Technical Description PCM Modules ZM modular

Transcription

Technical
Description
Date: July 2013
LJU Automatisierungstechnik GmbH
PCM Modules
ZM modular
Field bus connection: DeviceNet DN
Version 1
with ZM-DN modules WNR 60134 or WNR 60138
©
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.
July 2013
ZM modular-DN V1_TB0018_en
Technical Description
ZM modular DeviceNet DN
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
Principle of the modular PCM-System ........................................................12
2.2
Important Note - Power Supply ................................................................13
2.3
Important notice for command rail segmentation ........................................14
Central Module ZM-DN ................................................................................ 15
3.1
General Facts .........................................................................................15
3.2
Design of the Central Module ZM-DN .........................................................16
3.3
Monitoring and Protection Function ...........................................................16
3.4
Installation and Commissioning ................................................................16
3.4.1 Installation ....................................................................................16
3.4.2 Synchronization .............................................................................16
3.5
Technical Data and Connections ...............................................................17
3.5.1 Technical Data of the Central Module ZM-DN .....................................17
3.5.2 Connections of the Central Module ZM-DN ........................................18
3.6
DeviceNet Connection .............................................................................19
3.6.1 DeviceNet Connection .....................................................................19
3.6.2 DeviceNet Configuration Switch ........................................................20
3.6.3 LED Status Display .........................................................................20
3
Table of Contents
4
Pulse Code Module PCM-8-Bus.................................................................... 21
4.1
General .................................................................................................21
4.2
Design of the Pulse Code Module PCM-8-Bus ..............................................21
4.3
Monitoring and Protection Functions ..........................................................22
4.4
Installation ............................................................................................22
4.5
4.5.1 Technical Data of the Pulse Code Module PCM-8-Bus ...........................23
4.5.2 Connections of the Pulse Code Module PCM-8-Bus ..............................24
5
Input Module EM-8-Bus .............................................................................. 25
5.1
General .................................................................................................25
5.2
Design of the Input Module EM-8-Bus........................................................25
5.3
Installation ............................................................................................26
5.4
5.4.1 Technical Data of the Input Module EM-8-Bus ....................................26
5.4.2 Connections of the Input Module EM-8-Bus ........................................27
6
Digital Input Module DI-8-Bus .................................................................... 28
6.1
General .................................................................................................28
6.2
Design of the Digital Input Module DI-8-Bus ..............................................28
6.3
Installation ............................................................................................28
6.4
6.4.1 Technical Data of the Digital Input Module DI-8-Bus ...........................29
6.4.2 Connections of the Digital Input Module DI-8-Bus ...............................30
7
Digital Output Module DO-8-Bus ................................................................. 31
7.1
General .................................................................................................31
7.2
Design of the Digital Output Module DO-8-Bus ...........................................31
7.3
Installation ............................................................................................31
7.4
7.4.1 Technical Data of the Digital Output Module DO-8-Bus ........................32
7.4.2 Connections of the Digital Output Module DO-8-Bus............................33
8
4
Resistor Module RM-8-Bus (optional) ......................................................... 34
8.1
General .................................................................................................34
8.2
Design of the Resistor Module RM-8-Bus ....................................................34
8.3
Installation ............................................................................................34
Table of Contents
8.4
8.4.1 Technical Data of the Resistor Module RM-8-Bus ................................35
8.4.2 Connections of the Resistor Module RM-8-Bus ...................................35
9
Communication and System Configuration ................................................. 36
9.1
DeviceNet Communication .......................................................................36
9.2
Cyclic Data Exchange ..............................................................................37
9.2.1 Cyclic Data: System Controller -> ZM-DN: 28 bytes ..........................37
9.2.2 Cyclic Data:
ZM-DN -> System Controller: 11 bytes .........................38
9.2.3 Cyclic Data: Counter Connection ......................................................38
9.3
Acyclic Data Exchange .............................................................................39
9.3.1 Acyclic Data: System Controller -> ZM-DN: 244 byte ..........................39
9.3.2 Acyclic Data: ZM-DN -> System Controller: 244 byte ..........................39
9.3.3 Acyclic data: Message Structure and Handshake ................................40
9.3.4 Acyclic Data: System Access Indexes ................................................42
9.4
ZM-DN Parameterization 38 Byte ..............................................................43
9.5
Default System Structure.........................................................................45
5
General Information
1 General Information
1.1 Information about the Technical Description
This technical description contains technical information to the PCM-System with DeviceNet connection and the devices of the ZM modular system:
Central module ZM-DN (WNR 60134 and 60138)
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.
LJU-Automatisierungstechnik GmbH
Module
Type
24V DC
60xxx 123
WNR
Ser.-Nr.
Baujahr
2007
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
number is given on the type plate of the individual components. (see figure)
Type plate
with WNR
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 Principle of the modular PCM-System
internal
LJU-Bus
Field bus
Central module
ZM-DP
ZM-DN
L3
N
230 AC
max 3 modules
per type
PCM module
PCM-8-Bus
L+ L-
L3
max 2 modules
Input
Input
Output
module
module
module
EM-8-Bus
DI-8-Bus
DO-8-Bus
N
N
L-
L+
L-
24 V DC
8
8
Outputs
Inputs
PCM
230V 50 Hz
8
Inputs
digital 24 V
8
Outputs
digital 24 V
Command bar
Message bar
12
System - Overview
2.2 Important Note - Power Supply
Important!
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!
Principle:
to the PCM-modules
13
System - Overview
2.3 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.
14
Central Module ZM-DN
3 Central Module ZM-DN
3.1 General Facts
The ZM-DN module is a central module that can be controlled via DeviceNet and serves
to generate mains-synchronized clock signals.
A processor evaluates the mains power and sends mains-synchronized +24 VDC square
wave voltages with various clock combinations over the internal bus 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 the DeviceNet bus to the ZM-DN. These codes are transmitted over the internal bus
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.
15
3.2 Design of the Central Module ZM-DN

