 1 to +1 mm: int{( 0.6 / 1) 32767} = (decimal) or (binary) = or (decimal) The Prologic PL8AO has a 12 bit resolution. We have to shift the above value to the right (with 4 bits) to get the most significant bits; next value will be sent to the PL8AO: (this is 819 on a scale of 4096). This result will be written to address 508 in the PL101 and then sent to the PL8AO, where it generates an output of: 819 / = 7.2 ma Communication and power connections Table 2 Communication and power connections Communication link DMx Modbus RTU Gateway Master Modbus RTU Gateway Slave Prologic PL101 PLC Prologic PL8AO Signal Type RS485 + B RS485 A Power +24 V DC gnd

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