MDCplus Knowledge Base

CONNECTIVITY
www.mdc-plus.com Apr 12, 2019
System Requirements
Before you install or use any Zyfra MDCplus product, we recommend that you verify that your computer meets or exceeds the
minimum system requirements detailed below.

Server
Minimum HDD Recommended space on HDD
▪ 3 GHz CPU ▪ Ethernet card ▪ Quad-core ▪ Ethernet card OS: Windows XP (with SP3 service pack) or later, Windows Server 2003 or later
▪ 4 GB RAM (100 Mbit/s) 3 GHz CPU (1 Gbit/s) MDCplus must be running with administrator‘s privileges on a DEDICATED
▪ 10 GB free ▪ 8 GB RAM physical or virtual computer outside of the workshop.
space on ▪ 200 GB free For manufacturing with more than 200 Machines. SQL Server Standard is needed

Client and Collective Monitoring Panel (CPM)

Minimum OS: Windows XP (with SP3 service pack) or later, Windows Server 2003 or later
▪ 3 GHz CPU CMP installation is recommended on industrial PC or kiosk.
▪ 2 GB RAM Ports 80, 8080, 8081, 8082 and the ports used by the NC units must be enabled
▪ 1 GB free space on HDD on the network equipment to ensure normal system operation.
▪ Ethernet card CMP v 2.0 can be installed on Linux-based PC’s.
Mobile Pult Monitoring app (MPM)

Android version 4 and later

Infrastructure

The local network for all hosts, client workstations and server (Wi-Fi/Ethernet) with 100 Mbit/s bandwidth.

Anti-Virus Software
Most computers today have some kind of anti-virus software to protect from unwanted malware. In some cases, these have been found to interfere with applications such as
Mastercam which are running on the computer. Zyfra does not recommend specific anti-virus products, but if you see unexpected issues, it may be a conflict with anti-virus
software. Try temporarily disabling the anti-virus software or setting an exception for Zyfra MDCplus.
Connection types
• If the machine you wish to monitor has one of the data collection interfaces available, a Direct connection
can be achieved by simply connecting an Ethernet cable to the machine. In this case no additional
hardware is required beyond what might be needed for operator input (e.g. tablet or TVV-10 terminal).
However, it can be costly to activate or install the monitoring feature if not enabled on a machine control
and a Hardware connection might be preferred.
• Hardware based data collection for older CNCs, manual machines and other equipment. MDCplus
Adapters are din rail mounted and are wired into signal lamps, light towers, etc.
• Combined (Dual) connection - combines the benefits of two types of connection and data collection

Features\Connection Type Hardware Software Combined

Connection to any CNC or manual

+
machines
Data collection from CNC control + +
Base state history recovery in the event of
+ +
network failure
From TTV10 terminal on a Via CPM or MPM for From TTV10 terminal on a
Downtime reason input
machine machine group machine

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Connectivity. Direct software connection

Supported machine controls

If your control is not listed please contact us

for information about your specific machine
and control.

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Direct software connection. Scheme

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 Direct software connection. Features

If the machine you wish to monitor has one of the data collection interfaces
available, a Direct connection can be achieved by simply connecting an Ethernet
cable to the machine – plug&play. In this case no additional hardware is required
beyond what might be needed for operator input (e.g. tablet or TVV-10
terminal). However, it can be costly to activate or install the monitoring feature if
not enabled on a machine control and a Hardware connection might be
preferred.

Features:
▪ Ethernet port required.
▪ Certain options are required in certain cases (options are activated by the
customer, partner or CNC machine supplier independently).
▪ Operators enter downtime reasons and interact with the system using
Collective Monitoring Panel software installed on PC and tablets running
Windows OS as well as Mobile Pult Monitoring app installed on mobile
devices running Android OS.
▪ Data are collected from CNC (cycle, speed, feed, load, etc.), refer to the
specifications for each protocol.
▪ By default, monitoring object polling period is 5 s.

