A/D Converter FAD-40 Technical Manual Flintec GmbH Bemannsbruch 9 74909 Meckesheim GERMANY www.flintec.com FAD-40 Technical Manual, Rev. 1.
Table of Contents: 1. SAFETY INSTRUCTIONS ...........................................................................................................................4 2. DECLARATION OF CONFORMITY ...........................................................................................................5 3. 3.1. 3.2. 3.3. 3.4. INTRODUCTION .........................................................................................................................................6 Overview ..................
10. FAD-40CO – WITH CANOPEN INTERFACE ...........................................................................................47 10.1. Front View ..............................................................................................................................................47 10.2. Electrical Connections ............................................................................................................................48 10.3. Interfacing.............................................
1. SAFETY INSTRUCTIONS CAUTION READ this manual BEFORE operating or servicing this equipment. FOLLOW these instructions carefully. SAVE this manual for future reference. DO NOT allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment. ALWAYS DISCONNECT this equipment from the power source before cleaning or performing maintenance. CALL FLINTEC ENGINEERING for parts, information, and service. WARNING ONLY PERMIT QUALIFIED PERSONNEL TO SERVICE THIS EQUIPMENT.
2.
3. INTRODUCTION 3.1. Overview The type FAD-40 A/D Converter Series consists of powerful and economic state-of-the-art instruments for static and dynamic weighing applications plus force and torque measurements including digital I/O control. Each instrument of the series converts the analogue low level signal from a load cell or a strain gauge sensor to a digital high-resolution and high-accuracy signal and transmits the digital data to an external PLC or PC system.
FAD-40PB FAD-40PN FAD-40EN FAD-40CO Bipolar signal input in Force and Count modes 500 to 100 000 counts external resolution at calibrated data Unipolar 1 million and bipolar 2 million counts is adjusted and filtered to external resolution in count mode High internal resolution up to 8 million counts Up to 800 conversions per second 2 digital inputs/outputs + 1 additional digital outp.
Communication and Setup: RS232C with 9600 baud (8,N,1); for FAD-40 and FAD-40MB: RS485 with up to 57600 baud (8N1, 7E1, 7O1) Depends on instrument type < 4 ms (delay after each read or write command) By PC software via RS232C respective RS485, backup data stored on PC Serial interface Other interfaces Response time Setup and calibration Digital Inputs + Outputs Selectively configured as input (10...26 V DC) or open collector output (24 V DC, max. 100 mA) Open collector output (24 V DC, max.
Instrument with CANopen interface: Type FAD-40CO Communication: CANopen V.2.0 Address range Dimensions & weight 10 kbit/s...1 Mbit/s (automatic), galvanically isolated interface 1...126 99 x 45 x 114.5 mm (L x W x H), weighs appr. 150 g 3.3. Housing FAD-40 instruments come within a polyamide housing sealed to IP20. They are prepared for mounting on NS 37/7 or NS 35/15 standard DIN rails (see drawings).
4. INSTALLATION PRECAUTION: Please read this manual carefully before you install the instrument. If you apply all recommendations in this chapter you will increase the reliability and long term performance of your system. 4.1. Recommendations 4.1.1. Control Cabinet Design Warning: Please follow the following warnings for designing the control cabinet which will increase the reliability of your system. The control cabinet should be designed therefor the A/D converters can operate safely.
poor ground can result in an unsafe and unstable operation. It is important that the instrument should not share power lines with noise-generating equipment such as heavy load switching, motor control equipments, inductive loads, etc. If the condition of the power line in the plant is poor, prepare a special power line and grounding. Before interfering the instrument, turn off the power and wait at least for 30 seconds. 4.2.2.
4.2.4. Communication Interface Please refer to the corresponding chapter: FAD-40 (RS485) FAD-40MB (Modbus RTU) FAD-40PB (Profibus) FAD-40PN (ProfiNet) FAD-40EN (Ethernet and Modbus TCP) FAD-40CO (CANopen) see chapter 6.2 see chapter 6.2 see chapter 7.2 see chapter 8.2 see chapter 9.2 see chapter 10.2 4.3. Commissioning PRECAUTION: Please read this manual carefully before energizing the instrument. Perform the commissioning operation according the procedure given in this chapter.
