Technical Description PCM Modules ZM modular

Transcription

Technical
Description
Date: February 2014
LJU Automatisierungstechnik GmbH
PCM Modules
ZM modular
Field bus connection: Profibus DP
©
LJU Automatisierungstechnik GmbH
Am Schlahn 1
14476 Potsdam
Germany
Tel.: +49 (0) 33201 / 414-0
Fax: +49 (0) 33201 / 414-19
E-mail: [email protected]
Internet: www.ljuonline.de | www.grenzebach.com
The standard names, trade names, product names etc. used in this technical documentation may also be brand names even when not specially indicated and as such subject to
the statutory stipulations.
February 2014
ZM modular-DP_TB0019_en
Technical Description
ZM modular Profibus DP
Table of Contents
Table of Contents
1
General Information ..................................................................................... 6
1.1
Information about the Technical Description ................................................ 6
1.2
Symbols in the Documentation .................................................................. 7
1.3
Limitation of Liability ................................................................................ 8
1.4
Copyright................................................................................................ 8
1.5
Conformity .............................................................................................. 8
1.6
Proper Use .............................................................................................. 9
1.7
Spare Parts and Repair ............................................................................. 9
1.8
Disposal Instructions and Environmental Specifications ...............................10
1.9
Warranty ...............................................................................................10
1.10 Customer Service ...................................................................................10
1.11 Modifications and Alterations ....................................................................11
1.12 Personnel and Qualification ......................................................................11
2
3
System Overview ........................................................................................ 12
2.1
The PCM Command System .....................................................................12
2.2
Components ...........................................................................................12
2.3
Principle of the Modular PCM-System ........................................................13
Installation Notes ....................................................................................... 14
3.1
Important Note - Power Supply ................................................................14
3.2
Important Notes on Cable Layout .............................................................15
3.3
Important Notice for Command Rail Segmentation ......................................15
3.4
Installing Modules ...................................................................................16
3.4.1 Module Sequencing .........................................................................16
3.4.2 Mounting Dimensions ......................................................................16
3.4.3 Installation on Top Hat Rail ..............................................................17
3.4.4 Uninstalling a Module ......................................................................17
4
Central Module ZM-DP ................................................................................ 18
4.1
General Facts .........................................................................................18
4.2
Design of the ZM-DP ...............................................................................19
4.3
Monitoring and Protection Function ...........................................................19
4.4
Synchronization ......................................................................................19
3
Table of Contents
4.5
Technical Data and Connections ...............................................................20
4.5.1 Technical Data of the ZM-DP ............................................................20
4.5.2 Connections and Indicators of the ZM-DP .........................................21
4.6
Profibus Connection ................................................................................22
4.6.1 Profibus Connection ........................................................................22
4.6.2 Setting of Profibus Address ..............................................................22
5
Pulse Code Module PCM-8-Bus.................................................................... 23
5.1
General .................................................................................................23
5.2
Design of the PCM-8-Bus .........................................................................23
5.3
Monitoring and Protection Functions ..........................................................24
5.4
5.4.1 Technical Data of the PCM-8-Bus ......................................................25
5.4.2 Connections and Indicators of the PCM-8-Bus ....................................26
6
Input Module EM-8-Bus .............................................................................. 27
6.1
General .................................................................................................27
6.2
Design of the EM-8-Bus ...........................................................................27
6.3
6.3.1 Technical Data of the EM-8-Bus ........................................................28
6.3.2 Connections and Indicators of the EM-8-Bus ......................................29
7
Digital Input Module DI-8-Bus .................................................................... 30
7.1
General .................................................................................................30
7.2
Design of the DI-8-Bus ............................................................................30
7.3
7.3.1 Technical Data of the DI-8-Bus ........................................................31
7.3.2 Connections and Indicators of the DI-8-Bus .......................................32
8
Digital Output Module DO-8-Bus ................................................................. 33
8.1
General .................................................................................................33
8.2
Design of the DO-8-Bus ...........................................................................33
8.3
8.3.1 Technical Data of the DO-8-Bus .......................................................34
8.3.2 Connections and Indicators of the DO-8-Bus ......................................35
4
Table of Contents
9
Resistor Module RM-8-Bus (optional) ......................................................... 36
9.1
General .................................................................................................36
9.2
Design of the RM-8-Bus ...........................................................................36
9.3
Installation ............................................................................................36
9.4
9.4.1 Technical Data of the RM-8-Bus .......................................................37
9.4.2 Connections of the RM-8-Bus ..........................................................37
10 Communication and System Configuration ................................................. 38
10.1 Profibus Communication ..........................................................................38
10.2 Cyclic Data Exchange ..............................................................................38
10.2.1 Cyclic Data: System Controller -> ZM-DP: 26 bytes .........................38
10.2.2 Cyclic Data:
ZM-DP -> System Controller: 9 bytes ..........................39
10.3 Acyclic Data Exchange .............................................................................40
10.3.1 Acyclic Data: System Access Indexes ..............................................41
10.4 ZM-DP Parameter Settings 39 Byte ...........................................................42
10.4.1 Default System Structure ..............................................................43
10.4.2 Data Sources for PCM-8-Bus ..........................................................45
10.4.3 PCM Output Channels According to T3000 Specifications....................46
10.4.4 Data Targets for EM-8-Bus/DI-8-Bus/DO-8-Bus ................................46
10.5 Example ................................................................................................47
5
General Information
1 General Information
1.1 Information about the Technical Description
This technical description contains technical information to the PCM-System with Profibus
connection and the devices of the ZM modular system:
Central module ZM-DP
PCM module PCM-8-Bus
Input module EM-8-Bus
Input module DI-8-Bus
Output module DO-8-Bus
Resistor module RM-8-Bus (option)
It gives important information about the system and the devices.
Please read this technical description carefully before using the device!
It will ensure smooth operation and prevention of errors, defects and damage to the system. Moreover, universal safety and accident prevention specifications must be implemented at sites where the devices are in use.
The technical description includes important instructions regarding the operation and
safety; it is a part of the product and must readily available, close to the device, so that
it is accessible to the personnel at all times.
Every person who is assigned to work on or with the device must have read and understood this technical description before working with the devices. This is mandatory even
if the concerned person has already worked with such a device or the like, or has been
trained by the manufacturer.
6
General Information
1.2 Symbols in the Documentation
There are warning instructions and symbols in this technical description. It is absolutely
mandatory to comply with these and follow them. These are working aids and they will
warn you of possible damage to property and personnel. Always follow these instructions.
Moreover, always follow the universal safety specifications and accident prevention specifications.
Warning!
This symbol along with the signal word “Warning” refers to a potentially
dangerous situation that can lead to serious injuries or fatality if it is not
avoided.
Caution!
This symbol along with the signal word “Caution” refers to a potentially
dangerous situation that can lead to minor injuries and damage to property if it is not avoided.
Note!
This symbol indicates that there are additional and important information
and tips on the relevant topic.
See also!
This symbol indicates that other detailed descriptions on the particular
topic are available or provides references to other sections in this documentation.
7
General Information
1.3 Limitation of Liability
All data and instructions in this technical description have been compiled taking into consideration the applicable standards and specifications, the state-of-the-art technology
and our knowledge and experience gained over the years.
LJU Automatisierungstechnik GmbH is not liable for any damage or operational disorders
arising due to:

