Digi DC-190 Instruction manual

Digi DC-190 Instruction manual
Digital Cam Switch Unit
CamCon DC190
Digitronic Automationsanlagen GmbH
Steinbeisstraße 3 • D - 72636 Frickenhausen • Tel. +49 7022 40590-0 • Fax -10
Auf der Langwies 1 • D - 65510 Hünstetten-Wallbach • Tel. +49 6126 9453-0 • Fax -42
Internet: http://www.digitronic.com • E-Mail: [email protected]
Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
For your attention
This instruction manual relates to the CamCon DC190 from 11/2011. The company Digitronic
Automationsanlagen GmbH reserves the right to make changes which present an improvement of the
quality or functionality of the device without prior notice. The instruction manual was created with great
care, although it may not be error-proof. We would be grateful for any communication relating to any
errors you may have found.
Update
You can also obtain this instruction manual on the Internet at http://www.digitronic.com in the latest
version as PDF file.
Qualified personnel
This device may only be started and operated by qualified staff. By qualified we mean personnel who
are entitled to handle, to earth and to lable devices, systems and power circuits in accordance with the
technology safety standards.
Liability
(1) The supplier is liable for damages caused by himself or by the owner of the rights up to the sum of
the sales price. He is not liable for loss of profits, forfeited savings, intermediate and successive
damages.
(2) The above mentioned limits to liability do not apply to insurance of named characteristics and
damages which were caused deliberately or through negligence.
Protection
The CamCon DC190 and this instruction manual are protected by copyright. All rights are reserved.
Neither the CamCon DC190, nor this document may be copied as a whole or partially, photocopied,
reproduced, translated or transferred to electronic media of any kind or into machine readable format
without prior written permission by the company Digitronic Automationsanlagen GmbH.
Note:
Note:
Note:
We have examined the devices of the CamCon series for year 2000 compatibility and
have not found any adverse effects on any functions.
CamCon is a registered trademark of the company Firma Digitronic
Automationsanlagen GmbH.
The devices of the CamCon series comply with the standards for electromagnetic
compatibility: EN 55011, EN 55022, EN 55024 Part 2, EN 50082 Part 2, ENV 50140,
VDE 0843 Part 2,
VDE 0843 Part 4,
VDE 0871,
VDE 0875 Part 3 ("N"),
VDE 0875 Part 11, VDE 0877 Part 2, IEC 801 Part 3, IEC 801 Part 2, IEC 801 Part 4,
IEC 801 Part 5.
(c) Copyright 1992 - 2012 / File: DC190E.DOC
Digitronic Automationsanlagen GmbH
Auf der Langwies 1
D-65510 Hünstetten - Wallbach
Tel. (+49)6126/9453-0 Fax. (+49)6126/9453-42
Internet: http://www.digitronic.com
E-Mail: [email protected]
Version from: 19.04.2012
Page: 2
Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
Table of Contents
1. Introduction .......................................................................................................................................... 6
2. Operating Pinciples .............................................................................................................................. 7
2.1. Speed Compensation ....................................................................................................................... 8
2.1.1. Measuring delay time for Speed Compensation .......................................................................... 10
2.1.1.1. Measuring delay time through actual differences ..................................................................... 10
2.1.1.2. Measuring delay time by means of different measuring points................................................. 10
2.1.2. Speed Compensation using off-centre pressure, e.g. brake functions ........................................ 11
2.1.3. Not linear Speed Compensation (NLT)........................................................................................ 12
2.1.4. Separate delay time for Speed Compensation of switch-ON and switch-OFF points ................. 12
2.2. Time - Cam ..................................................................................................................................... 12
3. Installation .......................................................................................................................................... 13
3.1. Dimension ....................................................................................................................................... 13
4. Electrical connections ........................................................................................................................ 14
4.1. Pin allocation of the CamCon ......................................................................................................... 14
4.1.1. Pin allocation of the power supply................................................................................................ 14
4.1.2. Pin allocation of 1. Measuring System - Input.............................................................................. 14
4.1.2.1. Pin allocation of SSI Measuring System ................................................................................... 14
4.1.2.2. Pin allocation of the incremental Measuring System (optional) ................................................ 14
4.1.3. Pin allocation of the 2nd Measuring System input ....................................................................... 14
4.1.3.1. Pin allocation of the 2nd SSI Measuring System ...................................................................... 14
4.1.3.2. Pin allocation of the 2n incremental Measuring Systems (optional) ......................................... 14
4.1.4. Pin allocation of Inputs 1 - 16....................................................................................................... 15
4.1.5. Pin allocation of Ouputs 1 - 16 ..................................................................................................... 15
4.1.6. Pin allocation of outputs 17 - 32................................................................................................... 16
4.2. PIN - Allocation of the Serial Interface ............................................................................................ 16
4.2.1. PIN - Allocation of the Serial Interface RS232 ............................................................................. 16
4.2.2. PIN - Allocation of the Serial Interface RS485 (Optional) ............................................................ 17
4.2.2.1. Terminal Resistors of the RS485 Interface............................................................................... 18
4.3. PIN - Allocation external Interface .................................................................................................. 18
4.4. Connecting the Ethernet Interface .................................................................................................. 19
4.5. Connecting the EtherCAT Interface ................................................................................................ 19
4.6. The measuring system.................................................................................................................... 20
4.6.1. SSI Measuring system input ........................................................................................................ 20
4.6.2. Parallel measuring system input .................................................................................................. 20
4.6.3. Incremental measuring system input ........................................................................................... 21
4.6.3.1. Incremental measuring system input with 5V RS422 level ....................................................... 21
4.6.3.2. Incremental measuring system input with 24V PNP level......................................................... 21
4.6.3.3. Incremental Hiperface measuring system input with SINCOS level ......................................... 22
4.6.4. Analog measuring system input................................................................................................... 22
4.6.5. PLL measuring system input........................................................................................................ 23
4.6.6. Timer as a measuring system...................................................................................................... 23
4.6.7. RS232 as a measuring system .................................................................................................... 23
4.7. Outputs............................................................................................................................................ 24
4.8. Inputs .............................................................................................................................................. 24
4.9. Precautionary measures for welding work ...................................................................................... 24
4.10. Status Display ............................................................................................................................... 25
4.10.1. The DC190 Status LED ............................................................................................................. 26
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
5. Commissioning .................................................................................................................................. 26
5.1. Setting the IP-Address .................................................................................................................... 26
6. Programming ..................................................................................................................................... 28
6.1. Deleting the Cam Control................................................................................................................ 28
6.2. The Main Menu ............................................................................................................................... 29
6.3. Statusdisplay................................................................................................................................... 29
6.4. Project data ..................................................................................................................................... 29
6.4.1. CamCon device option................................................................................................................. 29
6.4.2. Offline - Simulation....................................................................................................................... 30
6.5. Cam programming .......................................................................................................................... 30