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Fanuc

Requirements:

• Network adapter is installed

• FOCAS option is available
• IP address setup

Compatible CNC models:

• Fanuc 0i (D, F)
• Fanuc 16i, 18i, 21i
• Fanuc 30i, 31i, 32i

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Fanuc

Discrete signals Measured Parameters

Current state Yes Spindle speed Yes

Feed Yes
NC program execution mode Yes
Spindle speed corrector Yes
NC program stop Yes
Feed corrector Yes
Alarm Yes Jog corrector Yes

Axis running Yes Coordinates Yes

Spindle loading Yes
M, S, T Yes
Axis loading Yes
Edit mode No
Part counter Yes
Spindle motor temperature No

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Fanuc

Technological data Variable

NC program name Yes

Time of machine is switching on Yes
NC program block Yes
Tool number No
Time of NC program executions Yes
Cycle time Yes

Information

NC program Yes PLC-signals: Yes

Messages, errors Yes
Pushed buttons Yes
Print screen No Refer to the “MDCplus Working with Fanuc CNC” manual for details.

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 Siemens. Connection options

1. Connection to PLC.
2. Connection via OPC UA protocol — Connect My
Machine (OPC UA) option is required: provides
maximum possible amount of data.
3. Software agent installation at CNC control. Pros:
no paid options required, a set of collected
parameters is close to OPC UA. Cons: our own
software is installed at CNC control, potential
problems with the warranty, not suitable for all
CNC models.

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Siemens PLC

Features:
• Paid option is not required
• Connection is achieved via X130 (Ethernet) or MPI port using special
adapters: IBH Link S7++ or AI-01D
• Additional study of the PLC project structure is required
• IBH Link S7++ or AI-01D require device configuration
OR
Supported CNC models:

Sinumerik 802D, 810D, 840D, 802D sl, 828D sl, 840D sl

Sinumerik 828D sl, 840D sl version 4.5

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Siemens PLC

Discrete signals Measured Parameters

Current state M0/M1 Spindle speed No

Feed No
NC program execution mode No
Spindle speed corrector Yes
NC program stop Yes
Feed corrector Yes
Alarm No Jog corrector Yes
Coordinates No
Axis running No
Spindle loading No
M, S, T M0/M1
Edit mode No Axis loading No
Part counter No
Spindle motor temperature No

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Siemens PLC

Technological data Variables

NC program name No
Time of machine is switching on No
NC program block No
Tool number No
Time of NC program executions No
Cycle time No

Information

NC program No PLC-signals: Yes

Messages, errors No
Pushed buttons No
Print screen No Refer to the “MDCplus Working with Sinumerik CNC” manual for details.

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Heidenhain. Connection options

1. HH2 protocol is used to work with the RemoTools SDK

library, which requires DNC18 option.
2. HH1 protocol is used to work with TNCCmd command
line, which requires DNC18 option.

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Heidenhain

Discrete signals

HH1 HH2
Current state Yes Yes
NC program execution mode Yes Yes
NC program stop (M0, M1, etc.) No No
Alarm Yes Yes
Axis running No No
M, S, T No No
Edit mode No No

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Heidenhain

Measured Parameters

HH1 HH2
Spindle speed No Yes
Feed No Yes
Spindle speed corrector Yes Yes
Feed corrector Yes Yes
Jog corrector Yes Yes
Coordinates Yes Yes
Spindle loading No Yes
Axis loading No No
Part counter No No
Spindle motor temperature No No

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Heidenhain

Technological data

HH1 HH2
NC program name Yes Yes
NC program block Block number Yes
Tool number No No
Cycle time No No

Variables

HH1 HH2
Time of machine is switching on Yes Yes
Time of NC program executions Yes Yes

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Heidenhain

PLC Signals

HH1 HH2

PLC-signals No Yes

Information

HH1 HH2
NC program No Yes
Messages, errors Yes Yes
Pushed buttons No Yes
Print screen No No

Refer to the “MDCplus Working with Heidenhain CNC” manual for details.

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Mitsubishi

Supported CNC models:

M700/M700V, M70/M70V, E70, M800/M80

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Mitsubishi

Discrete signals Measured Parameters

Current state No Spindle speed Yes

Feed Yes
NC program execution mode Yes
Spindle speed corrector No
NC program stop G-functions Feed corrector No
Alarm Yes Jog corrector No

Axis running No Coordinates Yes

Spindle loading Yes
M, S, T No
Axis loading No
Edit mode No Part counter No
Spindle motor temperature No

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Mitsubishi

Technological data Variables

NC program name Yes

Time of machine is switching on Yes
NC program block Yes
Tool number No
Time of NC program executions Yes
Cycle time No

