OU500560985 0 PSI300i Connection To Automation System

PSI 300i
Connection to Automation System
Doc. No. OU500560985, English 2015

Connection to
PSI 300i
Automation System
This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the
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consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of
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Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only.
Copyright © Outotec Oyj 2015. All rights reserved.
Outotec Oyj
Address: Rauhalanpuisto 9, P.O. Box 1000
FI-02231 Espoo, Finland
Telephone: +358 (0) 20 529 211
Fax: +358 20 529 2200
Internet: www.outotec.com
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Customer: Project Phase: Site No.:
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Document Title:
MANUAL
PSI 300i
Equipment No: Item No:

CONNECTION TO AUTOMATION SYSTEM
Language: EN
© Outotec Oyj 2015. All rights reserved. 2 (33)

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Outotec Document ID:
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Contents
Contents ............................................................................................................................. 3
1 Introduction.............................................................................................................. 4
1.1 Connection to automation system .............................................................. 4
1.2 Remote connection to analyzer ................................................................. 4
1.3 Remote connection for Outotec support .................................................... 4
2 Modbus TCP/IP ........................................................................................................ 5

2.1 Connecting Modbus TCP/IP ...................................................................... 6
2.2 Configuring Modbus TCP/IP connection .................................................... 7
2.3 Testing connection ..................................................................................... 8
3 Profibus DP ............................................................................................................ 10
3.1 Connecting Profibus DP ........................................................................... 11
3.2 GSD file .................................................................................................... 13
3.3 Configuring Profibus DP connection ........................................................ 13
3.3.1 Station address ................................................................................... 13
3.3.2 Variables ............................................................................................. 13
3.4 Testing connection ................................................................................... 14
4 4-20 mA analog signals ........................................................................................ 15

4.1 Connecting analog output modules ......................................................... 15
4.2 Configuring analog signals ....................................................................... 15
4.3 Testing connection ................................................................................... 16
5 Enabling remote connection ................................................................................ 17
6 Appendix A: Modbus variable data ..................................................................... 19
7 Appendix B: Profibus variable data..................................................................... 26

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1 Introduction
This document describes interfacing PSI 300i particle size analyzer to third party
automation systems (DCS) and to analyzer. This manual provides information on how to
install and configure the connections.
1.1 Connection to automation system

There are three ways to connect PSI 300i to the plant automation system:
 Modbus TCP/IP Ethernet connection

 Profibus DP connection
 4–20 mA analog signals.
Each connection type is different and requires configuration to work properly.
When the connection to the plant automation system is being established, co-operation
between both customer and PSI 300i supplier (Outotec) is required for a successful
project. The customer is responsible for configuring the plant automation system.
PSI 300i will be delivered with a standard communication configuration. The standard
communication configuration is described in this document and it is highly
recommended that these communication settings are applied to the communication
interface to the automation system.
If other than standard PSI 300i communication settings need to be applied for some
reason, these settings have to be negotiated with Outotec. This document describes
only PSI 300i standard communication settings.
Note that the configurations described in this document apply only to PSI 300i software
from version 0.1.0.34 onwards. Older software versions are configured according to
previous revisions of this document.
1.2 Remote connection to analyzer

You can use a web-based connection to the analyzer to view the analyzer user interface
remotely and to operate the analyzer remotely. You need an Ethernet connection,
Ethernet cable, and Google Chrome browser to use this option. For more detailed
instructions, refer to chapter 5 Enabling remote connection.
1.3 Remote connection for Outotec support

Outotec can also provide you with a remote connection through which Outotec service
personnel can monitor and troubleshoot the analyzer as necessary. For more details,
consult Outotec Service.

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2 Modbus TCP/IP
PSI 300i uses master-slave type Modbus communication where the master initiates a
transaction. Transactions can be either queries or responses.
By default, using a Modbus connection uses a static IP address.
Figure 1. Common Modbus TCP/IP connection
Available Modbus variables are listed in Appendix B: Profibus variable data.
Table 1. Modbus TCP/IP properties
Modbus TCP/IP properties
Module type Advantech Industrial PC
Communication type 10/100Base-T
Speed 100 Mbps
Maximum cable length 100 meters

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2.1 Connecting Modbus TCP/IP

Connect Ethernet cable of plant DCS to Ethernet port (LAN2) of Advantech Industrial
PC. PC is inside Probe Control Set (PCS), attached to the PCS door.
Figure 2. PC inside PCS
After the cable is connected, make sure that the Modbus slave is enabled in PSI 300i:
1. Open the PSI 300i user interface.