6.5.1. Entering Cams ............................................................................................................................. 30
6.5.2. Entering the Speed Compensation .............................................................................................. 31
6.5.3. Selecting the Non - Linear - Speed Compensation...................................................................... 31
6.6. System settings............................................................................................................................... 32
6.6.1. Measuring system ........................................................................................................................ 32
6.6.1.1. Select measuring system .......................................................................................................... 32
6.6.1.2. Value Hysteresis ....................................................................................................................... 32
6.6.1.3. Speed max or measuring system control ................................................................................. 32
6.6.1.4. Electronic Gear Transmission................................................................................................... 33
6.6.1.4.1. The Electronic Rotation Direction Switch ............................................................................... 33
6.6.1.5. Actual Value Display Format..................................................................................................... 33
6.6.1.6. Configuration of the special measuring system ........................................................................ 34
6.6.1.6.1. Special measuring system - SSI ............................................................................................ 34
6.6.1.6.2. Special measuring system - Parallel...................................................................................... 34
6.6.1.6.3. Special measuring system - Incremental ............................................................................... 35
6.6.1.6.4. Special measuring system - Multi .......................................................................................... 36
6.6.1.6.5. Special Measuring System - PLL ........................................................................................... 37
6.6.1.6.6. Special measuring system - Timer ........................................................................................ 37
6.6.1.6.7. Special measuring system - AG615....................................................................................... 38
6.6.1.6.8. Special measuring system - SIM ........................................................................................... 38
6.6.1.6.9. Special measuring system - HIPER....................................................................................... 39
6.6.2. Measuring offset .......................................................................................................................... 40
6.6.3. Speed........................................................................................................................................... 41
6.6.4. Cable length ................................................................................................................................. 42
6.6.5. Special outputs............................................................................................................................. 43
6.6.5.1. Special outputs digital ............................................................................................................... 43
6.6.5.2. Special outputs analog.............................................................................................................. 44
6.6.5.2.1. Analog cam configuring ......................................................................................................... 45
6.6.5.2.2. Programming analog cams .................................................................................................... 46
6.6.6. System upgrading ........................................................................................................................ 47
6.6.7. Masterprogram............................................................................................................................. 49
6.7. Configuration menu......................................................................................................................... 50
6.7.1. Configure hardware...................................................................................................................... 50
6.7.1.1. Advanced hardware configure .................................................................................................. 51
6.7.1.1.1. Advanced hardware configuration for CamCon and external interface ................................. 52
6.7.1.1.2. Back - Plan - Router Configuration ........................................................................................ 52
6.7.1.1.3. Ethercat hardware configuration ............................................................................................ 53
6.7.2. PLC configuration......................................................................................................................... 54
6.7.3. Key allocation ............................................................................................................................... 54
6.7.4. Unit Configuration ........................................................................................................................ 55
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
7. PLC - Logic - Module programming ................................................................................................... 55
8. Error messages and removal of errors (FAQ) ................................................................................... 56
8.1. Problem: Display shows "No contact to unit: XX". .......................................................................... 56
8.2. Problem: "Pos - Err:1" respectively error number 1. ....................................................................... 56
8.3. Problem: "Pos - Err:2" respectively error number 2. ....................................................................... 56
8.4. Problem: "Pos - Err:3" respectively error number 3. ....................................................................... 57
8.5. Problem: "Pos - Err:5" respectively error number 5. ....................................................................... 57
8.6. Problem: An "Pos-Error:" occurs during operation.......................................................................... 57
8.7. Problem: "RAM-Full" = RAM memoryis full..................................................................................... 57
8.8. Problem: The EEProm memory is full............................................................................................. 58
8.9. Problem: Outputs will not activate................................................................................................... 58
8.10. Problem: "Out - Error" respectively error number 4. ..................................................................... 58
8.11. Problem: Error in the EEPROM respectively error number 255. .................................................. 58
8.12. Problem: "Error ???" ..................................................................................................................... 58
8.13. Problem: "Clear...." respectively error number 3........................................................................... 59
9. Technical Data ................................................................................................................................... 60
10. Index ................................................................................................................................................ 61
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
1. Introduction
Electronic Cam Switch Units have been successfully used in industry for a long time. Experiences
collected in close liaison with users over the years have been included in the development of the
CamCon series. The result is a compact digital cam switch unit which is user friendly and reliable to a
high degree. The following characteristics testify the excellence of the CamCon:
*
Tested and reliable hardware
*
Short-circuit-proof outputs
*
Graphic liquid crystal display with 128x64 pixels in the CamCon DC50,51.
*
Large
and
clearly
visible
7-Segment
display
for
program,
position
and
speed
on
CamCon DC30,33 and 40.
*
Any number of cams per output can be programmed.
*
Up to 32000 Programs for product administration
*
Master, for example: machine cams
*
Optimising switch points when machine is in operation
*
Compensation of mechanical delay time of switch components for switch-ON and switch-OFF
points can be set in steps of 100µs separately (DTC = delay time or Speed Compensation).
*
Not linear Speed Compensation (NLT).
*
Position - Triggert - Time - Cams
*
Power supply 24V DC +/- 20%
*
Mounting of suspension rails to EN 50022 on CamCon DC16 and 90
*
Switchboard panel standard casing 144 x 144 x 63mm to DIN 43700 on CamCon DC33,40 and 51
*
S5 Components group for S5 115U, 135U and 155U on CamCon DC115
*
S7 Components group for S7 300 on CamCon DC300
*
AB Components group for ControlLogix 1756 on CamCon 1756-DICAM
*
S5 Switch-ON via PG interface with L1 - Bus on CamCon DC16,40,50,51 and 90
*
PLC Logic Module (optional)
*
Shift register (optional)
*
OP - Functions
*
Analog outputs (optional)
Cam switch units are used wherever switching operations are periodically repeated. Digital cam switch
units are an optimum replacement of mechanical units and offer in addition many other advantages,
such as:
*
Simplification of mounting and adjustment operations
*
Repeatable adjustment facility
*
Standardised for almost all areas of application
*
Reliability
*
High switch speed
*
Speed Compensation
*
Product administration for quick format change
Version from: 19.04.2012
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
2. Operating Pinciples
Diagram: Principles of a Cam Switch Unit
A principle for better comprehension of the function of a Cam Switch Unit is here presented. It has 3
outputs with the following cams:
Output 1:
Output 2:
Output 3:
Cam
Cam
Cam
Cam
Cam
Cam
1:
2:
3:
1:
2:
1:
Switch-ON position
Switch-ON position
Switch-ON position
Switch-ON position
Switch-ON position
Switch-ON position
60°
95°
325°
5°
95°
30°
Switch-OFF position
Switch-OFF position
Switch-OFF position
Switch-OFF position
Switch-OFF position
Switch-OFF position
85°
145°
355°
20°
145°
85°
The positions of the output signals, here presented as three tracks, occur when the three cam disks
turn anti-clockwise past a sensor, which scans the cams on the 0°-axis.
