MDT-150

Installation Guide
MS# 915017P7185

Document__________

Production Process Division of Industrial Marine Electronics, Inc.

61 Harvey Road, Londonderry, New Hampshire 03053 USA Tel 603-434-2300 Fax 603-434-7851 www.productionprocess.com

August 13, 2010 (4.0 update, PV output, LO pullup) KR

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2
 Table of Contents
1.0 Overview of an MDT System. ............................................................................................. 5

2.0 Detailed MDT installation and wiring instructions. ........................................................ 9

2.1 Mounting the MDT on your machine.................................................................................................................................. 9
2.2 Connecting continuously maintained AC power to the MDT. ......................................................................................... 9
2.3 Connecting Machine Signal Inputs to the MDT............................................................................................................... 11
2.3.1 Connecting switches, relays, or other types of “dry” contacts........................................................................... 13
2.3.2 Connecting 24V to 120V AC and DC Signal Inputs. ......................................................................................... 15
2.3.3 Connecting NPN (“sinking”) solid state proximity and photo sensor Signal Inputs.......................................... 17
2.4 Connecting Machine Lockout, Out of Limits and Batch Outputs. ................................................................................. 19
2.4.1 Use Lockout Output to ensure operator enters Down Reason before machine is allowed to start. .................... 19
2.4.2 Wiring diagram for all three outputs:.................................................................................................................. 19
2.5 Connecting (optional) 16 Input module for automatic sensing of Down Reasons......................................................... 20
2.6 Inserting an ID# and/or Operating MDT in “Local Mode” (without computer) to verify machine Signal Inputs.. 21
2.7 Relating PC Screens and reports to the two Automatic Down Reasons and one Reject input. .................................. 23

3.0 Connecting computer to MDT’s using VT-28 Communications Interface. .................. 25

3.1 Important rules for installing communications cable. ..................................................................................................... 26
3.2 Computer installation guidelines. Function of VT Communications Interface module. ............................................. 27
3.3 Connecting the VT-28 to your computer. ......................................................................................................................... 27
3.4 This paragraph intentionally left blank. ........................................................................................................................... 27
3.5 Wiring the MDT’s to the VT-28B ...................................................................................................................................... 28
3.6 Before starting system, perform this quick test of VT-28 communications wiring..................................................... 29
3.6.1 Problems with quick test? Troubleshooting VT communications. ................................................................... 29

4.0 Use PC to assign machine ID#s and configure MDT’s. ................................................... 31

4.1 Inserting or changing the ID# at the MDT instead of using the computer. ................................................................... 33

5.0 After the system is running, you may also configure: ..................................................... 33
5.1 Threshold Down Alarm Time: a Cycle Time (or equivalent Rate) that indicates machine is effectively “down”. .... 33
5.2 Tracking actual Pieces/Lineal Measure made each machine operation......................................................................... 33
5.3 Select parts made in Down or Setup condition are “good” or “reject”.......................................................................... 33
5.4 Enabling Production Hold capability:............................................................................................................................... 33
5.5 Enabling HELP call capability........................................................................................................................................... 33

3
 Overview of MDT-150 inputs and outputs.
The minimum connections for a basic system are shown in green. The other Signal Inputs and Outputs do not have
to be used. The Bar Code wand input device is an extra cost option.

Main AC Power connection Outputs--activate external, user-

supplied, solid state relays.
120VAC or 230 VAC uninterrupted power. MDT-150
Machine Down (Lockout).
MDT does not lose data when power is removed, but if Activates when Signal Input #5 is absent,
power is off during a Shift or Job change, the two shifts or or machine slows below user set limit
Jobs data get combined---thus the requirement of
uninterrupted power. MDT is all solid state and draws very Output de-activates when Operator enters a
little power---it is designed to be left on continuously. Down Reason from Keypad

This output is used to ensure the Operator

enters a Down Reason before machine is
allowed to start up after a “down” event.
Basic system: 1 or 2 Machine Signals
Both accept 24V-120V AC or DC or switches, relays.

Machine Cycling (Signal Input #1)

Signal is a (typically already existing) 24V-120V AC or DC,
switch or relay contact signal which is activated once each
machine operation. Machine Out of Limits Alarm :
Output is on when machine is running faster
Down “Manual” Time (Signal Input #5). or slower than user-set, Job-specific limits.
This input is typically found only in plastics processing
Use this output to activate a light, horn, etc.
machinery. If not used, Input must be wired “on” at
to indicate a “down” or out-of-limits
installation. machine.

Automatic Down, Reject and Case Count.

Two Automatic Down Reason Inputs: Direct connections to
machine to automatically track down time--total time and
number of incidences--in Reasons #21 and #23.

One Automatic Reject Input. Direct connection to machine Batch Count

to automatically track Rejects in Reject Reason #1. Activates for 1 second when Parts Count
equals batch count.
Case Count Input. Counts filled cases of Parts. You can
compare filled case count to parts made to track waste/rejects.

All inputs accept 24V-120V, AC/DC or switch and relays.

Optional Bar code Wand

Bar Code Wand is used to scan in new

Job which will be downloaded from
System Software Job Queue. As special
order option, can be used to log in
Operators by scanning employee badge. .

Windows PC collects data from MDT’s on shop floor

using PC’s standard RS-232 port or a USB port
VT-28 Comm Interface or Ethernet communicating through VT-28 Communications
Interface module located at PC. Only one VT is needed
Shields
Poll Test
for a typical maximum system size of 60 MDT.
R B G W R B G W

R B G W R B G W
Standard Ethernet Communications is optional.
R B G W R B G W

R B G W R B G W

REAR VIEW
AC Power
Poller PC communicates with other User PCs (or ERP
system) through standard LAN/WAN.
Windows Poller PC

4
 1.0 Overview of an MDT System.
(see drawing facing page)
Color coding conventions used in this manual.
Green: minimum connections to machine to implement a basic system.
Blue: important items for proper operation or understanding of system.
Red: VERY important or a potentially dangerous situation if recommendation is not observed.
MDT's accept existing "on/off" electrical signals directly from the monitored machine. Typically no additional relays or
interface devices are required.
Plant floor to computer communications. A small module (a VT-28 communications interface) located at the computer
enables a computer’s standard RS-232 communications port to “talk” to up to 100 MDT on the shop floor, using a low cost
shielded cable multi-dropped (“daisy chained”) from one MDT to the next MDT, then back to the computer.

Ethernet communications are available as options.

Your standard MDT-150 has six machine Signal Inputs. However, only the following two inputs must be
connected for basic system operation:
One input--a “machine cycling” input is connected to a device in the machine that is activated each time the machine cycles or a
part is produced. From this input is collected most of the “production data” such as parts count, lineal measure, productivity,
cycle time, production rate, run time, and total down time, etc.
One input to track “Manual” Downtime--that is when the machine is in a Manual/Jog condition (power on but machine not
running automatically). Typically used only by injection molding machines, if your machine doesn’t supply this signal, we’ll
tell you how to connect it inside the MDT instead of connecting it to the machine.

Four additional machine Signal Inputs expand functionality of System (but are not required for basic operation).
Two Automatic Down inputs can be used to automatically track downtime and number of down incidences automatically through
direct connections to the machine.
One Automatic Reject input can be used to automatically track rejects--for example from an automatic inspection point in the
process.
One input for Case Count. This input helps you track shrinkage/waste by comparing machine cycles/parts made against the filled
(good parts) cases. You may also configure it for a count of “one” instead of number of parts in the case.

