Motrona MS 640 Operating Instructions Manual
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Motrona MS 640 Operating Instructions Manual

Programmable motion monitor for secure and redundant control of motion sequences
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Programmable Motion Monitor for Secure and
Redundant Control of Motion Sequences
• Suitable for monitoring of overspeed, underspeed, standstill, direction of rotation,
slip, shaft or gearbox fracture, impermissible motion etc.
• Six logical inputs for plausibility considerations and control of logical conditions
• Two programmable inputs for quadrature encoders
(each A, /A, B, /B for counting frequencies up to 500 kHz)
• Four safety relays with forced-guided contacts and four high-speed transistor
outputs, all with feedback and control of the actual output state
• Serial RS232 and RS485 interfaces for remote access to all functions and data
• High safety level on the machine site by redundant and logical control algorithms
• High functional safety of the monitor itself by internal test routines and diagnostics
Ms640_02b_oi_e.docx / Sep-22
MS 640
Operating Instructions
Page 1 / 54

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Summary of Contents for Motrona MS 640

  • Page 1 MS 640 Programmable Motion Monitor for Secure and Redundant Control of Motion Sequences • Suitable for monitoring of overspeed, underspeed, standstill, direction of rotation, slip, shaft or gearbox fracture, impermissible motion etc. • Six logical inputs for plausibility considerations and control of logical conditions •...
  • Page 2 • Regarding installation, wiring, environmental conditions, screening of cables and earthing, you must follow the general standards of industrial automation industry • - Errors and omissions excepted – General instructions for cabling, screening and grounding can be found in the SUPPORT section of our website http://www.motrona.com Version: Description: MS64001a/mb/hk_05/2010...

  • Page 3: Table Of Contents

    Table of Contents Introduction and Application ......................... 4 Electrical Connections ........................... 5 2.1. Connection Diagram ........................5 2.2. Terminal Assignments ........................6 2.3. Power Supply ..........................7 2.4. Auxiliary Outputs for Encoder Supply ..................7 2.5. Impulse Inputs for Incremental Encoders ..................8 2.6.

  • Page 4: Introduction And Application

    “logical AND / OR” matrix on the screen. MS 640 provides various internal safety functions and automatic self-test routines in order to ensure a maximum of functional safety for the whole monitoring system (see 7.4 - 7.9).

  • Page 5: Electrical Connections

    2. Electrical Connections 2.1. Connection Diagram Power supply 24 VDC or 24 VAC Encoder 1*) Com+ Out 1n Fast transistor outputs Out 2n without control (n) *) The example shows TTL encoders using a Out 3n +5 V power supply XA = 1 - 16 Encoder 2*) Out 4n...

  • Page 6: Terminal Assignments

    2.2. Terminal Assignments XA/XB Name Function Common Ground Potential (0V) +5,2V out Aux. output 5.2V/150 mA for encoder supply +24V out Aux. output 24V/120 mA for encoder supply Common Ground Potential (0V) Encoder 2, /B Encoder 2, channel /B (B inverted) Encoder 2, /A Encoder 2, channel /A (A inverted) Encoder 1, /B...

  • Page 7: Power Supply

    Name Function Rel4-NO Relais 4, Schließer Rel4---C Relais 4, gemeinsamer Kontakt Rel4-NC Relais 4, Öffner Rel3-NO Relais 4, Schließer Rel3---C Relais 4, gemeinsamer Kontakt Rel3-NC Relais 4, Öffner Rel2-NO Relais 4, Schließer Rel2---C Relais 4, gemeinsamer Kontakt Rel2-NC Relais 4, Öffner Rel1-NO Relais 4, Schließer Rel1---C...

  • Page 8: Impulse Inputs For Incremental Encoders

    2.5. Impulse Inputs for Incremental Encoders All input characteristics of the impulse inputs can be set by the parameter menu, for each of the encoders separately. Due to the high safety demands made on this unit it is mandatory to use quadrature encoders only (A, B or A, /A, B, /B, 90°) The following levels and impulse standards can be used: Symmetric inputs (differential) according to RS422 standard...

  • Page 9: Control Inputs 1 - 4

    2.6. Control Inputs 1 – 4 These inputs can be configured for remote functions like Reset, disable of the keyboard or display selection purpose etc. All control inputs require HTL level (12 ... 30 volts). The characteristics can be individually set to either NPN (switch to -) or PNP (switch to +). For applications where edge-triggered action is needed, the menu allows to set the active edge (rising or falling).

  • Page 10: Forced-Guided Safety Relays Rel.1S - Rel.4S

    2.9. Forced-Guided Safety Relays Rel.1s - Rel.4s The four relays provide two dry change-over contacts each with forced-guided mechanical construction. The switching capability is 250 VAC / 1 A / 250 VA or 100 VDC / 1 A / 100 W and the response time of the relays is in a range of 5 to 10 msec.

