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TSMIU User`s Manual - Mattec MES Help Desk

1. be 18 gauge Upper Lower ow Row a eau oo ci a Machine 1 389 o 5 Machine 1 ee o pa a ku Machine 2 a E Ra E Machine 2 Ant as 10 a I Pa LI er se Machine 3 w gale Machine 3 ne one Machine 4 f d ADA M hine 4 em Er mn janie ac mal DO Guias naes 4 aie ci o mal DO pra IN 17 Machine 9 mA O magna Peak E E IN 18 Machine 9 E qui E IN 19 Machine 10 ma ES amant 2 1K MIE sk IN 20 Machine 10 nd 2 1K LT IN 21 Machine 11 quis Ema ROE E IN 22 Machine 11 gje gege Hri R 5 3 IN 23 Machine 12 IB o Sa aL LE E sh IN 24 Machine 12 E E mio fus ques pes EXT r ls al Ie jd 2 zn e E E IN 25 Machine 13 fefe gim fenan 2 1K ait Nas Machine 13 E esa ES LIL Lp IN 28 Machine 14 fA uma TR Tl ls Machine 14 m 3 mimine Cho e HE E IN 29 Machine 15 eos e IN 30 Machine 15 od smn ge ne LR IN 31 Machine 16 mae EL IN 32 Machine 16 a 1e rafi evar pammisese asuar emensoss ls IE a E ur of E Tl SE Machine 5 LAS pannes fomos a L Machine S eo em A amp Machine 6 calles A EB rafi ecersrmmisess eevarse
2. u11 JH11A1 uae v mm nn 90 Ki BERG EGG me 1234 1234 MIU 9DC Motherboard Copyright 1983 2007 4 47 810 0043 Revision R Mattec Corporation 5 MIU DC12 Mattec s MIU DC12 is a data concentrator It is an MIU that is capable of monitoring production information for one to twelve machines It does not have a user interface 5 1 Switch Settings The following switch settings are available in the MIU DC12 e SWI Set this switch to the address of the first machine that will be monitored by the MIU DC12 as configured in the Machine Configuration program at a computer terminal The MIU DC12 will take up the next 12 addresses regardless of how many machines are actually being monitored by the MIU e SW2 Set this switch down if high resolution cycle times are required e SW3 The MIU DC12 can be configured to monitor from one to twelve machines Use this rotary switch to select 1 through C 12 the number of machines that are actually being monitored Copyright 1983 2007 5 48 810 0043 Revision R Mattec Corporation 5 2 Motherboard The MIU DC12 operates on the principle that the machine provides a normally open dry contact This dry contact switches a volta
3. RED CREEN jeo RED o COMMON DC POWER SUPPLY EARTH GROUND 10X98 Power Supply Wiring Diagram Warning Do not bring AC voltage into the MIU Use the supplied 12 12 DC power supply only Components in the MIU are static sensitive Copyright 1983 2007 2 12 810 0043 Revision R Mattec Corporation Notes e A minimum 14 awg MTW must be used to connect the power supply to the MIU e The maximum distance from the power supply to the MIU should not exceed 35 feet For distances greater than 35 feet please consult with the Mattec Customer Service Department Warning Prior to connecting the power plug to the MIU verify the proper sequence of all voltages at the plug Perform this Test After installing a 10X98 MIU verify 5 Volts DC at the MIU with the MIU turned on Take the measurement at the test points to the right of the power plug Place the test leads on TP2 and TP7 The 5 voltage must be no less than 4 9 Volts and no more than 5 1 Volts If the measured voltage is not within this tolerance the power supply should be adjusted Adjust the power supply by changing the potentiometer that is located behind the 5 Volt terminal on the power supply Copyright 1983 2007 2 13 810 0043 Revision R Mattec Corporation 2 3 1 External Power Supply The following information applies to two of Mattec s standard external power supplies UV365 and UV440 These power supp
4. decreased scrap parts The ProHelp EPM system combines computer hardware computer software and Machine Interface Units MIUs into an efficient system to provide real time production monitoring production reports process alarms plant scheduling aids and SPC SQC process and part capability analysis Floor personnel can make use of the machine mounted terminals to signal different departments for help to view production results at the machine site and to enter downtime reasons or scrap reasons Production downtime and scrap reports can be generated on a shift and daily basis or the user can generate these reports for extended time periods by specifying a start and end date for the desired report Job history data is continuously summarized and available for management s review This manual describes how to install different versions of MIUs It is intended for advanced users only Copyright 1983 2007 1 5 810 0043 Revision R Mattec Corporation 1 1 System Components The following sections provide a brief overview of those components that comprise the ProHelp EPM system 1 1 1 Server Computer The main ProHelp EPM computer is referred to as the server host or monitoring node computer This is the only computer that is required to run the ProHelp EPM system This computer contains all of the configuration files data files and ProHelp EPM software The server computer runs Microsoft s Windows S
5. for additional information Copyright 1983 2007 3 39 810 0043 Revision R Mattec Corporation 3 4 Digital Input Wiring For the MIU Z1 a normally open contact must be provided This normally open contact will be closed by the cycle time signal The machine signal typically used may be called Inject Forward High Boost or Inject Boost Connect inputs as follow Customer provided relay 24V DC Machine Cycle Start Signal COM a 4 SS O GIGHHHHHSS RATEN MIU Z1 Digital Input Wiring Diagram Digital input connections are described in the following table Digital Input Parameter Il Cycle Time D Pulse 2 13 Pulse 3 I4 Pulse 4 15 Aux 1 16 Aux 2 I7 Aux 3 I8 Aux 4 Copyright 1983 2007 3 40 810 0043 Revision R Mattec Corporation 3 5 Digital Output Wiring The output contacts on the MIU Z1 are rated at 3 Amps per output These are limited by the power source The total output can not exceed the input of the power source The typical power source for the MIU Z1 that is supplied by Mattec has a maximum 1 Amp output SSSHHNSHHSS HHH 2222822226 SSPEfetes 388038588 11111 GR DIDI Notes e Outputs are PNP and source current to the load 24 V DC COMMON MIU Z1 Digital Output Wiring Diagram e Output is a FET with an on resistance of 0 2 Ohms or less Digital ou