Non-compliance with the technical description

Improper use

Employment of untrained personnel

Independent remodeling and modification of the device
Moreover, non-compliance with the technical description absolves LJU Automatisierungstechnik GmbH of the warranty obligation.
1.4 Copyright
The contents of this technical description should be treated as confidential. It is meant
solely for persons working with the device. Handing over this technical document to third
parties without written permission of the manufacturer is not allowed.
Note!
The content details, texts, drawings, images and other illustrations of the
technical description are protected by copyright and are subject to the
industrial property rights. Any improper utilization is punishable by law.
1.5 Conformity
Devices of LJU Automatisierungstechnik GmbH have been designed to conform to the EU
Guidelines.
A copy of the EU certificate of conformity can be requested from LJU Automatisierungstechnik GmbH at any time.
8
General Information
1.6 Proper Use
Devices of the ZM modular system are devices to control industrial and commercial
transportation systems via PCM commands.
Warning!
Danger due to improper use!
Any improper use and/or different use of the devices can lead to dangerous situations.
Therefore:
-
Only use the devices in a proper manner.
-
Under all circumstances, comply with all technical data and permissible conditions at the site of operation.
-
Do not operate the devices in environments with hazardous oils, acids, gases, vapors, dust, radiation, etc.
1.7 Spare Parts and Repair
Warning!
Risk of injury due to spurious spare parts and incorrect repair!
Spurious or faulty spare parts and repair can lead to damage, malfunctions or total failure and can impair safety.
Therefore:
-
Use only original spare parts of the manufacturer.
-
Replace defective devices immediately and send them for repair.
When ordering a spare part, specify the plant number
WNR of the component and send it to the address given on
the inner side of the covering sheet (page 2). The plant
Type plate
with WNR
number is given on the type plate of the individual components. (see figure)
Send in the defective device for repair with a short description of the error scenario, to the address given on the inner
side of the covering sheet (page 2).
9
General Information
1.8 Disposal Instructions and Environmental Specifications
Provided no agreement for take-back or disposal has been made, the individual components of the device, after appropriate dismantling, have to be segregated and disposed of
or recycled, according to the current stipulations.
Materials marked with the recycling symbol or green dot
have to be disposed of using the relevant recycling method.
1.9 Warranty
The warranty covers only production defects and component defects.
The manufacturer is in no way responsible for damage occurring during transit or unpacking.
In no case and under no circumstances shall the manufacturer be liable under warranty
for defects or damage caused by improper use, incorrect installation or impermissible
operating conditions, or due to dust or aggressive substances.
Consequential and accidental damage are excluded from the warranty.
The warranty is valid for 12 months from the commencement of operation or 24 months
after delivery, whichever is earlier.
Resellers or distributors may negotiate different warranty periods in accordance with
their terms and conditions of sale and delivery.
If you have further questions relating to the warranty, please contact your supplier.
1.10 Customer Service
Our service is available for technical information.
Information about the responsible contact persons is available via telephone, fax, email
or the Internet, see contacts on the inner side of the covering sheet (page 2).
10
General Information
1.11 Modifications and Alterations
To avoid danger and to ensure optimal performance, no modifications, remodeling or
add-ons are allowed on the device, unless expressly approved by LJU Automatisierungstechnik GmbH.
Warning!
Risk of injury due to design modification!
Unauthorized technical modifications can lead to considerable damage to
persons and property.
Therefore:
-
Replace the defective device!
-
Replace it with an LJU device of the same model.
1.12 Personnel and Qualification
Warning!
Risk of injury due to inadequate qualification!
Inappropriate handling can lead to considerable personal and property
damage.
Therefore:
-
The installation, operation and maintenance of the device must be
carried out by trained and instructed personnel.
11
System Overview
2 System Overview
2.1 The PCM Command System
The PCM Command System allows a large number of commands to trolleys to be
transmitted over a control rail. Command coding is used and commands are transmitted
synchronized with the mains as a combination of mains power half-waves.
With the ZM modular system connected to the superordinate system controller, up to 190
different half-wave patterns can be sent as commands to trolley controllers over a control
rail.
Messages from the trolleys are transmitted over the signal rail to the PCM system as
half-waves and full-waves.
Digital modules (DI and DO) are available to record signals from external sensors (such
as proximity switches) and to output signals (such as to signal lamps).
2.2 Components
The ZM modular system consists of stackable modules that can be interconnected
depending on the application.
Base configuration:
1 x ZM central module,
1 x PCM module,
1 x EM module.
Maximal configuration:
1 x ZM central module
3 x PCM module,
3 x EM module,
3 x DI module,
2 x DO module.
If more modules are required, further ZM modular configurations can be added and
synchronized with each other.
Also see!
Detailed information on the components can be found in the chapter of
the respective module in these instructions.
12
System Overview
2.3 Principle of the Modular PCM-System
Internal module connection
I/O’s and shifts
Field bus
Cental module
ZM
PCM module
PCM-8-Bus
Input module
EM-8-Bus
Input module
DI-8-Bus
Output module
DO-8-Bus
1 module
max. 3 modules
max. 3 modules
max. 3 modules
max. 2 modules
L3 N
230 VAC
L+ L24 VDC
L3
N
8
Outputs
PCM
N
8
Inputs
230 VAC 50Hz
Control bar S1
Message bar M
L-
8
Inputs
digital 24 VDC
e.g. initiators,
sensors
L+
L-
8
Outputs
digital 24 VDC
e.g. signal lamp
13
Installation Notes
3 Installation Notes
3.1 Important Note - Power Supply
Important note!
All mentioned devices with L3-reference are designed for use with
230VAC!
In case of main power of more than 230VAC it is mandatory to use
a transformer to generate 230VAC (L3)!
The following schematic circuit diagram shows one possible implementation, but is not included in LJU’s scope of delivery.
Principle:
to the ZM modules modular
14
Installation Notes
3.2 Important Notes on Cable Layout
Important notes on cable layout!
Must be followed!
The following cable layout notes must be followed to ensure
interruption-free signal transmission and minimize external
influences on signal transmission:

Cables to PCM, EM, DI and DO modules must be laid separately
from supply lines to the conductor rails and other power cables.

Cables to PCM, EM, DI and DO modules must in principle be laid
separately. In no case should signals from PCM and EM modules
be contained in one cable.

For cabling to EM, DI and DO modules, shielded cables should
be used.

It is recommended that shielded cables be used for cables to
PCM modules.
3.3 Important Notice for Command Rail Segmentation
Important notice!
Definitely to be observed!

Consecutive command rail segments where switchover from
PCM commands ≤10 to PCM commands >10 shall be performed,
must be separated by active changeover segments.

Carrier entry into changeover segment with previous segment
command, switchover to following segment command only
when carrier brush gear is located completely within changeover segment.

Combinations of PCM commands ≤PCM10 will result in recognition of the smaller command by the control box.
15
Installation Notes
3.4 Installing Modules
All system modules are meant to be installed horizontally in fixed housing and assembled
on a NS 32 or NS 35/7.5 top hat rail.
Note!
PCM modules in the ZM modular system are designed for operation at
ambient temperatures of up to 50°C.
The place where modules are installed should be such that cooling can take
place vertically.
Heat trapped in switch cabinets must be led away.
3.4.1 Module Sequencing

The central module is the first (left) in the module chain. Other modules are
connected to this module.

The sequence of the other modules in the module chain can be chosen as desired
at first installation.

Optional resistance modules (RM modules) are not included in the module chain.
These can be separately installed.
Note!
A replacement module in a pre-configured system must be installed in
the same place in the module chain as the module it is replacing.
3.4.2 Mounting Dimensions
The adjoining diagram shows the
general dimensions of the modules.
You can find module-specific widths
in the Technical Data Sheet of the
respective module.
Width
16
Installation Notes
3.4.3 Installation on Top Hat Rail
The modules are attached by snapping onto a top hat rail NS 32 or NS 35/7.5 and
pushing together.

There are two green top hat rail clamps
on the back side of the modules.
To ensure stable installation, the top hat
rail clamps must be positioned on the
outside of a module before the module
can be installed.

Next, the module must be snapped onto
the top hat rail. Ensure that the clamps
snap in place firmly.

Push adjacent modules together to integrate the module into the module chain.
Ensure that plug connections to adjacent modules are correctly made.

Sind alle Module montiert, sind die äußeren Module einer Modulkette gegen versehentliches Verschieben mit Hutschienen-Endklemmen auf der Hutschiene zu sichern.
3.4.4 Uninstalling a Module

Release the top hat rail end clamps of a module chain.

Move modules in module chain away from each other till the module to be
uninstalled is free and no longer connected to adjacent modules.

Uninstall the module.
Release the top hat rail clamps on the bottom surface of the module from the top
hat rail with a flat-tip screwdriver by leveraging lightly (pull downwards).
17
Central Module ZM-DP
4 Central Module ZM-DP
4.1 General Facts
The ZM-DP module is a central module that can be controlled via Profibus and serves to
generate mains-synchronized clock signals.
An electronic evaluates the mains power and sends mains-synchronized +24 VDC square
wave voltages with various clock combinations over the internal module connection to
one or more pulse code modules.
Up to 190 different codes can be generated:
PCM 6

16 PCM codes
PCM 10

190 PCM codes
The codes are generated through relevant parameters of the PLC, which are transmitted
over Profibus to the ZM-DP. These codes are transmitted over the internal module connection to the pulse code module PCM-8-Bus.
The pulse code module can convert these signals directly into 230 V quasi sine half-wave
combinations, since these signals run synchronized to the mains voltage, and feed them
to the trolley controllers over the control rails (S1).
Every pulse code command is detected depending to the software by the trolley controllers and executed.
The user can freely assign the various commands like various speeds, forward/backward,
for example, in trolleys controlled by frequency inverters. The hoisting function in integrated hoisting gears can be controlled in the same way.
The advantages of this form of differentiated instructions, sent over only one control rail,
(S1) are high jamming resistance and prevention of incorrect instructions caused by
short circuit, wire break or reflections.
Mix-up with the sinus signal of the mains power is avoided.
18
4.2 Design of the ZM-DP

The mains supply of 24 VDC and 230 VAC is provided through 2 separate printedcircuit sub-unit terminals with threaded ends.

The central module ZM is connected with the internal module connection using a
37-pin plug connector. Over the internal module connection, signals are
exchangend and other modules in the module chain are supplied with 5VDC.

The module is connected to the Profibus over a Profibus module (integrated in the
ZM-DP).

The reference phase of the trolley controllers and the modules is fixed at L3.

