KEPCO MMI-2 Series User manual

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MMI-2XX SERIES
Operating and Installation
Instructions
for use with MMI-200, 210, 220 and 240
essler Ellis Products
10 Industrial Way East
Eatontown, NJ 07724
Phone: [phone]
FAX: [phone]
$10.00
582REV030100
For use with Version 4.00

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PROPRIETARY NOTICE
The information contained in this publication is derived in part from proprietary and patent
data. This information has been prepared for the expressed purpose of assisting operating
and maintenance personnel in the efficient use of the instrument described herein.
Publication of this information does not convey any rights to use or reproduce or to use it
for any purpose other than in connection with the installation, operation and maintenance
of the equipment described herein.
Copyright 1997 by
essler Ellis Products
Contents
Section .................................................................................................. Page
1.0 Getting Started ................................................................................ 4
1.1 What is the MMI-2XX Series? .................................................... 4
1.1.1 The MMI Series and Its Environment ................................ 5
2.0 Installation Instructions .................................................................... 6
2.1 Mounting Instructions ................................................................. 6
2.1.1 Location Considerations. .................................................. 6
2.1.2 Making a NEMA4 Mounting. .............................................. 6
2.1.3 Environmental Considerations.......................................... 7
2.2 Power Connections ................................................................... 8
2.2.1 Power Requirements........................................................ 8
2.2.2 Grounding Requirements ................................................. 10
2.2.3 CE Requirements ............................................................. 10
2.2.4 Safety Guidelines .............................................................. 11
2.3 Communications Connections .................................................. 12
2.3.1 Connection to an External Device .................................... 12
2.3.2 Connection to a Personal Computer ................................ 13
2.4 CE Requirements...................................................................... 14
2.4.1 EU directives .................................................................... 14
2.4.2 General Installation Guide Lines for EU Installations......... 15
2.4.3 General Safety Guide Lines for EU Installations ............... 15

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Section ........................................................................................................... Page
3.0 MMI Operations .......................................................................................... 16
3.1 The Message Queue ............................................................................ 16
3.1.1 Queue Activation ........................................................................ 16
3.1.2 Queue Action ............................................................................. 16
3.1.3 The Interrupt Message ................................................................ 16
3.2 Alarm Messages.................................................................................. 17
3.3 Using the Function keys ...................................................................... 18
3.4 Entering Numerical Values................................................................... 20
3.5 Using the PREV and NEXT keys ......................................................... 22
3.6 Activating the Beeper ........................................................................... 22
3.7 Activating the Open Collector Output ................................................... 23
3.8 Using the Keypad Download ................................................................ 23
3. MMI Response..................................................................................... 24
3. .1 Response Time to Message Calls, LED and O.C. Output
Activation .................................................................................... 24
3. .2 Response Time to Function Key Presses ................................... 24
3. .3 Response Time to Serial Port Transmissions ............................. 24
4.0 Trouble Shooting ........................................................................................ 25
4.1 Power Problems .................................................................................. 25
4.2 Communications Problems .................................................................. 26
4.3 Commonly Asked Questions ............................................................... 26
4.4 Repair and Return Policies................................................................... 27
5.0 Specifications............................................................................................. 28
Function Key and LED Assignments................................................................ 2
Function Key Insert Drawings ........................................................................... 30
Alarm Planning Worksheet............................................................................... 31
MMI-200, 210, 220, 240 Panel Cutout Template (1:1) ................................ 32
Warranty .......................................................................................................... 33

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About this Manual
This document is based on information available at the time of its publi-
cation. While efforts have been made to be accurate, the information in
this document may not cover all details or variations in hardware or
software, nor does it provide for every possibility in connection with
installation, operation, or maintenance. Features may be described
herein which are not present in all hardware. Kessler Ellis Products
assumes no obligation of notice to holders of this document with respect
to changes subsequently made.
Information in this document is subject to change without notice and does
not represent a commitment on the part of Kessler Ellis Products.
Some common terms used:
PLC: Programmable Logic Controller. Typically, the MMI is connected
to one of these devices. This is a generic term covering a large range of
programmable devices used in machine control applications.
MTR: This stands for Message Triggering Register. The MTR is the
register that holds the message number for the MMI to display.
Symbology
Warning! Indicates that the reader should pay special
attention to the accompanying text. Precautionary steps
should be taken to insure that the installation is in compli-
ance with warnings. Warnings include hazardous condi-
tions that could cause personal injury or equipment
damage if care is not taken.