6. wire JX14A Off High speed Analog for IRQ7 JX14P Off Parallel Printer for IRQ7 JX14C On COM4 for IRQ7 JX3 2 3 COM High Speed for IRQ9 JX6 Off Provided to configure COM4 for RS 485 two 2 wire JX1 Off Provided to configure COM4 for RS 485 two 2 wire Copyright 1983 2007 Mattec Corporation 2 9 810 0043 Revision R Jumper s Default Description JX11 Off RTS CTS Connection for COM4 Jumper Reset On Removing the jumper reset will cause the MIU to remove a number of configuration files This is typically used to force a recalibration for a TSMIU or TSMIU 0 This will also erase all the signal map files for a TSMIU O JAI JAI4 On This jumper provides a ground reference for thermocouples where JAI Analog 1 JA2 Analog2 JA3 Analog3 JA4 Analog4 JAS Analog5 JA6 Analog6 JA9 Analog 7 JA10 Analog8 JA11 Analog9 JA12 Analog 10 JA13 Analog11 and JA14 Analog 12 JP1 1 2 This jumper is located on the door light bar for a TSMIU or TSMIU 0 only Do not change this jumper JX2 Long These jumpers enabled the screen saver for the MIU 10X JX3 Short MIU 5X and MIU OXS only JX4 Disabled R35 This adjusts the contract for an LCD MIU only Copyright 1983 2007 Mattec Corporation 2 10 810 0043 Revision R 2 2 Switch Settings The following diagram shows switch settings for MIUs that are based on the 10X98 motherboard including the TSMIU
7. 5 Tx Red 4 Rx Black Green 7 3 Rx Green D 2 Gnd 1 Sh X1 N MIU Z1 Host Communications Diagram Notes e Loosen the screw terminals all the way ccw e Strip the gray vinyl jacket of the RS 485 cable to a maximum of 2 5 inches e Strip the foil shields of the RS 485 cable to a maximum of 2 0 inches e Keep individual pairs of cables twisted together e Twist the shield drain wire together on the from cable e Tape back completely so there are no exposed bare wires on the shield drain wire on Copyright 1983 2007 3 38 810 0043 Revision R Mattec Corporation the to cable e Strip the individual color code wires approximately 1 4 inch e Insert the appropriate wires into the indicated terminals e Tighten the screws assuring that the insulation of the wire is not pinched in the connection e Gently tug on the contact wires to ensure you have made a good connection e Note that the Z1 CPU PCB must be connected to the ground lug in side the shell that in turn must be grounded to earth e Loosen the clamp screw on the ground lug Place the twisted shield drain wire on the From cable through the lug and secure the screw Twist the shield wires together on the cable coming in from the last MIU or Buffer Box and terminate to the Sh terminal on the communication adapter The last MIU on the channel should enable RS 485 termination Reference Section B 1
8. Some manufacturers prefer to calibrate to the machine gauges The following is the method to do so 3 Plug the transducer into the desired analog channel you wish to calibrate Ramp up the hydraulics to maximum pressure for the machine and record the value displayed on the MIU MIU CURRENT HIGH and the value on the gauge MIU SPEC VALUE 4 Release all pressure to the hydraulics of the machine and record the value displayed at the MIU as MIU CURRENT LOW 5 The formula used for calculating the SOFTWARE OFFSET and the SOFTWARE GAIN is as follows SOFTWARE GAIN MIU SPEC VALUE MIU CURRENT HIGH MIU CURRENT LOW SOFTWARE OFFSET 0 MIU CURRENT LOW SOFTWARE GAIN 6 Record these values aa SOFTWARE OFFSET and SOFTWARE GAIN 7 Return to the Host computer and enter the values under the GAIN and OFFSET fields for the appropriate channels Press F4 for update 8 Calibration is now complete Copyright 1983 2007 2 30 810 0043 Revision R Mattec Corporation 2 10 PLC Wiring The TSMIU MIU 10X and MIU 5XS are optionally capable of using a PLC interface to extract process information directly from a support machine controller Depending on the type of PLC interface you can extract between 11 and 30 process parameters from the control COM3 PLC Communications Mode COM3 PLC amp AIU Communications BRL TB5 1 TB5 2 TB5 3 TB5 4 RS 485 RS 232 CTS RTS Rx Tx RS 485 Rx Rx Tx Tx corrent Tx Tx Rx R
9. shunt jumper provides a connection to a ganged line so only one ground wire is needed assuming all ground references are the same For example if JP1 through JP8 are on this connects the negative terminal of inputs 1 through 8 together This allows the use of only one ground wire for inputs through 8 JP18 Off This jumper is typically not used It connects the ground of the ganged bus for JP1 through JP16 to the MIU s digital ground plane This jumper would only be used if the power supply for the MIU were used for the excitation voltage of the inputs The typical installation has open contacts in the machine and the 12 VDC is looped out to the contact and back to the appropriate input Using the 12 VDC this way can cause severe damage to the MIU if a short occurs at the machine A 100mA inline fuse should be used between the power supply and the outgoing wires JX13 NC Do not install a shunt on this jumper It is for use with an external PC speaker only Factory Use Only JX2 On This jumper connects earth ground to internal ground JX12A 2 3 Floppy keyboard enable Factory Use Only JX12B 1 2 FDRQ DRQO Factory Use Only JX12C 1 2 FDACK DACKO Factory Use Only JP17 Off This jumper is provided for end of line termination for MIU to host communications Only enable this jumper in the last MIU on each RS 485 channel JX7 Off Provided to configure COM3 for RS 485 two 2 wire JX8 Off Provided to configure COM3 for RS 485 two 2
10. v VA BARATA T En Channel 4 Channel 3 CS A 1 2 Use V and V Senon DD o 0 aia NOTE Internal jumpers X1 and 13 24 X2 must be set to local voltage Buffer Box Copyright 1983 2007 6 51 810 0043 Revision R Mattec Corporation
11. 1 Mattec s MIU Z1 is a low cost machine interface unit that provides basic production monitoring and an easy to use operator interface MIU Z1 Mount the MIU Z1 with the provided mounting bracket and hardware Select a suitable location keeping in mind operator convenience protection from damage during machine maintenance and local electrical codes Copyright O 1983 2007 3 35 810 0043 Revision R Mattec Corporation 3 1 Settings One all connections are made you must configure the MIU Z1 software To do this follow these steps Power on the MIU Press the ESCAPE key while the MIU is booting Use the arrow keys to select 1 Miu Address and press ENTER Enter the MIU address and press ENTER Press ESCAPE to return to the Setup menu Use the arrow keys to select 2 BaudRate and press ENTER Use the arrow keys to select the appropriate baud rate and press ENTER The typical baud rate is 4800 Press ESCAPE to return to the Setup menu Use the arrow keys to select 3 RS485 Termination and press ENTER Use the arrow keys to select the appropriate termination and press ENTER Turn the termination ON only if the MIU is the last device on the channel Only the last device on each channel should be terminated Press ESCAPE to return to the Setup menu Press ESCAPE again to reboot the MIU To reboot the MIU Z1 while the message Waiting for Host is displayed press ENTER Use the arrow keys to select Reboot the MIU and pr