  • Page 11: Serial Interface

    2.10. Serial Interface The serial RS232 interface can be used for the following purposes: • Set-up of the unit by PC by means of the OS32 PC software • Change of parameters during operation • Readout of actual speeds or positions or other counter values by PLC or PC •...

  • Page 12: Relevant Process Data And Setpoints

    3. Relevant Process Data and Setpoints 3.1. Available Actual Values Depending on the connected encoders and sensors, the monitor continuously measures and updates the actual values shown in the list below. This means that every of these actual values is available at any time for evaluation and can be combined with other functions to switch one of the outputs ON or OFF.

  • Page 13: Available Setpoints

    3.2. Available Setpoints For configuration of the switching conditions of the relays, the following setpoints are available. Every setting is individual for each of the four switching functions. In total there are 4 x 7 = 28 programmable setpoints available. Settings can be omitted if the corresponding setpoints have not been assigned to a switching function.
  • Page 14 3.3.2. Speed related switching conditions Condition Description of the Switching Condition [v1] ≤ Set Speed1.1 The absolute value of the actual encoder1 speed is lower or equal to the set speed 1.1 [v1] ≥ Set Speed1.1 The absolute value of the actual encoder1 speed is higher or equal to the set speed 1.1 [v1] ≥...

  • Page 15: Generation Of An Output Signal

    3.4. Generation of an Output Signal As a first step we have to arrange the desired Switching Events, which can be composed from any combination of the switching conditions as described above. Every event consists of one or several conditions according to the selection of check boxes on the PC screen (see 4.3). Several events (1 - 4) are combined to a Switching Function.

  • Page 16: Indication Of Switching Functions

    3.5. Indication of Switching Functions With some applications it can be useful to just present actual events and switching functions o the display without affecting an alarm output. Similarly a visual display of actually active events may be desirable in addition to an alarm output. Therefore, quite according to the parameters "Target Function", the parameters "Target Display"...

  • Page 17: Setup Of The Unit By Pc

    4. Setup of the Unit by PC 4.1. PC connection For initial setup of the MS640 Motion Monitor a PC with the motrona OS32 operator software is required (Software version OS32_02a or higher). This software is included on CD and is also available for free download from our homepage www.motrona.com.
  • Page 18 Ms640_02b_oi_e.docx / Sep-22 Page 18 / 54...

  • Page 19: Pc Screen For Configuration Of Switching Functions

    4.3. PC Screen for Configuration of Switching Functions To open the Assignment screen, select “Config. MM/MS” from the Tools Menu. You can assign any combination of switching events and functions to the outputs or relays by clicking to the corresponding boxes of conditions as described before. In the “Options”...
  • Page 20 Ms640_02b_oi_e.docx / Sep-22 Page 20 / 54...

  • Page 21: Keypad Operation

    5. Keypad Operation An overview of all parameters and explanations can be found under section 6. The menu of the unit uses four keys, hereinafter named as follows:  PROG DOWN ENTER Key functions depend on the actual operating state of the unit. Essentially we have to describe two basic states: •...
  • Page 22 Step State Key action Display Comment Normal operation Actual Display Value Display of the > 2 sec. Parameter group Level: F02 … F06 Select group # F06 Parameter group Confirmation of F06. F06.050 The first parameter of this group is F06.050 Level: F06.051…...

  • Page 23: Change Of Parameter Values On The Numeric Level

    5.3. Change of Parameter Values on the Numeric Level The numeric range of the parameters is up to 6 digits. Some of the parameters may also include a sign. For fast and easy setting or these values the menu uses an algorithm as shown subsequently.

  • Page 24: Code Protection Against Unauthorized Keypad Access

    5.4. Code Protection against Unauthorized Keypad Access Parameter group F11 allows to define an own locking code for each of the parameter menus. This permits to limit access to certain parameter groups to specific persons only. When accessing a protected parameter group, the display will first show “CODE” and wait for your entry.

  • Page 25: Menu Structure And Description Of Parameters

    6. Menu Structure and Description of Parameters All parameters are arranged in a reasonable order of functional groups (F01 to F11) You must only set those parameters which are really relevant for your specific application. Unused parameters can remain as they actually are. 6.1.
  • Page 26 Gruppe Funktion Gruppe Funktion Logical Inputs Delay Settings Command Setting Login 1 On Delay Key Up Action Login 1 Off Delay Key Down Action Login 2 On Delay Key Enter Action Login 2 Off Delay Input 1 Configuration Login 3 On Delay Input 1 Action Login 3 Off Delay Input 2 Configuration...

