Meter Proving Module Cat. No. Quantum Automation Series 140 MPM 204 00sc - 4 Channel Installation Instructions Owners Guide 0300190-01 Rev.
Meter Proving Module Preface Read this preface to familiarize yourself with the rest of the manual. This preface covers the following topics: • What this guide covers • Who should use this guide • Contents of the guide • Related publications • Conventions used in this guide What this Guide Covers This guide describes the hardware and firmware included in the 4- and 8-channel Quantum™ Counter/Flow Meter modules for the Schneider Automation Series Quantum PLC.
Quantum Series 140 MPM 204 00sc Related Documentation The table below lists a number of reference documents that provide information to assist you when working with one of the Quantum counter modules.
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Contents 11Chapter Chapter .................................................................................................................... 11 Overview ........................................................................................................................................................... 11 General Description ......................................................................................................................................... 11 Hardwar es .........................
Meter Proving Module 1Chapter Overview This chapter describes the 4-channel Quantum Meter Proving Module (called “MPM ” in this document). It also explains how the Schneider Automation Series Quantum PLC reads input data from a Quantum module. Shipped with your module is an MS-DOS formatted floppy disk titled “Quantum Runtime Files,” Spectrum Controls, Inc. The disk contains runtime files that are required to use all versions of this module.
Quantum Series 140 MPM 204 00sc Meter Input Modes The flow meter mode is compatible with a variable reluctance AC input, which counts AC zero crossing signals from 50 mV to 75V AC peak. The module accepts +5 to +45 V gating (enable) pulses for standard meter proving applications. This module does perform pulse interpolation for meter proving allowing short run prover verification. The module also has external inhibit/trigger lines using a 5V discrete pulse to regulate activity.
Meter Proving Module Hardware Features The Quantum counter module contains a removable Modicon 40-pin terminal block providing connections for up to eight input devices. The illustration below shows the hardware features of the module. The module supports these input types: • AC (50 mV to 75V peak) • 5VDC • 12VDC • 24VDC Both rate and count data are simultaneously available to the user. User selectable instantaneous or average rate modes are supported.
Quantum Series 140 MPM 204 00sc Hardwar Hardwaree Door (removable) Door label LED indicators Description Covers the terminal block and includes an identification label for terminals. Permits easy terminal identification. Display operating and fault status of module. Details are provided in “Diagnostic LEDs”. Provides module identification. Secure module in rack slot. Used for field wiring the module.
Meter Proving Module Table 1-3 Blink Codes for Fault LED Code (Number of Blinks) Off 1 2 3 4 5 6 7 8 9 10 Err or Type Error No Faults Dual Port RAM fault. FPGA init fault. FPGA1 program fault. FPGA2 program fault. FPGA1 fault. FPGA2 Fault. Watchdog Fault. ROM CRC fault. EEPROM fault. Both Speed mode and Autosequence mode selected (Mutually exclusive) Recommended Cables To minimize interference from radiated electrical noise, we recommend twisted-pair and shielded cables.
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Meter Proving Module 2Chapter Installation and W iring Wiring This chapter includes information about: • Module compliance with safety standards • Power requirements • Installation considerations, such as prevention of electrostatic discharge • Installing the module • Field wiring of the module and analog input devices Compliance with Safety Standards The module is compliant with the safety standards described in this section. It is intended for use in an industrial environment.
Quantum Series 140 MPM 204 00sc Low V oltage Directive Voltage This product is tested to meet Council Directive 73/23/EEC Low Voltage, since it operates with inputs under 75 VDC and 50VAC rms. It applies the safety requirements of EN 61131-2 Programmable Controllers, Part 2 – Equipment Requirements and Tests. For specific information required by EN 61131-2, see the appropriate sections in this publication. Power Requirements The module receives power through the PLC backplane from the +5VDC power supply.
Meter Proving Module Reducing Noise Most applications require installation in an industrial enclosure to reduce the effects of electrical interference. Electrical noise, to which analog inputs and outputs are highly susceptible, will reduce the performance (accuracy) of the module. Selecting a Location WARNING EXPLOSION HAZARD This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D or nonhazardous locations only.