In a mechanical cam switch unit, the switch interval, i.e. the range between switch-ON and switch-OFF
position are determined by the length of the cam. The length and the position of the cam can only be
varied marginally and this is mechanically highly demanding and time consuming. With CamCon such
adjustments can be realised in a fraction of time; in addition, there can be any number of tracks. A
measuring system which is fitted to the device reports the position to the CamCon. The CamCon
compares it with the programmed switch-ON and Switch-OFF positions of all outputs. If the position
lies in the range of a programmed switch-ON / switch-OFF position (cam), then the respective outputs
are active.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
2.1. Speed Compensation
Each mechanical switch component (e.g. shield, magnetic valve) has a delay time, i.e. the time
between the start signal and the actual switching of the contacts. In processes where positioning is
executed on a moving system, this can cause problems. If such a process is driven with different
speeds, different positions are caused. To avoid this happening, new timings for the switch signals of
each speed would have to be calculated.
In order to ilustrate the complicated issues surrounding delay time or speed compensation, this will be
shown on the example of a packaging machine. In the process shown in the diagram, a glue point has
to be placed in an exactly defined spot on a moving paper track.
magnetic valve
The system has the following parameters:
CamCon
vp
vT
d
glue nozzle
-
encoder
drop
TMV paper
Speed of the paper track
Falling speed of the drop of glue
Distance between the glue nozzle and
the paper track
Delay time of the magnetic valve
paper track
Points where the glue
hits the paper at the
different speeds
.
Without speed compensation the following would happen:
As soon as the measuring system has reached a certain position, the CamCon sends a signal to the
magnetic valve. The glue nozzle opens for a short time during which a drop of glue ejects. Between the
start of the impulse and the exit of the drop time passes, which is mainly caused by the delay time of
the magnetic valve TMV.. A further delay is caused by the time which the droplet needs to pass the
distance between the glue nozzle and the surface of the paper.
This flight time is calculated as follows:
d
tFlight = v
T
In total there the delay time is tFlight+TMV. During this time the paper track moves on by a specific
distance x.
It would now be possible to move the position, where the magnetic valve is switched on, forward by a
specific amount, so that the glue droplet hits the same spot again as during standstill. In this way a
speed compensation is created which works only at a specific speed of the paper. As soon as the
speed of the device and consequently that of the paper track is, for example, doubled, the hit point of
the glue droplet is shifted by the distance x, so that, without any speed compensation, it would move
backward by double the distance (2 ⋅ x) in total.
The automatic speed compensation of the CamCon makes it now possible to drive processes with
variable speed; CamCon registers the speed of the device continuously and adjusts the cams which
determine the switch time points "On Line" depending on the speed. This has the effect that the
outputs for the switch components are switched ON or OFF earlier. The direction of the movement is
of no significance in this instance.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
A small example in figures was designed to eludicate:
Supposing the drive cylinder with the measuring system has a circumference of 360mm, so that one
millimeter of the circumference corresponds to exactly one angle degree of the measuring system.
The device has the following parameters:
vdroplet
d
TMV
=
=
=
20m/s
20cm
20ms
This results in the following flight time of the droplet:
d
0,2m
tFlight =
=
10ms
vT
20m/s =
The total delay time is then Tdead, altogether = TMV + tFlight = 20ms + 10ms = 30ms
During this time the paper track moves on by the distance x = vpaper ⋅ Ttotal delay. = 1m/s ⋅ 30ms =
30mm. In order to compensate the delay time, the switch point for the magnetic valve must be moved
forward by 30°.
If the speed of the device and consequently that of the paper is doubled vpaper, then the distance x is
also doubled by the speed of the paper track. In this case the switch point must be moved by 60°.
Note:
Please take into account in these explanations that delay time is of a fixed size, which is
determined by the mechanical constants of the set and switch components and by the
dimensions of the construction and therefore does not change!
If the total delay time of 30ms was programmed into the respective output of CamCon, then the glue
droplet would always hit the right spot, regardless of the speed.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
2.1.1. Measuring delay time for Speed Compensation
Several ways of measuring delay time of a relay or valve are available.
2.1.1.1. Measuring delay time through actual differences
First the switch-ON point of a valve or relay is programmed. We assume that the programmed switch
point lies at 200 degrees in this case. If the machine is driven with a speed of for example 40 rpm, a
shift occurs due to delay time. This shift is then measured and, in this example, will amount to 40
degrees.
Warning:
For the calculation of the shift the programmed delay time in the cam switch unit must be
set to zero!
The delay time of the switch component is now calculated as follows:
∆ way (in °) * 60 (sec./min.)
Delay time ( in sec. ) = speed (in rpm) * 360 (°/turn)
40 * 60
Delay time ( in sec. ) = 40 * 360 = 0.1667 sec.
The resultant delay time is then entered into the cam switch unit.
See Chapter "6.5.2. Entering the Speed Compensation" an page 31.
2.1.1.2. Measuring delay time by means of different measuring points
First the switch point is calculated at a speed of, for example, 50 rpm. We assume that the
programmed switch point lies at 200° in this case. The second measurement is taken at a speed of 80
rpm The necessary switch point must be set to 160°, if the exact switch point is to be also achieved at
80 rpm.
Warning:
For the calculation of the two switch points the programmed delay time in the cam switch
unit must be set to zero!
The delay time of the switch component is then calculated with the following formula:
Delay time ( in sec. ) =
∆ way (in °) * 60 (sec./min.)
∆ speed (in rpm) * 360 (°/turn)
40 * 60
Delay time ( in sec. ) = 30 * 360 = 0.222 sec.
The resultant delay time is then entered into the cam switch unit.
See Chapter "6.5.2. Entering the Speed Compensation" an page 31.
Since the entered delay time shifts the switch point, the previously programmed cam must be changed.
For the calculation of the exact switch-ON position, the difference to the speed O rpm (here using 50
rpm) must be added to the first measured switch-ON point (here 200°). The difference is calculated
with the following formula:
∆ way (in degrees) =
dead time ( in sec. ) * ∆ time (in min-1) * 360 (degrees/rotations)
60 (sec./min.)
∆ way (in degrees) =
0.222 * 50 * 360
= 66.6 degrees
60
The switch-ON point of the cam is now shifted from 200° by approx. 67° to 267°.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
2.1.2. Speed Compensation using off-centre pressure, e.g. brake functions
The Speed Compensation of the CamCon Cam switch unit works using a linear function. If, for
example, the speed doubles, then the shift of the compensated cam changes and also moves forward
by twice the amount. If the ram on an eccentric press should be brought to a standstill at the exact
upper stop point, the brake action of the press under different speeds results in a quadratic function.
The Speed Compensation can therefore only find an approximation of the exact switch point for the
stopping of the press by adjusting the line of the cam lines to the brake curves in the working range of
the press.
Note: See also the next chapter "2.1.3. Not linear Speed
Compensation (NLT)".
In the graphic on the right the curved line represents the
brake point of the ram in relation to the speed.
For the calculation of the parameters to be programmed
please proceed as follows:
-
Define the working range (e.g. 20-50 rpm) and determine
two measuring points which have to be specified in the
working process (e.g. 30 and 40 rpm).
-
Now let the machine run at 30 rpm and program or
optimise a cam without Speed Compensation so that, at
switch-OFF, the ram comes to a halt in top stop. Note the
switch-ON point of the cam (e.g. 340°).