2. Select Settings > Advanced > Connectivity.
3. Make sure that the Modbus setting is enabled as shown in the following figure.

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Figure 3. Modbus slave enabled in PSI 300i user interface
2.2 Configuring Modbus TCP/IP connection

The default IP address of Modbus TCP/IP connection is set during PSI 300i
manufacturing. The default settings for LAN2 port are:
 IP address: 192.168.2.202
 Network mask: 255.255.255.0
 Default gateway: -
If you want to change the IP address or use the DHCP server to configure the IP
address of Modbus TCP/IP connection, contact Outotec service center.
PSI 300i uses the following Modbus protocol address ranges:

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Table 2. PSI 300i Modbus protocol address range
Address Data type Default
0xxx Discrete Output
1xxx Discrete Input
4xxx Integer or real Output
2.3 Testing connection

Test the Modbus TCP/IP connection as follows:
1. Install NodeJS software to your PC by using default installation settings.

- Program is located on the PSI 300i Software and Documentation USB
memory (file name NodeJS.msi).
2. Connect Ethernet cable of your PC to Ethernet port (LAN2) of Advantech Industrial
PC.
3. Make sure that your PC and the PSI 300i PC are in the same subnetwork. For
example, in Windows 7 you can do this as follows:
- Select Start > Control Panel > Network and Sharing Center.
- Select Change adapter settings.
- Right-click Local Area Connection and select Properties.’
- On the Networking tab, select Internet Protocol version 4 (TCP/IPv4) and
select Properties.
- On the General tab, select Use the following IP address.
- Enter the IP address of your PC in the IP address field so that the first three
decimal numbers are the same as in the PSI 300i LAN3 port IP address. The
default IP address of the PSI 300i LAN2 port is 192.168.2.202. Set the new IP
address so that the last decimal number is any number between 1 and 255,
but not 202. For example, you could set the address as 192.168.2.204.
- Set the Subnet mask as 255.255.255.0.
- You can leave the Default gateway field empty.
- Select OK to save the settings.
4. Go to the PSI300i_Modbus_Scanner folder located in PSI 300i Software and
Documentation USB memory and right click PSI300i_Modbus_Scanner.js. Select
Open with > Choose default program > Browse and find the node.exe.
- If you installed NodeJS software with default settings, node.exe is located
here C:\Program Files\nodejs.
5. Command prompt should open
- Do not shut down command prompt. If it shutdowns automatically, open it
manually and run PSI300i_Modbus_Scanner.js.
6. Go to the PSI300i_Modbus_Scanner folder located in PSI 300i Software and
Documentation USB memory and double click PSI300i_Modbus_Scanner.html. A

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browser should open with the page that can be seen in Figure Figure 4.
Modbus scanner view when connection is active.
7. Configure the connection settings of the scanner. If the IP address of the LAN2 port
has been set according to customer requirements during configuration, use that IP
address. If the IP address has not been changed, the default settings for the LAN2
interface are:
- IP address: 192.168.2.202.
- Port: 502
8. Set the connection settings by selecting the Set ip button.
Figure 4. Modbus scanner view when connection is active

9. Make sure that all variables shown in the scan result view have a value
10. Change the status of a single variable to see whether the value of the variable
changes accordingly.
- If all variables have a value and the value of the variable changes when the
status of the variable is changed, the connection is working.

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3 Profibus DP
PSI 300i Profibus DP (Decentralized Peripherals) connection allows the plant DCS
system to access PSI 300i analyzer data. The following instructions explain how to
prepare the connection and describe the connection parameters that need to be set in
the DCS system.
The information provided here is not specific to any particular automation system but
describes only the PSI 300i Profibus DP option properties.
The following figure shows a typical Profibus connection between PSI 300i and the plant
DCS. PSI 300i acts always as a slave in the communication network.
Figure 5. Typical Profibus DP communication network

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3.1 Connecting Profibus DP

Profibus DP connector is integrated in the I/O module of PSI 300i. The I/O module is
located inside Probe Control Set (PCS).
The following figure shows the location of Profibus DP connector on the I/O module.
Figure 6. Profibus DP connector on the I/O module of PSI 300i

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Connect the Profibus DP cable of the plant automation system to the Profibus DP
connector as shown in the following figure and table.
NOTE: Profibus DP cable must meet the IEC 61158 specifications.
Figure 7. Profibus DP connector
Table 3. Profibus DP connector wiring
Pin Signal Description
3 PB+ Receive/transmit data +
5 PB_GND Ground
6 PB_+5V Power supply
8 PB– Receive/transmit data -
The Profibus segment must be terminated at both ends with cable terminations in line
with the Profibus standard. The termination is passive and is supplied by the bus
subscribers. It ensures a defined level on the bus when no subscriber is active, in other
words, when all subscribers are in “Tri-state”.
Bus termination must meet the following requirements:
 The bus segment must be terminated at both ends.