5. SETUP PRECAUTION: Please read this manual carefully before energizing the instrument. Perform the commissioning according the procedure given in chapter 4.3. Only trained person are allowed for commissioning, checking, cleaning and servicing of the instrument. The interference of untrained person may cause some unwanted damages or injures. FAD-40 series instruments are setup and calibrated by the xFace software supplied with the instrument.
5.3. A/D Converter Setup and Calibration WARNING: Read this manual carefully before you setup and calibrate the instrument. This will increase the performance of your weighing system by applying proper setup and calibration. Visual Weight Display: Displays the weight, count or force value Toolbox: Contains shortcuts of some special commands A/D Converter Parameters: This block allows the user to setup the A/D Converter‟s parameter related to the operation mode. Refer to chapter 5.3.
Motion Detection This parameter defines the motion detection window which determines a stable weighing. If motion detection is not required, this parameter can be disabled. The available motion detection window values are: Weighing and Force Mode: Disable ± 0.3e ± 0.5e (default setting) ± 1e ± 2e ± 60 ± 100 (default setting) ± 200 ± 400 Count Mode: Disable Power On Zero This parameter enables automatic zeroing after powering on the instrument.
Checksum The checksum can be enabled or disabled within BSI data format. The checksum calculation can be found in the related data format description. Default setting: „Enable‟. Baud Rate One of the following baudrate will be selected for the RS-485 communication port. 1200 19200 2400 38400 4800 57600 9600 (default setting) Data Length and Parity The data length and parity can be selected as 8 None 1 (default), 7 Odd 1 or 7 Even 1. Address The address range is 01 (default) to 31.
Select the scale operation mode and the polarity. Then click the “Write to A/D Converter” button to save your mode selection. The default calibration of FAD-40 instruments is Count Mode and 10 mV unipolar input signal range. If you select the Count Mode, there is no scale build and instrument calibration. Each FAD-40 instrument is adjusted for high accuracy during the production. The FAD-40 input signal ranges and their external resolutions are shown in Table 5.1.
Span Adjustment If your scale has a span drift, you may perform a span adjustment only. After selecting “Span Adjustment” and pressing the “Start” button, enter the test weight value; place the test weights on the scale and press the “Yes” button. The [WAIT] message appears on the virtual display approximately for 5 seconds while the span calibration is being performed. After finalizing the span adjustment, the instrument will save the span coefficients automatically.
I/O1: Select function and polarity for I/O1 (output only) I/O2: Select function and polarity for I/O2 Select function and polarity for I/O3 I/O3: Setpoint entries: Enter setpoints. Setpoint1 for I/O1, setpoint 2 for I/O2 and setpoint3 for I/O3. Figure 5.7 – Digital I/O Setup Setup of Digital Output Function I/O1, I/O2 and I/O3 can be set up with the output functions described below. Standard output (Setpoint without hysteresis): Only one value is entered.
5.6. Bus Interface Setup FAD-40 instruments have a bus interface and these parameters have to be setup before the bus will be connected. Bus communication settings are done in the Gateway tab. Bus communication parameters and their descriptions can be found in the related instrument chapters.
5.9. BSI Data Structure (for FAD-40 and FAD-40MB only) Depending on their functionality all new generation Flintec instruments launched on the market support the standardized command set with BSI data structure. This easy data format gives a reliable and fast interface for communicating with PLC or PC for process control or transactional applications. You can expand your system with additional scales from Flintec without having to change your application program base. General Rules: 1. 2. 3. 4.