-
Now let the maching work with 40 rpm and program or
optimise one cam without Speed Compensation so that,
at switch-OFF, the ram comes to a halt in top stop. Once
again, note the switch-On point of the cam. (e.g. 332°).
-
U/min
Verlauf
Nocke 1
Nocke 2
Now calculate the delay time, taking into account the
distance and speed difference, using this formula:
Delay time ( in sec. ) =
∆ way (in °) * 60 (sec./min.)
340-332 * 60
= 40-30 * 360 = 0.133 sec.
∆ Speed (in rpm.) * 360 (°/turn)
-
The calculated delay time is now entered into the cam switch unit.
-
Since the switch-OFF point has shifted through the entered Speed Compensation, the previously
programmed cam must be changed first. For the calculation of the exact switch-ON position, the
difference to the speed 0 rpm (here 30 rpm) must be added to the first measured switch-ON point
(first measuring point here 340°) The difference is calculated with the following formula:
∆ way (in °) =
-
delay time ( in sec. ) * ∆ Speed (in rpm.) * 360 (°/turn)
0.133 * 30 * 360
=
= 23.94°
60 (sec./min.)
60
The switch-ON point of the cam has now shifted from 340° by approx. 24° to 364°.
As a result a cam with a switch-ON point of 4° and a speed compensation of 0.133 sec has been
calculated. This is entered in the cam switch unit as switch-OFF cam of the press.
Note:
If the degree of accuracy is no longer sufficient when switch-OFF is done with one cam, two
or several outputs can be switched in parallel and the cam of those is then adjusted to the
required working range. For the calculation of two switch-OFF cams divide the working
range in 5 parts with 4 measuring points and then calculate the delay time value and the
cam value with the same formula as described above. For the calculation of the first cam,
use the measuring points 1 + 2 and for the calculation of the second cam use the
measuring point 3 + 4.
Through this association of the linear cam functions to the brake functions it is now possible to switch
OFF the cam via the entire working range of the press in the top stop.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
2.1.3. Not linear Speed Compensation (NLT)
The method for the compensation of a not linear Speed Compensation, descriptive in the chapter
before can with devices with a software starting from 11/2004 by the non linear Speed Compensation
(NLT) simplified be entered. You need only one cam or a shift register output of the SPS - logic becomes module with NLT - speed compensation.
For this you have to define in the CamCon a table with
speed compensation - and velocity values.
To the right you see a characteristic curve with 5 base
points.
TZK (ms)
80
60
40
20
90
180
V (U/min)
2.1.4. Separate delay time for Speed Compensation of switch-ON and switch-OFF points
For CamCon devices of Software from 3/2002 Speed Compensation is now available for separate
switch-ON and switch-OFF points. This is necessary since some valves need longer to switch OFF
than to switch ON.
Switching attitude of a cam programs from 140° to 200° with 60 min -1.
Cam with 111ms Speed compensation for switch on point and 166ms
compensation for switch off point.
Cam with 111ms Speed compensation.
Cam without Speed compensation.
For the calculation of both delay times the same formuli are used as for a normal compensation. See
Chapter "2.1.1. Measuring delay time for Speed Compensation" on page 10 for entering delay time see
Chapter "6.5.2. Entering the Speed Compensation" on page 31.
Attention: If the switch-off-point of a Cam overtakes the switch on point at rising speed, the result will
be an non-defined signal.
2.2. Time - Cam
With nomale cam becomes with increasing plant speed switch-on time ever more briefly. If controlling
a glueing-station, the result would be an insufficent ammount of spreaded glue.
A Time - cam however has with each plant speed a firm temporal length, so that excactly the same
ammount of glue could be spread at changing speeds. The switch-on point of the Cam on a normal as
well as on a Time-Cam is appointed by a position-dependent Position value and a delay-time/speed
compensation.
Normal - cam
60min-1
30min-1
Time - cam
60min-1
30min-1
For CamCon devices of software releases after 3/2002 Time Cam is also available for devices without
PLC - Logic - Module.
For entering a Time - Cam see Chapter "6.5.2. Entering the Speed Compensation" on page 31.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
3. Installation
The device is snapped onto an "EN - carrier rail" in the switchboard (see chapter "3.1. Dimension" on
page 13). The grounding connections and the cable coverings are to be put on the shortest possible
way on the serial grounding clip next to the device. The grounded assembly plate and its electrical
connection to the "EN carrier rail" allow an excelent grounding of the disturbances onto the covering.
All cable connections are to be switched in a cold state ! If your CamCon has an external interface, it is
connected to the "ext.Int. IN" plug at the CamCon module (e.g. DAC16, DC16/IO, DC91/IO or DC92/I)
with a cable of the type: KKyy/IO-XX (yy = CamCon Type / XX = Length in meters). The data lines of
the external interface are galvanically separated through an optical coupler, they have to be covered,
and the cover has to be grounded on both ends. The connection cable (for the measuring system or
the serial interface) also has to be covered, and the cover has to be grounded on both ends. Analog
signals have to be covered, and the cover has to be grounded on one end.
3.1. Dimension
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4. Electrical connections
Before you begin with wiring, please consult the following chapters: "4.7. Outputs" on page 24, "4.8.
Inputs" on page 24 and "4.6. The measuring system" on page 20.
4.1. Pin allocation of the CamCon
.
4.1.1. Pin allocation of the power supply
Pin
Pin
1:
2:
+24V DC power supply (5L+)
0V power supply (L-)
4.1.2. Pin allocation of 1. Measuring System - Input
.
4.1.2.1. Pin allocation of SSI Measuring System
Pin
Pin
Pin
Pin
Pin
Pin
3:
4:
5:
6:
7:
8:
+24V DC power supply of the Measuring System (5L+)
Clock B or Clock A or +
Data B or Data A or +
0V power supply of the 1. SSI the Measuring System (L-)
4.1.2.2. Pin allocation of the incremental Measuring System (optional)
Pin
Pin
Pin
Pin
Pin
Pin
3:
4:
5:
6:
7:
8:
+24V DC power supply of the incremental Measuring System (5L+)
Clear 2
Clear 1
B Impulse
A Impulse
0V power supply of the incremental Measuring System (L-)
4.1.3. Pin allocation of the 2nd Measuring System input
.
4.1.3.1. Pin allocation of the 2nd SSI Measuring System
Pin
Pin
Pin
Pin
Pin
Pin
9:
10:
11:
12:
13:
14:
+24V DC power supply of the 2nd Measuring System (5L+)
Clock B or Clock A or +
Data B or Data A or +
0V power supply of the 2nd SSI Measuring System (L-)
4.1.3.2. Pin allocation of the 2n incremental Measuring Systems (optional)
Pin
Pin
Pin
Pin
Pin
Pin
Note:
9:
10:
11:
12:
13:
14:
+24V DC power supply of the 2nd incremental Measuring System (5L+)
Clear 2
Clear 1
B Impulse
A Impulse
0V power supply of the 2nd incremental Measuring System (shaft encoder) (L-)
You can determine which kind of Measuring System input (SSI or INK) you are using by
checking the markings on the DC190 housing
Attention: Pins 1, 3 and 9 are connected with each other within the unit (5L+).