12. L COMM 1 N 1B COMM 1 OUT A 7 ad CA 4 5 A ET g com 2 si Fm FE Eu 10X98 Host Communications Diagram Notes Loosen the screw terminals all the way ccw Strip the gray vinyl jacket of the RS 485 cable to a maximum of 2 5 inches Strip the foil shields of the RS 485 cable to a maximum of 2 0 inches Keep individual pairs of cables twisted together Twist the shield drain wire together on the from cable Tape back completely so there are no exposed bare wires on the shield drain wire on the to cable Strip the individual color code wires approximately 1 4 inch e Insert the appropriate wires into the indicated terminals e Tighten the screws assuring that the insulation of the wire is not pinched in the connection e Gently tug on the contact wires to ensure you have made a good connection e Loosen the clamp screw on the ground lug Place the twisted shield drain wire on the Copyright 1983 2007 2 16 810 0043 Revision R Mattec Corporation From cable through the lug and secure the screw Jumper JP17 is provided for end of line termination for MIU to host communications Only enable this jumper in the last MIU on each channel Reference Section for additional information Copyright 1983 2007 2 17 810 0043 Revisi
13. ProHelp EPM Production amp Process Monitoring System MIU Wiring and Installation Manual For ProHelp EPM Release 7 5 MANUAL 810 0043 Revision R December 4 2007 ATTENTION You can obtain service support by visiting Mattec s web site at http www mattec com by emailing the help desk at helpdesk mattec com or by telephone at 513 683 1802 This manual is intended for advanced users only Copyright 1983 2007 1 2 810 0043 Revision R Mattec Corporation TABLE OF CONTENTS Digital Input W101 ss at ni e AE 4 45 Digital Output Wiring Copyright 1983 2007 1 3 810 0043 Revision R Mattec Corporation Copyright 1983 2007 1 4 810 0043 Revision R Mattec Corporation 1 Introduction Mattec Corporation s ProHelp EPM Production and Process Monitoring System is specifically designed for real time monitoring of all types of production equipment It is used extensively in the plastics injection molding extrusion blow molding blown film metal stamping die casting printing painting and assembly industries The basis behind the benefits from the ProHelp EPM system is the rationale that plant managers and operational people will take corrective actions to solve problems on production equipment when they are aware of such problems ProHelp EPM is the device to alert employees to problems immediately when the problems occur Therefore tremendous savings can occur in increased productivity and
14. TSMIU 0 MIU 10X and MIU 5XS i 0 OFF 123 4 6 8 ON il LILI OFF 1 2 3 4 6 8 J ETERRA MUUUUULL O OF RER Pa TES EG PES meu OF 125 4 6 8 ON Umm LIL UL OFF 125 45 6 78 ON O OFF OFF 123 45 6 8 ON uA Lm LLL UL OFF OFF ONLY ME CONTACTS JRE S Jw Be GAGE PORT BAUD RATE 1200 BAUD OFF ON 2400 BAUD OFI DDRESS SWITCH 2 SW2 O 1st PHYSICAL MIU ON CHANNEL ON 4800 BAUD F LAST PHYSICAL MIU ON CHANN OFF ON U OFF ON EL S OFI TOUCHSCREEN OFF ELO CONTROLLER ON CONTROLLERLESS SHOWN Notes 10X98 Switch Settings e The Host Baud Rate SW3 and SW4 for the TSMIU and the TSMIU 0 are set on the Service Display of the MIU Copyright 1983 2007 Mattec Corporation 2 11 810 0043 Revision R 2 3 Power Supply Do not bring AC voltage into the TSMIU TSMIU 0 MIU 10X MIU 5XS or MIU OXS Use the supplied 5 12 12 volt power supply only The 5 volt connection is typically not needed Reference Section for additional information wif DO LED11 sf gH O LED12 SIDE OF LED13 sata COMPONENT H1141 RELAY PRHALAesB 2 RELAY PRMALAaSB RELAY PRMALAGSE LED26 LeDe4 LEDES TED27
15. aandeis N 38 Input 13 IN 27 00 oo IN 28 Input 14 z IN 29 Input 15 0 IN 30 IN 31 __ Input 16 IN 32 Caution Using the MIU power supply for 12 digital input excitation voltage may stop the MIU from operating or damage it if done incorrectly 12 Volts from Power Connector TB6 6 or Preferably an alternate 12 VDC source Current draw O 12 VDC for all inputs on is less tha 100mA Common for 12 VDC source If all inputs have same power source use JP1 16 so only one common wire is needed TSMIU 0 Digital Input Dry Contact Method Wiring Diagram Digital inputs must be 12V to 50V DC The suggested cable for this method is Belden 8205 This is a two conductor 20 gauge unshielded cable One of the conductors carries an excitation voltage to the dry contact at the machine When the contact closes the other conductor returns the voltage to the MIU input cycle start signal The power supply of the MIU can be used for the excitation voltage but you must use caution Incorrect implementation will damage the MIU and this damage is not covered by the MIU s warranty For digital contacts with the same ground reference a single ground wire is sufficient if you use Jumpers JP1 through JP16 and JP18 Reference Section 2 1 for additional information Start of stage will read Analog 6 only Copyright 1983 2007 2 20 810 0043 Revision R Matte
16. aeLar pemtaass KB 10X98 Motherboard Do not bring AC voltage into the MIU Use the supplied 5 5 12 12 DC power supply only Components in the MIU are static sensitive Do not remove the MIU s battery Copyright 1983 2007 2 33 810 0043 Revision R Mattec Corporation 2 13 Product Specifications Physical Height 11 0 27 94 cm Width 14 0 35 56 cm Depth 4 50 11 43 cm Weight incl Bracket MIU 10X 11 Ibs 5 kg TS MIU 13 lbs 5 9 kg Housing 18 ga Cold rolled steel with powdercoat finish Electrical Requirements 5 Vdc 2 O 3 15 A max 12 Vdc 5 O 1 2 A max 5 Vdc 5 1 A max 12 Vdc 5 2 A max Power entry to the MIU should be enclosed in conduit appropriate to environment Typically Liquidtight Installation category 1 Environmental For indoor use only Altitude Up to 2000m Operating Temperature 5 C to 40 C Relative Humidity Max 80 up to 31 C decreasing linearly to 50 O 40 C Pollution degree 2 Safety Should equipment be used or installed in a manner not specified by Mattec protection provided may be impaired Maintenance No routine maintenance or cleaning is required If required replace BIOS battery with equivalent type BR2325 3 Volt Lithium Manufacturer Mattec Corporation 1301 Mattec Drive Loveland OH 45140 USA Copyright 1983 2007 2 34 810 0043 Revision R Mattec Corporation 3 MIU Z