Your MDT-150 has three outputs to activate solid state relays for “alarms” and machine Lockout as follows:
Machine (Down) Lockout: Whenever the machine slows below a computer inserted Threshold Down Alarm time (corresponding
to a machine cycle time of from 0.1 to 999.9 seconds--or an equivalent machine rate), or machine Signal Input #5 is deactivated,
this output stays activated until the Operator enters a Down Time Reason from the keypad. Use this output to ensure Operator
enters a Down Reason before machine is allowed to start back up after a “down” event.

DANGER: The “Lockout” output can only be used in machinery that has a
separate, “latching” run/start circuit. That is, Lockout output should not be
connected to a simple machine “on/off” control such that the machine could
start up when the Operator enters a Down Reason thus allowing the
machine to start running because its on/off switch is in the “on” position.
Machine Out of Limits Alarm: This output is activated when machine is running faster or slower than user-set, Job specific limits.
Use this output to activate a light, horn, etc. to indicate the machine is operating outside normal limits.

Batch Count: At the beginning of each Job, the computer downloads the Batch Size. Upon reaching the batch count this output
activates for one second and resets the internal Batch Counter. .

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MDT outline drawing and mounting considerations. TB-262 D

.75

(EIGHT DIGIT NUMERIC DISPLAY)

(20 OR 40 CHARACTER You can make a list of Down and Reject

ALPHANUMERIC DISPLAY)
Reasons for each machine and insert
(MENU OF: 1 2 3 (1)
them in this Menu area. Each machine can
DATA FUNCTIONS
DOWNTIME CAUSES
4 5 6 (2) have its own list of up to 40 out of a total of
REJECT CAUSES )

7 8 9 (3)
999 Reasons. You can change the list at any
0 (4) time as you minimize Reasons.
DISP ENTER CLEAR (5)
A slot is provided on the bottom edge of the
blue keypad to insert the list.
A CD with a MS Word document for
entering Down and Reject Reasons is
supplied with the MDT-150 User Guide. It
will enable you to quickly make and print a
list.

If stainless steel (splashproof)

enclosure is provided:
1. Overall dimensions 11” x 9 ¼”
2. To ensure seal integrity, make sure
all four latches for the sealing flange
are locked.
3. Be sure to use sealed fittings for
electrical connections.

7
 TECHNICAL BULLETIN
TB-351

MDT POWER CONNECTIONS

12 CT 12 E

E (GREEN) EARTH GROUND

240 CONNECT EITHER 120v HOT

LINE LEAD OR 240v HOT LEAD
ON
120 TO APPROPRIATE TERMINAL
N (WHITE) NEUTRAL
OFF
5AF1
This replaceable 5 Ampere fuse (“F1”) is
E1963 designed to operate in the event of a miswire
REV A
or other “significant” fault event such as
5V 24V connecting 240V to the 120V connections.

Internal, automatically resettable (when

power is removed) over-current devices
protect MDT from other types of faults.

BLACK
WHITE
WHITE BLACK
GREEN 1 2 3 4 5 PRE-WIRED CONNECTOR
PLUGS INTO COVER
ASSEMBLY

8
 2. 0 Detailed MDT installation and wiring instructions.

2.1 Mounting the MDT on your machine.

Refer to drawing previous page

Mount the enclosure to provide operator comfortable access to the keyboard and ability to view the data function
display.

Important: Leave one and one-half inches (1 1/2) clearance on the left side (as facing unit) to allow the door to be
removed for installation, servicing. Also allow frontal clearance, as noted, for the door to drop down.

Critical Instructions--failure to do any of the following will void your warranty!

1. Do not use the enclosure as a junction box for relays, extra wiring, etc.
2. You must use shielded wire for computer communications wiring and connect shields exactly as instructed
at each MDT.
3. You must supply an AC "green" (ground) connection to EARTH GROUND terminal..

CAUTION: The 120/240V AC power should be disconnected from the unit when
removing the MDT for servicing. The “on/off” switch on the power module (drawing,
opposite page) will remove power from the cover assembly, but NOT the power module.
Also, if using 120VAC machine "Signal Inputs", dangerous 120V AC could be present on
the connector P2 if the machine is still running, even though the MDT is turned off.

2.2 Connecting continuously maintained AC power to the MDT.

IMPORTANT: You must wire the MDT to a secure, continuous source of AC power, independent of the machine
being monitored.

Connection Instructions:
Connect continuously maintained source of 120V or 240V AC 50/60 Hz. to terminal strip as noted in drawing on opposite
page making sure you supply a "green" ground wire connected. The MDT draws 0.5 Ampere maximum.

The MDT-150 has two “fuses”:

1. One is a 5 Ampere customer replaceable fuse designed to protect the unit in the event to an event such as wiring the
MDT to the wrong voltage--eg: 220VAC applied when MDT is wired to accept 120VAC main power.
2. A second “fuse” is designed to protect the MDT from damage in the event of an overload or short circuit. This
device is a solid state fuse that resets itself after main power is removed for two minutes or so.

While there is a main power on/off switch provide on the power supply, for safety you should provide a breaker for main
AC power. See CAUTION note above.

9
 Overview of MDT-150 inputs and outputs.
Your system may not be supplied with all the options shown here. The minimum connections for a basic system are
shown in green. Each input can accept three types of input. Each input can be a different type.

Main AC Power connection Outputs--activate external, user-

supplied, solid state relays.
120VAC or 230 VAC uninterrupted power. MDT-150
MDT does not lose data when power is removed, but if
power is off during a Shift or Job change, the two shifts or
Jobs data get combined---thus the requirement of Machine Down (Lockout).
uninterrupted power. MDT is all solid state and draws very Activates when Signal Input #5 is absent,
little power---it is designed to be left on continuously. or machine slows below user set limit.

Output de-activates when Operator enters a

Down Reason from Keypad

Basic system: 1 or 2 Machine Signals This output is used to ensure the Operator
Both accept 24V-120V AC or DC or switch and relays. enters a Down Reason before machine is
I allowed to start up after a “down” event.
Machine Cycling (Signal Input #1)
Signal is a (typically already existing) 24V-120V AC or DC,
switch or relay contact signal which is activated once each
machine operation.
Machine Out of Limits Alarm :
Down “Manual” Time (Signal Input #5). Output is on when Cycle Time or Rate is
This input is typically found only in plastics processing running faster or slower than user-set, Job-
machinery. If not used, input must be wired “on” at specific limits.
installation.
Use this output to activate a light, horn, etc.
Automatic Down, Reject and Case Count. to indicate a machine operating outside
normal limits.

Two Automatic Down Reason Inputs: Direct connections

to machine to automatically track reasons for down time.

One Automatic Reject Input. Direct connection to

machine to automatically track Rejects.

Case Count Input. System can compare filled case count

to parts made to track waste/rejects.
Batch Count
Activates for 1 second when Parts Count
All inputs accept: 24V-120V, AC/DC or switch and relays. equals batch count.

Optional Bar code Wand

Bar Code Wand is used to scan in new Job from System Bar Code Wand is used to scan in new
Software Job Queue. Can also be used to log in Operators by Job which will be downloaded from
scanning employee badge. System Software Job Queue. As special
order option, can be used to log in
Operators by scanning employee badge. .