Pins 2, 8, 14, 21, 31, 41, 51, 61 are connected with each other within the unit (L-).
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.1.4. Pin allocation of Inputs 1 - 16
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
21:
22:
23:
24:
25:
26:
27:
28:
29:
30:
31:
32:
33:
34:
35:
36:
37:
38:
39:
40:
0V Input signal ground (L-)
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
+24V DC Output power supply for outputs 1 - 8 (1L+)
0V Input signal ground (L-)
Input 9
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Input 16
+24V DC Output power supply for outputs 9 - 16 (2L+)
4.1.5. Pin allocation of Ouputs 1 - 16
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
41:
42:
43:
44:
45:
46:
47:
48:
49:
50:
51:
52:
53:
54:
55:
56:
57:
58:
59:
60:
0V Output power supply for outputs 1 - 8 (L-)
Output 1
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
Output 8
+24V DC Output power supply for outputs 1 - 8 (1L+)
0V Output power supply for outputs 9 - 16 (L-)
Output 9
Output 10
Output 11
Output 12
Output 13
Output 14
Output 15
Output 16
+24V DC Output power supply for outputs 9 - 16 (2L+)
Attention: Pins 30 and 50 are connected with each other within the unit (1L+).
Pins 40 und 60 are connected with each other within the unit (2L+).
Pins 2, 8, 14, 21, 31, 41, 51, 61 and 71 are connected with each other within the unit (L-)
Pins 2, 41, 51, 61 and 71 always have to be connected.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.1.6. Pin allocation of outputs 17 - 32
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
61:
62:
63:
64:
65:
66:
67:
68:
69:
70:
71:
72:
73:
74:
75:
76:
77:
78:
79:
80:
0V Output power supply for outputs 17 to 24 (L-)
Output 17
Output 18
Output 19
Output 20
Output 21
Output 22
Output 23
Output 24
+24V DC Output power supply for outputs 17 to 24 (3L+)
0V Output power supply for outputs 25 to 32 (L-)
Output 25
Output 26
Output 27
Output 28
Output 29
Output 30
Output 31
Output 32
+24V DC Output power supply for outputs 25 to 32 (4L+)
Attention: Pins 2, 8, 14, 21, 31, 41, 51, 61 and are connected with each other within the unit (L-).
Pins 2, 41, 51, 61 and 71 always have to be connected.
4.2. PIN - Allocation of the Serial Interface
When ordering the CamCon DC190, you can select between two types of serial interface: Options are
the RS232 or the RS485. Depending on the type of interface used, the pin allocation and the wiring
varies.
Note:
You can determine which kind of interface your device uses by checking the markings on
the DC190 housing.
4.2.1. PIN - Allocation of the Serial Interface RS232
DSUB 9 male:
Pin
Pin
Pin
Pin
RS232 interface for the connection with a PC (max. 15m cable length)
2
3
5
1, 4 and 6 - 9
TxD
RxD
Ground
not connected (NC).
Example: Connecting cable / order No.: KK33-190 2-03
Attention: The DIP - switch (Term.) for the RS485 load resistors must never be shut (ON) when
using an RS232 interface.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.2.2. PIN - Allocation of the Serial Interface RS485 (Optional)
DSUB 9 male:
Pin
Pin
Pin
Pin
Regard:
RS485 interface for the connection with a PC or other DC190 units (max.
1000m cable length).
2
3
5
1, 4 and 6 - 9
B (-)
A (+)
Ground
Not connected (NC).
When using the RS485 interface, the first and last units in the chain have to have their
data transfer cables closed with a terminal resistor. See also next chapter.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.2.2.1. Terminal Resistors of the RS485 Interface
To switch the terminal resistors of the CamCon DC190 on or off, a bipolar DIP – switch (labeled
“Term”) on the unit can be actuated using a screw driver. If the switches are closed (ON), the RS485 wiring is shut with a terminal resistor of about 2300/220/3200 Ohm. Therefore, always use both
switches simultaneously, otherwhise the unbalanced load can disturb the data transmission.
Attention: If the CamCon DC190 is equipped with an RS232 interface (factory setting), the DIP –
Switch must never be shut (ON).
4.3. PIN - Allocation external Interface
The CamCon DC190 has an external interface with the option to expand the unit with a CamCon
DC91/IO -, DC92/I -, DC16/IO – or AWA Analog/Digital Module. Expansion modules can easily be
snapped onto the mounting rail in the cabinet and connected with a 6 pole KK190/IO-XX cable using
the CamCon’s 9 pole D-sub pin-plug "external Inter. in" (max. 30m cable length). The data is
transferred isolated and potential free via optocouplers. A connecting cable for the DC190 with a DSUB
ribbon cable connector can be ordered using order No. "KK190-16/IO-XX" with XX being the cable
length in meters.
DSUB 9 female:
Pin 1,4,7
Pin 2
Pin 6
Pin 8
Pin 3
Pin 5
Pin 9
Connector for external in- and output modules like the DC91/IO or DC16/IO.
Ground
TxD +
TxD CLK +
CLK RxD +
RxD -
Connector cable CamCon DC91/IO:
Connector cable CamCon DC16/IO:
CamCon DC16/IO
Stift
9
8
6
5
3
2
4
7
1,10
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.4. Connecting the Ethernet Interface
Connecting the CamCon to the EtherNet or local area network is done using a RJ45-connectoor
(Registered Jack) and a standard EtherNet Cat.5 cable with 10/100 Mbit.
The Connector is switched as following:
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
TxD
TxD
RxD
RxD
-
+
+
-
Connect the network interface card of your PC using a cross over EtherNet cable directly with the
DC190 or via a standard EtherNet Cat.5 cable with an additional switch, that can be connected with the
DC190 using a second EtherNet Cat.5 cable.
4.5. Connecting the EtherCAT Interface
The standard connection to the EtherCAT terminal uses a RJ45 – connector (Registered Jack) and a
standard EtherNet Cat.5 cable with 100 MBit transmission rate.
The Connector is switched as following:
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
TxD
TxD
RxD
RxD
-
+
+
-
Connect the EtherCAT Master-Interface of the CamCon DC190 with a standard EtherNet Cat.5 cable
to an EtherCAT Slave terminal like the Beckhoff EK1100 at the RJ45 jack labeled “IN” or with a
CamCon DC190 IO EtherCAT Slave at the same connector.
Note:
Do not set up the EtherCat cables next to strong electro-magnetic disturbances (like motor
cables or power lines). To increase the electromagnetic compatibility, you can equip the
EtherCAT cables with additional ferrite bead suppressors or separately ground the
EtherCAT cables shielding.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.6. The measuring system
The measuring system is designed to record the necessary actual values (positions) for the Cam
Switch Unit. Many different measuring system can be linked with the CamCon.
See chapter "4. Electrical connections" on page 14 and for adjustment of the measuring system to the
software of the CamCons please also consult Chapter "6.6.1. Measuring system" on page 32.