Quantum Series 140 MPM 204 00sc • Routing field wiring in a grounded conduit can reduce electrical noise. • If field wiring must cross AC or power cables, ensure that they cross at right angles. • If multiple power supplies are used with analog inputs, the power supply commons must be connected. • To ensure optimal accuracy, limit overall cable impedance by keeping a cable as short as possible. Locate the module as close to input devices as the application permits. • Tighten terminal screws with care.
Meter Proving Module Inserting the Module in the PLC Rack Do the following to place the module in the PLC rack: 1. Ensure that the rack is properly grounded and installed in a NEMA-rated enclosure. 2. Disconnect all power to the module, and disconnect it from any connected devices. See “ Removing Power.” WARNING Installation or removal of the module with power applied can cause an electrical arc.
Quantum Series 140 MPM 204 00sc Removing and Replacing the T erminal Block Terminal When wiring the module, it is not necessary to remove the terminal block. However, if necessary, you can use this procedure for removal and replacement. 1. Loosen the upper and lower retaining screws, alternating between screws. The terminal block backs away from the module as you remove the screws. 2. Carefully pry the terminal block loose. 3.
Meter Proving Module Wiring the T erminal Block Terminal The module terminal block has eight shield terminals provided as frame ground connections for input wire shielding. There are 8 counter enable lines that are compatible with 5, 12, and 24 VDC inputs. If pulled low with one of these inputs, a channel is disabled. The enable is internally pulled high.
Quantum Series 140 MPM 204 00sc Pin 1 Channel 1 Hi Channel 2 Hi Pin 2 Pin 3 Channel 1 Lo Channel 2 Lo Pin 4 Pin 5 Channel 1 Shield Channel 2 Shield Pin 6 Channel 2 Enable Pin 8 Pin 7 Channel 1 Enable Pin 9 N/C N/C Pin 10 Pin 11 Channel 1 Gate Hi Channel 2 Gate Hi Pin 12 Pin 13 Channel 1 Gate Lo Channel2 Gate Lo Pin 14 Pin 15 Shield Shield Pin 16 Pin 17 N/C N/C Pin 18 Pin 19 N/C N/C Pin 20 Pin 21 Channel 3 Hi Channel 4 Hi Pin 22 Pin 23 Channel 3 Lo Channel 4 Lo Pin 24 Pin 25 Channel 3 Shield Channel 4 Sh
Meter Proving Module Specification Wire Type Wire Size Terminal Screw Torque Retaining Screw Torque Value Stranded, Cu-90°C (194°F) 16 to 22 AWG 0.68 Nm (6 in-lb) 0.46 Nm (4.1 in-lb) To wire the terminal block: 1. Determine the length of cable you need to connect a channel to its field device. Remember to include additional cable to route the drain wire and foil shield to their ground points. 2.
Quantum Series 140 MPM 204 00sc 3. At the module end of the cable, cut the drain wire and foil shield. 4. Check the signal wires to ensure that they are the correct length to connect to the terminal block. 5. At the input device end of the cable, twist the drain wire and foil shield together. Under normal circumstances, you will connect the drain wire and shield to earth ground, via a panel or DIN rail mounting screw at the end of the module. Keep the length of the drain wire as short as possible. 6.
Meter Proving Module 3Chapter Module Configuration This chapter includes information on the following: • Module addressing • Setting up the PLC configuration software (ModSoft, Concept, and SCIOCFG) • Making bit settings for zoom (parameter) registers • Making bit settings for 4X configuration (output) registers • Making bit settings for 3X data and status registers Some configuration can be performed using the ModSoft, Concept, and SCIOCFG configuration programs.
Quantum Series 140 MPM 204 00sc Module Addressing The module uses nine zoom (parameter) registers, six 4X (output) registers for configuration words, and eleven 3X (input) registers for data and status words. Table 3-1 Module Registers Register Function Zoom+0..3 Basic Configuration data Zoom+4 Autocycle time delay in milliseconds Zoom+5 Channel 1 frequency reading timeout period in seconds. Zoom+6 Channel 2 frequency reading timeout period in seconds.
Meter Proving Module application programming examples. Table 3-2 Module Files File Name GCNFTCOP.SYS LMSFDT.SYS QUANTUM.SYS Installation Disk Dir ector y Director ectory \MODSOFT\ \MODSOFT\ \MODSOFT\ Description ModSoft I/O map module definitions ModSoft zoom screens Quantum help screens for ModSoft SCIOCFG.EXE \CONCEPT\ Spectrum utility that runs under Concept to provide help setting up configuration I/O files; this is a 32-bit Windows program requiring Windows 95/98/NT SPECTRUM.