Commands and Responses A Command: Response: Example: Read all weight data [ADR][A] [ADR][A][STATUS][SIGN][NET W][SIGN][TARE W][SIGN][GROSS W] Command : Response : Comments: B Command: Response: Example: 01A 01AS+000123.4+000111.1+000234.5 01AD+000123.4+000111.1+000234.5 01AO ( ADC out error ) The response is net, tare and gross weight values or error status. All weight data will be transmitted immediately after receiving the command.
Q Command: Response: Example: Load setpoints [ADR][Q][SP NUMBER][SP TYPE][SIGN][SP VALUE] [ADR][Q][A] Command: Response: Comments: R Command: Response: Example: 01Q01L+000123.4 01QA (123.4 loaded to SP1_L) 01QN (could not load) 01QU (Mismatch of decimal point of SP VALUE) SP No is 2 byte ASCII char. Use 01 for SP1, 02 for SP2 and 03 for SP3. SP Type is 1 byte ASCII char. Use “L” for SPx_L and use “H” for SPx_H. SP VALUE data is 8-byte ASCII char with dot and non-significant zeros on the left.
V Command: Response: Example: Read digital outputs [ADR][V] [ADR][V][A][OUTPUTS] Command: Response: Comments: OUT-3 0 3 OUT-1 1 01W3 01WA3 01WN (Output 1 and output 2 will be set active) (could not set/reset outputs) . Outputs Bitwise ASCII X Command: Response: Example: OUT-2 1 Set/reset digital outputs [ADR][W][OUTPUTS] [ADR][W][A] Command: Response: Comments: (Output 1 and output 2 are active) (could not read outputs) .
5.10.
Address R/W Word Command 40015 R/W 1 mV operation in Count Mode 40016 R/W 1 Digital filters 40017 40018 1 R/W 1 Definition 0 1 2 3 0 1 2 3 4 5 6 7 8 9 Status of Digital I/O D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D7 R/W 1 Setup for I/O1 and I/O2 D8…D14 D15 D0…D6 40020 R/W 1 Medium Default Slow Not used D0…D6 40019 5 mV 10 mV 15 mV 18 mV Fast Setup for I/O3 D7 FAD-40 Technical Manual, Rev. 1.
Address 40021 40023 40025 40027 40029 40031 R/W R/W R/W R/W R/W R/W R/W Word 2 2 2 2 2 2 Command Description Setpoint 1 Low for I/O1 Setpoint 1 High for I/O1 Setpoint 2 Low for I/O2 Setpoint 2 High for I/O2 Setpoint 3 Low for I/O3 Setpoint 3 High for I/O3 40033 R/W 1 Save I/O settings 23205 (Dec) Load 23205 to save and activate I/O settings and setpoints Note: Standard setpoint output function uses only setpoint low.
5.11.
FAD-40Px Output to PLC Input 3rd Dword Bit no.
PLC Output to FAD-40Px Input Dword D31 D15 D30 D14 D29 D13 D28 D27 D12 D11 D26 D10 D25 D9 D24 D8 D23 D7 D22 D6 D21 D5 D20 D4 D19 D3 D18 D2 D17 D1 D16 D0 st 1 Dword Reserved W31 W30 W29 W28 W27 W26 W25 W24 W23 W22 W21 W20 W19 W18 W17 W16 nd MSB 2 Dword W0 W15 W14 W13 W12 W11 W10 W9 W8 W7 W6 W5 W4 W3 W2 W1 LSB rd 3 I/O3 I/O2 I/O1 Not in use Dword out out out New Not in use Command List Data Selection CMD PLC Output to FAD-40Px Input 2nd Dword nd The 2 Dword contains the setting / paramete
PLC Output to FAD-40Px Input 3rd Dword Bit no. D31…D19 D18 D17 D16 D15…D11 D10…D6 D5...
5.12.
FAD-40CO Output to PLC Input T_DW3 Bit no.