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1.0 Getting Started
1.1 What is the MMI-2XX Series?
MMI-2XX Series MMI Units are operator interfaces for PLCs. They allow the
operator to interact with the machine by displaying messages
that are preloaded into them with a Personal Computer and/or
turning on LED's. They have legendable keys which can be
programmed to perform various functions for the operator.
Equipment
Checklist
An MMI
system should include:
• An MMI-2XX Series base unit.
• An interface cable to the programmable controller.
• A personal computer with MMI programming
software. A PC to MMI cable is required.
• View machine status and
parameters.
• Change machine status or
applicable operating param-
eters of the machine.
• Maintain the running of the
machine.
Designed
For Use
Provides a convenient way
for a machine operator to:
It also gives enhanced
capabilities to the machine
through:
• RS232 ASCII output.
• Direct keypad interface.
• Visually displayed
prompts.

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1.1.1 The MMI Series and Its Environment
Where
Used
The MMI Series is designed for use in a factory environment.
They are designed to operate under the same temperature
conditions as PLC's used in an industrial environment. They
may not be suitable for use in certain outdoor applications.
Please consult the factory for advised usage in outdoor
applications.
NEMA
Rating
The MMI-2XX Series front bezel is NEMA 4 rated. When
installed properly in a NEMA 4 panel, the NEMA 4 rating of
the panel will not be compromised. This means that fluids will
not enter the panel during wash downs.
Electrical
Environment
The DC powered MMI Series has been tested to conform to
European CE requirements. This means that the MMI circuitry
is designed to resist the effects of electrical noise. This does
not guarantee noise immunity in severe cases. Proper wire
routing and grounding will insure proper operation of the MMI
unit.
Mechanical
Environment
Avoid installing MMI units in environments where severe
mechanical vibration or shock are present.
Do not operate the MMI in areas subject to explosion hazards
due to flammable gases, vapors or dusts.
The MMI should not be installed where fast temperature
variations and/or high humidity are present. This will cause
condensation of water in the device.
Caution!

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2.0 Installation Instructions
2.1 Mounting Instructions
2.1.1 Location Considerations.
Care should be taken when locating equipment behind the
MMI to ensure that AC power wiring, PLC output modules,
contactors, starters, relays, and any other source of
electrical interference are located away from the back of
the unit.
Particular note should be taken to the position of variable
speed drives and switching power supplies. Their input
and load cables should be screened to a central star earth
point.
2.1.2 Making a NEMA-4 Mounting.
Panel
Details
5.1"
(12 mm)
The MMI can be mounted into panels with a depth of
3"(76mm). It is recommended that the MMI be mounted
on the front panel of a steel enclosure, through a
7.1"(180mm) X 5.1"(12 mm) opening. Allow a clearance
of 1"(25mm) on each side of the cutout for clip mounting
hardware. Allow clearance for cable connections to the
bottom of the unit. Clearance may vary according to cable
type used. Typically, plan a clearance to accommodate at
least 3"(76mm) below the cutout.
Standard
7.1"(180mm)
PANEL
CUTOUT
(Not to Scale)
See Table of Contents for location
of full scale template.

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Mounting
Put the MMI through
the panel cut out. Insert the clamps into the case. Pull back
on the clips until they seat into the retaining slots. Tighten
clamping screws to 3 in.lb. of torque in an even pattern until
the MMI is secured in the panel.
NEMA-4
Mounting
Slide the gasket over the case so that it rests behind the
Bezel Frame. Continue with standard mounting as described
above. Avoid over tightening.
Specifications Note: To seal to NEMA-4 specifications, supplied gasket must
be used and panel cannot flex more than 0.010".
When a gasket is used, the gasket may be sealed to the
case using an adhesive to maintain NEMA-4 rating.
• The MMI is to be used indoors as a built-in interface. Make sure that
the unit is installed correctly and that the operating limits are followed
(See Specifications).
• Do not operate the MMI in areas subject to explosion hazards due to
flammable gases, vapors or dusts.
• The MMI should not be installed where fast temperature variations and/
or high humidity are present. This will cause condensation of water in the
device.
2.1.3 Environmental Considerations
Panel
Gasket
Bezel Frame
Mounting Clip
Connectors
Clamping
Screw