  • Page 27: Description Of The Parameters

    6.2. Description of the Parameters 6.2.1. Settings for Switching Function 1 Range Default F01.000 Set Speed 1.1 0 … 999 999 11001 First Setpoint for a switching condition of Function1 in dependence of the encoder1 speed F01.001 Set Speed 1.2 0 …...
  • Page 28 Range Default F01.011 Switch on Delay 0.000 … 9.999 0.000 Delay time between event appearance and (sec.) switching response of Function 1. 0 = immediate response F01.012 Pulse Time 0.000 … 9.999 0.000 Duration time of Switching Function 1 (sec.) 0 = static operation F01.013 Lock Function 0 …...
  • Page 29 6.2.3. S Settings for Switching Function 3 (Description see Function 1) Range Default F03.032 Set Speed 1.1 0 … 999 999 13000 F03.033 Set Speed 1.2 0 … 999 999 23000 F03.034 Set Speed 2.1 0 … 999 999 23000 F03.035 Set Speed 2.2 0 …...
  • Page 30 6.2.5. Delay setting for logical Inputs Range Default F05.064 Login 1 On Delay 0.000 … 9.999 0.000 The input must be HIGH for at least this delay time 0 = no delay, immediate (seconds) to set the internal input state to high. response F05.065 Login 1 Off Delay 0.000 …...
  • Page 31 Range Default F06.080 Multi. Speed 1 **) 0 … 999 999 F06.081 Divi. Speed 1 **) 0 … 999 999 F06.082 Offset Speed 1 **) -99 999 … 99 999 Parameters F06.080 to F06.082 are used to scale the frequency of encoder 1 (XXXXX.X Hz) to customer units. F06.083 DP Speed 1 0 …...
  • Page 32 6.2.7. Encoder 2 Settings (Description see “Encoder 1 Settings”) Range Default F07.091 Factor Counter 2 0.00001 … 9.99999 1.00000 F07.092 Multi. Counter 2 1 … 99 F07.093 DP Counter 2 0 … 5 F07.094 Dir Window Counter 2 1 … 99 F07.095 Multi.
  • Page 33 6.2.9. Characteristics and functions of the Control Inputs Range Default F08.109 Input 1 Configuration 0 … 7 NPN (switch to -), function active LOW NPN (switch to -), function active HIGH NPN (switch to -), rising edge NPN (switch to -), falling edge PNP (switch to +), function active LOW PNP (switch to +), function active HIGH PNP (switch to +), rising edge...
  • Page 34 Range Default F08.117 Target Function 1 0 ... 255 *) 1+16=17 Output assignment for Function 1 1 => Relay 1 F08.118 Target Function 2 2+32=34 Output assignment for Function 2 2 => Relay 2 F08.119 Target Function 3 4+64=68 Output assignment for Function 3 4 =>...
  • Page 35 Range Default F08.125 Target Display 0 … 15 (see clarification under 7.7) Presentation of actual switching events on the LED display 0= no display 4-bit binary code: 1 => Function 1 1= Display when Switching Function 1 is true 2 => Function 2 2= Display when Switching Function 2 is true 4 =>...
  • Page 36 6.2.10. Serial communication settings Range Default F09.132 Unit Number 11 … 99 F09.133 Serial Baud Rate 0 … 6 9600 Baud 4800 Baud 2400 Baud 1200 Baud 600 Baud 19200 Baud 38400 Baud F09.134 Serial Format 0 … 9 7 Data, Parity even, 1 Stop 7 Data, Parity even, 2 Stop 7 Data, Parity odd, 1 Stop 7 Data, Parity odd, 2 Stop...
  • Page 37 6.2.11. Special Functions Range Default F10.138 Input filter: must be set to “0”. 0 … 3 F10.139 Trigger Threshold 1 for encoder1 inputs *) 30 … 250 F10.140 Trigger Threshold 2 for encoder2 inputs *) 30 … 250 F10.141 Brightness of the 7-segment LED display 0 …...

  • Page 38: Important Hints For The User

    7. Important Hints for the User 7.1. Description of keypad commands and remote commands No. Command Description Assignment to Keypad Input Do nothing No commands are assigned to keypad and inputs Reset Counter 1 Sets the internal position counter for encoder 1 to zero.
  • Page 39 No. Command Description Assignment to Keypad Input n.a. Parameter Disables the keypad for any access to parameters. Disable Commands assigned to the keypads will remain executable Store EEProm Stores actual operational settings to the EEProm, so they remain available also after power down. Release Function Releases all switching functions defined by Lock...

  • Page 40: Hints For Scaling Of The Unit

    7.2. Hints for Scaling of the Unit The scaling parameters of the unit will affect the display of the actual values as well as the associated Setpoints for the switching functions. In principle, there are two fully independent sets of scaling parameters: a.
  • Page 41 7.2.2. Standstill Definition (Wait-Time) This definition is related to the input frequency only and does not depend on any other scaling parameters. It is necessary to set the period time of the minimum frequency that the unit still should consider as “motion”. When e.g.