Note: Please also consult the instruction manual for your measuring system.
4.6.1. SSI Measuring system input
Systems with a synchronous series interface = SSI. The SSI interface is widely used in industry for
absolute single and multi-turn angle encoder. At this interface the CamCon supplies the measuring
system with 24Volt. For the purpose of data reading the CamCon sends a stroke signal (clock) with
RS422 level to the measuring system. This answers synchronously with the data output of the position
in the grey code. The frequency of the pulse signal depends on the length of the cable to the
measuring system and can be set in the CamCon.
Note: The data record corresponds to the Stegmann SSI Standard!
Clock
Tp
Data
Tmono
= clock impulse
max. 1MHz to min. 66kHz.
(adjustable through the cable
length)
= Mono flop time 25µs
Encoder
CamCon
+24V DC
0V
Clock +
Clock -
Please note:
Use a screened dual strand connection cable. Do not place
the cable parallel to a high voltage cable. If possible, lay the
screening down on both sides.
Data +
Data -
4.6.2. Parallel measuring system input
Systems with parallel 24V data leads, e.g. single turn - angle encoder or via a transformer with parallel
data output.
In this instance a gray or binary encoded value is attached to the free inputs of the CamCon and this
will be read as actual value. Since the connection cable are quite expensive and the EMV compatibility is limited, this interface type is rarely used in industry nowadays.
Note:
Since the outputs are partly switched parallel to the inputs in CamCon DC16, DC115,
DC300 and CamCon 1756-DICAM, these must not be programmed under any
circumstances and this reduces the number of available outputs.
Warning:
Reading a binary encoded value into the CamCon is only permitted after consultation with
the Service department of the company Digitronic.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.6.3. Incremental measuring system input
Systems with 90° phase shift signals such as turning angle encoders, glass measuring rods or flow
measuring devices.
At the present time incremental measuring inputs for the CamCon DC16/50/51/115/300 and DC1756
are available as an option. We differentiate between three signal levels:
Note:
24V PNP Signal inputs
5V RS422 Signal inputs
Hiperface Signal inputs
(Order number Option: J)
(Order number Option: I)
(Order number Option: H)
For the CamCon DC16 and DC300 only the version with 24V PNP signal is available. For
the CamCon 1756-DICAM the version with 24V PNP signal and Hiperface Signal is
available. If a different signal level is necessary, this can be converted externally with the
INCDRV converter.
In all cases the CamCon supplies the measuring system with 24Volt/DC or in CamCon DC115
optionally with 5 or 24Volt/DC. As a counting signal the measuring system gives out two impulses at a
time shifted by 90° (A + B). These are counted in the CamCon and are evaluated as position values. In
addition, for each rotation another zero impulse (Clear 1) is given out for synchronisation purposes. In
order to stop synchronisation (zero setting) of the counter, a further clear signal (Clear 2) is available
on the CamCon.
The signals Clear 1 and Clear 2 are to standard AND linked and can be
changed in their function with the software. See Chapter "6.6.1.6.3. Special
measuring system - Incremental" on page 35
A Imp.
B Imp.
Clear 1
4.6.3.1. Incremental measuring system input with 5V RS422 level
Clear 2
If the 5V RS422 system is used, all signals of the measuring
system input must be active, otherwise the input conditions are
undefined. If no signal is available for one of the two Clear
inputs, then this input must be switched to mass on the (+)
signal in order to switch the input to low. The inputs of the
measuring system can be activated with a maximum voltage of
5V. Please pay attention to the power supply of the angle
encoder which can be 5Volt as well as 24Volt. Only the CamCon
DC115 can at present provide a voltage of 5Volt for the supply of
the angle encoder.
4.6.3.2. Incremental measuring system input with 24V PNP level
If a 24V PNP signal is used for data input, then only the (+)
signals of the inputs may be connected. The (-) signals must
stay inactive in this case. The connection of such a measuring
system requires a change of the interal switch system and must
therefore be stated on the order form.
Note:
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At the incremental input of the CamCon DC16,
DC300 and DC1756 no (-) signals are available.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.6.3.3. Incremental Hiperface measuring system input with SINCOS level
The Hiperface measuring system is a feedback system for servo-motors of the company Stegmann.
It is a mixed system and consists of an absolute measuring system and an incremental measuring
system. The absolute measuring system sends its values via RS485 interface to the counter. The
incremental measuring system works with analog sine - and cosine interface with a resolution of 512 or
1024 impulses per revolution.
The CamCon with the Hiperface signal input
(option: H) reads only the incremental sine - and
cosine signal. The signals are converted and
counted in the CamCon into normal incremental
measuring system signals.
CamCon
Since the absolute measuring system of the
Hiperface interface is not used and no clear signals are available, the CamCon must be
initialized after each restart.
controller
SINCOS
This must be done by the preset input of the
CamCon. See for this to chapter 6.6.2.
Measuring offset on page 40.
Note:
The maximum number of
revolutions per minute is 3000 min-1 with 512 Impulse per revolution.
The maximum number of revolutions per minute is 1500 min-1 with 1024 Impulse per
revolution.
4.6.4. Analog measuring system input
These are systems which receive their actual value through conversion of current or voltage signal,
such as temperature or pressure sensors.
For the recording of analog signals the analog to SSI conversion module AWA/SSI in 8 and 12 bit
resolution is available for the CamCon. This module is connected to the SSI of the CamCon and is
switched ON through the selection of the analog measuring system in the menu ”Measuring system”.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.6.5. PLL measuring system input
Systems with Phase - Lock - Loop data recording. In these systems the actual value is found through
interpolation of initiator impulses. This measuring system is applied to machines with constant speed
and with a cyclic pulse.
= Initiator impulse
= Found actual value
The Initiator can be connected to any free input of the CamCon.
Note:
For CamCon DC115 a special input is available on the 25pol. SUB-D plug.
See also chapter "6.6.1.6.5. Special Measuring System - PLL" on page 37.
4.6.6. Timer as a measuring system
Systems which are controlled by elapsed time. In this case the CamCon makes a time available with a
time basis of minimum 1 ms as actual value. Through laying on of input signals it is possible to
influence the elapsed time. This measuring system is applied to machines with a fixed time scanner as
a control feature, e.g. washing machines.
See also chapter "6.6.1.6.6. Special measuring system - Timer" on page 37.
4.6.7. RS232 as a measuring system
Systems, receiving their actual position through the RS232 interface, e.g. for a junction of a Stegmann
POMUX linear scale to a RS232 data output.
Warning
The activation of this measuring system blocks the RS232 interface for
programming. This measuring system is only reasonable with a CamCon
DC50/51.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.7. Outputs
The CamCon DC190 features 32 on board short circuit proof outputs. They deliver 24 volt high-active
HTL signal with 0.5 amps steady current (100%ED). They are, nevertheless, not potentially free to the
unit’s or the CPU’s power supply.
The 32 outputs are gathered in four blocks of eight outputs each and have a separate power supply
(1L+ to 4L+), that can be switched on or off individually.