The mains supply of 24 VDC and 230 VAC is provided through 2 separate printedcircuit sub-unit terminals with threaded ends.

The connection to the activating modules is implemented through a 37-pin plug
connection. Besides the transmission of 5 VDC power supply for the downstream
modules, this connection implements the coupling with the internal bus.

The module is connected to the DeviceNet over a certified standard DeviceNet
module AB4004 of HMS (integrated in the ZM-DN).

The reference phase of the trolley controllers and the modules is fixed at L3.

The 24VDC power supply is safeguarded using multi fuses.

The ZM-DN can be optionally fitted with a 16 x 4 LCD display module.
3.3 Monitoring and Protection Function

Monitoring of the mains voltage and supply voltage

Error messages via DeviceNet bus

Synchronization with other central modules in the installation

Display “Ready for operation“ through 3 red LEDs for 24VDC, Main and Online
(top down)

Display “Synchronization” through separate red LED (down)
3.4 Installation and Commissioning
3.4.1 Installation
The ZM-DN is designed for horizontal installation in a stationary housing.
The module is mounted by locking on to a carrier rail.
3.4.2 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
16
Sync2
ZM 2
Sync1
Sync2
ZM x
Sync1
Sync2
3.5 Technical Data and Connections
3.5.1 Technical Data of the Central Module ZM-DN
General
WNR
60134 for 50Hz
60138 for 60Hz
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
DeviceNet over DeviceNet card
Addressing
2 x HEX switch
Outputs
System bus
Error reporting
via DeviceNet DN
Potential isolation
Optocoupler
Isolation voltage Ueff
2.5kV
Fuse protection of the 24 VDC supply voltage
Multi-fuses
DeviceNet card
AB4004
Supply input24VDC
Current consumption ZM-DN:
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-DN:
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!
17
3.5.2 Connections of the Central Module ZM-DN
X5
ZM-DN
ZM-
1
2
3
X2
1
2
3
4
X4
X3
Programming
10 pole
Pin assignment X2
1
N
2
L3
3
PE
Pin assignment X4
18
1
Sync 1
2
Sync 2
3
L+
4
L-
LJU System bus
37 pole
DeviceNet
5 pole
3.6 DeviceNet Connection
The central module is connected to the system controller via DeviceNet.
The central module is equipped with a certified standard DeviceNet card AB4004 of HMS
for the bus connection.
See also!
Detailed technical information of the used DeviceNet card can be obtained
from the descriptions of the manufacturer.
 Can be obtained from www.hms.se!
The field bus is connected to this module.
The bus address (MAC-ID) is set via the DIP switch and the desired Baud rate is set.
AB4004
1
2
3
#
Description
1
DeviceNet connection
2
Configuration switch
3
Status-LEDs
3.6.1 DeviceNet Connection
The ZM-DN is connected to the DeviceNet with a 5 pole printed-circuit sub-unit terminal
with threaded ends.
These are numbered from 1 to 5 (from left to right).
Pin
Signal
Description
1
V-
-24 VDC
2
CAN_L
CAN_L bus line
3
Shield
Cable shield
4
CAN_H
CAN_H bus line
5
V+
+24 VDC
19
3.6.2 DeviceNet Configuration Switch
The configuration switch is used to setting the baud rate and MAC-ID.
The switches are numbered from 1 to 8 (from left to right).
Setting of Baud rate:
Switches 1-2
Setting of address:
Switches 3-8 (MAC ID)
Baud rate
Sw. 1
Sw.2
125k
OFF
OFF
250k
OFF
ON
500k
ON
OFF
(reserved)
ON
ON
MAC-ID
Sw. 3
(MSB
Sw. 4
Sw. 5
Sw. 6
Sw. 7
Sw. 8
(LSB)
0
OFF
OFF
OFF
OFF
OFF
OFF
1
OFF
OFF
OFF
OFF
OFF
ON
2
OFF
OFF
OFF
OFF
ON
OFF
3
OFF
OFF
OFF
OFF
ON
ON
…
…
…
…
…
…
…
62
ON
ON
ON
ON
ON
OFF
63
ON
ON
ON
ON
ON
ON
3.6.3 LED Status Display
The actual state of the module is displayed with several LEDs.
LED
1
Reserved
2
Network State
3
Reserved
4
Module State
20
Status
Description
-
Reserved
Off
Green
Green (flashing)
Red
Red (flashing)
Not powered / not online
Link OK, online, connected
Online, not connected
Critical link failure
Connection timeout
-
Reserved for later use
Off
Green
Green (flashing)
Red
Red (flashing)
No power to device
Device operational
Data size bigger than configured
Irrecoverable fault
Minor fault
Pulse Code Module PCM-8-Bus
4 Pulse Code Module PCM-8-Bus
4.1 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 DeviceNet from the PLCs at higher levels are converted
by the central module ZM-DN into mains-synchronized timing signals and then converted
by the pulse code module into a pulse-code, which can be clearly recognized by the
trolley controller.
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 DeviceNet

Galvanic isolation through Optocoupler

Unlimited hysteresis by using semiconductor switches

Protection wiring of the output ports and short-circuit protection

Error reporting over DeviceNet
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.
4.2 Design of the Pulse Code Module PCM-8-Bus
The pulse code module PCM-8-Bus is connected to the internal bus over a 37-pin plugconnector.
The timing signals are transmitted from the central module over the internal bus.
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 8 output ports must be connected with the assigned control rail sections using
printed-circuit sub-unit terminals with threaded terminal ends.
The other modules of the system are connected over the internal bus, using a 37-pin
plug-connector.
The reference phase of the trolley controller and the module is assigned to L 3.
21
4.3 Monitoring and Protection Functions

Output-side short circuit protection (semiconductor switches)
Error monitoring for:

Interruption of the supply voltage

Activation of the safety circuit (multi-fuse)

Disturbance reports over the bus

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.
4.4 Installation
The pulse code module is designed for horizontal installation in a stationary housing.
The module is secured by fastening it to a mounting rail.
Anti-capacitance shielded signal cable is to be used for connections between the pulse
code modules and the control rail sections, and is to be separated from power cables.
Use load resistors against over-crossings.
Recommendation : e.g. UNITRONIC Li2YCY signal cable
22
4.5.1 Technical Data of the Pulse Code Module PCM-8-Bus
General
WNR
60336
Housing
Transparent lid
112 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
Inputs
System bus
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
23
4.5.2 Connections of the Pulse Code Module PCM-8-Bus
X5
LJU System bus
37 pole
LJU System bus
37 pole
X3
PCM-8-Bus
X1
1
2
3
4
5
6
7
8
9
10
Pin assignment X1
1
L3
2
PCM 1
3
PCM 2
4
PCM 3
5
PCM 4
6
PCM 5
7
PCM 6
8
PCM 7
9
PCM 8
10
24
N
Input Module EM-8-Bus
5 Input Module EM-8-Bus
5.1 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 bus.
This provides for transmission of the input signals over DevicNet 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 signals with positive and negative half-waves are displayed differently by LED in the
module for each input port.
The advantages:

Compact modular design


Input switching threshold 140VAC

Differentiated display of (positive/negative) half-waves for each input
5.2 Design of the Input Module EM-8-Bus
The input module EM-8-Bus is connected with the internal bus using a 37-pin plug
connector.
The input signals are sent via internal bus to the DeviceNet module, which then transmits
them via DeviceNet 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.
The reference phase of the trolley controllers and of the module is assigned to L3.
25
5.3 Installation
The input module EM-8-Bus is designed for horizontal installation in a stationary housing.
Anti-capacitance shielded signal cable is to be used for the cable connections between
the input modules and the control rail sections, and is to be separated from power
cables.
Recommendation : e.g. UNITRONIC Li2YCY signal cable
5.4.1 Technical Data of the Input Module EM-8-Bus
General
WNR
60247
Housing
Transparent lid
112 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
Inputs
8
Outputs
System bus
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
26
5.4.2 Connections of the Input Module EM-8-Bus
X5
LJU System bus
37 pole
LJU System bus
37 pole
X3
EM-8-Bus
X1
1
2 3 4
5 6
7 8 9 10
Pin assignment X1
1
2
Input E 1
3
Input E 2
4
Input E 3
5
Input E 4
6
Input E 5
7
Input E 6
8
Input E 7
9
Input E 8
10
N
27
Digital Input Module DI-8-Bus
6 Digital Input Module DI-8-Bus
6.1 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 data bus to the DeviceNet module, which in turn
sends them to the PLC.
These input signals can also be transmitted over the internal data bus 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 bus.
The advantages:



Input switching threshold 10VDC

LED display for each input port
6.2 Design of the Digital Input Module DI-8-Bus
The digital input module DI-8-Bus is connected with the internal bus using a 37-pin plug
connector.
The input signals are sent via the internal bus to the DeviceNet 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.
6.3 Installation
The digital input module DI-8-Bus is designed for horizontal installation in a stationary
housing.
28
6.4.1 Technical Data of the Digital Input Module DI-8-Bus
General
WNR
60003
Housing
Transparent lid
78 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
Inputs
8
Outputs
System bus
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
29
6.4.2 Connections of the Digital Input Module DI-8-Bus
X5
LJU System bus
37 pole
LJU System bus
37 pole
X3
DI-8-Bus
1
2 3 4
5 6
7 8 9 10
X1
Pin assignment X1
1
2
Digitaler Input DI 1
3
4
5
6
7
8
9
10
30
L-
Digital Output Module DO-8-Bus
7 Digital Output Module DO-8-Bus
7.1 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 DeviceNet and the internal data bus.
The incoming digital signals, which result in a digital output signal, are transmitted via
the internal bus.
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
7.2 Design of the Digital Output Module DO-8-Bus
The digital output module DO-8-Bus is connected with the internal bus using a 37-pin
plug connector.
The signals from the DeviceNet module and/or from a digital input module are
transmitted over the internal bus.
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.
7.3 Installation
The digital output module DO-8-Bus is designed for horizontal installation in a stationary
housing.
31
7.4.1 Technical Data of the Digital Output Module DO-8-Bus
General
WNR
60004
Housing
Transparent lid
78 x 126 x 80mm
+10C to +50C
-10ºC to +50ºC
Humidity
Inputs
System bus
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
32
7.4.2 Connections of the Digital Output Module DO-8-Bus
LJU System bus
37 pole
X5
LJU System bus
37 pole
X3
DO-8-Bus
1
2 3 4
5 6
7 8 9 10
X1
Pin assignment X1
1
L+
2
Digitaler Output DO 1
3
4
5
6
7
8
9
10
L-
33
Resistor Module RM-8-Bus (optional)
8 Resistor Module RM-8-Bus (optional)
8.1 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.
8.2 Design of the Resistor Module 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.
8.3 Installation
The resistor module RM-8-Bus is designed for horizontal installation in a stationary housing.
Caution!
The module can warm up!
The installation must permit adequate air-circulation to prevent the accumulation of heat.
L3
L3
rail section
34
Resistor Module RM-8-Bus (optional)
8.4.1 Technical Data of the Resistor Module 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
8.4.2 Connections of the Resistor Module 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
35
Communication and System Configuration
9 Communication and System Configuration
9.1 DeviceNet Communication
The system controller communicates with the ZM-DN central module over the DeviceNet
module.
The DeviceNet module makes available several data areas for data exchange.
Data from system controller -> ZM-DN:
Name:
Size:
Reached with:
[Bytes]
Content:
Offset:
[Bytes]
Output 1
28
Polled IO
Cyclic data:
Outputs on the slave
0
Output 2
244
Generic Message
Acyclic data:
Handshake + messages
240
Output 3
(Not used)
8
Generic Message
Acyclic data:
Handshake + message header
240
Output 4
(Not used)
240
Generic Message