Computer communications
Windows PC collects data from MDT’s on shop floor using PC’s
standard RS-232 port or a USB port communicating through VT-28
Communications Interface module located at PC. Only one VT is
needed for a typical maximum system size of 60 MDT.
Standard Ethernet Communications is optional.
Poller PC communicates with other User PCs (or ERP system)
through standard LAN/WAN.

10
2.3 Connecting Machine Signal Inputs to the MDT.
(Refer to MDT-150 block diagram drawing facing page).
About Machine Signal Inputs.
All six inputs can accept literally any machine “signal”: switches or relay contacts, open collectors from photo and proximity
sensors and AC or DC voltages from 24 to 120V. Retrofitted proximity or photo sensors can be powered from the MDT for lowest
installed cost.
Definition: an “activated” input means:
If a DC or AC voltage input, when the voltage is applied.
If a contact/relay, when the contact is closed.
If an open collector, when the open collector is "on".
Machine Signal Input minimum “on” time and maximum rates:
Minimum signal “on” time is 15 milliseconds (.015 seconds). Normally this is not a concern because any electromechanical device
that is electrically operated within the machine will require at least this duration signal. Where this requirement might be a
problem is a photo/proximity detector sensing small, fast-moving parts or targets (for example a once-per-revolution sensor). For
this situation, the factory can modify the inputs to accept signals as short as 2 milliseconds for a modest charge.
Maximum Signal Input repetition rate is 1500 per minute, assuming an approximate 50% duty cycle (on/off time) of the input.
Higher rates to 2200 per minute can be accepted through modifications to the MDT. Consult Production Process.

Note: Only Signal Inputs #1 and #5 are required for basic system, however Signal Input #5 “Down Manual” can be
jumpered “on” and not connected to machine if your process doesn’t provide this signal.
Signal Input # Used for
#1 Machine cycling. Must be connected to a device within the machine that is activated once per
R
Machine Cycling machine operation. Most production, rate and cycle time data is derived from this signal, as is
E Dwell/Duration (on) time of the Signal.
Q #5 Down Manual When the input is de-activated, it indicates the machine is in Down Manual mode--
U Down Manual that is, as when the machine is taken out of Automatic/Run mode of operation and placed into
I Manual or Jog mode--as when operator is making adjustments or clearing jams or blockages.
R When machine is in Down Manual, Signal Input should be deactivated.
E In some applications Down Manual time may not be important to track. In this event, connect
D Signal Input #5 permanently “on” (that is, its internally jumpered “on”-- see circled text in 2.3.1
following page and refer to drawing on page 12). Additionally, some molding machines have two
“automatic” run control positions that make it difficult to combine into a single Down Manual
sensing signal. For this problem we can supply an external module to combine two 24 to 120V
AC/DC inputs into one. Contact Production Process
Inputs in shaded boxes below are not required for basic system operation

#2
When activated, tracks time down and increments incidences by one count in Down Reason #21.
Automatic Down
Reason Input
#3 When this input is activated, it adds one count to Reject Reason #1
Automatic
Reject Input
#4 When activated, tracks time down and increments incidences by one count in Down Reason #23.
Automatic Down
Reason Input
#6 Case Count. Totalizes number of filled cases. Each activation indicates one case filled. (Number
Case Count of parts per case is set by computer for each Job).

Important: As you install MDT, record serial number (on label on back of cover and on front of MDT)
and Machine Identification Number (ID#): the number you have assigned to the machine to uniquely identify
it to the system computer.

11
Switch and “dry” contact closure Signal Input connections.
By “dry” we mean no voltage is supplied by the contact. Instead the MDT supplies the voltage
(+24VDC) to the contact closure. Contact is momentarily closed when the machine cycles.

OR
P5

22 23 24 25 26 27 28 29 30 31 32 33
P4

P3

6
P2

5
9 10 11 12 13 14 15 16 17 18 19 20 21

SIGNAL

4
INPUT
#5

3
INDICATORS
#5

2
1
#1
#1
+24v DC JP1
JP5 JP2
Ground
8

JP3
JP4
7
6
5
4
3

Notes:
2
1

1. Each Signal Input may have a different

P1
source.

2. Assuming you won’t normally use it,

Signal Input #5 is shown wired
normally “on” in this example.

3. If each machine signal represents more

than one part, the System Software will
automatically insert a “Scale Factor” (2,
7, 8, 32, 1.234, etc., ) to calculate actual
parts made or material processed each
machine cycle. (Scale Factor for each
Job is defined in the System Software).

12
2.3.1 Connecting switches, relays, or other types of “dry” contacts.
Refer to drawing facing page. It shows an example of a switch wired to Signal Input #1. Other Signal Inputs would be wired
similarly. Switch Signal Inputs are wired so they switch a 24VDC voltage supplied by the MDT.

Only Signal Inputs #1 and #5 are required for basic system operation.

Signal Input # Connect P2 Comments

Terminal # to
R #1 8 to one side of switch Supplies ground to one side of Switch.
E Machine 11 to one side of switch Switch supplies Ground to Signal Input.
Q Cycling 10 to Terminal # 9 Supplies 24VDC to Signal Input.
U #5 8 to one side of switch Required for basic system operation, but if you
I Down Manual 19 to one side of switch don’t use this signal, you must connect:
R 18 to Terminal # 9 Terminal #18 to Terminal #8 and
E
D Terminal #19 to Terminal #9

Inputs in shaded boxes below are optional and not required for basic system operation

#2 8 to one side of switch When activated, tracks time down and increments
Automatic 13 to one side of switch incidences by one count in Down Reason #21
Down Reason 12 to Terminal # 9
#3 8 to one side of switch When activated, increments Reject Reason #1 by one
Automatic 15 to one side of switch count.
Reject Input 14 to Terminal # 9
#4 8 to one side of switch When activated, tracks time down and increments
Automatic 17 to one side of switch incidences by one count in Down Reason #23
Down Reason 16 to Terminal # 9
#6 Each activation indicates one case filled.
Case Count 8 to one side of switch Supplies ground to one side of Switch.
21 to one side of switch Switch supplies Ground to Signal Input.
20 to Terminal # 9 Supplies 24VDC to Signal Input.

Initial testing and troubleshooting of Switch Signal Inputs. (See drawing facing page).
Each Signal Input has an associated small red lamp (LED) "SIGNAL INPUT INDICATORS" on the circuit board.
The LED illuminates when the signal is activated. Viewing the indicators will assist you in troubleshooting
problems--be sure that when the Signal Input is activated, the respective indicator is illuminated.

13
24V to 120V AC or DC voltage Signal Input connections.
Voltage is momentarily present when the machine cycles.

P5
24v DC

22 23 24 25 26 27 28 29 30 31 32 33
or
120v AC
INPUT

P4

P3

Filler

6
P2

5
9 10 11 12 13 14 15 16 17 18 19 20 21
SIGNAL

4
INPUT
#5

3
INDICATORS
#5

2
1
#1
#1
+24v DC JP1
JP5 JP2
GROUND
8

JP3
JP4
7
6
5

Notes:
4
3

1. Each Signal Input may have a different

2

source.
1

P1

2. Assuming you won’t normally use it,

Signal Input #5 is shown wired
normally “on” in this example.

3. If each machine signal represents more

than one part, the System Software will
automatically insert a “Scale Factor” (2,
7, 8, 32, 1.234, etc., ) to calculate actual
parts made or material processed each
machine cycle. (Scale Factor for each
Job is defined in the System Software).