Information

NC program Yes PLC-signals: No

Messages, errors Yes
Pushed buttons No
Print screen No

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Okuma

Features:
• MTConnect required

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Okuma

Discrete signals Measured Parameters

Current state Yes Spindle speed Yes

NC program execution mode Yes Feed Yes

Spindle speed corrector No
NC program stop No
Feed corrector Yes
Alarm Yes
Jog corrector No
Axis running No Coordinates Yes

M, S, T No Spindle loading Yes

Axis loading Yes
Edit mode Yes
Part counter No
Spindle motor temperature No

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Okuma

Technological data Variables

NC program name Yes

Time of machine is switching on No
NC program block Yes
Tool number No
Time of NC program executions No
Cycle time No

Information

NC program No PLC-signals: No
Messages, errors Yes
Pushed buttons No
Print screen No

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MAZAK

1. MTConnect is a paid option, which uses a standard protocol providing a

large set of data.
2. Our protocol — no paid option is required, the protocol works with a delay
of up to 3 hours, and a limited set of data is provided (basic parameters),
the Satellite software shall be configured.
3. Our satellite-based protocol, which uses a Mazak connectivity software,
which has to be installed on CNC.

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MAZAK

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HAAS

1. If the machine is equipped only with RS-232, a TP terminal-

recorder with special firmware is used.
2. For NGC controls, HaasConnect option is required, and only a
limited set of data will be available (as in case 1).

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HAAS

Discrete signals Measured Parameters

RS-232 NGC RS-232 NGC

Spindle speed Yes Yes
Current state Yes Yes
Feed No No
NC program execution mode Yes Yes
Spindle speed corrector No No
NC program stop Feed corrector No No
Yes No
(M0, M1, etc.)
Jog corrector No No
Alarm No Yes Coordinates No Yes
Axis running No No Spindle loading Yes Yes
M, S, T No No Axis loading No Yes
Edit mode Yes No Part counter No
Spindle motor temperature No No

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HAAS

Technological data Variables

RS-232 NGC RS-232 NGC

NC program name Yes Yes
Time of machine is switching on Yes Yes
NC program block No No
Tool number Yes Yes
Time of NC program executions Yes Yes
Cycle time Yes Yes

Information

RS-232 NGC RS-232 NGC

NC program No No
Messages, errors No Yes
PLC-signals No Yes
Pushed buttons No No
Print screen No No

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Robots

• FANUC
• KUKA — requires OPC Server installation
and configuration on the control panel

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Hardware connection
If your machine does not support one of the monitoring interfaces signals
can be acquired from the machine using an input device such as the
MDCplus Adapter or Moxa ioLogik device. These devices handle the
connection between your machine and network and facilitate signal
transmission, in the form of machine event data, to MDCplus system.
Operators enter downtime reasons and interact with the system using
TVV-10 terminal or Collective Monitoring Panel software installed on PC
and tablets running Windows OS as well as Mobile Pult Monitoring app
installed on mobile devices running Android OS. Only basic signals (on,
off, cycle, alarm) are collected from the machine's analogue outputs.

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Hardware connection. Scheme

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 ZYFRA MDCplus Kit

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 MDCplus Kit

Ready-to-use “out of the box” hardware kit

▪ Monitoring Terminal TVV-10
▪ Barcode scanner
▪ MDCplus Adapter R-03D
▪ MDCplus Adapter PU-03
+ ▪ Power unit +
▪ ADC / DC Clamp TK-3 - 3 pcs
▪ Mounting Kit MK-1
▪ Mounting Bracket for TVV-10
▪ Connecting wires

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MDCplus TVV-10 sample of installation

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MDCplus TVV-10 sample of installation

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MDCplus TVV-10.2
4,3″ display Fast speed MicroSD

1-Wire RFID connector

Case with splash

protection

Jumpers for 24/5V Voltage

New fast-access mount

Extra buttons for DTR input
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MDCplus TVV-10. Legacy machines

▪ Machine is switched on/off;

▪ On-load operations;
▪ Machine downtime;
▪ Power consumption;
▪ Part counter (if machine has it).