  • Page 42: Example For The Function Of The Digital Filter

    7.3. Example for the Function of the Digital Filter Filter settings are intended to have an effect on speed measurement only but not on the positional counting. The diagrams below explain the response of the monitor with different filter settings. In our example the following initial situation is assumed: •...

  • Page 43: Internal Self-Testing Functions Of The Monitor

    7.4. Internal Self-Testing Functions of the Monitor The MS 640 monitor is equipped with comprehensive and profound self-testing routines in order to ensure a maximum of functional safety and reliability of the whole control process. These tests provide at an early stage detection and immediate indication of possible failures inside the monitor itself.

  • Page 44: Manual Release Of A Self-Testing Cycle

    7.5. Manual Release of a Self-Testing Cycle At any time the operator can release a complete self test by means of a corresponding manual command (see assignments of commands to keys and inputs, chapters 6.2.8 and 6.2.9). • Every manually released testing cycle will also commutate all relays and outputs to both directions.

  • Page 45: Behavior In Case Of Error, Error Messages

    7.6. Behavior in Case of Error, Error Messages Every detected error will immediately switch the Ready signal off. At the same time an error message is indicated on the LED display and an error status word is sent to the corresponding memory location (serial access code 8 A).

  • Page 46: Display Of Switching Functions And Principle Of Operation Of Parameter "Target Display

    7.7. Display of Switching Functions and Principle of Operation of Parameter "Target Display" Many times it may be useful to see the actual state of the switching matrix on the display (cf. 3.4 and 4.3). When the scrolling function of the display has been enabled, it is possible at any time to scroll to the corresponding switching state indication (see "Scroll Display"...

  • Page 47: Temporary Interruption Of The Display Of Switching States

    7.8. Temporary Interruption of the Display of Switching States Whenever parameter "Target Display" causes overwriting of the actual display, or when an Error Message appears, the normal scrolling of the display values according to chapter 7.1 will be disabled until the event of higher priority has disappeared. Where you still like to get access to other actual display values (e.g.

  • Page 48: Serial Access Codes

    8. Serial Access Codes Parameters Menu Description Code Minimum Maximum Default Set Speed 1.1 999999 11001 Set Speed 1.2 999999 11002 Set Speed 2.1 999999 21001 Set Speed 2.2 999999 21002 Setpoint Counter 1 999999 31000 Setpoint Counter 2 999999 41000 Differential Setpoint 999999...
  • Page 49 Parameters (cont.) Menu Description Code Minimum Maximum Default Switch Event 1 -2147483648 2147483647 Switch Event 2 -2147483648 2147483647 Switch Event 3 -2147483648 2147483647 Switch Event 4 -2147483648 2147483647 Switch on Delay 9999 Pulse Time 9999 Lock Function Polarity Reserved 999999 Set Speed 1.1 999999 14000...
  • Page 50 Parameters (cont.) Menu Description Code Minimum Maximum Default Factor Counter 1 999999 100000 Multi. Counter 1 DP Counter 1 Dir Window Counter 1 Multi. Speed 1 999999 Divi. Speed 1 999999 Offset Speed 1 -99999 99999 DP Speed 1 Sampling Time 1 9999 Wait Time 1 9999...
  • Page 51 Parameters (cont.) Menu Description Code Minimum Maximum Default Target Function 1 Target Function 2 Target Function 3 Target Function 4 Target Status 1 Target Status 2 Target Status 3 (keypad) Target Status 4 (READY) Target Display Release Action Freeze Action Output Error Config.
  • Page 52 Control Commands No. Command Code Wert Serial Remote Reset Counter A 0080 Reset Counter B 0040 Reset Difference 0020 Scroll Display 0010 Activate Data 0008 Keyboard Disable 0004 Store EEProm 0002 Release Function Lock 0001 Freeze Function 8000 Reset Total 4000 Start Self Test 2000...

  • Page 53: Technical Specifications

    9. Technical Specifications AC power supply 24 V~ +/-10%, 15 VA DC power supply 24V- (17 – 40V), approx. 100 mA (+ encoders) Ripple ≤ 10% @ 24VDC Aux. encoder supply outputs 2 x 5,2 VDC, 150 mA each 2 x 24V DC, 120 mA each Inputs 2 universal encoder inputs, A, /A, B, /B each 4 digital control inputs HTL/PNP-NPN (Ri = 3.3 kΩ)

  • Page 54: Dimensions

    110,0 (4.331’’) 88,5 (3.484) 96,0 (3.780’’) With optional plexi glass cover for protection class IP65 motrona part # 64026) 9,0 (.345) 129,0 (5.079) 140,5 (5.531) 18,5 (.728) Panel cut out (b x h): 89 x 91 mm (3.504’’ wide x 3.583’’ high) Ms640_02b_oi_e.docx / Sep-22...

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