10000004379ea PSI 300 Connection To Automation System

Code 10000004379 Revision A Page 1 (26)
Connection to automation system

Contents
1. INTRODUCTION ............................................................................................................................................3
2. OPC connection............................................................................................................................................4
Introduction ....................................................................................................................................4
OPC client configuration ................................................................................................................5
3. Profibus connection .....................................................................................................................................6

Introduction ....................................................................................................................................6
Installing Profibus DP slave card to Panel .....................................................................................7
Configuring Profibus DP Master ....................................................................................................9
4. Modbus RTU................................................................................................................................................11
Introduction ..................................................................................................................................11
Configuring Modbus RTU master ................................................................................................12
5. Modbus TCP................................................................................................................................................13
Configuring Modbus RTU/TCP converter ....................................................................................13
Configuring Modbus TCP master.................................................................................................15
READER COMMENTS
1. INTRODUCTION
This manual provides detailed information on how to install and configure PSI
300 connection to plant automation system. There are five ways to connect PSI
300 to plant automation system:
1. OPC communication link
2. Profibus DP communication link
3. Modbus RTU serial line communication link
4. Modbus TCP Ethernet communication link
5. 4-20 mA analog signals.
Each communication type is different and requires additional configuration.

2. OPC connection
Introduction
OPC (OLE for Process Control) is a general communication standard what
allows communication between different control devices from different
manufacturers.
The OPC connection for PSI 300 requires OPC server and Ethernet connection
to PSI 300. The OPC server software is provided with PSI 300 but the customer
provides OPC client.
The OPC server can be installed to any workstation in plant network. It is

recommended that the OPC server runs on same computer as the OPC client.
If OPC server and OPC client are on separate workstations, additional
configuration in Windows DCOM settings is required to establish connection
between server and client.
Plant DCS
PSI 300
PARTICLE SIZE ANALYZER
OPC Server (and client)
Ethernet
OPC client
Figure 1. OPC connection diagram

OPC client configuration

After the OPC server is installed, you can test connection to PSI 300. To
Connect PSI 300, you need to know the PSI 300 IP address. The OPC
connection is created with two important settings; OPC server name and tag
address.
The OPC server name is always:
View.OpcServer.1
(Case sensitive)
The tag address (or ID in some cases) is formed from PSI 300 IP address and
variable name. For example the address for variable “OPC_test” in address
10.0.0.1 is:
10.0.0.1\OPC_test
Unfortunately browsing variables through OPC is not supported. Each tag must
be created separately. Appendix A. OPC variable data includes list of available
tags for PSI 300.
Follow the steps to test OPC connection:

Use OPC client to connect the OPC server View.OpcServer.1.
Create a new group “test”
Add a Boolean type item/tag to the group.
The address (or ID in some cases) of the tag is following:
xxx.xxx.xxx.xxx\OPC_test
Where xxx.xxx.xxx.xxx is the PSI 300 IP address.
If the tag gives value “1” (or true), OPC connection to PSI 300 is working.
3. Profibus connection
Introduction
Profibus DP (Decentralized Peripherals) is a widely used field bus standard for
field devices. Mainly it is pictured as a link between PLC (master) and I/O or
instrument (slave).
Usually PSI 300 profibus connection is following type:
Plant DCS
Operator station
PSI 300
Profibus DP
slave PLC/Process station
Profibus DP
master
Profibus DP
Figure 2. Common Profibus DP connection diagram
To be able to use Profibus DP with PSI 300, the panel in PSI 300 requires
additional Profibus DP slave card. This card is not a standard component for
PSI 300 and is included only with Profibus option.
Profibus cable must be according to IEC 61158 specifications.

Installing Profibus DP slave card to Panel
Profibus DP
interface
Termination
switch
Address
switches LED indicators
Figure 3. Profibus DP slave module
Follow the steps to install Profibus communication module:

Disconnect DC input power.
Open the back cover of Panel
Attach the Profibus communication module to the unit by plugging the
module into the mating connectors on the back of the unit.
Install the three screws to secure the card in the unit
Note: Profibus slave card package does not include mounting
screws.
Close the cover.
Figure 4. Application connector and mounting screws inside the panel
Figure 5. Profibus module and connector
The card includes two settings what must be set correctly: Termination switch
and Address switches.
Termination switch must be on when the PSI is the last Profibus device on the
same cable. Termination is always required at the beginning of the cable and at
the end of the cable. Notice that many Profibus cable plugs include termination
switch also.
Address switches define the Profibus DP slave address (figure 3.).
Address = (left switch settings x 10) + (Right switch settings x 1)
Following table shows general properties of Profibus DP slave:
Profibus slave properties