The 24VDC power supply is safeguarded using multi fuses.
4.3 Monitoring and Protection Function

Monitoring of the mains voltage and supply voltage

Error messages via Profibus

Synchronization with other central modules in the installation

4 red status LEDs (see “Connections and Indicators of the ZM-DP“)
4.4 Synchronization
For synchronization with other central modules, these are connected with each other.
The sync connections of the ZM modules must be connected in parallel.
ZM 1
Sync1
Sync2
ZM 2
Sync1
Sync2
ZM x
Sync1
Sync2
Wiring:
It is recommended that shielded cables be used for the synchronization
cables between ZM modules.
Synchronization cables must be laid separately from the supply line to the
conductor rails and other power cables.
19
4.5 Technical Data and Connections
4.5.1 Technical Data of the ZM-DP
General
WNR
60132
Housing
Polyamide attachable to rails
Transparent lid
Polycarbonate, break-proof
Dimensions (W x H x D)
182 x 126 x 80mm
Ambient temperature range
+10C to +50C
Storage temperature range
-10ºC to +50ºC
Humidity
< 80% non-condensing
Inputs
Profibus DP over LJU Profibus module
Addressing
2 x HEX switch
Internal modul connection
1 x 37pole
Error reporting
via Profibus DP
Potential isolation
Optocoupler
Isolation voltage Ueff
2.5kV
Fuse protection of the 24 VDC supply voltage
Multi-fuses
Profibus module / provided baud rates
LJU / 9.6kBd to 12MBd
Supply input24VDC
Current consumption ZM-DP:
with 1 PCM and 1 EM module
with 2 PCM and 2 EM modules
110mA
140mA
170mA
Supply input 230VAC
Reference phase
L3 230V /50Hz
Reference potential
N
Power
max. 50W
Current consumption ZM-DP:
with 1 PCM and 1 EM module
additional
55mA
110mA
165mA
10mA per trolley in control segments
Power dissipation
No-load
Full-load
1W
2W
We reserve the right to make technical changes!
20
4.5.2 Connections and Indicators of the ZM-DP
Profibus
Profibus
D-Sub
D-Sub
ZM-DP
9 pole
pole
9
LED1
LJU System bus
37 pole
X1
X1
LED2
LED3
1
1
2
2
3
3
LED4
1 2
2 3
3 4
4
1
X2
X2
37pole
X5
X5
X4
X4
X3
X3
Programming
Programming
10 pole
Pin assignment X2
Pin assignment X4
1
N
1
Sync 1
2
L3
2
Sync 2
3
PE
3
L+
4
L-
LED indicators of the ZM-DP
LED 1
Supply 24VDC
LED 2
ZM online
LED 3
Mains voltage 230VAC
LED 4
Synchronization pulses
Wiring:
It is recommended that shielded cables be used for the synchronization
cables between ZM modules.
Synchronization cables must be laid separately from the supply line to the
conductor rails and other power cables.
21
4.6 Profibus Connection
The central module is connected to the system controller via Profibus.
The central module is equipped with a LJU Profibus module for the bus connection.
The field bus is connected to this module.
4.6.1 Profibus Connection
The ZM-DP is connected to the Profibus with a standard D-Sub.
The Profibus interface is a RS-485 interface according the Profibus standard EN 50170.
Pin
Signal
1
2
3
Rx/Tx+
4
5
ISO-GND
6
VP
7
8
Rx/Tx-
9
Assignment for Profibus RS-485
4.6.2 Setting of Profibus Address

The Profibus address is set on the ZM-DP using the two HEX switches S1 and S2 (top
right in the module).

Set the Profibus address in hexadecimal format.

The left switch sets the High Nibble, the right switch sets the Low Nibble.
Example:
Profibus address: 109
109dec  6Dhex
 high nibble = 6
 low nibble = D
22
Pulse Code Module PCM-8-Bus
5 Pulse Code Module PCM-8-Bus
5.1 General
The pulse code module PCM-8-Bus serves to control trolleys over a control rail with up to
190 different commands.
Such as slow/fast forward, slow/fast reverse, variable speeds in assembly areas,
hoist/lower to various positions with various speeds and various positioning behaviors.
The commands transmitted over the used field bus from the PLCs at higher levels are
converted by the central module into mains-synchronized timing signals and then
converted by the connected pulse code module into a pulse-code, which can be clearly
recognized by the trolley controller.
By using mains-synchronized pulses, the output signal is always started in the voltage
zero-crossing of phase L3 (disconnect in power zero-crossing). The maximum delay time
between input and output signals caused by this is 10 ms at 50 Hz.
The reference phase of the trolley controller and the module is assigned to L 3.
The advantages:

Safeguard against incorrect instructions that could be caused by short circuit,
grounding or line break

Differentiated control transmission over one control rail

System realization without N-type rail

Control from the PLC directly via the used field bus.

Galvanic isolation through Optocoupler

Unlimited hysteresis by using semiconductor switches

Protection wiring of the output ports and short-circuit protection

Error reporting over the used fieldbus.
The pulse code module has 8 output ports, which means that up to 8 control rail sections
can be driven by one pulse code module.
5.2 Design of the PCM-8-Bus
The pulse code module PCM-8-Bus is connected to the internal module connection over a
37-pin plug-connector. The timing signals are transmitted from the central module over
this internal module connection.
The 8 output ports must be connected with the assigned control rail sections using
printed-circuit sub-unit terminals with threaded terminal ends.
The connection to the other modules of the module chain is realized via a second 37-pin
connector.
23
5.3 Monitoring and Protection Functions

Output-side short circuit protection (semiconductor switches)

LED indicator for each output (see "Connections and Indicators PCM 8-Bus")
Error monitoring for:

Interruption of the supply voltage

Activation of the safety circuit (multi-fuse)

Disturbance reports over the internal modul connection

Can be used as individual disturbance report or together with several modules as
composite disturbance