14
2.3.2 Connecting 24V to 120V AC and DC Signal Inputs.
Refer to drawing facing page. It shows two machine signals: 24VDC and 120VAC connected to Signal Inputs #1 and #2
respectively. The other Signal Inputs would be wired similarly. Note that Photo and Proximity Sensors can be powered by the
MDT’s 24VDC (nominal, its not regulated) power supply to provide these voltages to the Signal Inputs.

Signal Inputs will accept any voltage from 24V to 120V, AC or DC and draws a maximum .003 Ampere at 24VDC and .01
Ampere at 120VAC. Since inputs are electrically isolated from each other, each Signal Input may be different.

Important: you need only connect Signal Inputs #1 and #5 for basic system operation.
Signal Input # Connect P2 Comments
Terminal # to
R #1 11 to AC or DC signal If using DC signals, polarity is not important.
E Machine Cycling 10 to AC or DC signal
Q #5 19 to AC or DC signal If you don’t use this signal, you must connect:
U
I Down Manual 18 to AC or DC signal Terminal #18 to Terminal #8 and
R Terminal #19 to Terminal #9
E
D
Inputs in shaded boxes below are optional and not required for basic system
operation. If using DC signals, polarity is not important.
#2 13 to AC or DC signal When activated, tracks time down and increments
Automatic Down 12 to AC or DC signal incidences by one count in Down Reason #21
Reason
#3 15 to AC or DC signal When activated, increments Reject Reason #1 by one
Automatic 14 to AC or DC signal count.
Reject Input
#4 17 to AC or DC signal When activated, tracks time down and increments
Automatic Down 16 to AC or DC signal incidences by one count in Down Reason #23.
Reason
#6 21 to AC or DC signal Each activation indicates one case filled.
Case Count 20 to AC or DC signal

Initial testing and troubleshooting of 24V to 120V Inputs.

(refer to drawing facing page for location of the six “SIGNAL INPUT INDICATORS”).
Each Signal Input has an associated small red lamp "Signal Input Indicators" on the circuit board. The LED illuminates when the
respective signal is activated (power is applied to input). Viewing the indicators will assist you in troubleshooting problems--be
sure that when the Signal Input is activated, the respective indicator is illuminated.

Potential Problems and solutions:

Missing counts?
Have you connected Signal Input #5 (Down Manual) to a machine signal? If you’re not using the Down Manual machine
connection, you must jumper this input “on” (wire it as described above).

Signal Inputs not turning off?

If your controller/PLC is not driving some other load device in the machine, that is, is driving only the MDT input directly, you
should install a 2000 ohm, 10 watt resistor across the Signal Input to provide a load to the PLC output. Production Process can
supply small quantities of the resistor free of charge. Ask for part number 041910.

15
Connecting NPN (“sinking”) solid state Proximity or Photo
TECHNICAL BULLETIN
MDT-150
Sensors or similar devices as machine signal inputs.
TB-350-4
MDT
Inputs SIGNAL
are wired so that oneINPUT WIRING
side of the Signal Input is INFORMATION
supplied 24VDC from the MDT, the
otherFor
side of
NPNthe input is switchedSolid
(Sinking) to “ground”
State with the output ofSensors,
Proximity the Sensor. Current
or into
input is less than .003 milliamperes—be sure the Sensor will stay turned “on” with that low
Similar Devices.
current. If not, you may have to connect a “load” resistor across the input to the MDT to
increase the current to a value which will keep the sensor turned “on”
(Note that terminal designations have been removed for clarity.)
Note: Each input may be wired differently, some “prox”, some AC, some switch..

NPN / SINKING
PROXIMITY P5
PICKUP

22 23 24 25 26 27 28 29 30 31 32 33
NPN ONLY
BLK

BRN
PROX
PICKUP
P4
BLU

P3

6
P2

5
9 10 11 12 13 14 15 16 17 18 19 20 21

UNIVERSAL SIGNAL INPUT #6 SIGNAL

4
UNIVERSAL SIGNAL INPUT #6 INPUT
UNIVERSAL SIGNAL INPUT #5

3
INDICATORS
UNIVERSAL SIGNAL INPUT #5
UNIVERSAL SIGNAL INPUT #4 2
1
UNIVERSAL SIGNAL INPUT #4
UNIVERSAL SIGNAL INPUT #3
JUMPER UNIVERSAL SIGNAL INPUT #3
REQUIRED UNIVERSAL SIGNAL INPUT #2
UNIVERSAL SIGNAL INPUT #2
UNIVERSAL SIGNAL INPUT #1
UNIVERSAL SIGNAL INPUT #1
UNREG. +24vDC JP1
JP5 JP2
GROUND
8

JP3
JP4
7

Repeat above for any of the other

6
5

Universal Signal inputs you wish

4

to use. Always jumpering one of

3

the input connections to pin 9

2

and the other input connection

1

to the output of the proximity.

P1
Power for the proximity is from
pin 9.

When using proximity pickups to sense fast moving targets (that is, with activation/sense
time of under .005 seconds.) you should remove two jumpers JP1, JP2. If you are not sure
of your signal activation time, contact Production Process.

16
2.3.3 Connecting NPN (“sinking”) solid state proximity and photo sensor Signal Inputs.
Refer to drawing facing page. It is example of a NPN Sinking output proximity pickup connected to Signal Input #1.
To ensure proper operation of the pickup, we recommend using shielded wire if the leads to the pickup are run in the same
conduit as 120/220/440 VAC power. (Use the communications cable).

Note only Signal Inputs #1 and #5 are required for basic system operation.
Signal Input # Connect P2 Comments
Terminal # to
R #1 8 to Pickup Blue wire Supplies ground (0V) to pickup.
E Machine 9 to Pickup Brown wire Supplies 24VDC to pickup.
Q Cycling 11 to Pickup Black wire Pickup open collector output to Signal Input.
U 10 to P2, Terminal 9 Supplies 24VDC to Signal Input.
I #5 8 to Pickup Blue wire Required for basic system operation, but if you don’t
R Down Manual 9 to Pickup Brown wire use this signal, you must connect:
E 19 to Pickup Black wire Terminal #18 to Terminal #8 and
D 18 to P2, Terminal 9 Terminal #19 to Terminal #9
Inputs in shaded boxes below are optional and not required for basic system
operation

#2 8 to Pickup Blue wire When activated, tracks time down and increments
Automatic 9 to Pickup Brown wire incidences by one count in Down Reason #21.
Down Reason 13 to Pickup Black wire .
12 to P2, Terminal 9
#3 8 to Pickup Blue wire When activated, increments Reject Reason #1 by one
Automatic 9 to Pickup Brown wire count.
Reject3 15 to Pickup Black wire
14 to P2, Terminal 9 .
#4 8 to Pickup Blue wire When activated, tracks time down and increments
Automatic 9 to Pickup Brown wire incidences by one count in Down Reason #23
Down Reason 17 to Pickup Black wire
16 to P2, Terminal 9
#6 8 to Pickup Blue wire When activated, increments Case Count by one count.
Case Count 9 to Pickup Brown wire
21 to Pickup Black wire
20 to P2, Terminal 9

Initial testing and troubleshooting Proximity Inputs. (refer to facing page for location of “Signal Input Indicators”).
Each input has an associated small red lamp (LED) "Signal Input Indicators" on the circuit board. The LED
illuminates when the Signal Input is activated. Viewing the indicators will assist you in troubleshooting problems--be
sure that when the Signal Input is activated, the respective indicator is illuminated.
Potential Problems: Missing counts?
Is the part or target the proximity sensing providing a signal duration (activation time) that is shorter than .010
seconds? If so, you may miss inputs. Production Process can supply a module to accept very short duration, fast
signals such as those from an encoder).