Maximum cable length 200 meters
Station address User defined by address switches
Connection speed 1.5Mbps
Not used Ready (online)
Offline Diagnostics
Figure 6. Profibus module LED indicators
LED Indication Description

Not used - Not used
Ready Green Green – Module is On-line and data exchange is possible.
Turned off – Module is not On-line
Offline Red Red – Module is Off-line and no data exchange is possible.
Turned off – Module is not Off-line
Diagnostics Red Flashing red 1 Hz – Error in configuration: IN and/or OUT
length set during initialization of the module is not equal to the
length set during configuration on the network.
Flashing red 2 Hz – Error in User Parameter data: The
length/contents of the User parameter data set during
initialization of the module is not equal to the length/contents
set during configuration of the network.
Flashing red 4 Hz – Error in initialization of the PROFIBUS
communication ASIC.
Turned off – No diagnostics present.
Configuring Profibus DP Master

Appendix B. Profibus variable data includes list of available information from
PSI 300 through Profibus DP. Notice that because of limited amount of space in
Profibus DP, it does not include any floating point values. This means that the
raw values from PSI 300 does not include decimals. All available variables that
include decimals are multiplied by x10 or x100. Mostly this means assays. See
appendix B for more information.
Following table shows general properties of Profibus DP master.
Profibus master properties

Station address User defined
Slave station addresses User defined by address switches in PSI 300
panel.
Connection speed 1.5Mbps
Maximum amount of slaves 126
4. Modbus RTU
Introduction
Modbus is a communication protocol designed for Modicon devices. Due to its
versatility it has become common communication method for several different
PLCs and automation systems. Modbus is a master-slave type of
communication where the master initiates a transaction. Transactions can be
either query / response.
Plant DCS
Operator station
PSI 300
Modbus slave
PLC/Process station
Modbus
Modbus RTU with master
RS485
Figure 7. Common Modbus RTU connection
Modbus RTU in PSI 300 uses RS485 serial communication. RS485 allows
longer distances between devices than RS232.
For Modbus RTU, the cable must be twisted pair cable. Figure 5. displays
connectors for Modbus RTU. (Surge arrester BVT RS485 is required for
protecting the panel from overvoltage.)
25 Pin RS485
female connector Surge Arrester Customer DCS
(in panel) BVT RS485
GND 4 4 GND
1
TxD- 5 5 TxD-
11
TxD+ 6 OUT IN 6 TxD+
15
RxD- 7 7 RxD-
10
RxD+ 8 8 RxD+
16
Figure 8. Modbus RTU with RS485 connection
The Modbus protocol address range is following type:
Address Data type Default

0xxxx Discrete Output
1xxxx Discrete Input
3xxxx Integer or real Input
4xxxx Integer or real Output
PSI 300 uses only 0xxxx, 1xxxx and 4xxxx.
Configuring Modbus RTU master

Modbus RTU slave does not require any configuration, but Modbus master
communication link in DCS must match following Modbus RTU properties.
Modbus RTU properties

Communication type RS485 serial
Speed 9600
Data bits 8
Parity Even
Mode RTU
Stop bits 1
Flow control none
Maximum cable length 1200m
Available data through Modbus RTU is listed in Appendix C. Modbus variable

data.
5. Modbus TCP
Modbus TCP is very similar to Modbus RTU but transmits the protocol packets
within TCP/IP data packets. Modbus TCP can use normal plant network for
communicating.
Modbus TCP properties

Module type VersaMax SE Serial to Ethernet adapter
IC200SET001-CC
Communication type 10/100Base-T
Speed 100 Mbps
IP-address Customer specified
Maximum cable length 100 meters
In PSI 300 Modbus TCP is converted from Modbus RTU (RS232) with
VersaMax SE Serial to Ethernet adapter. Following picture shows pin
assignments in Modbus RTU/TCP converter.
25 Pin RS232 VMSE

female connector Customer DCS
Modbus RTU/TCP
(in panel) converter
GND 8 GND
7 10/100 Base-T
TxD 4 TxD RJ45
2
RxD 1 RxD
3
Figure 9. Modbus TCP connection
Customer only connects the Ethernet-cable to Modbus RTU/TCP converter