Quantum Series 140 MPM 204 00sc 2. Open ModSoft, and access the I/O map screen. 3. Select the slot in which you have installed the module. 4. Now enter Shift+? to display a list of modules available for placement in the selected slot. 5. Choose your Quantum counter module from the list. For module-specific help, enter Alt+H. 6. Choose the first 3X and 4X registers to be used in the system for the module. 7. Now enter the zoom screens by highlighting the entry for your module and pressing Alt+Z.
Meter Proving Module 1. Ensure that the Concept software has been updated from the installation disk as described in “Setting Up Concept.” 2. Start the Concept Modconnect tool (Modconf.exe). 3. From Modconnect, open the file SPECTRUM.MDC. 4. Select the Quantum counter module, or click Add All All. 5. Save your changes and exit Modconnect to update the Concept database. The changes are permanent unless you later undo the changes using Modconnect, or perform a new Concept software installation. 6.
Quantum Series 140 MPM 204 00sc In the synchronous mode, SCIOCFG runs in the background waiting for you to select the module in the Concept generic I/O parameter configuration menu. When this occurs, SCIOCFG reads the data from the Concept generic I/O parameter configuration menu, and activates the appropriate I/O parameter configuration menu. When you click the SCIOCFG OK button, the new data is sent to Concept. Set up SCIOCFG as follows to run the utility from Concept: 1.
Meter Proving Module Zoom Register Layout The following table shows the layout for each of the zoom registers.
Quantum Series 140 MPM 204 00sc Count Size, Bit 10 This bit determines the maximum counter value. When set to 0 the channel counter will count up to 65,535 (1- 16bit word of data). When the maximum value of 65,535 is reached, the Maximum Count flag is set, and rollover will occur at this point. When the count size is extended to 16,777,216 by setting this bit to 1, the Counters Maximum flag is extended to 16M and data output is formed using two words.
Meter Proving Module Making Bit Settings for 4X Registers You can only set 4X register bits using ladder logic. This section describes the layout for the registers and defines the bits. Ladder logic examples are provided in chapter 4, “Programming.” The first 4X register controls channel enabling and multiplexing. The following table shows the bit settings for this register.
Quantum Series 140 MPM 204 00sc Multiplexing Contr ol: Bit 13 Control: This bit allows the user to determine if multiplexed registers must be manually specified before retrieval or if these registers are automatically sequencially reported. Setting this bit to 0 activates the Manual mode. OSetting this bit to 1 activates the Autosequence mode. Parameter Definition: Bits 10- 12 These bits determine which Parameter Value is being prepared for programming into EEPROM.
Meter Proving Module Load Scale/Limit Word: Bit 1 Asserting this bit enables register 4X+1. The value in register 4X+1 is defined by the Channel Number bits and the Parameter Definition bits. If the customer desires to update the K, M, R, or rate limit values the enable scale/limit word bit must be set. The default values for all of these scaling and limit words is initially 0. Programming these values in EEPROM so that the values will need to be stored only once.
Quantum Series 140 MPM 204 00sc The R scale factor can be used for scaling of the output frequency. The output frequency is divided by the R scale value. Typically a factor of two will be used. The result is the rate data value being 1/2 of the actual value. R factors must be positive numbers.
Meter Proving Module Layout for 4X+2 through 4X+5 Registers Registers 4X+2 through 4X+5 registers contain control word information for the each channel. The information includes runtime configuration and control options. The next table shows the bit settings for these control word registers.
Quantum Series 140 MPM 204 00sc Pulse Fidelity Fidelity,, Bit 15 When this bit is enabled, the module will perform pulse fidelity monitoring of an input channel pair. The bit needs to be set on both channels being monitored. For example both channels 1 and 2 must have this bit set to do pulse fidelity monitoring on channels 1 and 2. Both channels must have the same configuration settings, such as input range, for pulse fidelity to be performed. If they do not, then a configuration error will be set.
Meter Proving Module Rate Mode, Bit 8 When this bit is reset to “0” the frequency detection circuit operates in “Instant” mode. Instant mode times the period of a single input transition from one rising edge to the next rising edge of an input signal. Instant measurements are fast, in that they calculate a frequency based on one cycle. However the accuracy of the measurement degrades as the input clock frequency goes up to 50KHz, and any jitter within one cycle will be measured.