When using proximity pickups to sense fast moving targets (that is, with activation/sense time of under
.005 seconds.) you should remove all three jumpers JP1, JP2, JP3. If you are not sure of your signal
activation time, contact Production Process.

17
 Wiring MDT outputs. Note: You must use only solid state relays with a “coil”
rating of from 3 to 30VDC at .010 amperes or less.
keypad.

DANGER: The “Lockout” output can only be used in machinery that

has a separate, “latching” run/start circuit. That is, Lockout output
should not be connected to a simple machine “on/off” control so as to
avoid start up when the Operator enters a Down Reason, otherwise
the machine could start running because its on/off switch is in the
“on” position.

WIRED TO BE NORMALLY
DE-ENERGIZED. ENERGIZES
WHEN DOWN
3 - 30v DC
50mA. MAX.
+
P5
SOLID

22 23 24 25 26 27 28 29 30 31 32 33
STATE
RELAY
-

Typical AC output Solid State Relays

RECOMMENDED MFG. TYPES P4
1. Potter and Brumfield SSR-240D25
CRYDOM - SERIES-1 CSD & CTD
(240V, up to 25 Amperes)
GRAYHILL - MINI PUCK SERIES DRIVER SUPPLY (+24v)
2. Crouzet G240D10
BATCH DRIVER P3
(240VAC, up to 20
MAGNECRAFT amperes)
- CLASS 6
SLOW DRIVER
3. Crydom 1210& BRUMFIELD - EOM TYPE
POTTER DOWN "LOCKOUT" DRIVER

6
(120VAC, up to 10 Amperes
GUARDIAN - MSSR SERIES P2

5
9 10 11 12 13 14 15 16 17 18 19 20 21

GORDOS CORP. - G SERIES

Typical DC output Solid State Relay SIGNAL

4
OMRON - G3NA-210B-DC5-25 INPUT
1. Crydom D1D07

3
INDICATORS
(up to 100VDC at up to 7 amperes)

3 - 30v DC 2
1
50mA. MAX.
+

SOLID
STATE
RELAY JP1
JP2
JP5
8

- JP3
JP4
7
6

Note that “normally energized” and “normally

5

WIRED TO BE NORMALLY
4

de-energized wiring applies ONLY to Lockout Driver.

ENERGIZED. DE-ENERGIZES
3
2

WHEN DOWN
1

P1

18
2.4 Connecting Machine Lockout, Out of Limits and Batch Outputs.
The MDT can energize three solid state relay outputs:
1. A Lockout Output is activated when machine is “down”; caused by either Signal #5 being absent, or
machine running slower than a Threshold Down Alarm Time---a user-set, Job-specific value.
2. A Machine Down and Out of Limits Output is activated when machine is running faster or slower than user-set, Job-
specific limits.
3. Batch Counter Output is activated when a Batch Count is reached.
The MDT can activate most typical solid state relays only with a "coil" input of 3 to 30VDC at .010 amperes typical.

2.4.1 Use Lockout Output to ensure operator enters Down Reason before machine is allowed to start.
Output is used as "Machine Lockout". That is, if the machine slows or stops, this output can activate a relay to lock out machine
to keep it from operating until the Operator enters a down Reason. This output only (not Machine Slow or Batch) can be wired
as “normally on”—that is, it turns off when machine is “down” or slow, or it can be wired “normally off”—that is, it turns on
when machine is “down” or slow.

See DANGER note on facing page. Use Lockout only on machine

with separate “run” and “stop” circuits
2.4.2 Wiring diagram for all three outputs:
(see drawing, facing page).
Notes: 1. Connections are made on connector P3.
2. This connector “strip” is actually three connectors, P5, P4 and P3. Be sure of your connections.
3. For the normally energized connection of the Lockout output, notice that the (-) terminal of the relay
goes to connector P2, not P3 as all the other connections do.
Output used for Connections on P3 Description
Machine Down For normally de-energized Use to force Operator to enter a Down Reason to silence an
(Mach. Lockout) mode: alarm or to prevent machine operation until a down reason is
(user must add relay) Terminal 22 to relay (-) entered.
Terminal 25 to relay (+) Turns “on” (or “off” see drawing opposite) when Signal #5 is de-
Relay must be a activated and/or machine cycle is longer (or machine hasn't cycled
modern “solid state For normally energized for longer than) "Threshold Down Alarm". Output turns “off” (or
relay with a “coil” mode: “on” see drawing) when Operator enters a Down Time Reason.
voltage of 3 to Terminal 22 to relay (+) Threshold Down Alarm is inserted by system PC for each Job.
24VDC. The MDT P2 Terminal 8 to relay (-)
can supply nominal Electrical notes about normally energized lockout: P3, Terminal
24VDC at 5 22 is connected to 24VDC through a 1200 ohm resistor which will
milliamperes in the keep the relay continually energized until a down event occurs.
normally energized
mode. P2, Terminal 8 is connected to 0 V (ground).

Machine Out of Terminal 23 to relay (-) Machine Out of Limits Alarm.

Limits or Down: Terminal 25 to relay (+) Output is “on” when:
(user must add relay) 1. Machine Cycle Time or Rate is running faster or slower than user-set,
Job-specific limits.

Use this output to activate a light, horn, etc. to indicate machine is

operating outside its normal operation limits.
Batch Terminal 24 to relay (-) Activates for one second when Batch Count is reached.
(user must add relay) Terminal 25 to relay (+)

19
2.5 Connecting (optional) 16 Input module for automatic sensing of Down Reasons.
An optional 16 input board is used to automatically collect Down Reason time/incidences. If this module has been
installed, an Addendum: MDT-150 16 Input Module will be provided. Refer to it for installation instructions.

20
 2.6 Inserting an ID# and Operating MDT in “Local Mode” (without computer) to verify
machine Signal Inputs.
At this point, you have completed wiring and installation of the MDT's on your machines. To identify each machine/MDT to the
computer, each MDT needs a unique Machine Identification Number (ID#). If you know the Machine Identification Number (ID#)
you can insert it now through the MDT keypad as described in 1. Here’s how to enter….. below.

If you want to see if the MDT is operating before you activate the system software but after you enter an ID#, you may use a MDT
feature called Local Mode to check your installation and machine Signal Input wiring: See 2, Enter Local Mode…. below.

1. Here's how to enter an ID# (from first power-up of MDT).

a. Reset MDT by connecting together for 6 seconds the two pins (a paper clip works well) on the left hand corner of the circuit
board on the door labeled MASTER RESET. (See drawing following page). Display will show Monitor ID Lost
b. Press CLEAR key. Display will show Monitor Number 0 Press ENTER key. Display will show Monitor Num ---0
c. If you know the actual ID# enter it now or a “dummy” number 999 to enter Local Mode as below, then press ENTER.
Display will show Reset Mon # 999 (or ID# you entered)
2. Enter Local Mode to check Signal Input connections as follows:
a. Press CLEAR key.
b. Press DISP key.
c. Press the numbers 9 and 8.
d. Press the ENTER key.
MDT may be prompting you to enter a Down Time Reason, which must be entered before you may view any Data Functions. To
do this, press any number key, then ENTER key twice.
You are now in Local Mode. View Data Function 98 Sig Set which shows status of the six machine Signal Inputs, left to right:

Signal Input #1
indicator

Sig Set 100010

Signal Input #5
. indicator

When “0” changes to a “1”, the respective Signal Input is activated.