17. c Corporation e Typically inputs are connected consecutively with machine connected to input 1 machine 2 connected to input 2 etc This must then be defined in the machine s Signal Map The TSMIU 0 is shipped with a default signal map that coincides with consecutive connections e If all inputs are not used the unused inputs must be blocked in the Signal Map Copyright 1983 2007 2 21 810 0043 Revision R Mattec Corporation 2 8 Digital Output Wiring The output contacts on the TSMIU TSMIU 0 MIU 10X MIU 5XS and MIU OXS are rated at 200 Volts DC maximum at 0 5 Amps maximum An external secondary contact is required for all external loads Siemens KHAU 17D11 12 or equivalent 12 volt coil ee 75 mA A e rss orme EU Los LOAD VOLTAGE 12V COM LOAD VOLTAGE COMMON 10X98 Digital Output Wiring Diagram Warning Do not bring AC voltage into the MIU Copyright 1983 2007 2 22 810 0043 Revision R Mattec Corporation 2 8 1 Stack Lights The TSMIU TSMIU 0 MIU 10X MIU 5XS and MIU OXS support optional stacklights that mirror the 4 lights on the outside of the MIU Neutral 120 VAC 10X98 Stacklight Output Diagram Additional Pa
18. cable Tape back completely so there are no exposed bare wires on the shield drain wire on the to cable Strip the individual color code wires approximately 1 4 inch Insert the appropriate wires into the indicated terminals Tighten the screws assuring that the insulation of the wire is not pinched in the connection Gently tug on the contact wires to ensure you have made a good connection Loosen the clamp screw on the ground lug Place the twisted shield drain wire on the From cable through the lug and secure the screw Jumper JXS is provided for end of line termination for MIU to host communications Only enable this jumper in the last MIU on each channel Reference Section 4 1 for additional information Copyright O 1983 2007 4 44 810 0043 Revision R Mattec Corporation 4 4 Digital Input Wiring The digital input connections on the MIU 9DC must be 12V to 50V DC Contact wiring should be 18 gauge dE us rear 2 RCJ E z eae er DC Cycle Input Selection Ui INPUT BEBE tata SEL Hu ik res Lista a fg HI ES For DC Input PEE epee JM is JAMA JAZ Cycle Time DC Pulse 2 Input Selection cle lime Pulse 2 JA JBI Pulse 2 JA2 JB JB3 JB3 MIU 9DC Digital Input Wiring Diagram Notes e Digital inputs must be 12V to 50V DC e Contact wiring should be 18 gauge e Individual commons may also be used for differentl
19. d to an MIU 10X 1 e can not have optional analog inputs It has a 16 by 40 character LCD display e MIU OXS The MIU OXS is an MIU that has digital input monitoring only for 2 to 16 machines It has a 16 by 40 character LCD display Warning Do not bring AC voltage into the MIU Use the supplied 5 5 12 12 DC power supply only Components in the MIU are static sensitive Do not remove the MIU s battery Diagnostics When the TSMIU is restarted it will display a large Mattec logo until it is configured You can press the Mattec logo to go to the Service Display This will allow you to configure settings that are used by the MIU to communicate with the host computer When an LCD MIU is started is will display the message PRESS ANY KEY FOR DIAGNOSTICS Simply press a key on the MIU to enter the configuration and diagnostics mode When the MIU displays AWAITING HOST press the left most function button beneath the LCD display to access the Service Display Copyright 1983 2007 2 8 810 0043 Revision R Mattec Corporation 2 1 Jumper Settings The following table lists jumper settings for MIUs that are based on the 10X98 motherboard including the TSMIU TSMIU 0 MIU 10X MIU SXS and MIU OXS Jumper s Default Description JP1 JP16 Off These jumpers are provided to allow for single connection of ground references for the digital input signals Each
20. erver 2003 operating system and Microsoft s SQL Server 2005 database All MIUs connect to the server computer All data from MIUs is automatically recorded at the server and can be viewed from other computers in real time 1 1 2 Machine Interface Unit MIU The Machine Interface Unit MIU is an industrial strength data collection device that has been designed and manufactured by Mattec It is used to collect production and process information from the manufacturing machine and transmits that data in real time to the server computer There are a wide variety of MIUs Most have a graphical interface that allows the machine operator to view data about the current job and input relevant information e g scrap parts Many MIUs have both analog and digital inputs Many MIUs have an optional PLC interface that can be used to extract data directly from supported machine controllers 1 1 3 PLC Interfaces Many MIUs are capable of optionally extracting information directly from the machine s programmable logic controller PLC PLC wiring connections are described in this manual For additional information regarding software configuration for PLC interfaces reference the PLC Subsystems Manual 810 0078 on Mattec s website 1 1 4 RocketPort Serial Communication Board And Buffer Box MIUs are connected to the server computer via RS 485 cabling Typically up to 16 MIUs can be daisy chained together on a single channel Multiple channels ca
21. ess ENTER To access sales demo mode for the MIU Z1 reboot the MIU and press the DWN key while the MIU is booting Copyright 1983 2007 3 36 810 0043 Revision R Mattec Corporation 3 2 Power Supply If Mattec has provided you with a 24 volt power supply for the MIU Z1 mount the power supply in a nearby electrical panel according to local codes and regulations Use the provided bracket and screw to mount the bracket to the power supply Mount as shown below MIU Z1 Power Supply Mounting Diagram Use the provided self tapping sheet metal screw to mount the bracket to a suitable surface Reference the wiring legend stamped above the terminals Using a 16 gauge MTW or TFFN cable connect power with the following minimum specifications 8 45 Volt DC unregulated with a nominal rating of 24 Volts DC 500mA 8 45 V DC unregulated with nominal rating of 24 VDC 500mA Common ga 7 Lt MIU Z1 Power Supply Wiring Diagram Copyright 1983 2007 3 37 810 0043 Revision R Mattec Corporation 3 3 Host Communications The MIU Z1 is connected to the host computer buffer box via an RS 485 cable that is daisy chained from one MIU to the next and is eventually connected to the buffer box This MIU is capable of communicating with the host computer at a number of baud rates Reference Section 3 1 for additional information x 6 Tx Black Red