Quantum Series 140 MPM 204 00sc Bit Settings for 3X+0 Registers The 3X registers contain data, scaling and status information for channels 1 through 8. You can only set 3X register bits using ladder logic. This section describes the layout for the registers and defines the bits. Ladder logic examples are provided in chapter 4, “Programming.
Meter Proving Module The process for updating the scale coefficients and the count limits is as follows: 1. Set the Scale/Limit Word to its desired value (4x+1 register). This must be performed before updating the module control word. 2. Set the following bits on the module control word (register 4X+0) to the appropriate state for the value to be written: a. Channel Number b. Parameter Definition c.
Quantum Series 140 MPM 204 00sc Bit Settings for 3X Registers The 3X registers (3X+1 through 3X+8) contain data and status information for channels 1 through 8. You can only set 3X register bits using ladder logic. This section describes the layout for the status registers (3X+1 through 3X+8) and defines the bits. Ladder logic examples are provided in chapter 4, “Programming.
Meter Proving Module Pulse Fidelity: Bit 15 This bit activates the pulse fidelity feature. Meter Pr oving Finished/Not Finished: Bit 14 Proving This bit indicates whether the meter-proving run has finished or not. When the Meter proving bit (Gate enable on the control register) gets set, the meter proving process will begin. This consists of counting the number of pulses from the first ball detector pulse till the second ball detector pulse.
Quantum Series 140 MPM 204 00sc Pr eset to Other Channel’ Preset Channel’ss Value: Bit 8 Use this bit when in pulse fidelity mode. When in pulse fidelity mode this bit will cause the channel to be preset to the value of teh complimentary channel’s accumulator. For example: if this bit is set in the 4x+2 (Channel 1) then channel 1 will be preset to channel 2’s accumulator value. If this bie is set in the 4x+3 register (channel 2) then channel 2 will be preset to channel 1’s value.
Meter Proving Module Table 3-7 Meter -pr oving Status Word (3X+9 Bank 2 and 3) Meter-pr -proving Function Chan 1 Waiting for first gate pulse First gate pulse occurred. Second gate pulse occurred. Third gate pulse occurred. Fourth gate pulse occurred. Chan 2 Waiting for first gate pulse First gate pulse occurred. Second gate pulse occurred. Third gate pulse occurred. Fourth gate pulse occurred. Chan 3 Waiting for first gate pulse First gate pulse occurred. Second gate pulse occurred.
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Meter Proving Module 4Chapter Programming With configuration complete, it is time to prepare ladder logic to reflect your configuration settings. Programming the module requires knowledge of counter configuration, PLC ladder logic, and data management.
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Meter Proving Module General Programming Examples Example 1: Loading Scaling Factors The following sample ladder logic shows how to load scale factors into the module. Refer to the configuration bit table for information regarding factor and channel bit settings Rungs 1 and 2 are used as a handshake to verify that valid data is being passed to the card and that the counter card has received the data and is ready for the next packet. Rung 3 enables the K value for channel one to be set.
Quantum Series 140 MPM 204 00sc Sample Configuration Using the Meter Proving Inputs A ball proving system would use the meter proving input found on the module. The ball meaures the flow velocity over a fixed length of line. When the ball crosses the starting point a momentary high signal from a proximity switch starts the counter. When the ball crosses the prover exit another proximity switch triggers causing the counter to stop. During the movement of the displacer the meter count is monitored.
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Meter Proving Module 5Chapter Maintenance and Diagnostics This chapter describes maintenance and diagnostics for the Quantum counter module. Provided information includes: • Safety considerations during maintenance • Preventive maintenance • Internal diagnostics • Startup testing • Troubleshooting • Module errors Safety Considerations Safety considerations are an important element of proper maintenance and diagnostic procedures.
Quantum Series 140 MPM 204 00sc Standing Clear of the Equipment When troubleshooting any system problem, have all personnel remain clear of the equipment. The problem can be intermittent, and sudden unexpected machine motion can occur. Have someone ready to operate an emergency stop switch in case it is necessary to shut off power.