 No more than 2 terminations per bus segment may be used.
 At least 1 of the two terminations must be supplied by the bus subscriber.
 Operation without proper termination of the Profibus network may result in
transmission errors.

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The following figure shows the Profibus line termination.
Figure 8. Profibus line termination based on EN 50170
3.2 GSD file

The GSD file contains the characteristics of the Profibus DP interface and information
about its communication capabilities and the fieldbus variables that can be used for the
exchange of process data.
The GSD file (PSI300i_Profibus.gsd) required for Profibus DP connection is located on

the PSI 300i Software and Documentation USB memory stick delivered with the
analyzer.
When installing the GSD file, please refer to the information provided in the
documentation of the configuration software which you are using.
3.3 Configuring Profibus DP connection
3.3.1 Station address

PSI 300i is always a Profibus DP slave device. By default, the Profibus DP station
address for PSI 300i is 126. If you need to change this address, consult Outotec
Service.
3.3.2 Variables
The total amount of Profibus data is 144 bytes of input and 2 bytes of output.
NOTE: PSI 300i Profibus DP slave devices use byte addressing, so a Profibus DP
master must use byte addressing as well.

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A Profibus DP slave always transmits the whole 139 bytes of input and 3 bytes of output
in the order shown in Table 7.
 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)
For more details about registers, refer to Table 7 in Appendix B: Profibus variable data.

Profibus connection has been tested during PSI300i manufacturing. Testing the
connection after that requires a Profibus master device. Testing on the site is done by
connecting PSI 300i to the automation system during PSI 300i commissioning.

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4 4-20 mA analog signals
Using 4-20mA analog signal option requires installing additional analog output modules
on the WAGO I/O module assembly. WAGO I/O module assembly is located inside
PCS.
The module assembly can include a maximum of eight analog output modules. Each
module has two outputs, which means that the available number of channels is 2–16.
4.1 Connecting analog output modules

Connect the wires between the 2-channel analog output module and plant DCS as
shown in the following figure.
Figure 9. Analog output module connections
 Connect one wire to AO 1.

 Connect other wire to 0 V.
For more information about the wiring of analog output modules, refer to electrical
drawings provided with PSI 300i.
4.2 Configuring analog signals

PSI 300i allows you to decide what information is directed to which output. This is done
in Analog Outputs view in PSI 300i user interface. For more information about
configuring analog output settings, refer to the PSI 300i Operation manual.

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You can test analog signals by connecting a current meter between AO 1 and 0 V. The
measured current must be 4–20 mA, and the current measurement result must vary
logically according to the assay configured for the output: the higher the assay result,
the higher the measured milliampere current must be. Note that the analyzer must
perform at least one measurement in order to update the analog output signal.
For more details on assay configuration, refer to the analyzer Operation manual.

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5 Enabling remote connection
You can enable a remote connection to the analyzer from your PC as follows:
1. Connect an Ethernet cable between your PC and the Ethernet port (LAN3) of the
PSI 300i PC.
2. Make sure that your PC and PSI 300i PC are in the same subnetwork. For example,
in Windows 7 you can do this as follows:
- Select Start > Control Panel > Network and Sharing Center.
- Select Change adapter settings.
- Right-click Local Area Connection and select Properties.’
- On the Networking tab, select Internet Protocol version 4 (TCP/IPv4) and
select Properties.
- On the General tab, select Use the following IP address.
- Enter the IP address of your PC in the IP address field so that the first three
decimal numbers are the same as in the PSI 300i LAN3 port IP address. The
default IP address of the PSI 300i LAN3 port is 192.168.15.203. Set the new
IP address so that the last decimal number is any number between 1 and 255,
but not 203. For example, you could set the address as 192.168.15.204.
- Set the Subnet mask to 255.255.255.0.
- You can leave the Default gateway field empty.
- Select OK to save the settings.
3. Type the default IP address 192.168.15.203 to the address field of Google Chrome
web browser (from the browser version 40.0.2214.115 m onwards).
- The IP address is shown on the PSI 300i screen.
The remote connection is now available.
CAUTION
. After enabling remote connection, every command you type on your PC affects the
analyzer operation.