See also chapter "6.6.6. System upgrading" on page 47.
Attention: Inductive Reactances always have to be switched with a recovery diode!
4.8. Inputs
The CamCon DC190 features 16 on board inputs with active 24 volt signal (not potentially free). The
number of inputs can be increased by adding an external interface or an EtherCAT BUS up to 248
inputs.
The input wiring:
The input resistance
is about 5.7 KOhm.
The inputs of the CamCon have
not been covered with functions by
the factory. The user would have to do this himself in the process of setting system data of the
CamCon depending on his requirements. See chapter "6.6.6. System upgrading" on page 47, chapter
"6.6.1. Measuring system" on page 32, chapter "6.6.6. System upgrading" on page 47 and chapter
"6.6.6. System upgrading" on page 47.
4.9. Precautionary measures for welding work
Attention: For the duration of welding operations carried out at the machine, the
connecting wires concerning the data exchange from the measuring system to
the CamCon and the power supply as well as the grounding connections and
inputs and outputs have to be separated from the CamCon.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.10. Status Display
The CamCon DC190 features several status displays: 32 output indicators, 16 input indicators, 5
indicators for the power supply (1..5L+), one display for the internal DC190 BUS (BUS-Run), one for
output-errors or overload, one DC190 Status LED (Device-Status) and status LEDs for EEtherNet and
EtherCAT (Link and active).
EtherNet LAN aktiv
EtherCAT link
EtherNet LAN link
EtherCAT aktiv
CamCon DC190
status LED
see capter:
Status LED
Power supply indicator
CPU, encoder
and internal wardware
Overload indicator
of the outputs
LED BUS-Run
Status indicator
for input 1-8
Status indicator
for output 1-8
Status indicator
for input 9-16
Power supply indicator
for output 1-8
Power supply indicator
for output 9-16
Status indicator
for output 9-16
Power supply indicator
for output 17-24
Status indicator
for output 17-24
Power supply indicator
for output 25-32
Status indicator
for output 25-32
-
The BUS-Run LED BUS-Run indicates that the CamCon DC190 CPU has contact with in- and
outputs. If the LED does not light up, it is because of an error or a restart process or a startup is
interrupted and the DC190 cannot be started.
-
The Ethernet LAN Link LED indicates a successful connection to the switch or EtherNet-card.
-
The EtherNet LAN Active LED shows that data can be transmitted.
-
The EtherCAT Link LED indicates the connection to an EtherCAT terminal like a Beckhoff EK1100
or a CamCon DC190 IO.
-
The EtherCAT Active LED shows the transmission of I/O data.
-
The LED Output-Error indicates an output overload by short circuits or a too high load or
temperature.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
4.10.1. The DC190 Status LED
The status LED of the CamCon shows the different blinking intervalls of the the device state. This way,
the operation state of the device can be seen without a PC or a terminal.
total time: 3.2 seconds
State
=
=
=
=
=
=
=
=
"OK"
"Clear..."
"Pos.Error: 1"
"Pos.Error: 2"
"Pos.Error: 3"
"Pos.Error: 5"
"Output Error"
"indicates an error in the EEPROM memory"
See also chapter "8. Error messages and removal of errors (FAQ)" on page 56.
5. Commissioning
Please check the device’s wiring before you switch it on. See also chapter "4. Electrical connections"
on page 14 for hints.
Attention: Inductive Reactances always have to be switched with a recovery diode!
Inductors or contactors that are mounted in proximity to the DC190 or the
wiring of which could affect the unit must be switched with RC elements.
The CamCon acknowledges the start-up with a flashing Status LED. After an internal
check-up, the system is booted (e.g. the EEPROM’s checksum is determined as is the Flash’s). This
procedure takes a few seconds.
The CamCon DC190 can be programmed via the EtherNet TCP/IP interface, the integrated Web
server DigiWEB or a Web-Browser like Internet Explorer or FireFox. It is therefore necessary to know
or set the unit’s correct IP-address.
5.1. Setting the IP-Address
Attention: Any IP – address must only be given once within a LAN. If you do not know any free IP,
please necessarily contact your network administrator before you connect the DC190 to
the network.
The factory setting of the device’s IP address is 192.168.3.128 / 255.255.255.0.
Should you decide to use another address, take down the MAC address of your CamCon (see type
plate) first (e.g. 00:50:C2:1E:21:6C).
Connect the CamCon with a CAT5 Ethernet Cable with a switch of your
LAN or connect it via a Cross – Over – Cable with the RJ45 Connector of
your PC’s network card. Now open a command prompt (e.g. by typing CMD
in the “Run” command line in Windows).
Now type the command
"ipconfig" in the command
prompt, to determine your computer’s IP and subnet
mask.
If no IP address or subnet mask is displayed here or
the IP is displayed as 0.0.0.0, a network connection is
not yet set or set incorrectly. Please contact your
network administrator if necessary.
In our example the IP-address is 192.168.2.41 while the subnet mask is shown as 255.255.255.0. That
would indicate that the DC190’s IP must be configured within the range of 192.168.2.1 to
192.168.2.254. It must, nevertheless, not be identical to the IP of the computer itself. You could use,
for example, the IP 192.168.2.128. or similar.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
If the IP address is 169.254.148.76 (for example when using a cross over cable) and the subnet mask
255.255.0.0, the CamCon DC190 can be configured within an address range of 169.254.0.1 up to
169.254.254.254. It must never equal the computer’s IP (like 169.254.148.75, for example).
If you know of a free address in the network or the administrator assigned one for you, you can
continue with the setting of the IP.
For this purpose, enter the CamCon’s MAC – Address (Media - Access - Control) using the command
"arp" in your system’s network card.
For the MAC address "00:50:C2:1E:21:6C" (e.g.) the correct command would be:
arp -s 169.254.148.75 00-50-C2-1E-21-6C or arp -s your.ip.address.please your-MAC-Address
Note:
Windows uses hyphens instead of colons !
To activate the IP address in the CamCon and to check the connection between device and computer,
deactivate the firewall first, the set the following command:
"ping 169.254.148.75" respectively
"ping your.ip.address.please"
The answer should look like this:
If the ping was successful, the set IP address
can be used until the next system restart of the
computer. The IP address is only temporary!
To set a permanent IP address, you have to
use
the
CamCon
DC190’s
network
configuration. Open a web browser and type in
the following address:
"http://169.254.148.75/config.htm" respectively "http://our.ip.address.please/config.htm"
Note: Depending on the LAN, there is possibly an HTTP proxy server set for the browser.
Check the menu extras -> internet options -> connections -> LAN settings (IE) or
extras -> options -> extended -> network -> connections (FF).
This HTTP proxy must be switched of or the CamCon DC190’s IP must be configured as an
exception for which the proxy server is not used.
After a login procedure (for which a user: ftp and a
password: ftp is used) you can configure the
CamCon DC190 or the DigiWEB in respective.
For this purpose, set the desired IP the subnet mask
and (if needed) a gateway.
Other parameters are not needed to use the DC190
as a cam controller. They are explained in detail in
the manual of the DigiWEB webserver.