Meter Proving Module Internal Diagnostics The module performs internal diagnostics at both the module and channel levels of operation. When detected, module error conditions are immediately indicated by the ready (module status) LED. Channel errors are reported at their respective LEDs. The module reports error conditions to the PLC. Channel error conditions are reported in the module’s input data table. Module hardware errors are typically reported in the PLC I/O status file.
Quantum Series 140 MPM 204 00sc Startup T esting Testing This section presents testing procedures recommended for use at module startup to verify correct installation and configuration. Physical Inspection 1. Inspect the module to ensure that all wire connections are correct and secure and that no wires are missing or broken. 2. Ensure that the shield for the cable used to wire your module is properly grounded. Refer to Chapter 2, “Installation and Wiring” for more information. 3.
Meter Proving Module Health Status T est (Concept) Test 1. In Concept, access the I/O configurator and ensure that the module description, slot location, and register assignments are correct. 2. Use the controller status to verify that the module is recognized and reported as healthy. If you find an asterisk in front of the module name, the rack does not recognize the module. To correct the problem, see troubleshooting. Register Operation T est Test 1.
Quantum Series 140 MPM 204 00sc Active LED Does Not Illuminate Possible Causes The module is not communicating with the PLC rack. Corr ective Action Corrective 1. Deinstall the module. See chapter 2, “Installation and Wiring.” 2. Place the rack in run mode. 3. Reinstall the module in the rack. See chapter 2, “Installation and Wiring.” Fault LED Does Not Illuminate Possible Causes • Module self-test error • Fatal hardware error Corr ective Action Corrective Contact your local distributor.
Meter Proving Module Corr ective Action Corrective If necessary, install a pull-down resistor between the channel input and channel common or a pull-up resistor to a positive voltage source. Module Not Recognized by Rack (ModSoft) Possible Causes • Module not correctly installed. • Module runtime files not correctly installed. Corr ective Action Corrective 1. Reinstall the module in the rack. See chapter 2, “Installation and Wiring.” 2.
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Meter Proving Module A Appendix Specifications This appendix lists the specifications for the Quantum counter module. Specification Value Data Registers 11 - 3X registers 6 - 4X registers 9 - zoom (parameter) registers LED Indicators: 1 Green LED, Module Status The module status LED indicates the status of the power-up self-test. The LED is on when the module is ready. Any self-test error is indicated with a blink code.
Quantum Series 140 MPM 204 00sc Electrical Fast Transient IEC 801-4 Radiated Emissions CISPR 11 Class A Surge Impulse IEC 801-5 Conducted Immunity IEC 801-6 Fast Surge Immunity EN61000-4-5 Voltage Dropouts (Variation and Dips) EN61000-4-11 Electrical Specifications Specification Configuration Input Modes Voltage Range: (Signal & Gate) VIL1 VIH Vmax CE Current Range Input Impedance Counter Speed: DC Inputs 5V, 12V, 24V, AC Input Frequency: DC Inputs AC Inputs Counter Enable Input: Value 4 channels - coun
Meter Proving Module Standards Compliance The following certifications will be obtained: • UL 508. • CUL and Class 1, Division II (CSA equivalent). • CE compliance with EN 61010-1 and EN 61131-2, EN50081-2, EN50082-2. This allows for the application of the CE mark and will include the low-voltage directive (LVD).
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Meter Proving Module Glossary The following terms and abbreviations are used throughout this manual. A/D converter – The analog-to-digital converter used in the module. The converter produces a digital value with a magnitude that is proportional to the magnitude of an analog input signal. attenuation – Reduction in the magnitude of a signal as it passes through a system. bus connector – A 16-pin male and female connector that provides electrical interconnection among modules in a controller system.
Quantum Series 140 MPM 204 00sc input data scaling – Data scaling that depends on the data format selected for a channel configuration word. LSW – Least significant word. module update time – The time required for the module to sample and convert the input signals of all enabled input channels and make the resulting data values available to the processor. MSW – Most significant word. multiplexer – A switching system that allows several input signals to share a common A/D converter.
Spectrum Controls Support If you need technical assistance, please review the information in chapter 5, “Maintenance and Diagnostics.” If you still have questions, call your local distributor of Spectrum Controls products. Note that your module contains electronic components that are susceptible to damage from electrostatic discharge (ESD). An electrostatic charge can accumulate on the surface of ordinary plastic or cushioning material.
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