PLC Output to FAD-40CO Input Dword D31 D15 D30 D14 D29 D13 D28 D27 D12 D11 D26 D10 D25 D9 RxPDO 1 (R_DW1) D24 D8 D23 D7 D22 D6 D21 D5 D20 D4 D19 D3 D18 D2 D17 D1 D16 D0 Reserved W31 W30 W29 W28 W27 W26 W25 W24 W23 W22 W21 W20 W19 W18 W17 W16 RxPDO 2 MSB (R_DW2) W00 W15 W14 W13 W12 W11 W10 W9 W8 W7 W6 W5 W4 W3 W2 W01 LSB I/O3 I/O2 I/O1 Not used out out out RxPDO 3 (R_DW3) New Not used Command List Data Selection CMD PLC Output to FAD-40CO Input R_DW2 R_DW 2contains the setting / parameter
PLC Output to FAD-40CO Input R_DW3 Bit no. D31…D19 D18 D17 D16 D15…D11 D10…D6 D5...
6. FAD-40 / FAD-40MB – WITH RS-485 INTERFACE FAD-40 and FAD-40MB instruments are state-of-the-art strain gauge load cell signal digitizers with RS-485 interface. These instruments are used for any type of process weighing and force measurement including tank and silo weighing, dynamic weighing, check weighing, filling, tension /compression force measurement etc. 6.1. Front View There are 3 status LEDs on the front panel which indicate the operational instrument status (Refer to table 6.1).
6.2. Electrical Connections RS-485 connection is shown in figure 6.2. Figure 6.2 – FAD-40 / FAD-40MB serial interface connection RS-485 Serial Interface Use Data format Baud rate Length and parity Start / Stop bits Interfacing with PC or PLC, setup via xFace BSI (default for FAD-40), Modbus RTU (for FAD-40MB only, default) 1200 / 2400 / 4800 / 9600 (Default) / 19200 / 38400 / 57600 bps 8 None 1 (default), 7 odd 1, 7 even 1 1 start bit and 1 stop bit Warning: Connect the shield to the reference ground.
7. FAD-40PB – WITH PROFIBUS INTERFACE FAD-40PB instruments are state-of-the-art strain gauge load cell signal digitizers with Profibus DP interface. These instruments are used for any type of process weighing and force measurement including tank and silo weighing, dynamic weighing, check weighing, filling, tension /compression force measurement etc. The GSD file is available on a CD which is supplied together with the instrument. 7.1.
ST Status LED State Off Green Flashing Green Red Indication No power or not initialized Initialized Initialized, diagnostic event(s) present Exception error Comment No power or profibus module is in initializing Diagnostic is active There is an exception error OP Operation Mode LED State Off Green Flashing Green Flashing Red (2x) Indication Not on-line / No power On-line, data exchange On-line, clear PROFIBUS configuration error Comment Check power and cable Check GSD file configuration. 7.2.
Load Cell Connection See chapter 4.2.2 Digital I/O Connection See chapter 4.2.3 Power Supply Connection: See chapter 4.2.1 7.3. Interfacing FAD-40PB instruments have two interface connectors on the front of the instrument: Profibus and RS-232C. The table below describes the data formats for interfacing the peripherals and their application. Data Format Profibus Description Profibus interfacing. Refer to chapter 5.12 Application Interfacing with PLC Hardware Profibus-DP-V1 Table 7.
8. FAD-40PN – WITH PROFINET INTERFACE FAD-40PN instruments are state-of-the-art strain gauge load cell signal digitizers with ProfiNet interface. These instruments are used for any type of process weighing and force measurement including tank and silo weighing, dynamic weighing, check weighing, filling, tension /compression force measurement etc. The EDS file is available on a CD which is supplied together with the instrument. 8.1.