22. ge provided by the MIU to create a cycle start signal MIU DC12 Wiring Diagram Wire one conductor of Belden 8761 from TB3 17 TB3 18 or TB3 19 to one side of the machine contact Connect the other conductor from the other side of the normally open contact to the appropriate input terminal of the MIU DC12 Repeat this process for all machines that will be monitored by the MIU Notes e Leave preinstalled wires in place e Led 20 lights when the MIU has passed diagnostics e Led 18 lights when all machines have configured Copyright 1983 2007 5 49 810 0043 Revision R Mattec Corporation 6 Buffer Box The Buffer Box is a small device that has been designed and manufactured by Mattec It is usually located within a few feet of the server computer The Buffer Box converts the RS 485 signal to an RS 232 signal and conditions the signal A channel of MIUs RS 485 is wired into the Buffer Box on one side On the other side the Buffer Box outputs an RS 232 signal that is connected to a serial communication port on the server computer 6 1 MIU to Buffer Box Wiring Green Connector Wire the Belden 8777 cable or equivalent to the green male connectors that will be connected to the
23. h SIMM card in the MIU has 6 analog channels Gain resistors are located on the SIMM itself see figure below Channel 1 R18 Channel 4 R13 Channel 2 R15 Channel 5 R22 Channel 3 R14 Channel 6 R23 Sensor Type Common Value J Type TC standard 182 Q K Type TC 182 Q 3 0 mV V standard 150 Q 2 0 mV V 100 Q Copyright 1983 2007 2 25 810 0043 Revision R Mattec Corporation 10X 98 Analog SIMM Card J and K type thermocouples both use 182 ohm 1 precision resistor Prior to calibration allow at least 15 minutes for the internal temperature of the MIU to stabilize From the factory each SIMM is set up for four 4 thermocouples and two 2 linear devices The linear channels are set up for a 3mV V device Gain resistors and current loop load resistors are located on the SIMM Reference the table below for the designator for each Current Loop Channel Gain Resistor Load Resistor 1 R18 R17 2 R15 R16 3 R14 R19 4 R13 R20 5 R22 R21 6 R23 R24 Use of Altek model 322 1 thermocouple simulator or equivalent will be required to calibrate using the following procedure Be certain that JX2 is ON Itis located next to the power plug Copyright 1983 2007 2 26 810 0043 Revisi
24. inear Ground Analog Da Potentiometer Analog m 9 0 Current Analog W source Insert external resistor Rv in terminal plug Rv 10 Maximum input current e Linear pots can be used by removing the gain resistor on that channel no gain A pressure transducer is based on a 3 mv v gain Different transducers can be used by changing the gain resistor for the appropriate channel e For all devices that use excitation voltage use 10 excitation voltage rated at 1A maximum Copyright 1983 2007 2 24 810 0043 Revision R Mattec Corporation 2 9 1 Analog Gain Resistors The analog SIMMs maximum 2 each contains six instrumentation amplifiers Each of these amplifiers has a fixed input impedance of 50K The gain of an analog channel can be changed by simply replacing the gain resistor located on the SIMM Rg with a different value The gain resistor should be a high precision 1 resistor The gain resistor is determined by the following formula Rg 50000 10 Vs 1 where Vs is the maximum voltage the sensor will produce For example if the pressure transducer is rated at 3 0 mV V with 10X excitation voltage of 10 Volts then is follows that Vs 10V x 3 0 mV V 30 mV Refer to the charts below for information on gain resistors Eac
25. lies can be used with the TSMIU TSMIU 0 MIU 10X MIU 5XS and MIU 9DC Warning The terminal strips on these two power supplies are different Be sure you wire them to the MIU correctly UD UOUOUY OU Be TN ss LA ERREI E HU RE External Power Supply Types UV365 and UV440 Notes e Mount the power supply in the machine s power panel and according to local electrical codes and regulations e A minimum 14 AWG MTW must be used to connect the external power supply to the MIU e The maximum distance from the power supply to the MIU should not exceed 35 feet For distances greater than 35 feet please consult with the Mattec Customer Service Department e Use the supplied mounting brackets The brackets may be attached to the back or the side of the power supply as required Only use the supplied mounting screws maximum screw length is 0 25 e Local the label above the terminal strip for connection reference Copyright O 1983 2007 2 14 810 0043 Revision R Mattec Corporation Wire 85 264 Volts AC to the power supply as shown below 85 264 VAC Power Supply Connection Earth Ground ACG Line ACL Neutral ACN Wire the MIU supply voltage for the specified MIU type s as follows 10X98 MIU MIU 9 Power Supply TB6 1 Earth TB1 4 TB6 2 Common TB1 2 COM TB6 3 12 12V TB6 4 5 5V o
26. mmuvonn fr EI Machine 7 re aur EM LT e Machine 7 a EE rs Machine 8 DEVA ma cof sa rms saem lina a o T TF3 ta Pe TSMIU 0 Digital Input Wiring Diagram Notes e Digital inputs must be 12V to 50V DC e Contact wiring should be 18 gauge e For digital contacts with the same ground reference a single ground wire is sufficient if you use Jumpers JP1 through JP16 and JP18 Reference Section 2 1 for additional information e Start of stage will read Analog 6 only e Typically inputs are connected consecutively with machine 1 connected to input 1 machine 2 connected to input 2 etc This must then be defined in the machine s Signal Map The TSMIU O is shipped with a default signal map that coincides with consecutive connections e If all inputs are not used the unused inputs must be blocked in the Signal Map Copyright 1983 2007 Mattec Corporation 2 19 810 0043 Revision R 2 7 Digital Input Wiring Dry Contact Method TSMIU 0 The digital input connections on the TSMIU 0 must be 12V to 50V DC Contact wiring should be 18 gauge Notes Upper Lower Row Row d Input 1 Paps Input 2 O o IN 17 S IN 18 Input 9 IN 19 IN 20 Input 10 IN 21 Input 11 gt o IN 22 IN 23 Input 12 IN 24 Inputs 3 8 same e yon SS Ea gt ast