Ethernet-slot.
Configuring Modbus RTU/TCP converter

The VersaMax SE Serial to Ethernet adapter requires some configuration to
work properly. A PC is required for module configuration. More information
about the module can be found from ‘VersaMax Serial to Ethernet Adapter
User’s Manual GFK-1852’.
First task is to set up correct IP-address for the Modbus RTU/TCP converter.
This is done by assigning IP-address with arp (address resolution protocol).
Follow the steps to set up IP-address:
Open Command prompt
type command:
arp –s inet_addr eth_addr
where:
inet_addr is the IP-address
eth_addr is the Module MAC-address. the MAC-Address is located on

side of the module. VMSE always has first three bytes fixed and read 00-
20-4A.
For example:
arp –s 192.168.0.1 00-20-4a-01-01-01

Test the connection by pinging the module IP-address. For example:
ping 192.168.0.1
Now the IP address is set up. Next task is to configure the module.
Use windows telnet to connect the Modbus RTU/TCP converter. The port is
‘9999’.
Figure 10. Telnet on command prompt
After connect, press enter to go into setup mode.

Figure 11. Configuration window
See that the configuration is following:

IP address: Customer specified
Default gateway: Customer specified
Netmask: Customer specified
Protocol: Modbus/RTU, Slave
Serial interface: 9600,8,E,1,RS232
After configuration, type S to save and restart module.
Now the Modbus RTU/TCP converter is configured and should be working.
Configuring Modbus TCP master

The only information regarding Modbus TCP master in customer DCS required,
is the IP-address of the Modbus RTU/TCP converter (ie. Modbus TCP slave).
Modbus TCP in PSI 300 includes same data as in Modbus RTU. Appendix C.
Modbus variable data.
Appendix A: OPC variable data

Tag address Type Description Value
Alarm_NoFlow[1] BOOL No Flow Warning L1 on/off
Alarm_Blockage BOOL Probe hose line blockage on/off
Alarm_condition BOOL General alarm on/off
Alarm_NoSignal BOOL No measuring signal on/off
St_Dev_In_ZC_Too_High BOOL Alarm Standard deviation in ZC too high on/off
Zero_Level_Below_Low_Limit BOOL Alarm Zero level below low limit on/off
Zero_Level_Over_High_Limit BOOL Alarm Zero level over high limit on/off
AIRPRES BOOL Air pressure OK on/off
WTRPRES BOOL Water pressure OK on/off
Zerocheck_alarm BOOL Zero Check Measurement Failed on/off
OPC_test BOOL OPC connection test variable on/off
W_St_Dev_In_ZC_Too_High BOOL Warning Standard deviation in ZC too high on/off
W_Zero_level_over_high_limit BOOL Warning Zero level over high limit on/off
W_Zero_level_below_low limit BOOL Warning Zero level below low limit on/off
Composite_sample_running BOOL Composite sample running on/off
Meas_running BOOL Measurement running on/off
ZeroCheck_running BOOL State of zero check sequence in logic on/off
Sampler_clean_running[1] BOOL Primary sampler 1 cleaning on/off
Sampler_clean_running[2] BOOL Primary sampler 2 cleaning on/off
Sampler_clean_running[3] BOOL Primary sampler 3 clieaning on/off
NLA1MSW BOOL Primary sampler 1 standby switch on/off
Density_enabled BOOL Density measurement enabled on/off
Ph_enabled BOOL Ph measurement enabled on/off
PSI_OK BOOL PSI operation is correct on/off
Simlevel_ON BOOL Level switch simulation state on/off
LastValue DINT Last particle measurement value from probe 0-32000
DensMean_Value_inZC LREAL Densitymeter weight in zero check kg
SL_DENS DINT Slurry density input 0-32000
SL_PH DINT Slurry pH input 0-32000
Zero_Level LREAL Zerocheck level 0-4000 um
LineInMeasurement DINT Current Line in measurement 1-3
Line_label[1] STRING Line 1 label text
Assay_Invalid[01] BOOL Assay 1 invalid on/off
: : : :
: : : :
Tag address Type Description Value