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The following figure shows the remote connection view of PSI 300i analyzer.
Figure 10. Remote connection view of PSI 300i user interface

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6 Appendix A: Modbus variable data
Assay values are scaled by the assay type. The following table shows the multiplier for
the assays:
Table 4. Multiplier for assays
Assay type Scale Decimals
1. Particle size x10 1
2. Particle size from distribution x100 2
3. Flow rate x100 2
4. Density x100 2
5. Solids % x100 2
6. pH x100 2
The following register table lists Modbus variable data.
Table 5. Modbus variable data
Tag 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

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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

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40001 DINT Assay 1 value depends on type*

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40041 DINT Assay 1 type 1-6

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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

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40084 DINT Zero level value (0-4000.0) x 10
40085 DINT Reserved -
40086 DINT Reserved -
40087 DINT Current line in measurement 1-3

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7 Appendix B: Profibus variable data
Assay values are scaled by the assay type. This is needed because Profibus cannot
transmit floating point (REAL) data. The following table shows the multiplier for the
assays:
Table 6. Multiplier for assays
Assay type Scale Decimals
1. Particle size x10 1
2. Particle size from distribution x100 2
3. Flow rate x100 2
4. Density x100 2
5. Solids % from mass x100 2
6. Ph x100 2
The following register table lists Profibus variable data.
Table 7. 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

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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

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IW9 WORD DINT Assay value 1 depends on type*

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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

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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

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Outotec
P.O. Box 1000, FI-02231 Espoo
Tel +358 (0) 20 529 211
www.outotec.com
E-mail info@outotec.com
© 2015 Outotec Oyj. All rights reserved.

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PSI 300i

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Doc. No. OU500560985, English 2015

Outotec logo is a registered trademark of Outotec Oyj.

Copyright © Outotec Oyj 2015. All rights reserved.

Address: Rauhalanpuisto 9, P.O. Box 1000

FI-02231 Espoo, Finland

Telephone: +358 (0) 20 529 211

Fax: +358 20 529 2200

Customer: Project Phase: Site No.:

Project Name: Customer Document ID:

Replaced by: Replaces:

Equipment No: Item No:

© Outotec Oyj 2015. All rights reserved. 2 (33)

2 Modbus TCP/IP ........................................................................................................ 5

4 4-20 mA analog signals ........................................................................................ 15

5 Enabling remote connection ................................................................................ 17

6 Appendix A: Modbus variable data ..................................................................... 19

7 Appendix B: Profibus variable data..................................................................... 26

© Outotec Oyj 2015. All rights reserved. 3 (33)

1.1 Connection to automation system

 Modbus TCP/IP Ethernet connection

Each connection type is different and requires configuration to work properly.

1.2 Remote connection to analyzer

1.3 Remote connection for Outotec support

© Outotec Oyj 2015. All rights reserved. 4 (33)

By default, using a Modbus connection uses a static IP address.

Figure 1. Common Modbus TCP/IP connection

Available Modbus variables are listed in Appendix B: Profibus variable data.

Table 1. Modbus TCP/IP properties

Modbus TCP/IP properties

Module type Advantech Industrial PC

Communication type 10/100Base-T

Speed 100 Mbps

Maximum cable length 100 meters

© Outotec Oyj 2015. All rights reserved. 5 (33)

2.1 Connecting Modbus TCP/IP

Figure 2. PC inside PCS

1. Open the PSI 300i user interface.

© Outotec Oyj 2015. All rights reserved. 6 (33)

Figure 3. Modbus slave enabled in PSI 300i user interface

2.2 Configuring Modbus TCP/IP connection

PSI 300i uses the following Modbus protocol address ranges:

© Outotec Oyj 2015. All rights reserved. 7 (33)

Table 2. PSI 300i Modbus protocol address range

Address Data type Default

0xxx Discrete Output

1xxx Discrete Input

4xxx Integer or real Output

2.3 Testing connection

1. Install NodeJS software to your PC by using default installation settings.

© Outotec Oyj 2015. All rights reserved. 8 (33)

Figure 4. Modbus scanner view when connection is active

© Outotec Oyj 2015. All rights reserved. 9 (33)

Figure 5. Typical Profibus DP communication network

© Outotec Oyj 2015. All rights reserved. 10 (33)

3.1 Connecting Profibus DP

Figure 6. Profibus DP connector on the I/O module of PSI 300i

© Outotec Oyj 2015. All rights reserved. 11 (33)

NOTE: Profibus DP cable must meet the IEC 61158 specifications.

Figure 7. Profibus DP connector

Table 3. Profibus DP connector wiring

Pin Signal Description