27. n be used in order to reach the maximum 4 096 MIUs per system The Buffer Box is a small 4 channel device that has been designed and manufactured by Mattec It is usually located within a few feet of the server computer The Buffer Box converts the RS 485 signal to an RS 232 signal and conditions the signal Copyright 1983 2007 1 6 810 0043 Revision R Mattec Corporation A channel of MIUs RS 485 is wired into the Buffer Box on one side On the other side the Buffer Box outputs an RS 232 signal that is connected to a serial communication port on the server computer In most applications Mattec will have installed a RocketPort Serial Communication Board in the server computer The RS 232 signal from the Buffer Box is connected to one of the channels on the RocketPort board The RocketPort board contains multiple communication ports and is a smart device that improves the communication process 1 1 5 Client Computers Although the server computer is a fully functioning client system most users will want to connect to the system from their own computer To do so they will need to have an approved Microsoft operating system loaded on their computer The System Manager will load the ProHelp EPM Client software on that computer and configure it to connect to the server computer The user will be given permissions to access or modify data as appropriate These users with then be able to view data for the entire facilit
28. n that came with your transducer to see if it has one Typically when the shunt resistor is shorted it gives a 80 output This output can then be used for calibration For example a Dynisco PT 130 pressure transducer is a 0 to 3000 psi transducer This means that 80 of maximum output would be 2400 psi This 80 output will be referred to later as the MIU SPEC VALUE 3 Plug the transducer with the shorted shunt resistor into the desired analog channel you wish to calibrate and record the value displayed on the MIU current analog value screen This value will be referred to later as the MIU CURRENT HIGH 4 With the machine at idle and all pressure bled off unshort the shunt resistors The output should be approximately 0 Record the value This reading will be referred to later as the MIU CURRENT LOW 5 The formula used for calculating the SOFTWARE OFFSET and the SOFTWARE GAIN is as follows SOFTWARE GAIN MIU SPEC VALUE MIU CURRENT HIGH MIU CURRENT LOW SOFTWARE OFFSET 0 MIU CURRENT LOW SOFTWARE GAIN Record these values aa SOFTWARE OFFSET and SOFTWARE GAIN 6 Enter these values at the MIU as the GAIN and OFFSET fields for the appropriate channels Calibration is now complete Copyright 1983 2007 2 29 810 0043 Revision R Mattec Corporation 2 9 5 Transducer Calibration Procedure Machine Gauge Method 1 For transducers enable as linear in the MIU setup screen No other selections are needed 2
29. nications port on the next Use the following tables for wiring Reference the picture in Section 2 10 for additional information Host MIU TB5 Remote AIU TB1 R T R T T R T R Remote AIU1 TB1 Remote AIU2 TB2 T T T T R R R R Contact the Mattec Customer Service Department for additional information Copyright 1983 2007 Mattec Corporation 2 32 810 0043 Revision R 2 12 Motherboard The following diagram shows the motherboard for MIUs that are based on the 10X98 motherboard including the TSMIU TSMIU 0 MIU 10X and MIU 5XS 181 COMM 1 IN TB1B COMM 1 OUT ao LCD SG QUI 124 8 ND 54 GND DE LL Aee E e ves EE Ca 2 RE R at 19st sms eme emas Les ue wmo e Ea La E sip RESERVED PINS O FRONT PANE INGO HIS 40 3018 ININOENCO H TH SIDE OF SIMM MODULE ANALOG SIMM 1 ANALOG NT SIDE OF SIMM MODULE COMPONEN Sarg LI GES SES 2 p ienr Leur fa 3 EN RELAY Panotaass RELAY PRYALACS KS g N kel Reay penataan RELAY erviateosa ke Rav pragse f ReLav ernataesa K af mavera
30. on R Mattec Corporation 2 5 Digital Input Wiring The digital input connections on the TSMIU MIU 10X MIU 5XS and MIU OXS must be 12V to 50V DC Contact wiring should be 18 gauge Reference Section 2 6jor Section 2 7 for digital input wiring information for the TSMIU 0 4 Hrad attatCuea g aag aag a n 2 1K E guus d mem 2 Em a R g Haha Dies E 2 gt es st mag K iiaghuiet Cias COMPONENT E 4 10X98 Digital Input Wiring Diagram Notes e Digital inputs must be 12V to 50V DC Contact wiring should be 18 gauge e For digital contacts with the same ground reference a single ground wire is sufficient if you use Jumpers JP1 through JP16 and JP18 Reference Section 2 1 for additional information e Start of stage will read Analog 6 only Copyright 1983 2007 2 18 810 0043 Revision R Mattec Corporation 2 6 Digital Input Wiring TSMIU 0 The digital input connections on the TSMIU 0 must be 12V to 50V DC Contact wiring should
31. on R Mattec Corporation 2 9 2 Calibration You access the Analog Calibration page on the Service Display for a TSMIU or screen 22 MIU Information for an LCD MIU You may be prompted to enter the password that has been configured in System Configuraiton 1 Set the gain on the channels being calibrated to 1 000 Set the offset to 0 2 If you are unsure whether the thermocouples are grounded use an ohmmeter and test for 9 continuity between the casing and the negative pin If the circuit is open it is ungrounded The ohm value will vary with individually grounded thermocouples but will generally be less than 25 ohms For ungrounded thermocouples ensure that the grounding jumpers JA1 14 on the MIU are ON for each individual ungrounded thermocouple channel For grounded thermocouples make sure that the grounding jumpers JA1 14 on the MIU are OFF for each individual grounded thermocouple channel The grounding jumper JA1 14 must be ON for an individual channel to correctly read the thermocouple calibrator To facilitate accurate calibration of grounded thermocouples it is good practice to first remove the ground jumpers for those channels keep the door closed to allow thermal stabilization and inject the calibration signal at the external junction box In doing so you must properly ground the negative terminal of the calibrator to the machine to assure a correct reading Set the simulator to a temperature that rep