MS Module Status LED LED State Description Off No power or not initialized Green Green, 1 flash Initialized Initialized, diagnostic event(s) present Green, 2 flashes Blink Red Red, 1 flash Red, 2 flashes Red, 3 flashes Exception error Configuration error IP address error Station name error Red, 4 flashes Internal module error Comment No power or ProfiNet module is in initialization state Diagnostic is active Used by engineering tools to identify the node on the network There is an exception erro
See chapter 4.4.2 Digital I/O Connection See chapter 4.2.3 Power Supply Connection See chapter 4.2.1 8.3. Interfacing FAD-40PN instruments have two interface connectors on the front of the instrument: ProfiNet and RS-232C. The table below describes the data formats for interfacing the peripherals and their application. Data Format ProfiNet Description ProfiNet interfacing. Refer to chapter 5.12 Application Interfacing with PLC. Hardware ProfiNet Table 8.
9. FAD-40EN – WITH ETHERNET INTERFACE FAD-40EN instruments are state-of-the-art strain gauge load cell signal digitizers with Ethernet interface. These instruments are used for any type of process weighing and force measurement including tank and silo weighing, dynamic weighing, check weighing, filling, tension /compression force measurement etc. 9.1. Front View There are 3 status LEDs on the front panel which indicate the operational instrument status (Refer to table 9.1).
9.2. Electrical Connections Ethernet and RS-232C connections are shown in figure 9.2 to 9.4.
Load Cell Connection See chapter 4.2.2 Digital I/O Connection See chapter 4.2.3 Power Supply Connection See chapter 4.2.1 9.3. Interfacing FAD-40EN instruments have two interface connectors on the front of the instrument: Ethernet and RS-232C. The table below describes the data formats for interfacing the peripherals and their application: Data Format Modbus TCP/IP Description Ethernet interfacing. Refer to chapter 5.11 Application Interfacing with PLC Hardware Ethernet Table 9.
10. FAD-40CO – WITH CANOPEN INTERFACE FAD-40CO instruments are state-of-the-art strain gauge load cell signal digitizers with CANopen interface. These instruments are used for any type of process weighing and force measurement including tank and silo weighing, dynamic weighing, check weighing, filling, tension /compression force measurement etc. The EDS file is available on a CD which is supplied together with the instrument. 10.1.
RUN LED State Off Green Green, flashing Green, single flash Green, flickering Red Indication No power or not initialized On-line, data exchange On-line, initializing Stopped Auto baud rate detection in progress Exception error Comment No power or cable broken Check for hardware damages Check EDS file ERR LED State Off Red, single flash Red, flickering Indication No error Warning limit reached LSS Red, double flash Error count event Red Bus off (fatal event) Comment No power or CANopen module is in
CANopen Interface Use Data format Interfacing with PC or PLC CANopen Automatically detected and supported baud rates are 10 kbps, 20 kbps, 50 kbps, 100 kbps, 125 kbps, 250 kbps, 500 kbps, 800 kbps, 1 Mbps; Autobaud is default setting. Baud rate Warning: Connect the shield to the reference ground or shield pin of the power connector. Warning: Disconnect xFace PC software for Profibus interfacing. Load Cell Connection See chapter 4.2.2 Digital I/O Connection See chapter 4.2.
11. ERROR TABLE The FAD-40 A/D Converters have been designed as very reliable and virtually error free instruments. However if an error occurs do not attempt to repair the equipment before you understand what caused the error. Note the problems you have with your instrument and the error messages shown by the LEDs located on the front panel. Then try to solve the problem according to the error table given below.
12. DIAGNOSTICS In this test menu serial interface tests (RC-232C and/or RS-485) and load cell signal analog to digital conversion and processing tests are performed sequentially. For entering the diagnostics mode, press the setup switch before power on and release the switch after the instrument is powered on. The instrument will go into the RS-232C RXD test mode which is indicated by lighted LED and flashed Err LED as shown below.
13. FREQUENTLY ASKED QUESTIONS Question : Answer : Question : Answer : Question : Answer : Question : Answer : Question : My PC has a COM port but I cannot see any COM port in the Connection Setting menu. How can I solve that problem? Answer : Another software may be connected to that COM port. Close all applications before you start xFace. Question : Answer : My PC cannot interface with FAD-40. How can I check the COM ports? Short circuit the RXD and TXD pins of your COM port.