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2.2 Power Connections
Make sure that all local and national electrical standards are met when installing the
MMI. Contact your local authorities to determine which codes apply.
2.2.1 Power Requirements
Power The MMI can be powered by AC or DC power, depending on
the part number ordered. The MMI-2xx specified DC voltage
range is +12 to 27 Volts DC. This insures compatibility with
most DC systems. The MMI-2xxA can be powered by 115
VAC only. The MMI-2xxB can be powered by 230 VAC only.
The power conditioning circuitry inside the unit is accomplished
by a switching power supply. Due to the nature of switching
power supplies, a wide range of over and under voltages may
be used without adversely affecting the unit.
The MMI-2XX series is fused internally with a self resetting
60V 400mA fuse. It is recommended that all input power lines
be protected from product failure by a fuse or breaker.
If the display does not come on within 2 seconds of power up,
remove power. An internal diode will prevent damage if the
polarity of the DC power is incorrect. Check wiring to insure
proper connections and try to power up again.
Fusing
Requirements
Caution
Strain Relief
Adequate strain relief must be provided for the power connec-
tor, to ensure that vibration or the disturbance of cables during
maintenance does not cause the connector to pullout. Reten-
tion of the power cables by a tye-wrap onto the trunking, or an
adhesive pad mounted tye-wrap point is normally suitable.
Caution
High Voltage
Connecting high
voltages or AC power mains to the DC input will make the
MMI unusable and may create an electrical shock hazard to
personnel. Such a failure or shock could result in serious
personal injury, loss of life and/or equipment damage.
DC voltage sources should provide proper isolation from main
AC power and similar hazards.
Caution
Emergency
Stop
A hard wired
EMERGENCY STOP should be fitted in any system
using the MMI to comply with ICS Safety Recommen-
dations.

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Caution
Supply Voltage
Condition
Do not power the MMI and inductive DC loads, or input
circuitry to the PLC, with the same power supply.
The 24 VDC output from some PLC's may not have enough
current to power the DC powered MMI.
Terminal Block
Connections
To make a connection, strip about 1/4" of insulation off the
end of the wire, turn the connector screw counterclockwise
until the gap is wide open, insert the wire all the way in, and
turn the screw clockwise until it is tight.
For DC powered units, connect the positive DC line to terminal
3 and the DC ground to terminal 4. For AC
powered units, connect the AC lines to terminals 3 and 4.
Caution
Power Cycling
Power supplies with large capacitive outputs may cause
problems if power is cycled within a short time period. The
power supply’s capacitor will supply enough current to keep
the microprocessor running for a few minutes but not enough
to keep the display active. If full power is restored during that
time, the microprocessor may not initialize the display
module. The result is that the display will remain blank or
show just the cursor in the upper left-hand corner and the rest
of the unit will be fully functional.
To remedy this problem, run power to the unit through a
“seal in” circuit or remove the capacitor (the MMI is not
affected if power is unregulated) or wait sufficient time between
power cycles.
Caution
Wire Routing
Wire lengths should be minimized (Maximum 1600' (500 m)
shielded, 1000' (300 m) unshielded).
Wires should be run in pairs with a neutral or common paired
with a hot or signal line.
If wiring is to be exposed to lightning or surges, use appropri-
ate surge suppression devices.
Keep AC, high energy, and rapidly switching DC wiring
separate from signal wires.
Equip ungrounded DC supplies with a resistor and capacitor in
parallel to earth ground. This provides a path for static and
high frequency dissipation. Typical values to use are 1MOhm
and 4700pF.

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2.2.2 Grounding Requirements
Earth ground must be used. DC ground (Terminal 4) is
not directly coupled to Earth ground internally. It is preferable
not to ground DC negative return to earth ground, terminal 5,
as poor site earths can introduce noise into a system, but if
necessary an earth connection should be made, from the
power supply return point to the central star earth point.
Ground conductors should be as short and as large in size as
possible. The conductors must always be large enough to
carry the maximum short circuit current of the path being
considered. Ground conductors should be connected from a
tree from a central star earth ground point. This ensures that
no ground conductor carries current from any other branch.
2.2.3 CE Requirements (DC Powered MMI)
To make the DC powered MMI comply with EMC directives, and to reduce
susceptibility to electrical interference, a separate #14 AWG ground wire
should be taken to terminal 5 of the power connector. This ground connection
should be run directly to the central star earth connection point (as recom-
mended in most PLC Installation Instructions).
Typical Label on Rear of MMI-2XX Series unit
showing connection points.