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 3rd party hardware

• IOLOGIK MOXA series devices

• Available in your country
• Required configuration
• Recommended models: E1210, E1242
and other with Modbus protocol

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Hardware mounting requirements

▪ Relay ladder logic system circuit is required

▪ Certified electronics engineer required
▪ A set of special-purpose tools required
▪ Supervisor from the customer's side is required
▪ Partial machine disassembly and installation of fasteners
on the machine housing is required
▪ Approximately 2 machines per day per 1 person

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Installation process

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 Equipment installation. Step by step

Step 1. Equipment layout planning

▪ Define the place, where TVV-10 terminal with barcode scanner will be installed on the machine. Arrangement of the terminal
shall be convenient for operator and located in close vicinity of operator’s machine control panel.

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 Equipment installation. Step by step
Step 1. Equipment layout planning
▪ Part of equipment shall be arranged inside electrical cabinet. It is necessary to find a free space for arrangement of recording
terminal, power unit, automatic circuit breakers and power supply unit. This equipment is installed on a DIN rail. For this
purpose it is possible to use a free DIN rail available in the cabinet or the one included in delivery set.

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 Equipment installation. Step by step

Step 2. Equipment and tolls preparation

▪ Unpacking the set of equipment.
▪ Preparation of required tools, as well as documentation for the machine (if necessary).

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 Equipment installation. Step by step

Step 3. Installation of TVV-10 terminal

▪ There are different options for fixing the terminal on the machine:
▪ With the use of mounting bracket (included in delivery set) or without it.
▪ With the use of magnets (alternative method).

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 Equipment installation. Step by step

Step 4. Cables laying

▪ Cable lines are used for integration of all components of the system. Usually there are 3 cables required: power supply cable
24 VDC; communication cable RS-485; Ethernet cable (not included in delivery set). For cables laying there are usually used
existing or external cable channels, plastic pipes etc.

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 Equipment installation. Step by step

Step 5. Connection of cables to TVV-10 terminal

▪ If tight cable entries are required it is necessary to use glands.
▪ When cover of TVV-10 terminal is removed, it is necessary to connect cables properly in accordance with User Manual.

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 Equipment installation. Step by step
Step 6. Equipment installation inside electrical cabinet
▪ It is necessary to install automatic circuit breakers, power supply unit, registering terminal and power unit on a DIN rail.
▪ Connection of wires shall be performed in accordance with User Manual and technical documentation on the machine.

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 Equipment installation. Step by step

Step 7. Installation of current clamps

▪ Current clamps with different ratings shall be installed immediately before or after the the main switch of the machine.
▪ It is important to provide same position of clamps on power cables, as well as their proper phasing.

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 Equipment installation. Step by step

Step 8. Settings on the Server and on terminal

▪ Making settings for TVV-10 by document “MDCplus. TVV-10 monitoring console”.
▪ Adding new Machine to the directory with TVV-10 protocol and configuring by document “MDCplus. Basic module
Preparation”.

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Connectivity. Combined (Dual) connection

Combined (Dual)
connection utilizes two
connections types —
hardware (TVV-10 is
installed) and software (via
machine’s Ethernet port).
The advantages include
the ability to enter
downtime reasons from
the machine (via TVV-10)
while simultaneously
collecting data directly
from the CNC control.

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Wi-Fi

• Machines and terminals can be connected to the

corporate LAN via Wi-Fi, which is not desirable
because of potential problems with the signal
stability and potential problems with packets loss
due to low connection speed.
• We recommend to use TP Link RE305 router.

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Network hardware

• Please use specialized industrial switches with a

DIN-rail mount and 24V power supply.
• Recommended model - MOXA EDS 205.

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Video monitoring

• It’s possible to use video camera for discovering a

troubles and abnormal situations.
• States on time line chart will be linked with time-
marks on the video stream.
• Recommended model - D-Link DCS-2130 or
compatible.

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 Tablets for Collective monitoring panel (CMP)

• Any industrial tablets with Google Chrome and Android 7+.

• Recommended diagonal 10’’ with minimum resolution
1280*768 and more than 2Gb RAM
• USB interface has to be supported if it’s needs for barcode
reader
• Recommended models:
➢ Advantech AIM-68
➢ Zebra XSLATE D10
➢ Getac F110
➢ HP ElitePad G2 1000
➢ PRODVX APPC-10DSK

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Kiosks for Collective monitoring panel (CMP)

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Vibration monitoring. Hardware

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Vibration monitoring. Installation

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Pasilankatu 2, 00240 Helsinki
+358 (0) 9 4273 4852
[email protected]

www.mdc-plus.com