Protective wiring of the output ports to prevent overvoltage (varistors)
The signal form of the pulse code module's output signals (e.g. drive commands) is
monitored by the micro-controller integrated in the trolley controller.
If the signal form varies due to disruptive influences, the trolley is stopped immediately.
This also holds good for line breaks, short circuits and grounding.
Mixing different pulse code signals, e.g. when traversing rail sections, is possible only to
a
limited
extent
when
using
asynchronous
drive
commands
(codes
2-9)
(discussion and approval required).
Mixing asynchronous drive commands (codes 2-9) with code numbers > 9 is to be
avoided at all costs.
24
5.4.1 Technical Data of the PCM-8-Bus
General
WNR
60336
Housing
Transparent lid
112 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
2 x 37pole
Outputs
8
Error reporting
via System bus
Potential isolation
Optocoupler
2.5kV
Output parameters
Reference phase
L3
Output switch elements
FET
Protection wiring
Varistor
Output power per output
max. 1A
Total output power
max. 1A
Short circuit protection
Semiconductor switches
Trolley stops for:

Short circuit against N, L1, L2

Line break

Interruption of the supply voltage
Power dissipation
No-load
Full-load
2W
10W
25
5.4.2 Connections and Indicators of the PCM-8-Bus
X5
37pole
37pole
X3
PCM-8-Bus
X1
1
Pin assignment X1
2
3
4
5
6
7
8
9
LED indicators of the PCM-8-Bus
1
L3
2
PCM 1
LED PCM 1
3
PCM 2
LED PCM 2
4
PCM 3
LED PCM 3
5
PCM 4
LED PCM 4
6
PCM 5
LED PCM 5
7
PCM 6
LED PCM 6
8
PCM 7
LED PCM 7
9
PCM 8
LED PCM 8
10
10
The LED associated with the
channel blinks at an intensity
corresponding to the PCM halfwave sample applied to the
output.
If the channel diode is off, no PCM
command is sent.
N
Wiring:
It is recommended that shielded cables be used for the connection
between the PCM modules and the control rail sections.
PCM wiring must be laid separately from the supply line to the conductor
rails and other power cables.
Signals from PCM and EM modules should not be contained in one cable.
26
Input Module EM-8-Bus
6 Input Module EM-8-Bus
6.1 General
The input module EM-8-Bus converts the 230V AC composite error messages, relayed
from the trolley over the status rail, to the signal level of the internal module connection.
This provides for transmission of the input signals over used field bus to the PLC.
The module has 8 input ports. This means that signals from up to 8 rail sections can be
converted by one input module.
The signal input ports are designed to distinguish between positive half-waves (presence)
and negative half-waves (error messages).
The reference phase of the trolley controllers and of the module is assigned to L3.
Signal inputs
In general, positive half-waves are interpreted as a "presence" and negative half waves as an "error".
Depending on the project.
See software description of the used project.
The advantages:

Compact modular design


Input switching threshold 140VAC

Differentiated display of (positive/negative) half-waves for each input (see “Connections and Indicators of the EM-8-Bus“)
6.2 Design of the EM-8-Bus
The input module EM-8-Bus is connected with the internal module connection using a 37pin plug connector. The input signals are sent via the internal module connection to the
central module, which then transmits them via the used field bus to the PLC.
The 8 input ports and the reference potential (N) must be connected to the assigned
control-rail sections or the power supply using printed-circuit sub-unit terminals with
threaded terminal ends.
Other modules of the system are connected using a second 37-pin plug connector.
27
6.3.1 Technical Data of the EM-8-Bus
General
WNR
60247
Housing
Transparent lid
112 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
2 x 37pole
Inputs
8
Potential isolation
Optocoupler
2.5kV
Input parameters
Reference phase
L3
Reference potential
N
Input voltage for signal 0
0V to 110VAC
Input voltage for signal 1
140V to 245VAC
Input power per input
max. 10mA
Power dissipation
No-load
Full-load
2W
10W
28
6.3.2 Connections and Indicators of the EM-8-Bus
X5
37pole
37pole
X3
EM-8-Bus
X1
1
Pin assignment X1
2 3 4
5 6
7 8 9 10
LED indicators of the EM-8-Bus
1
2
Input E 1
2 x LED E 1
3
Input E 2
2 x LED E 2
4
Input E 3
2 x LED E 3
5
Input E 4
2 x LED E 4
6
Input E 5
2 x LED E 5
7
Input E 6
2 x LED E 6
8
Input E 7
2 x LED E 7
9
Input E 8
2 x LED E 8
10
The status of each input is displayed
with two LEDs.
left LED = ON:
negative half-wave at the input
right LED = ON:
positive half-wave at the input
N
Wiring:
It is recommended that shielded cables be used for the connection
between the EM modules and the signal rail sections.
EM wiring must be laid separately from the supply lines to the conductor
Signals from EM and PCM modules should not be contained in one cable.
29
Digital Input Module DI-8-Bus
7 Digital Input Module DI-8-Bus
7.1 General
The digital input module DI-8-Bus is used to get 24VDC digital signals from automation
devices in the process.
For example, signals are received from the most varied sensors, such as approach
switches, photoelectric barriers and limit switches, and converted in such a way that they
can be transmitted over the internal module connection to the central module, which in
turn sends them to the PLC.
These input signals can also be transmitted over the internal module connection to a
digital output module, to control indicator lamps in the process for example.
The module has 8 digital 24VDC input ports, which means that signals from as many as 8
different devices can be converted and transmitted over the internal module connection.
The advantages:



Input switching threshold 10VDC

LED indicator for each input port (see “Connections and Indicators of the DI-8Bus”)
7.2 Design of the DI-8-Bus
The digital input module DI-8-Bus is connected with the internal module connection using
a 37-pin plug connector. The input signals are sent via the internal module connection to
the central module and/or to a digital output module.
The 8 input ports must be connected to the required devices, initiator lamps etc., over
printed-circuit sub-unit terminals with threaded terminal ends.
Other modules e.g. an output module, are connected using a second 37-pin plug
connector.
30
7.3.1 Technical Data of the DI-8-Bus
General
WNR
60003
Housing
Transparent lid
78 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
2 x 37pole
Inputs
8
Potential isolation
Optocoupler
2.5kV
Input parameters
Reference potential
- 24VDC
Digital 24 VDC for signal 0
0V to 3.5VDC
Digital 24 VDC for Signal 1
10V to 30VDC
Input power per input
< 10mA
Power dissipation
No-load
Full-load
1W
2W
31
7.3.2 Connections and Indicators of the DI-8-Bus
X5
37pole
37pole
X3
DI-8-Bus
1
2 3 4
5 6
7 8 9 10
X1
Pin assignment X1
LED indicators of the DI-8-Bus
1
2
Digital Input DI 1
LED DI 1
3
Digital Input DI 2
LED DI 2
4
Digital Input DI 3
LED DI 3
5
Digital Input DI 4
LED DI 4
6
Digital Input DI 5
LED DI 5
7
Digital Input DI 6
LED DI 6
8
Digital Input DI 7
LED DI 7
9
Digital Input DI 8
LED DI 8
10
The status of each DI input is displayed with a LED.
LED = ON:
signal at the input
L-
Wiring:
It is recommended that shielded cables be used for the connection to DI
modules.
DI cabling must be laid separately from the supply lines to the conductor
32
Digital Output Module DO-8-Bus
8 Digital Output Module DO-8-Bus
8.1 General
The digital output module DO-8-Bus serves to output 24VDC digital signals to automation
devices in the process.
For example, signals based on converted signals from a digital input or from the PLC can
be sent to signal or indicator lamps.
Signals from the PLC are transmitted via the used field bus and the internal module
connetion.
The incoming digital signals, which result in a digital output signal, are also transmitted
via the internal mudule connection.
The module has 8 digital 24VDC output ports, which means that as many as 8 signals
can be output.
The advantages:



LED display for each output port (see “Connections and Indicators of the DO-8Bus”)
8.2 Design of the DO-8-Bus
The digital output module DO-8-Bus is connected with the internal module connection
using a 37-pin plug connector. The signals from the central module and/or from a digital
input module are transmitted over the internal module connection.
The 8 output ports and the 24 VDC power supply are connected with the devices,
indicator lamps etc., using printed-circuit sub-unit terminals with threaded terminal ends.
Other modules e.g. an input module, are connected using a second 37-pin plug
connector.
33
8.3.1 Technical Data of the DO-8-Bus
General
WNR
60004
Housing
Transparent lid
78 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
2 x 37pole
Outputs
8
Potential isolation
Optocoupler
2.5kV
Output parameters
Reference potential
+ 24VDC
Outputs
Digital 24 VDC
max. power per output
1A
Total output power
< 2A
Power dissipation
No-load
Full-load
1W
4W
34
8.3.2 Connections and Indicators of the DO-8-Bus
X5
37pole
37pole
X3
DO-8-Bus
1
2 3 4
5 6
7 8 9 10
X1
Pin assignment X1
LED indicators of the DO-8-Bus
1
L+
2
Digital Output DO 1
LED DO 1
3
Digital Output DO 2
LED DO 2
4
Digital Output DO 3
LED DO 3
5
Digital Output DO 4
LED DO 4
6
Digital Output DO 5
LED DO 5
7
Digital Output DO 6
LED DO 6
8
Digital Output DO 7
LED DO 7
9
Digital Output DO 8
LED DO 8
10
The status of each DO output is displayed with a LED.
LED = ON:
output signal +24VDC is switched
L-
Wiring:
It is recommended that shielded cables be used for the connection to DO
modules.
DO cabling must be laid separately from the supply lines to the conductor
35
Resistor Module RM-8-Bus (optional)
9 Resistor Module RM-8-Bus (optional)
9.1 General
The resistor module RM-8-Bus serves the compensation of the capacities of the control
bus and rails, that is used to the transfer of PCM- and half-wave signals for the control of
trolleys.
The use of load-resistors in the control bus is necessary to the guarantee of a certain
signal transfer.
9.2 Design of the RM-8-Bus
The resistor module has 8 outputs, that at most 8 rail sections can be compensated.
The 8 output cables and L3 will be connected by using printed-circuit sub-unit terminals
with threaded terminal ends.
9.3 Installation
The resistor module RM-8-Bus is designed for horizontal installation in a stationary housing.
The module is secured by fastening it to a mounting rail.