Assay_Label[01] STRING Assay label 1 text
: : : :
: : : :
Assay_Line[01] DINT Line number for assay 1 1-3
: : : :
: : : :
Assay_Type[01] DINT Assay 1 type 1-6
: : : :
: : : :
1. Particle size
2. Particle size from distribution
3. Flow rate
4. Density
5. Solids % from mass
6. Ph
Assay_Value[01] LREAL Assay 1 value depends from type
: : : :
: : : :
Controls from DCS
Bypass[1] BOOL Line 1 bypass (inverted) on/off

Reset_alarms BOOL Alarm reset on/off
Appendix B: Profibus variable data

Address Addr type Data type Description Value
I0.0 BIT BOOL Motor alarm on/off
I0.1 BIT BOOL Standard deviation in zero check too high on/off
I0.2 BIT BOOL Zero level over high limit on/off
I0.3 BIT BOOL Zero level below low limit on/off
I0.4 BIT BOOL general alarm on/off
I0.5 BIT BOOL Air pressure alarm on/off
I0.6 BIT BOOL Blockage alarm on/off
I0.7 BIT BOOL Water pressure alarm on/off
I1.0 BIT BOOL No flow from line 1 on/off
I1.3 BIT BOOL No signal from measurement probe on/off
I1.4 BIT BOOL Standard deviation in zero check too high on/off
I1.5 BIT BOOL Warning zero level over high limit on/off
I1.6 BIT BOOL Warning zero level below low limit on/off
I2.0 BIT BOOL Composite sample running on/off
I2.1 BIT BOOL Measurement running on/off
I2.2 BIT BOOL NLA 1 standby switch state on/off
I2.5 BIT BOOL Level switch simulation state on/off
I2.6 BIT BOOL PSI 300 standby state on/off
I2.7 BIT BOOL Profibus state on/off
I3.0 BIT BOOL Zero check running on/off
I3.1 BIT BOOL Bypass 1 state on/off
I4.0 BIT BOOL Assay invalid 1 on/off

IW9 WORD DINT Assay value 1 depends on type*

IW89 WORD DINT Measurement value (0-4000.0) x 10
IW91 WORD DINT Density value (0-4.00) x 100
IW93 WORD DINT Ph value (0-14.00) x 100
IW95 WORD DINT Zero level (0-4000.0) x 10
IW97 WORD Reserved
IB99 BYTE DINT Assay 1 type 1-6

IB139 BYTE DINT Current line in measurement 1-3
Q0.0 BIT BOOL Line 1 bypass control on/off

Q1.0 BIT BOOL Alarm reset on/off
Total amount of Profibus data is 144 Bytes input, 2 Bytes output.
PSI 300 Profibus slave uses byte addressing. Profibus master must use
byte addressing also.
Profibus slave always transmits the whole 139 bytes input and 3 bytes output in
previous table order.
1 byte = 8 bit
1 word = 2 byte
IW = Input word (reserves 2 bytes) (range: 0-32767)

IB = Input byte (range: 0-255)
I = Input bit (range: 0-1)
Q = Output bit (range: 0-1)

QB = Output byte (range: 0-255)
Assay values are scaled by assay type. This is needed because Profibus
cannot transmit floating point (REAL) data. Following table shows multiplier for
assays:
Assay type scale decimals

1. Particle size x10 1
2. Particle size from x100 2
distribution
3. Flow rate x100 2
4. Density x100 2
5. Solids % from mass x100 2
6. Ph x100 2
Appendix C: Modbus variable data

Address Type Description value
00001 BOOL Motor alarm on/off
00002 BOOL Alarm Standard deviation in zero check too high on/off
00003 BOOL Alarm Zero level over high limit on/off
00004 BOOL Alarm Zero level below low limit on/off
00005 BOOL General alarm on/off
00006 BOOL Air pressure alarm on/off
00007 BOOL Blockage alarm on/off
00008 BOOL Water pressure alarm on/off
00009 BOOL No flow from line 1 on/off
00012 BOOL No signal from measurement probe on/off
00013 BOOL Warning Standard deviation in zero check too high on/off
00014 BOOL Warning zero level over high limit on/off
00015 BOOL Warning zero level below low limit on/off
00016 BOOL Composite sample running on/off
00017 BOOL Measurement running on/off
00018 BOOL NLA 1 standby switch state on/off
00021 BOOL Level switch simulation state on/off
00022 BOOL PSI 300 standby state on/off
00023 BOOL Connection state on/off
00024 BOOL Zero check running on/off
00025 BOOL Reserved -
Alarm reset (can be set from DCS (only if PSI is in
00028 BOOL standby state)) on/off
00029 BOOL Line 1 bypass (can be set from DCS) on/off
10001 BOOL Assay 1 invalid on/off