Note that the display update time is approximately 1 second, therefore if machine Signal Inputs are faster
than this the display won’t “track” them exactly, thus, short signals may indicate only occasionally.
If this is the case, another way to confirm the operation of the six Machine Signal Inputs is to view six small red indicators located on
bottom edge of circuit board in cover as shown in drawing following page. Labeled 1 through 6, these indicators correspond to
Machine Signal Inputs 1 through 6 respectively. When the indicator is illuminated, the corresponding Machine Signal Input is
activated.

Here’s two Data Functions you can review to test your installation.
Data Function FX # Function Description
Cycle Time 1 Last Cycle Time in seconds from Signal Input #1.
Machine Rate 6 The machine cycling rate (Signal Input #1)

If you don’t get any data, make sure Signal Input #5 is either connected to machine or wired “on” as previously instructed in
Section 2.3.1

21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

JP4
JP5
JP1
JP3
JP2

P-XXXX
Production Process

MASTER RESET

1 2 3 4 5 6

Reset Pins---connect with Six Signal Input Indicators, corresponding

paperclip for 6 seconds to reset to Signal Inputs #1 through #6
MDT. respectively, left to right.

22
2.7 Relating PC Screens and reports to the two Automatic Down Reasons and one Reject
input.
Here’s where the two Automatic Down Reason Inputs and the one
Automatic Reject inputs appear in the System’s real time screens.
Note the Reason Description is assigned by the user to replace the
“default” reasons supplied with the software.
P5
In addition to these automatically entered Reasons, each machine may

22 23 24 25 26 27 28 29 30 31 32 33
have its own list of up to 40 Down and 20 Reject Reasons that are
entered by the Operator.
Automatic Reject Reason Signal Input P4

#3, terminals 14 and 15.

Tracks Rejects in Reject Reason #1 P3

1 2 3 4 5 6
P2

9 10 11 12 13 14 15 16 17 18 19 20 21
SIGNAL
INPUT
Automatic Down Reason Signal Input INDICATORS

#4, terminals 16 and 17.

Tracks time in Down Reason #23

JP1
Automatic Down Reason Signal JP5 JP2

8
JP3
JP4

7
Input #2, terminals 12 and 13.

6
5
Tracks time in Down Reason #21

4
3
2
1

P1

NOTE: The MDT

automatically tracks in
Reject Reason #20 all
Parts made in Setup,
Down Manual, Down
Slow and the down
state triggered by the
two Automatic Down
Inputs.

You can change this to

“good” via the system
software.

23
There are two basic types of (standard, wired) computer Communications Interfaces that
may be supplied with your system.
(If you are supplied with Ethernet or Wireless Communications an Addendum will be supplied detailing
these options. )

)
"PHONE" TYPE
CONNECTOR FOR
One type: VT28 and VT-28A. RS232 CONNECTIONS
TO COMPUTER
Identified by a single connector for communications
cable connections.
1 2 3 4 5 6 7 8
VT-28 and VT-28A can drive 10,000 of communications
cable organized in up to four Groups (described later). POLL TEST
Red 1
Grn 4
Black
Green 3 Green 1
Green 2 Wht
Red 2
MONITOR

AC
POWER PLUG
Shields

REAR VIEW

"PHONE" TYPE
CONNECTOR FOR
RS232 CONNECTIONS
TO COMPUTER

Second type: the VT-28B, for all systems

shipped after September 2006. Shields
Poll Test
Identified by four individual communications cable
R B G W R B G W
connectors.
R B G W R B G W
VT-28B can drive 8,000 feet of communications cable
organized in up to four Groups of 2000 feet each
(described later).
R B G W R B G W
AC Power
R B G W R B G W

REAR VIEW

If you have a single machine “Pilot” system,

you’ll receive a VT-05 (shown below) and receive an
Addendum for connections instructions.

EITHER
OR
THIS

Production Process
A division of Industrial Marine Electronics, Inc.
61 Harvey Road, Londonderry, N.H., 03053 U.S.A.

VT-05

SHIELD
RED
BLACK
GREEN
WHITE

24
3.0 Connecting computer to MDT’s using VT-28
Communications Interface.
Description of computer communications using VT interface.
Production Process' VT-28 Communications Interface/RS-232 Translator provides electrical isolation between the MDT and
computer, and enables a PC's standard RS-232 port to communicate with the MDT's on your plant floor. A USB interface can
be provided--contact Production Process.
The VT drives up to 100 MDT located up to 8,000 cable-feet distant, arranged in one or more Groups as outlined below. Do not
run more than 2000 feet of communications cable in a Group.
Within a Group, wiring to each MDT is "daisy chain"; that is, a single cable runs from one MDT to the next.

THIS:
To PC Serial
MDT MDT MDT MDT VT-28 PortTO
orPC
USB
Port.

NOT THIS: (You can wire it this way, but it takes lots more wire)

MDT

MDT
To PC Serial
MDT VT-28 TO or
Port PCUSB
Port.
MDT

For installations of over 20 MDT, we strongly suggest you divide the shop floor into several groups of approximately 20 MDT
and "daisy-chain" within each Group. Run a separate cable from each Group of 20 MDT's to the VT--there are four connectors, one
for each Group. This simplifies troubleshooting in the event of a wiring problem—you can isolate the problem to a Group.

MDT

MDT
MDT VT-28 TO PC
MDT

25
 FERRITE BEADS ARE SUPPLIED
WITH THIS UNIT CONNECT COMMUNICATION CABLE
DRAIN WIRES TO GROUNDING STUDS
LOCATED IN THE BASE OF THE ENCLOSURE.
AN INSULATED PIGTAIL WIRE MAY BE USED.

FERRITE BEADS SHOWN INSTALLED

COMMUNICATIONS CABLE OUT

COMMUNICATIONS CABLE IN

NOTE: TERMINATE ALL THREE DRAIN WIRES

PER CABLE (IN, OUT)

COMMUNICATION CABLE DRAIN WIRES

3.1 Important rules for installing communications cable.

Failure to observe the following procedures will void your warranty

or cause false data readings.
1. Use only four conductor , double foil shielded cable as described below for communications wiring. You
can buy cable from most full line electronics distributors, or Production Process can supply at $.40 per foot.

Supplier Part #
Alpha Wire 1243/2C
Manhattan/CDT M14474
Quabbin Wire and Cable 7455

2. See drawing above. Connect shield (bare) wires to the stud closest to the point where cable enters enclosure.

3. Install two gray metallic ferrite “beads” on the communications cable as shown in drawing above.

4. Do not bundle communications cable with power or fluorescent lighting leads. Do not drape cable over
fluorescent lamp fixtures.

5. Make sure the cable shields (3 bare “drain” wires in each cable) are connected at each MDT and to the VT.
If this is not done, improper operation may result.

6. Do not place communications cable in the same conduit as 120/220/440VAC power lines.
(Communications voltage is low voltage-- under 24V--so it doesn't have to run in metallic conduit).