32. pF UM INPUT SEL u RAB RRB 12 Volts Common No Connect Earth Ground MIU 9DC Power Supply Wiring Diagram Warning Do not bring AC voltage into the MIU Use the supplied 12 12 DC power supply only Components in the MIU are static sensitive Copyright 1983 2007 4 43 810 0043 Revision R Mattec Corporation 4 3 Host Communications The MIU 9DC is connected to the host computer buffer box via an RS 485 cable that is daisy chained from one MIU to the next and is eventually connected to the buffer box The MIU 9 is capable of communicating with the host computer at 4 800 baud only Notes To next MIU Red my Green Edo 177 Belden IBSA 3 Txt rem Bir Q Belden 877 For Isolation System Only DO NOT REMOV F TB3A 4 Tx Black Red Green 1B3 1Rxt fo pair used r From computer or TBSA 2 Rx IB3 STx Previous MIU TB3A 1 Rx Creen ack Red 1B5 4 Ground Lug Drain Wires elo E Sore MIU 9DC Host Communication Wiring Diagram Loosen the screw terminals all the way ccw Strip the gray vinyl jacket of the RS 485 cable to a maximum of 2 5 inches Strip the foil shields of the RS 485 cable to a maximum of 2 0 inches Keep individual pairs of cables twisted together Twist the shield drain wire together on the from
33. r NOTE Remove all other connections to analog input channels 2 3 4 5 and 6 to display the value you have set on the simulator 9 Set the simulator to read the thermocouple type you are calibrating 10 Plug the desired thermocouple for channel into the simulator and record the value 11 Use the equation in step 17 to determine the offset to enter at the host computer After entering the offset connect the thermocouple to analog channel 1 on the MIU The reading should be within 1 degree 12 DO NOT ADJUST P1 AGAIN Calibrate channels 2 then 3 then 4 by connecting the thermocouple to the simulator and record the values as SIMULATOR VALUE 13 Connect the thermocouples to the MIU and record the values displayed at the MIU as MIU DISPLAYED VALUE 14 Return to the Host computer and use the equation below to calculate the offset to enter at the Host computer MIU setup page SOFTWARE OFFSET SIMULATOR VALUE MIU DISPLAYED VALUE Copyright 1983 2007 2 28 810 0043 Revision R Mattec Corporation 15 All values can be entered at the MIU if you put the system into remote calibration mode Refer to the Operator s Manual for further information on remote calibration 2 9 4 Transducer Calibration Procedure Shunt Resistor Method 1 For transducers enable as linear in the MIU setup screen No other selections are needed 2 Most pressure transducers come with a calibration shunt resistor Consult the instructio
34. r no connection TB6 5 5 5V TB6 6 12 TBI 1 12V Warning Damage May Occur Do not plug in TB6 or power on the MIU until the sequence of voltages is verified Perform this Test After the MIU installation is complete verify 5 Volts DC at the MIU with the MIU turned on Take the measurement at the test points to the right of the power plug Place the test leads on TP2 and TP7 The 5 voltage must be no less than 4 9 Volts and no more than 5 1 Volts If the measured voltage is not within this tolerance the power supply should be adjusted Adjust the power supply by changing the potentiometer that is located behind the 5 Volt terminal on the power supply Copyright 1983 2007 2 15 810 0043 Revision R Mattec Corporation 2 4 Host Communications The TSMIU TSMIU 0 MIU 10X MIU SXS or MIU OXS is connected to the host computer buffer box via an RS 485 cable that is daisy chained from one MIU to the next and is eventually connected to the buffer box These MIUs are capable of communicating with the host computer at a number of baud rates Reference Section 2 2 for additional information Black White pair used For Isolation System Only DO NOT REMOVE Black Red TB1 4Tx e Red Belden 8777 tj From computer Wisst Black Green R Belden 8777 or Previous MIU CHE 131 1 Rx Green 18 i 1 To next MIU rain Wires Ground Lug FT g TB
35. rear of the buffer box Notice that there are two MIU channels per green connector The upper row upper green connect is for Channels 1 and 2 The lower row is for Channels 3 and 4 If you are using the Mattec standard color coded wiring described in the MIU Wiring and Installation Manual 810 0043 do the following Connect the GREEN BLACK wire to T reference the diagram below Connect the GREEN wire to T Connect the RED BLACK wire to R Connect the RED wire to R Connect the green connector to the rear of the buffer box as appropriate 6 2 Buffer Box to Computer Wiring When connecting the buffer box to a Rocketport board that is installed in the host computer that was manufactured after 1996 follow these steps Connect Channel 1 of the buffer box to the Rocketport cable marked 0 Connect Channel 2 to cable 1 Connect Channel 3 to cable 2 Connect Channel 4 to cable 3 Connections for older RocketPort boards may differ slightly Connect the RocketPort cable to the RocketPort board that is installed in the host computer Copyright 1983 2007 6 50 810 0043 Revision R Mattec Corporation FRONT VIEW T Channel 1 Channel 2 Channel 3 Channel 4 REAR VIEW Channel 2 Channel RAR TT v va Ra Tal 120 230 VAC THtOMIU RK y va Rap Ta T
36. resents the lowest value you would expect to read Record the value that is read by the MIU and make a note of it Set the simulator to a temperature that represents the highest value you would expect to read Record the value that is read by the MIU and make a note of it Note the error at both settings e g Set for 1000 F MIU reads 1004 F and reduce or increase the gain until the error on the high setting is the same as the error on the low setting This may require a few passes to get completely correct Gains will almost be 1 e g 996 or 1 002 Once the error is the same at the high and low setting use this error as the offset 10 Record the gain and offset and enter them at the MIU Copyright 1983 2007 2 27 810 0043 Revision R Mattec Corporation 2 9 3 Thermocouples Calibration Procedure 1 Identify what type of thermocouple you are going to calibrate i e J or K 2 Enable the channel properly in the Machine Configuration program 3 You must now go to the machine MIU you have decided to do the calibration on 4 Ensure the MIU has been closed and sealed shut for approximately one hour 5 Set the simulator to the correct thermocouple type 6 Set the simulator to a value in the middle range of the actual value that you want to monitor and connect it to the MIU 7 At the MIU select the function that will display the actual value for analog number one 8 Adjust the Pl temperature compensation potentiomete