Cyclic data:
Even unused areas
0
Data from ZM-DN -> System controller:
Name:
Size:
Reached with:
[Bytes]
Content:
Offset:
[Bytes]
Output 1
11
Polled IO
Cyclic data:
Outputs on the slave
0
Output 2
244
Generic Message
Acyclic data:
Handshake + messages
11
Output 3
(Not used)
15
Generic Message
Acyclic data:
Handshake + message header
0
Output 4
(Not used)
4
Generic Message
Cyclic data:
Even unused areas
11
Following data is exchanged here:
Cyclic
Output 1
28 Bytes
data:
Input 1
11 Bytes
Acyclic
Output 2
244 Bytes
data:
Input 2
244 Bytes
Hint!
The transfer of acyclic data from and to the module is necessary only if the
options of enhanced parameterization are used!
36
9.2 Cyclic Data Exchange
In cyclic data exchange, the system controller sends the desired output data to the slave
and reads the current input data from the slave.
The communication takes place over the access points Output 1 and Input 1.
The data flow is parameterized in the DeviceNet parameterization as “polled” connection.
(see ZMDN_52_Zyklisch_Azyklisch_11inp_28outp.pdf: section 2.1)
In case of ZM-DN, the slave is a modular parameterizable slave!
In the default configurations described here, 28 / 11 Bytes are transferred cyclically between the system controller and the slave!
As described later in this documentation, the slave (if necessary) can also be operated
with parameterizations other than this default configuration!
Then the number of inputs/outputs as well as the significance and position of the bytes
within the messages can differ from the following details.
9.2.1 Cyclic Data: System Controller -> ZM-DN: 28 bytes
Byte Meaning
Note
0
Command Byte
00H = Normal mode
88H = Without Online->Offline Automatic reset
1
Cyclic Counter
see 9.2.3
2
9
PCM – Output 1.0
PCM – Output 1.7
1. Output card
8 x PCM outputs
10
17
PCM – Output 2.0
PCM – Output 2.7
2. Output card
8 x PCM outputs
18
25
PCM – Output 3.0
PCM – Output 3.7
3. Output card
8 x PCM outputs
26
DIG – Output Byte 1
1. Output card
8 x Digital 24 VDC outputs
27
2. Output card
8 x Digital 24 VDC outputs
37
9.2.2 Cyclic Data:
ZM-DN -> System Controller: 11 bytes
Byte Meaning
Note
Error status Byte
(Automatically resetting)
00H
01H
02H
04H
08H
10H
20H
40H
80H
1
Cyclic Counter
see 9.2.3
2
EM – Input 1 Pos.
3
EM – Input 1 Neg.
1. Input card
8 x PCM inputs: Positive half wave
8 x PCM inputs: Negative half wave
4
EM – Input 2 Pos.
5
EM – Input 2 Neg.
6
EM – Input 3 Pos.
7
EM – Input 3 Neg.
8
DIG – Input Byte 1
1. Input card
8 x Digital 24 VDC inputs
9
2. Input card
10
3. Input card
0
=
=
=
=
=
=
=
=
=
No error
Error Configuration
Error Mains frequency
Error PCM output card
Error Digital output card
Error EEPROM
Reserved
Error Communication DeviceNet
Error Parameterization
2. Input card
3. Input card
9.2.3 Cyclic Data: Counter Connection
The ZM-DN module sends back the counter received in Byte 1 in its response message to
Byte 1. If the module is in ONLINE state and the counter reading does not change within
2000 ms, then it switches to OFFLINE state, deletes all connected outputs and triggers a
(local) hardware reset, if this is not disabled due to an entry of 88H in the command
byte.
The system control must cyclically activate this counter to maintain the data flow.
Moreover, the system controller (regardless on the bus cycle running asynchronous to
the program cycle) can thus easily detect whether a new response message exists.
Recommended procedure:

Comparison: Counter of output data equal to counter of input data?
yes => Receive new data from slave! => Evaluate + Trigger monitoring
38

Program processing

Equalize output data counter to (counter of input data + 1)
9.3 Acyclic Data Exchange
In acyclic data exchange, the system controller can send data messages to the slave or
read data messages from it using CIP Generic Messages.
The communication takes place over the access points Output 2 and Input 2.
The messages are always 244 Bytes long and consist of a message header that always
needs to be filled up as well as the useful data.
9.3.1 Acyclic Data: System Controller -> ZM-DN: 244 byte
Configuration of message for Output 2:
Message type:
CIP Generic
Service Code:
10 Hex
Object Type:
04 Hex
Object ID:
151 Decimal
Object Attribute:
03 Hex
Source:
244 Byte memory in Scanner Scope with sending message
Num. of elements:
244 Decimal
Destination:
244 Byte Dummy memory in Scanner Scope
DeviceNet-Code: SetData
9.3.2 Acyclic Data: ZM-DN -> System Controller: 244 byte
Configuration of message for Input 2:
Message Type:
CIP Generic
Service Code:
0E Hex
Object Type:
04 Hex
Object ID:
101 Decimal
Object Attribute:
03 Hex
Source:
DeviceNet-Code: GetData
-
Num. of elements:
0 Decimal
Destination:
244 Byte Memory in Scanner Scope with receipt message
39
9.3.3 Acyclic data: Message Structure and Handshake
The acyclic messages from and to the slave have the following structure:
Byte Meaning
Note
0
Acyclic counter
Job number
1
Service Code
Response Code
10 Hex
0E Hex
2
Access index
see 9.3.4.
3
Length of following data
0 … 240
4
243
DeviceNet-Code: SetData
DeviceNet-Code: GetData
Data
Max. 240 Byte
ata flow between System controller -> Slave -> System controller:
If data is to be sent to the slave, the following schema is to be applied!

Acyclic counter, job number:
A new job number is to be entered in this counter for every new message.
The slave evaluates this number and processes the message only if the job number has changed!
(After a reset, the slave initializes itself with the job number 80 Hex.)

Service Code:
Enter 10 Hex => Data master -> Slave
Enter 0E Hex => Data slave -> Master

Access index / Enter length of following data
See 9.3.4.

Send the job to the memory area Output 2 via message
See 9.3.1.
As soon as the slave has received the message, it processes the message and generates
a response message in its memory area Input 2.
The system controller must wait for this (timer and/or wait counter in cyclical data exchange) or must read the response several times if need be, via read message!

Read the response from the memory area Input 2 via message
See 9.3.2.

Acyclic counter, job number:
The slave enters the job number of the received message in its response message. If the job number does not match (yet), the slave has not yet processed the
slave. The response must be read again.
40

Access index:
The slave copies the access index of the received message into its response message.

Response Code:
The slave codes its response in this byte:

80 Hex = 1000 0000:
ERROR
40 Hex = 0100 0000:
OK
10 Hex = 0001 0000:
Response to DN code: SetData => Data Master -> Slave
0E Hex = 0000 1110:
Response to DN code: GetData => Data Slave -> Master
Response Code ERROR with enhanced error message:
If the slave responds with an error (Bit 7 = 1) (at least during the software development!), the enhanced error code, if generated, should be evaluated.
If 2 is entered in Byte 3 “Length of following data“ (i.e. 2 bytes of data follow), the
error reason is entered in Byte 4 and 5.
Following error codes are currently generated by the standard LJU firmware:
0xFF: False data length
0xB0: Access to an invalid index OR Access locking error during access
0xC3: Resource not available
0xC9: Resource not in this segment
0xC8: Resource not reachable (no communication)
0xC2: Resource is busy