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Hardware
Considerations
WARNING!
The system designer should be aware that control devices in
Programmable Controller systems can fail and thereby create
an unsafe condition. Furthermore, electrical interference in an
operator interface, such as the MMI, can lead to equipment
start-up, which could result in property damage and/or physi-
cal injury to the equipment operator.
If you, or your company, use any programmable control
systems which require an operator or attendant, you should
be aware that this potential safety hazard exists and take
appropriate precautions. Although the specific design steps
depend on your particular application, the following precau-
tions generally apply to installation of solid-state program-
mable control devices. In addition, these precautions conform
to the guidelines for installation of Programmable Controllers
as recommended in the NEMA ICS 3-304 Programmable
Control Standards.
Programming
Considerations
To conform with ICS Safety Recommendations, checks
should be placed in the PLC program to ensure that all
writable registers that control critical parts of plant or machin-
ery should have upper and lower limit checks built into the
program, with an out-of-limit safe shut down procedure to
ensure safety of personnel.
ICS 3-304.81 Safety Recommendations:
Consideration should be given to the use of an emergency stop function which is indepen-
dent of the programmable controller.
Where the operator is exposed to the machinery, such as in loading or unloading a
machine tool, or where the machine cycles automatically, consideration should be given to
the use of an electromechanical override or other redundant means, independent of the
programmable controller, for starting and interrupting the cycle.
If provision is required for changing programs while the equipment is in operation,
consideration should be given to the use of locks or other means of assuring that such
changes can be made only by authorized personnel.
These recommendations are intended as safeguards against the failure of critical compo-
nents and the effects of such failures or the inadvertent errors that might be introduced if
programs are changed while the equipment is in operation.*
* The ICS 3-304.81 Safety Recommendations are reproduced by permission of the National
Electrical Manufacturers Association from NEMA ICS 3-304, Programmable Controller
Standard.
2.2.4 Safety Guidelines
This section presents recommended installation practices and procedures.
Since no two applications are identical, these recommendations should be
considered as guidelines.

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2.3 Communications Connections
2.3.1 Connection to an External Device
The DB port farthest from the power connector as you look at the back of the
case (labeled SMIC PORT) is the port for connecting to a PLC or external device
using KEP's SMIC adaptor cables.
Cable
Requirements
Different cables are required for various devices. The KEP part
numbers have the SMIC prefix. Refer to a KEP catalog or
datasheet for a complete listing of MMI-2XX compatible
devices.
These cables can be obtained from the same distributor where
you purchased the MMI-2XX.
Caution Restrict cable length to less than 500' (150m) for RS485/422
devices and 50' (15m) for RS232 devices to avoid communica-
tions problems. Communications problems cause the MMI
display to hold until communications can be established.
Shielded cable must be used for long lengths or cables run in
an electrically noisy environment.
Do not run cables next to AC power lines or near sources of
electrical noise.
Be sure that the cable ends have been inserted all of the way
into mating connectors and are secure.

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SMIC Port
Pin Designations
Pin assignment of the pole SUB-D RS232 to external device
port
Pin# Symbol Function
1 Not used
2 TxD Transmitted Data
3 RxD Received Data
4 Not used
5 GND Signal Ground
6 Vcc DO NOT GROUND THIS PIN
7 Not used
8 CTRL Flow Control Line for RS485
RSV DO NOT USE
Reserved for MMI use
2.3.2 Connection to a Personal Computer
The Pin Female connector closest to the power connector as you look at the
back of the unit is the programming port (labeled PC PORT).
Connection This port can be attached to a Computer via a DB Male to
DB Female straight through cable. Make sure 2 and 3 are
not reversed.
This port is always active. When Uploading and Downloading
information to the PC, PLC operations are suspended.
Note: The PC Port is not a pass thru port to the PLC.
Port Activation
Print Out The MMI-220 and 240 have print out capabilities. When a
message is assigned to be sent out the serial port, the
transmit line of the computer port becomes active momen-
tarily.