37. rts Needed 1 One 1 light stack and mounting bracket 2 Four 4 DIP reed relays to be installed in the MIU 3 Four 4 ice cube relays and bases to be installed in the control panel Notes e Install the supplied DIP relays in sockets K5 K8 located next to the terminal blocks shown in the diagram above e Mount the external relays as close as possible to the stack lights Do not mount the relays inside the MIU shell e Connect an external relay coil power 12V and COM in diagram to the MIU power connector e Use 18 gauge wires for all connections e Ifneeded ensure that the MIU is running the most recent version of code that is available from Mattec Contact the Mattec Customer Service Department for additional information Copyright 1983 2007 2 23 810 0043 Revision R Mattec Corporation 2 9 Analog Input Wiring The TSMIU TSMIU 0 and MIU 10X are optionally capable of monitoring up to 12 raw analog values and two derived analog values In the standard configuration the MIU analogs 1 4 and 7 10 are configured for J type thermocouples and analogs 5 6 and 11 12 are configured for a pressure transducer Upper Terminals Lower Terminals 1 Anal ats gt Thermocouple Analog An3 Analog Es An3 Analog 10 v pr Ti gt r 1 Pressure Ground Ground gt Transducer An6 10 v war An6 10 v Ground uou AUWNE Analog FR L
38. tput connections are described in the following table Ol Out 1 O2 Out 2 03 Out 3 O4 Out 4 Copyright 1983 2007 Mattec Corporation O5 Out 5 06 Out 6 O7 Out 7 O8 Out 8 3 41 810 0043 Revision R 4 MIU 9DC The MIU 9DC is a low cost machine interface unit that provides basic production monitoring and an easy to use 16X40 character LCD Display 4 1 Jumper Settings Jumper settings for the MIU 9DC are shown below MIU 9 SWITCH SE 1st PHYSICAL MIU ON CHANNEL AST PHYSICAL MIU ON CHANN MIU 9DC Switch Settings The following switch settings are available in the MIU 9DC e JA1 JA2 and JR1 Cycle Time Jumpers JA1 JA2 and JR1 are provided to select the input voltage type The only available section is DC e JB1 JB2 and JR2 Pulse 2 Jumpers JB1 JB2 and JR2 are provided to select the input voltage type The only available selection is DC e JX2 Default ON Jumper JX2 connects Earth Ground to Logic Ground e JX5 Default OFF Jumper JXS is provided for end of line termination for Copyright 1983 2007 4 42 810 0043 Revision R Mattec Corporation MIU to host communications Only enable this jumper in the last MIU on each RS 485 channel e JX3 and JX4 Consult Mattec for use 4 2 Power Supply Do not bring AC voltage into the MIU 9DC Use the supplied 12 12 DC power supply only d aL 1 reL 22
39. x Rs 485 NEG POS SHORT SHORT 2WIRE TB5 1 TB5 2 Current oe Loop RS 232 RS 485 2WIRE MOTT ee TTT OL gt T E gt of ess ET 4 10X98 PLC Wiring Diagramm COM3 Notes e If you are using a TSMIU ensure that you select the correct PLC interface on the Service Display If you are using an LCD MIU ensure the MIU s disk on chip corresponds to the appropriate PLC interface In both cases ensure that you specify the appropriate PLC interface in the Machine Configuration program via a computer e Jumpers such as J9 or J5 are no longer needed Reference the PLC Subsystems Manual 810 0078 for additional information Copyright 1983 2007 2 31 810 0043 Revision R Mattec Corporation 2 11 AIU Wiring Some MIUs are capable of supporting one or more external AIUs to extend the process monitoring capabilities of the host MIU This requires you to use the PLC Port COM3 on the host MIU for communications with the remote AIU Notes e Set JA 7 through JE 7 for RS 485 on the host MIU e Connect the PLC Port COM on the host MIU to the host communications port on the remote AIU e On subsequent remote AIUs connect the host communications port on one to the host commu
40. y in real time 1 2 Shut Down Procedure ProHelp EPM is intended to run 24 hours per day every day When it does become necessary to reboot the system use this procedure It will bring the system to an orderly shut down e Announce to all users that you will be taking the system down Have all users exit the ProHelp EPM software e Assure that no ProHelp EPM job changes are under way e Assure that a shift change is not in progress e Login to the server computer as an authorized user e Using the mouse click on the Microsoft Windows Start Menu and select Shut Down The Shut Down Windows dialog box will be displayed e Select Shut Down the computer and press Ok Copyright 1983 2007 1 7 810 0043 Revision R Mattec Corporation 2 TSMIU TSMIU 0 MIU 10X MIU 5XS MIU 0XS Many of Mattec s more advanced MIUs are based on the 10X98 motherboard including e TSMIU The TSMIU is a color touch screen MIU that has optional analog inputs and an optional PLC interface e TSMIU 0 The TSMIU 0 is a color touch screen MIU that is capable of monitoring 2 to 16 machines It has optional analog inputs but can not have a PLC interface e MIU 10X The MIU 10X is an MIU with optional analog inputs and an optional PLC interface It has a 16 by 40 character LCD display e MIU 5XS The MIU 5XS is an MIU with an optional PLC interface Some of these MIUs can be upgraded to an MIU 10X while others can not be upgrade
41. y sourced input signals e Loosen the screw terminals all the way ccw e Strip the contact wire approximately 1 4 inch e Insert the appropriate contact wires into the indicated terminals e Tighten the screws assuring that the insulation of the wire is not pinched in the connection e Gently tug on the contact wires to ensure you have made a good connection Copyright 1983 2007 4 45 810 0043 Revision R Mattec Corporation 4 5 Digital Output Wiring The output contacts on the MIU 9DC are rated at 500ma maximum An external secondary contact is required for all external loads ua c18 ree 2 RC 2 Er enr F uit PR TE iK Le Bete 995 Eire pria Piik Eeke KI xe ar ir njrees 3 4 External Customer Supplied DC Relay Coil 100 v max 5 max MIU 9DC Digital Output Wiring Diagram Warning Do not bring AC voltage into the MIU Copyright 1983 2007 4 46 810 0043 Revision R Mattec Corporation 4 6 Motherboard The Motherboard for the MIU 9DC is shown below R8 6ni3s 6N138 BE ES R18 R12 6N138

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