7. Don’t run communications cable bundled with plastic resin feed lines (high static discharges are present).

8. Do not run more than 2000 feet of communications cable in one Group.

26
3.2 Computer installation guidelines. Function of VT Communications Interface
module.

Note: if you have received a single machine “Pilot” installation, refer to the Addendum at the end of this manual. It describes
the low cost VT-05 Communications Interface supplied with Pilot System. When you expand your system beyond 5 MDT,
you’ll need to utilize the VT-28B Communications Interface as described below:

Overview, Definitions, and Conventions:

The VT-28 provides electrical isolation so that if high voltages are accidentally connected to the communications line,
only limited (repairable) damage will occur to the VT-28 or MDT, but no damage will occur to the computer.

Computer installation guidelines.

The computer must have a supply of "clean" 120VAC power. That is, it must not be subject to significant surges,
"brownouts", etc. If your plant is at the end of long power lines or you have other significant power problems
(lightning strikes in the summer for example), we recommend an Uninterruptable Power Source (UPS) which supplies
power from internal batteries to the computer during power outages or "brownouts". We can provide
recommendations for UPS’s.

3.3 Connecting the VT-28 to your computer.

Shields
VT-28B
R B G W R B G W
POLL TEST

R B G W R B G W

R B G W R B G W
AC Power
R B G W R B G W

REAR VIEW

COIL CORD*

CONNECTS TO
COMPUTER

If using USB Adapter, it

DB9*
ADAPTER
plugs into this connector
EITHER THIS
OR
THIS

DB25*
ADAPTER

* Denotes Items Included In Accessory Package

VT-28 is supplied with a 9 pin (DB9) connector, a 25 pin (DB25) connector, and a coil cord. Choose one DB
connector to plug into your computer's RS-232 Communications Port (COM1 or COM 2 depending on what your
System is configured for--see System User Guide). Plug the coil cord between the DB adapter and the VT socket
labeled POLL. In case your PC has only a USB port, you may use the (supplied) USB to Serial Adapter. Plug
the (male) DB9 connector on the USB Adapter into the (female) DB9-to-coil-cord -phone-plug adapter. Follow
instructions with the USB adapter disk.

3.4 This paragraph intentionally left blank.

27
 MDT TO
VT-28B WIRING
MDT to VT-28B wiring
Cover Assembly
COMM. OUT MDT-150
COMM. IN CONNECT COMMUNICATION CABLE SHIELDS
CONNECT SHIELDS AT EACH MDT AS SHOWN IN INSET.
TO GROUND STUDS
LOCATED IN BASE
OF ENCLOSURE.

To next MDT in the

COMMUNICATIONS TO NEXT MDT P5
Group,
WIRE LIKE connecting
PINS, (eg. MDTred to DATA TO MDT (RED)

22 23 24 25 26 27 28 29 30 31 32 33
26, 27, AND SO ON). DATA COMMON (BLACK)
red, black to black, green DATA FROM MDT (GREEN)
to green, white to white., DATA TRANSMIT SUPPLY (WHITE) TRANSMIT SUPPLY (WHITE)
DATA FROM MDT (GREEN)
P4
and shields to stud in DATA COMMON (BLACK)
DATA TO MDT (RED)

bottom of case. P3
Shields connect to Stud
In base of enclosure. P2

9 10 11 12 13 14 15 16 17 18 19 20 21
DETAIL

ABOVE COLORS REPRESENT

PRODUCTION PROCESS' RECOMMENDED
COLOR CODING USING ALPHA
#1243/2C CABLE.
(4 CONDUCTOR DOUBLE SHIELDED)

8
7
6
5
4
3
2
TO MONITORS FOUR CONNECTIONS

1
TO MONITORS
(PLUS SHIELD ON STUD) P1
DATA TRANSMIT SUPPLY (WHITE)
DATA FROM MDT (GREEN) "PHONE" TYPE
DATA COMMON (BLACK) CONNECTOR FOR
RS232 CONNECTIONS
DATA TO MDT (RED) TO COMPUTER
SHIELD (BARE)
UP TO
4000' Shields
Poll Test

R B G W R B G W

R B G W R B G W

Four separate connectors provide

R B G W R B G W
AC Power
ability to easily wire four separate
R B G W R B G W

DISPLAY MENU DISPLAY MENU

REAR VIEW Groups. This simplifies
01 SEAL TIME

troubleshooting and installation.

01 SEAL TIME
02 SEAL TEMP 02 SEAL TEMP
03 AIR PRESS 03 AIR PRESS
04 CYCLE TIME 04 CYCLE TIME
05 TOTAL PARTS 05 TOTAL PARTS
06 TOTAL REJ. 06 TOTAL REJ.

1 2 3 Setup
1 2 3 Setup

4 5 6 Rejects 4 5 6 Rejects

7 8 9 7 8 9
0 Operator
0 Operator
Special Special
DISP ENTER CLEAR DISP ENTER CLEAR
Function Function
ALL SHIELDS MUST BE CONNECTED TO VT-28
AND TO MDT OR WARRANTY IS VOID.
MDT MDT
MONITOR #001 MONITOR #988

3.5 Wiring the MDT’s to the VT-28B

We suggest organizing the production floor into up to 4 Groups of no more than 20 MDT in each Group, with wiring
to each Group connected to one of the 4 terminal connectors on the VT-28B.

Connect:
MDT’s 4 pin connector, P4 To one of the four 4 pin connectors on VT-28B
Terminal 26 DATA TO MDT (red wire) Terminal “R”
Terminal 27 DATA COMMON (black wire) Terminal “B”
Terminal 28 DATA FROM MDT (green wire) Terminal “G”
Terminal 29 TRANSMIT SUPPLY (white wire) Terminal “W”

CABLE SHIELDS ( total of 6 bare “drain” wires Bare stud labeled Shields.
connected to VT terminal labeled “Shields”—
that is, each cable--incoming and outgoing--
has three bare wires in it.

28
3.6 Before starting system, perform this quick test of VT-28 communications wiring.
1. Connect the MDT to the VT. Power up the VT, MDT’s, and the PC with System software, but don’t run software yet.
2. You should see four green indicators on the VT:
--if you do, proceed to Section 4: Use PC to assign ID# and configure MDT’s (next page).
--if you don’t, proceed to Problems with quick test? Troubleshooting VT communications immediately below.
FRONT VIEW

VT-28
MDT’s Receive Indicator
Computer’s Transmit Indicator Normally green, pulses red when
N
Normally green, pulses red when TA computer requests data from MDT
transmitting data to MDT. (MENU OF:

DATA FUNCTIONS
DOWNTIME CAUSES
(EIGHT DIGIT NUMERIC DISPLAY)

1
4
(20 OR 40 CHARACTER
ALPHANUMERIC DISPLAY)

2
5
3
6
(1)
(2)
REJECT CAUSES)

7 8 9 (3)

0 (4)
DISP ENTER CLEAR (5)

Production Process
Division OF
M
Computer’s Receive Indicator Industrial Marine Electronics MDT’s
T Transmit Indicator
61 Harvey Road
Normally green, pulses red when N
Londonderry, N.H. 03053, U.S.A. Normally green, pulses red when MDT
receiving data from MDT is sending
T
data to computer.

"PHON

3.6.1 Problems with quick test? Troubleshooting VT communications.

1. With software running, click on Poller button. Click Stop MDT Poller and click “yes” when prompted.
2. Click on Poller button again. Select Terminal to MDT’s.
A screen will show titled Dumb Terminal to MDT’s. Anything you type in this screen will be transmitted to the MDT-150
for troubleshooting purposes.
3. Proceed to A. Testing the PC Communications Card immediately below.