Response Code OK:
If the slave responds with an OK (Bit 6 = 1), the message sent to it could be processed correctly and any received data can be copied.
41
9.3.4 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
11
28
7F Hex (R/W) Parameter (setting, mapping of I/O ranges)
38
38
Access
Index
Index 01H: Cyclic input/output data
Through this access point, the same variables as in cyclic data exchange can be
addressed. (see 9.2.1.)
Index 7FH: Parameter (setting, mapping of I/O areas)
Through this access point, the IO mapping of the slave can be set.
Parameters!
A table with the meaning of the parameters is given under “ZM-DN Parametrization”.
Warning!
The number and position of I/O data for the cyclic data exchange is calculated from this parameter data!
The parameters are stored on the slave in an EEPROM, so that the slave
can automatically start with the specified parameters.
An incorrectly parameterized slave cannot be addressed correctly through
the cyclic service!
These parameters CANNOT be set through the DeviceNet parameterization!
Only the memory areas of the DeviceNet communication modules can be
set (conditionally) there.
Therefore we recommend that the slave be operated in its default configuration!
If a different system-specific parameterization is selected, the system controller can (must) supply the slave with a parameterization through this
access point
42
9.4 ZM-DN Parameterization 38 Byte
In case of ZM-DN, the slave is a modular parameterizable slave!
In the default configurations described here, 28/11 Bytes are transferred cyclically between the system controller and the slave!
The number and position of I/O data for the cyclic data exchange is calculated from this
parameter data!
The parameters are stored on the slave in an EEPROM, so that the slave can automatically start with the specified parameters.
Attention!
A slave with incorrect parameter settings cannot be correctly addressed
through the cyclic service!
Permanently defined parameterizations:

Some parameterizations are permanently defined in the firmware of the ZM-DN
module.

For selecting these, the mode configuration switch present on the module (2 x
16 time rotary switch in the middle of the assembly) is used.
This is requested when the system software is started, the desired parameter record is determined depending on the setting, and saved in the EEPROM of the assembly.
Coding
Switches
00 Hex
Function
Normal” start with the parameters saved currently in the EEPROM
Saves the DEFAULT parameters (described here) in the
FF Hex
EEPROM and then starts the module with these values!
Determines the assemblies connected to the central module using
FE Hex
Autodetect, generates the parameters using this data, saves these in
the EEPROM and then starts the module with these values.
FD Hex
Byte
Deletes the parameters saved in EEPROM.
Def.
Value
Param.
Meaning
Defaultpos.
Output
Input
Byte
Byte
0
PCM Module 1: Fixed code Enable Mask
0
1
PCM Module 1: Channel 1: PCM-Code: 0 - 190
1
2
2
2
3
3
3
4
43
Byte
Def.
Value
Param.
Meaning
Defaultpos.
Output
Input
Byte
Byte
4
4
5
5
5
6
6
6
7
7
7
8
8
8
9
9
0
10
9
10
11
10
11
12
11
12
13
12
13
14
13
14
15
14
15
16
15
16
17
16
17
18
19
17
18
20
18
19
21
19
20
22
20
21
23
21
22
24
22
23
25
23
24
26
24
25
27
EM Module 1: Positive half-wave
1
2
28
EM Module 1: Negative half-wave
2
3
29
3
4
30
4
5
31
5
6
32
33
DA Module 1: Dig 24V outputs
25
26
34
DA Module 2: Dig 24V outputs
26
27
35
DE Module 1: Dig 24V inputs
7
8
36
8
9
37
9
10
0
6
7
The activation as well as the position of variables is parameterized in the data for the
cyclic data flow.
In case of default parameterization, the central module is a ZM-DN central module with
maximum expansion of input/output modules.
We recommend the use of this configuration for all the central modules present in the
system and then to mark all the input-/output modules that are not connected in the system controller as “reserved” or “optional”.
44
9.5 Default System Structure
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
Protocol
PCM-8-Bus
PCM-8-Bus
PCM-8-Bus
DO-8-Bus
DO-8-Bus
Outputs:
2 byte
8 byte
8 byte
8 byte
1 byte
1 byte
28 byte
Protocol
EM-8-Bus
EM-8-Bus
EM-8-Bus
DI-8-Bus
DI-8-Bus
DI-8-Bus
Inputs:
2 byte
2 byte
2 byte
2 byte
1 byte
1 byte
1 byte
11 byte
45

Technical Description PCM Modules ZM modular

Transcription

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