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PC Port
Pin Designations
Pin assignment of the pole SUB-D RS232 to Computer port
Pin# Symbol Function
1 Not used
2 TxD Transmitted Data
3 RxD Received Data
4 Not used
5 GND Signal Ground
6 Not used
7 Not used
8 Not used
Not used
2.4 CE Requirements
2.4.1 EU directives that apply to the MMI-2XX (DC) Series:
• EMC Directive (8 /336/EEC, 1/263/EEC, 2/31/EEC, 3/68/EEC) electromag-
netic emissions and immunity
DC powered MMI products will be CE-marked to indicate compliance with the EMC
Directive. Declarations of Conformity that specify the directive(s) and the catalog
numbers of the products covered are available from Kessler Ellis Products.
Although the DC powered MMI-2XX products are CE compliant, it is the responsibil-
ity of the person who finally implements the system, that the machine (including
other electrical and electronic devices) will meet the EMC requirements.
The DC powered MMI has been designed to operate satisfactorily in electromag-
netic noise (immunity) and without emitting high levels of electrical noise into the
environment (emission). The DC powered MMI was designed to meet European
Community standards when installed per the wiring instructions in this manual.
Compatibility
Standards
electromagnetic compatibility for industrial environments.
• CISPR (EN 55011) Group 1, Class A Radiated Emissions
levels
• EN50081-2 Generic emission standard, industrial
environment (Also US FCC Class A)
• EN50082-2 Generic immunity standard, industrial
environment
The DC powered
MMI has been
designed to meet

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2.4.2 General Installation Guide Lines for EU Installations.
• Be aware that wiring leaving the cabinet where the MMI is installed may be
exposed to interference sources.
• The installation practices in the individual product installation manuals of other
components in the system must also be followed.
• Locally applicable grounding safety regulations and machinery directives should
be followed for providing a protective ground to earth. The EMC ground must be a
low impedance, low inductance path to the machine chassis ground.
• The MMI power supply must be through an IEC-rated isolation transformer.
• The Power supply to the PLC must be controlled to ensure that it does not
exceed overvoltage category II per EN60204-1 (IEC 240).
• Other requirements of the Machinery Directive involving displays, languages,
instructions, Emergency Stop functions, machine operation, protective guards and
interlocks are the responsibility of the machine manufacturer.
2.4.3 General Safety Guide Lines for EU Installations.
• Only qualified personnel should be allowed to specify, apply, install, operate,
maintain or perform any other function related to MMI products. Qualified persons
are defined as follows:
System application and design engineers who are familiar with the safety
concepts of automation equipment. Installation, start-up, and service personnel
who are trained to install and maintain automation equipment. Operating
personnel trained to operate automation equipment and trained on the specific
safety issues and requirements of the particular equipment.
• Before switching on the equipment, make sure that the voltage range for the
equipment is correct.
• Emergency tripping devices in accordance with EN60204/IEC204 must be
effective in all operating modes of the automation equipment. Resetting the emer-
gency off device must not result in any uncontrolled or undefined restart of the
equipment.
• Automation equipment and its operating elements must be installed so that
unintentional operation is prevented.
• Make sure that operating sequences interrupted by a voltage dip or power supply
failure resume proper operation when the power supply is restored. If necessary,
the equipment must be forced into the “emergency off” state.
• Install the power supply and signal cables so that inductive and capacitive
interference voltages do not affect automation functions.

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3.0 MMI Operations
Once the MMI is programmed and connected to the PLC, normal operation begins.
The MMI establishes communications with the PLC. It then requests the number in
the Message Triggering Register (MTR), if used, and displays the corresponding
message. It then requests the bit pattern in the LED Control Register and lights
the corresponding LED's.
3.1 The Message Queue MMI-220, 240
Occasionally, messages are called up faster than they can be displayed. When
this happens messages are held in a Queue and wait their turn to be displayed.
The message Queue holds up to 3 message numbers.
3.1.1 Queue Activation
3.1.2 Queue Action
The Queue is emptied on a first in, first out basis. If the Queue is full, additional
messages will be lost.
Messages are stored in the Queue when:
1. A series of Chained messages are being displayed.
2. A message with a long minimum display time is displayed.
3. A message with a long scrolling time is displayed.
Warning Function keys that have displayable message text assigned
to them clear the Queue.
3.1.3 The Interrupt Message
Message number 65535 is the Interrupt message. When message 65535 is called,
the Queue is immediately cleared. The next message number that appears in the
message triggering register is then displayed.
An example of Queue operations:
Message 23 is being displayed with a minimum time of 10 seconds.
Display Queue
23 —
During that period message numbers 34, 15 and then 211 are called for by the
MTR.
Display Queue
23 34
15
211