40001 DINT Assay 1 value depends on type*

40041 DINT Assay 1 type 1-6

40081 DINT Measurement value (not valid in standby) (0-4000.0) x 10
40082 DINT Density value (0-4.00) x 100
40083 DINT Ph value (0-14.00) x 100
40084 DINT Zero level value (0-4000.0) x 10
40085 DINT Reserved -
40086 DINT Reserved -
40087 DINT Current line in measurement 1-3
Assay values are scaled by assay type. Following table shows multiplier for
assays:
Assay type scale decimals

1. Particle size x10 1
2. Particle size from x100 2
distribution
3. Flow rate x100 2
4. Density x100 2
5. Solids % from mass x100 2
6. Ph x100 2
TELEFAX MESSAGE DATE: Page 1
READER COMMENTS
The design team of Outotec is committed to ensure the quality and usefulness of this manual
and the PSI 300 Particle Size analyzer system. Your comments, recommendations and
suggestions will help make our continuous effort more effective.
Please take few moments to write your comments either directly on the form provided or on a
photocopy of it.
Your assistance is greatly appreciated.

Thank you for choosing the PSI 300 Particle Size analyzer system.
Outotec, Analyzers
Fax to: FAX: INT + 358 205 292998
or mail to: P.O. Box 84, FI-02201 Espoo, Finland
or e-mail to: analyzers@outotec.com
Attn: Manager, Analyzer Sales Support
From:
Analyzer Serial Number:
Manual:

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Code 10000004379 Revision A Page 1 (26)

Connection to automation system

3. Profibus connection .....................................................................................................................................6

1. OPC communication link

2. Profibus DP communication link

3. Modbus RTU serial line communication link

4. Modbus TCP Ethernet communication link

5. 4-20 mA analog signals.

Each communication type is different and requires additional configuration.

The OPC server can be installed to any workstation in plant network. It is

OPC Server (and client)

Figure 1. OPC connection diagram

OPC client configuration

The OPC server name is always:

Follow the steps to test OPC connection:

Usually PSI 300 profibus connection is following type:

Figure 2. Common Profibus DP connection diagram

Profibus cable must be according to IEC 61158 specifications.

Installing Profibus DP slave card to Panel

Figure 3. Profibus DP slave module

Follow the steps to install Profibus communication module:

Figure 4. Application connector and mounting screws inside the panel

Figure 5. Profibus module and connector

Address switches define the Profibus DP slave address (figure 3.).

Address = (left switch settings x 10) + (Right switch settings x 1)

Following table shows general properties of Profibus DP slave:

Profibus slave properties

Not used Ready (online)

Figure 6. Profibus module LED indicators

LED Indication Description

Configuring Profibus DP Master

Following table shows general properties of Profibus DP master.

Profibus master properties

Figure 7. Common Modbus RTU connection

Figure 8. Modbus RTU with RS485 connection

The Modbus protocol address range is following type:

Address Data type Default

PSI 300 uses only 0xxxx, 1xxxx and 4xxxx.

Configuring Modbus RTU master

Modbus RTU properties

Available data through Modbus RTU is listed in Appendix C. Modbus variable

Modbus TCP properties

25 Pin RS232 VMSE

Figure 9. Modbus TCP connection

Customer only connects the Ethernet-cable to Modbus RTU/TCP converter

Configuring Modbus RTU/TCP converter

arp –s inet_addr eth_addr

inet_addr is the IP-address

eth_addr is the Module MAC-address. the MAC-Address is located on

arp –s 192.168.0.1 00-20-4a-01-01-01

Figure 10. Telnet on command prompt

After connect, press enter to go into setup mode.

Figure 11. Configuration window

See that the configuration is following:

After configuration, type S to save and restart module.

Now the Modbus RTU/TCP converter is configured and should be working.

Configuring Modbus TCP master

Appendix A: OPC variable data

Tag address Type Description Value

Controls from DCS

Bypass[1] BOOL Line 1 bypass (inverted) on/off

Appendix B: Profibus variable data