A. Testing the PC Communication Card. (see drawing immediately below)

1. Plug the VT end of the coil cord into the "PHONE" TYPE
CONNECTOR FOR
"TEST” socket. RS232 CONNECTIONS
TO COMPUTER

2. Test by typing a character on the

keyboard; it will display twice on your Shields
Poll Test

PC screen if the communication card is R B G W R B G W

operating properly. If it does, Plug the R B G W R B G W

coil cord cable back into VT socket

“POLL” , then continue to B: Testing R

R
B

B
G

G
W

W
R

R
B

B
G W

G W
AC Power

the VT below. REAR VIEW

VT-28B
B. Testing the VT:
1. Remove all but one communications cable connector, then remove the four wires from the connector (removing
the wires makes it easier to perform #2 below).
2. Temporarily jumper the terminals that were connected to the red and green wires.
3. Type a character.
If you don't see the characters you type twice, the problem is in the VT.
If you do see character twice, verify shop floor wiring, then reconnect the red, green, white and black wires (they are labeled
on the connector R, G, W, B), but then separate Group wiring into smaller and smaller sections while repeating the test. The
reason for separating wiring is that a short at one MDT will affect all MDT in the Group. Similarly, an open connection could
interrupt communications for all MDT further down the line.

29
This page intentionally left blank

30
 4.0 Use PC to assign machine ID#s and configure MDT’s.
Each MDT must have a unique one-to-three digit machine "Identification Number" (ID#) to identify it to the system polling PC.
Following are instructions on how to insert an ID# into each MDT, using the Poller PC, not a “Node” PC.
Step 1: Before you can assign an ID#, you must do the following:
a. Your system must be connected and the VT, MDTs and PC are “powered up”.
b. Have the listing of each MDT Serial Number and associated machine Identification Numbers (ID#) ready. You'll
find the serial number ---a 5 to 8 digit number--on MDT's internal label and front panel.
c. Start the System Software, then: 1. Click on Poller button, a menu will pop up.
2. Click on Stop MDT Poller if not grayed out, and click YES when prompted.
If the system is ending a shift, a prompt will inform you, and you’ll have to
wait until the shift end finishes to click the Stop MDT Poller
3. Click on Poller button again and a menu will pop up.
4. Click on MDT Configuration. The following screen will display:

You will enter MDT’s serial number here.

Not yet received

You will enter Machine Identification
Number (ID#) here.

Ignore Ignore

No messages yet

Step 2: Assign (or change) a Machine Identification Number (ID#) to each MDT.
a. To confirm a MDT is communicating, in the screen above, enter MDT serial number into the box titled Serial #, then click
Read button. If MDT is communicating, some data will display in Communications box starting with an asterisk and the MDT
Serial number. If it does, continue with b (next). If the message: “No response from MDT…” displays, then there is a
communication problem between the PC and the MDT. Review your installation for problems.
b. Enter the desired ID# for this MDT (from 1 to 899 ( 899, not 999 is maximum) in the box titled ID #, then click on
the Reset button. Answer “yes” to “Reset this MDT?” 123456+123 (MDT Serial Number, plus sign, and MDT ID#)
This will display in Communications box: OK

(The MDT will display “Reset Mon #XXX” until the Poller PC restarts its normal polling routine).
c. Repeat this step for each MDT and be sure you don't assign duplicate ID# numbers.
d. When finished setting ID#s in all the MDTs, click the Exit button. If system asks Resume Polling?, click Yes.
Resetting may take up to a minute for each MDT that is being reset. You’ll see this activity at the bottom of your
screen: Send #002 I etc., as reset process is happening.
Step 3: Enter the MDT machine Identification number (ID#) in the system's Machine List.
a. Click on the Utility button highlight System Configuration, then select Machine List. (A List of Active Machines will
be shown in the box on the left, and Machine Configuration will be shown on the right).
b. Click the Add button to create a new machine/MDT. Enter the new machine's ID# you assigned in Step 2, c, above. If you attempt to
enter the same ID# twice, the message “MDT ID in use; choose another” will pop up. You will be given the opportunity to enter a
different ID# without having to click the Add button again. Continue until all MDT ID#s are added.
c. When the Exit button is clicked, the program briefly shuts down and then restarts the system.
You are ready to run the System Software. Refer to System User’s Guide for more instructions.
.
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 TECHNICAL BULLETIN
TB-350-9

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JP4
JP5
JP1
JP3
JP2

P-XXXX
Production Process

MASTER RESET

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MDT SHOWN WITH SHIELD PLATE REMOVED FOR CLARITY

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4.1 Inserting or changing the ID# at the MDT instead of using the computer.
1. Refer to drawing opposite, see the two pins labeled “MASTER RESET”. Connect them together for at least six
seconds--use a paper clip--the voltage is very low.
2. The display will show: “Reset Mon # XXX”, where XXX is the Machine ID# previously entered.
3. Press the CLEAR key. Press ENTER key. The display will show “Monitor Num. XXX”.
4. Enter the correct/new ID#, (leading zeros are not needed in ID#), followed by the ENTER key
5. When computer is active and communicating with the MDT, it will start normal system operation.

5.0 After the system is running, you may also configure:

The list of configurable items below are those typically and routinely changed and are thus given as examples. Many
more are configurable as detailed in your System Software Manual.

The value of two items (5.1 and 5.2) may change depending on the Product/Job being run. Therefore they are
configured either from the Machine List screen (if you have Production Manager software) or the Job
Queue/Production Standards screen (if you have Job Monitoring Software).

5.1 Threshold Down Alarm Time: a Cycle Time (or equivalent Rate) that indicates
machine is effectively “down”.
Your System Software will provide instructions. However, to simplify system startup, before shipping a “default”
value preprogrammed into the MDT-150 is 180 seconds.

5.2 Tracking actual Pieces/Lineal Measure made each machine operation.

To track actual parts or product made, the MDT can accept two “Factors” as follows: (as supplied, Factor is 1)
1. The number of whole parts made each machine cycle. For example, number of tools or active cavities. The value
may range from 1 to 999. While the computer software inserts the initial value (a maximum number), the Operator
can change this number in Data Function “Act Pcs/Lin Meas” (refer to MDT User Guide for instructions).
2. You may insert the lineal measure of product produced each machine operation. This could be the circumference
of a drum/wheel in contact with the material. Or, it could be the length of material fed each machine operation,
etc. This value may be from .0001 to 999.9999 and can be inserted only by the computer.

The following items don’t normally change depending on the Job, thus are configured only when MDT is installed on
machine. The System Software Manual, System Configuration Options, to activate.

5.3 Select parts made in Down or Setup condition are “good” or “reject”.
You have the option of having parts made in any Down condition or in Setup automatically assigned to Reject
Reason 20. The “default” condition as supplied is parts made in Down and Setup are “Reject”. If you wish to
change this, contact Production Process for instructions.

5.4 Enabling Production Hold capability:

To make productivity reports more accurate, Production Hold is a feature you can use to ignore time not available for
production, that is, breaks or lunch. The MDT as shipped has Production Hold disabled.

5.5 Enabling HELP call capability.

Help call causes Machine’s display line to change color to purple to alert supervisors. As shipped Help call is “off”.

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