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the MTR or a function key is pressed.
The MMI will put message 34, 15 and 211 in the Queue. When message 23 has
timed out, message 34 will be called up and displayed.
Display Queue
34 15
211
When 34 is done, message 15 will be displayed.
Display Queue
15 211
When 15 is done, message 211 will be displayed.
Display Queue
211 EMPTY
Message 211 will continue to be displayed until a new message number is put in
3.2 Alarm Messages
You can define up to 32 alarms. These can be defined either by 2 Words (16 bits)
or 32 distinct bits. Alarms can take up to 304 bytes of memory. Alarms have a
hierarchical structure and are triggered by bit ON status only.
Note: The host PLC has the entire responsibility for performing all acknowledges
and clear functions. It is suggested that the function keys on the MMI and their
existing functions be used for these purposes in conjunction with the PLC program.
If Alarms are defined wordwise, the unit reads the designated (2) alarm registers.
The registers bits are then parsed from 0 to 15 (Register 1) then 0 to 15 (Register
2). If Alarms are defined bitwise, MMI reads the bits as a cluster or individually in
order as specified by a list of designated bits. The first logical 1 bit encountered is
processed as an alarm. Its associated message is displayed and acted upon.
Further parsing action is inhibited until the alarm is cleared or an alarm of higher
priority is encountered in subsequent reads.
Note: If a bit is not assigned a message number then activating the bit suppresses
all alarms after that bit.
Alarms interrupt MTR operations. MTR operations resume when all alarms are
cleared or inhibited.

Page 1
Description of alarm operation
Triggering a message
Bit 1 of alarm register one is assigned message #34, which reads This is a test
message.
Bit 5 of alarm register one is assigned message #35, which reads The phone is ringing.
Bit 2 of alarm register two is assigned message #36, which reads An alarm message.
Bit 2 of register two goes to the ON state. The display shows message 36:
AN ALARM MESSAGE.
Then bit 1 of alarm register one goes to the ON state. The display shows message 34:
THIS IS A TEST MESSAGE.
Finally, bit 5 of alarm register one changes to the ON state. The display shows mes-
sage 34:
THIS IS A TEST MESSAGE.
Note how the first alarm encountered inhibits the message from bits 5 of reg. 1 and 2 of
reg. 2 from being displayed. Actually, they are never processed.
Bit 0 of register one goes to the ON state. Since no message is assigned to that bit
the display shows the message that is in the Message Triggering Register or the
default message.
3.3 Using the Function Keys
Simply press a Function key to initiate their programmed action and/or call up their
associated messages.

Page 20
When a function key is pressed, one of the following conditions will apply.
3.3.1 The Function key may have message text assigned to it, request
the operator to edit a value or chain to another message.
1. The Function key message will interrupt the active display.
Note: Function keys with message text assigned to them clear the message Queue
and interrupt minimum display times, chained and scrolling messages.
2. The message assigned to the Function key will be displayed.
3. At the end of a Function call and after all data entry and message chaining is
done, the display does one of the 3 options listed in priority below.
A. Chains, if programmed, to the next message.
B. Displays the message whose number is next in the message Queue.
C. Displays the message whose number is in the MTR.
3.3.2 No message text is assigned to the Function key and no mes-
sages are chained to or from the Function key. The function key is
assigned to download a constant or change a bit status only.
Press the Function key. The Queue is not cleared and the display is not interrupted
but the function is carried out.
3.3.3 No message or action is assigned to the Function key.
When the Function key is pressed, nothing happens.
SHIFT EY The SHIFT key is used to activate shifted functions. Press the
SHIFT key and the LOCK LED will light. This indicates that
the function keys will perform their shifted function when
pressed. To deactivate the SHIFT, press it again. The LOCK
LED will go out indicating that the function keys are back to
non-shifted functions. This feature is not available on the MMI-
200.