Caution!
The module can warm up!
The installation must permit adequate air-circulation to prevent the accumulation of heat.
L3
L3
rail section
36
Resistor Module RM-8-Bus (optional)
9.4.1 Technical Data of the RM-8-Bus
General
WNR
60412
Housing
Transparent lid
112 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
Inputs
1 x L3
Outputs
1 x L3
8 x Resistor 22kOhm
Power dissipation
No-load
Full-load
0W
20W
9.4.2 Connections of the RM-8-Bus
Pin assignment X1
RM-8-Bus
X1
1
2
3
4
5
6
7
8
9
1
L3 IN
2
L3 OUT
3
Output R1
4
Output R2
5
Output R3
6
Output R4
7
Output R5
8
Output R6
9
Output R7
10
Output R8
10
37
Communication and System Configuration
10 Communication and System Configuration
10.1 Profibus Communication
The system controller communicates with the ZM-DP via the Profibus module.
10.2 Cyclic Data Exchange
In cyclic data exchange, the controller sends the required output data to the slave and
reads the actual input data from it.
The ZM-DP is a modular slave!
Up to 26/9 Bytes are exchanged cyclically between the system controller and the slave!
As described later in this documentation, the slave can also be operated with parameter
settings differing from this default configuration!
The number, the significance and the position of the bytes in the messages can differ
from the following values!
10.2.1 Cyclic Data: System Controller -> ZM-DP: 26 bytes
(Default configuration for maximum enhancement)
Byte Meaning
Note
0
7
PCM – Output 1.0
PCM – Output 1.7
1. Output card
8 x PCM outputs
8
15
PCM – Output 2.0
PCM – Output 2.7
2. Output card
8 x PCM outputs
16
23
PCM – Output 3.0
PCM – Output 3.7
3. Output card
8 x PCM outputs
24
DIG – Output Byte 1
1. Output card
8 x Digital 24 VDC outputs
25
DIG – Output Byte 2
2. Output card
8 x Digital 24 VDC outputs
38
10.2.2 Cyclic Data:
ZM-DP -> System Controller: 9 bytes
(Default configuration for maximum enhancement)
Byte Meaning
Note
1. Input card
8 x PCM inputs: Positive half wave
8 x PCM inputs: Negative half wave
0
EM – Input 1 Pos.
1
EM – Input 1 Neg.
2
EM – Input 2 Pos.
3
EM – Input 2 Neg.
4
EM – Input 3 Pos.
5
EM – Input 3 Neg.
6
DIG – Input Byte 1
1. Input card
8 x Digital 24 VDC inputs
7
2. Input card
8
2. Input card
2. Input card
3. Input card
39
10.3 Acyclic Data Exchange
In the acyclic data exchange, the system controller can send data messages to the slave
or read from it by means of read requests or write requests.
Response Code ERROR with extended error message:
If the slave responds with an error, the extended error code must be analyzed (at
least during the software development) if it has been generated.
Following error codes are generated currently by the LJU standard firmware
(ErrorCode1):
0xFF: False data length
0xB0: Access to an invalid index or Access locking error during access
0xB1: Access with an invalid length
0xB7: Access to an invalid range
0xC2: Resource is busy
0xC3: Resource not available
0xC8: Resource not reachable (no communication)
0xC9: Resource not in this segment
40
10.3.1 Acyclic Data: System Access Indexes
The following system access points are implemented in the slave:
Meaning
Length
READ
[Byte]
Length
WRITE
[Byte]
01 Hex (R/W) Cyclic input / output data
9
26
Access
Index
7F Hex (R/W) Parameter (setting, mapping of I/O ranges)
1
40
1
39
In read access, the last byte contains the mains frequency with which the central module is currently working
Index 01H: Cyclic input/output data
The same variables as in the cyclic data exchange are addressed through this access point.
Index 7FH: Parameter (setting, mapping of I/O ranges)
The IO mapping of the slave can be set through this access point.
Parameters!
A table with the meaning of the parameters is given under “ZM-DP Parameter settings”.
Warning!
The number and position of the I/O data for the cyclic data exchange are
calculated from this parameter data!
The parameters are stored by the slave in an EEPROM, so that the slave
can start automatically with specified parameters.
A slave with incorrect parameter settings cannot be correctly addressed
through the cyclic service!
Therefore we recommend that the ZM-DP be operated with its default configuration!
41
10.4 ZM-DP Parameter Settings 39 Byte
The ZM-DP is a modular slave, for which parameters can be set!
Maximum 26/9 Bytes are exchanged cyclically between the master and the slave!
The position of the I/O data for the cyclic data exchange is calculated from this parameter data! The parameters are stored by the slave in an EEPROM, so that the slave can
start automatically with the specified parameters.
Attention!
A slave with incorrect parameter settings cannot be correctly addressed
through the cyclic service!
Fixed parameter settings:

The parameter settings described in this document are hard-coded in the firmware
of the ZM-DP.

The mode configuration switches (2 x 16 HEX switches in the middle of the assembly) present on the module are used for selection. These are polled when the
system software is started. Depending on the setting, they determine the required
parameter record and stores it in the EEPROM of the assembly. Moreover, other
functions can be activated with these switches at startup (see following table).
Coding
Switches
Function
00 Hex
“Normal” start with parameters actually stored in the EEPROM
FF Hex
Stores the DEFAULT parameters (described here) in the
EEPROM and then starts the module with these values!
FE Hex
Determines by Autodetect the assemblies connected to the central
module, generates the parameters from this data, stores these in the
EEPROM and then starts the module with these values.
FD Hex
Deletes the parameters stored in the EEPROM.
FA Hex
Sets the PCM coding (at the time of commissioning) 1
F9 Hex
Sets the PCM coding to PCM 6 (at the time of commissioning)
F8 Hex
Sets the PCM coding to PCM 10 (at the time of commissioning)
FC Hex
Sets the mains frequency (at the time of commissioning) 1
F5 Hex
Sets the mains frequency to 50 Hz (at the time of commissioning)
F6 Hex
Sets the mains frequency to 60 Hz (at the time of commissioning)
FB Hex
Sets the serial number (only for production!)
1
Only for modules with LCD display
Attention!
After the execution of one of the above-mentioned functions, switch off the
ZM-DP once again and set the configuration switches to Profibus address!
42
10.4.1 Default System Structure
A default configuration is hard-coded in the firmware of the ZM-DP and the supplied GSD
file. It represents an enhancement with the maximum number of modules that can be
operated on a central module.
Default (maximum) configuration:
Device list
PCM-8-Bus
EM-8-Bus
DI-8-Bus
DO-8-Bus
Slave configuration
(modules used)
8
2
1
1
bytes
bytes
byte
byte
PCM-8-Bus
PCM-8-Bus
PCM-8-Bus
DO-8-Bus
DO-8-Bus
Outputs:
8 bytes
8 bytes
8 bytes
1 byte
1 byte
26 bytes
EM-8-Bus
EM-8-Bus
EM-8-Bus
DI-8-Bus
DI-8-Bus
DI-8-Bus
Inputs:
2
2
2
1
1
1
9
bytes
bytes
bytes
byte
byte
byte
bytes
Parameter table with default parameter values:
Def.
Value
Param.
Byte Meaning
Default pos.
Output
Input
Byte
Byte
0
Info byte for SPC
0
1
PCM Module 1: Fixed code Enable Mask
0
2
PCM Module 1: Channel 1: PCM-Code: 0 - 190
1
2
3
PCM Module 1: Channel 2: PCM-Code: 0 – 190
2
3
4
3
4
5
4
5
6
5
6
7
6
7
8
7
8
9
8
9
10
0
11
9
10
12
10
11
13
11
12
14
12
13
15
13
14
16
14
15
43
Def.
Value
Param.
Byte Meaning
Default pos.
Output
Input
Byte
Byte
17
15
16
18
16
17
19
20
17
18
21
18
19
22
19
20
23
20
21
24
21
22
25
22
23
26
23
24
27
24
25
28
EM Module 1: Positive half wave
1
2
29
EM Module 1: Negative half wave
2
3
30
3
4
31
4
5
32
5
6
33
6
7
34
DO Module 1: Dig 24V outputs
25
26
35
DO Module 2: Dig 24V outputs
26
27
36
DI Module 1: Dig 24V inputs
7
8
37
8
9
38
9
10
0
Parameters are set for activation as well as the position of the variables in the data for
the cyclic data exchange.
A central module with maximum enhancement of input/output modules is the default
parameter setting.
We recommend using this configuration for all the central modules available in the system and then flagging all the input/output modules that are not connected in the system
controller as “Reserved” or “Optional”. Thus it is possible to enhance the module chain at
any time without resetting the parameters.
Data source:
Number of the output byte from which the particular module gets its
data.
Data target:
Number of the input byte to which the particular module copies its
data.
The data sources and the data targets for the individual module types are defined in the
following points.
44
10.4.2 Data Sources for PCM-8-Bus
Data source = 0:
Release bit string not used; channel or module not used or
not available.
Output byte 0-28; for this PCM channel, 1 output byte is
Data source = 1-29:
used, thus up to 190 drive commands can be output on
this channel.
Output byte 0-28; for this PCM channel, the 4 higher-value
Data source = 31-59:
bits of this output byte are used for coding the drive command, thus the commands according to the T3000 specifications can be output.
Output byte 0-28; for this PCM channel, the 4 lower-value
bits of this output byte are used for coding the drive command, thus the commands according to the T3000 specifications can be output.
On this channel, a hard-coded drive command 0-155 is
output, if the corresponding bit in the release bit string is
set to 1 for this module. No output bit for coding the drive
command is needed here.
The release bit string is needed only in connection with the hard-coded drive commands
(data source 100-255).
The various data sources can be randomly grouped to allow individual adaptation to the
given requirements.
45
10.4.3 PCM Output Channels According to T3000 Specifications
The required PCM command code for each channel can be specified with 4 Bits.
The following assignment is applicable here:
Two channels are assigned to
one Byte.
Following PCM command codes can be generated:
Bit:
or:
1
7654
3210
0000
Command code 0;
Stop Low priority
0001
Command code 1;
Stop Highest priority1
0010
Command code 2;
PCM drive command High priority
0011
Command code 4
0100
Command code 6
0101
Command code 8
0110
Command code 10
2-18: Scope:
0111
Command code 12
Prioritizable PCM commands
1000
Command code 14
1001
Command code 16
1010
Command code 18; PCM drive command Low priority
1011
Command code 3;
1100
Command code 5
1101
Command code 7
3-11: Range
1110
Command code 9
Reserve PCM commands
1111
Command code 11; PCM drive command Low priority
PCM drive command High priority
Reserved Stop mode: To be used only under certain circumstances.
The controller interprets the two Stop modes.
10.4.4 Data Targets for EM-8-Bus/DI-8-Bus/DO-8-Bus
Data target = 0:
Module not used or not available.
Data target = 1-10: Input byte 0-9.
EM-8-Bus:
If the positive and negative half waves of a module are assigned to
the same data target, then full waves are analyzed.
DI-8-Bus:
DO-8-Bus:
46
Data target = 0:
Data target = 1-10: Input byte 0-9.
Data source = 0:
Data source = 1-29: Output byte 0-28.
10.5 Example
The following design must be implemented:

PCM-8-Bus module 1 all channels must be able to output the drive commands 0190.

PCM-8-Bus module 2 all channels must be able to output the drive commands according to the T3000 specifications.

PCM-8-Bus Module 3 all channels hard-coded, release through bit string.

DO-8-Bus Module 1

EM-8-Bus Module 1 pos. and neg. half waves should be analyzed separately.

EM-8-Bus Module 2 only full values must be analyzed.

DI-8-Bus Module 1

DI-8-Bus Module 2
Following module types are selected during the configuration:
1x "PCM-8 8 Byte outputs"
1x "DO-8 1 Byte outputs"
1x "EM-8 HW 2 Byte inputs"
1x "EM-8 VW 1 Byte inputs"
2x "DI-8 1 Byte inputs"
Example of a hardware configuration with Simatic Manager
The I/O range results from this configuration:
14 Output bytes (2-15)
5
Input bytes (2-6)
47
With the user parameters, now these input and output bytes are assigned to the inputs
or outputs of the modules:
Param.
Byte
48
Meaning
Used I/O Range
0
Release bit string PCM-8-Bus Module 1
OFF
1
Data source PCM-8-Bus Module 1 Channel 1
Output Byte 0
2
Output Byte 1
3
Output Byte 2
4
Output Byte 3
5
Output Byte 4
6
Output Byte 5
7
Output Byte 6
8
Output Byte 7
9
OFF
10
High nibble Output Byte 8
11
Low nibble Output Byte 8
12
13
14
15
16
17
18
Output Byte 12
19
PCM Code 2
20
PCM Code 3
21
PCM Code 4
22
PCM Code 5
23
PCM Code 6
24
PCM Code 7
25
PCM Code 8
26
PCM Code 9
27
Data target EM-8-Bus Module 1 pos. half wave
Input byte 0
28
Data target EM-8-Bus Module 1 neg. half wave
Input byte 1
29
Input byte 2
30
Input byte 2
31
OFF
32
OFF
33
Data source DO-8-Bus Module 1
Output byte 13
34
Data source DO-8-Bus Module 2
OFF
35
Data target DI-8-Bus Module 1
Input byte 3
36
Input byte 4
37
OFF
This data must be entered in the hardware configuration of the system controller (PLC)!
Example of a parameter setting with Simatic Manager
49

Technical Description PCM Modules ZM modular

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