Pressing the OK button saves the IP in the
CamCon’s permanent memory for future use.
To access the programming interface of the
CamCon, type the unit’s new IP (e.g.
http://192.168.2.101) into your browser address
line.
The picture on the following page will be displayed.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6. Programming
Note:
The Web programming requires Java Script and ActiveX (Internet Explorer Only). Any
popup-blocker must be deactivated for the CamCon’s IP address!
6.1. Deleting the Cam Control
The cam control’s memory should be deleted for commissioning, since remains of testing programs
needed in the manufacturing process, still are present within the memory. It is nevertheless possible to
delete the memory later or at any time to reset the device to its initial state.
Attention:
It is not possible to restore deleted memory!
To delete the memory, use the memory:
"Configuration menu" -> "Configure unit" -> "Format unit"
After a safety request the cam controller’s memory will be deleted completely. All cams are deleted, all
system register are set back to standard.
You can them begin with programming.
To activate the unit at your machine, a minimum of parameters must be set for the CamCon. The
following order our suggestion for setting the parameters – the required procedure can be found in the
corresponding chapters.
1)
2)
3)
4)
Menu: "Configuration menu" -> "Configure hardware" see chapter "6.7.1. Configure
hardware"
Menu: "System setting" -> "System upgrading" see chapter "6.6.6. System upgrading"
Menu: "System setting" -> "Cable length" see chapter "6.6.4. Cable length"
Menu: "System setting" -> "Measuring system" see chapter "6.6.1. Measuring system"
After the corresponding entries have been made, the CamCon should be ready for service.
Of course we recommend to work through the complete configuration menu to get a maximum
handling and functional options.
After the cam controller is configured, the cams can be programmed.
If you want to use the CamCon cam switch as a cam controller with PLC logic option, set the PLCLogic option in the "Configuration menu", using the "PLC configuration" menu. The cam outputs
can be switched to e.g. the inputs using the menu "PLC - Logic - Module".
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.2. The Main Menu
Every configuration starts in the main menu. No matter what sub menu you are in, the main menu
helps you to access every other menu with just one click.
The recently selected menu is highlighted.
According to the menu configuration the look of the main menu can vary. Options can be
missing or additional options can be available (like e.g. tool protection).
The recent status of the unit is indicated by a green (OK) or red (error!) highlight of the
“Status Display” option. One further click gives you access to a more detailed error
report.
By clicking the Digitronic logo you can get information on the used firmware version, the
DigiWEB version, the DigiWEB webpage version and the instance and port number of
the webpage.
6.3. Statusdisplay
Access the status display (pop-up) by clicking "Statusdisplay",
showing the actual value, the recent speed, a
program number as well as any potential error
message but also the status of all outputs, inputs, cams, flags
and other signals.
To increase the display speed or to decrease the update
speed, use the “Fade out” option to mask the respective block
from the display.
Error messages can be easily acknowledged by clicking
“Restart”.
If an error can only be
cleared
by a
total
deletion,
a
security
request precedes the
delete.
6.4. Project data
Here you can save general information about your machine in the CamCon’s memory (like e.g.
machine number or output conditions). For these purpose, there are seven lines with 21 characters
each available.
6.4.1. CamCon device option
Currently, you can order the CamCon with four options:
1. PLC - Logic - Module (S).
2. PLC - Logic - Module with text display (M).
3. PLC - Logic - Module with text display and remanent memory (C....M).
Note:
"Remanent Memory" is used to secure counter value and flags against power shortages.
For this option, the hardware configuration EEProm – Memory Extension “C” is mandatory.
This optional hardware is included as a standard in the CamCon190.
4. PLC – Logic - Module with text display and Tool Protection (W).
Select available options for your CamCon in this menu. The type plate indicates all installed options in
the last digits of the order number: 0 = none selected / S = PLC – Logic - Module / M = PLC – Logic Module with text display / W = PLC – Logic - Module with text display and Tool Protection. The optional
remanent memory is indicated by the character C in the memory extension (e.g. DC51 S5C24002M,
DC16 S5C04S or DC190 SS82W).
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.4.2. Offline - Simulation
The Digisoft 2000 Program gives you the opportunity to simulate the encoders like the Measuring
System, hardware inputs (l) and backplane inputs (V) of an S7 (CamCon DC300 or ControlLogix 1756DICAM) in the "Offline" programming. This option makes it possible to test a PLC logic program on
your computer without having to install a CamCon or further machinery. This option is not available
"Online". The Digisoft 2000 program can be downloaded at http://www.digitronic.com.
6.5. Cam programming
Cam programming is used to select a program number for the programming of a cam. You can name
any program number (with a tool or recipe number, e.g.). Programmed cams are displayed graphical
on a scale in the resolution of the used measuring system. Maximum and minimum values (actual or
cam values) will be displayed to the left and right above the scale (e.g. 0° - 359°).
You can access the programming options by clicking the "Edit" button.
6.5.1. Entering Cams
The cam programming can be used to address a name to any cam output, to enter or edit the
switching points of the cams, to adjust the Delay Time compensation or to shift all cams of an output or
an output track stepwise.
In addition, the option "Programm Multicams" can be used to fill up a cam track with multiple cams
automatically.
Hint:
If you let the cursor „hover“ above the green box of a cam, the switching points will be
displayed in a small pop up box.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.5.2. Entering the Speed Compensation
You can select between five different modes of Delay Time compensation according to the
configuration in the menu "System setting" -> "System upgrading".
Note:
You will find information about the function and calculation of the speed compensation in
chapter "2.1. Speed Compensation".
"Normal"
The selected Delay Time affects in- and outputs similarly.
"In/Out"
Different times can be selected for in- and outputs.
Attention: If the off-switching point overtakes the switching on at increasing velocity in this
mode, a non-defined signal occurs !
"Way/Time"
Note:
A way/time cam has a defined length at each velocity. It enables e.g. to control the
dispersion of glue so that a defined amount is dispersed at any velocity. The
switching is defined by position triggered values and the selected speed
compensation.
The cam itself has also a selected switching point for on- and off switching. The on
switching is used as a positive trigger edge, the out switching as a negative. If
several cams are programmed and the next trigger edge reaches an off-switched
cam at increasing velocity, both cams will be combined to a single cam.
6.5.3. Selecting the Non - Linear - Speed Compensation
"NLDTC Normal"
The non-linear speed compensation makes it possible to trigger or
compensation switching procedures that show a non-linear behavior, like break
or accelerating ramps. For this purpose, a chart with Delay Time and velocity
values is created within the unit to create a speed compensation characteristic.
The selected speed compensation
affects the on and off switching DTC80(ms)
equally.
60
On the right you can see a characteristic with five
interpolation points from 20 ms to 30 rev/Min. In the range of
30 to 50 rev/Min, the speed compensation interpolates a
raise to about 40 ms. The maximum speed compensation is
reached at 90 rev/Min with 60 ms.
40
20
90
"NLDTC Way/Time"
180
V (rpm)
This mode requires – just as it is
with the normal speed compensation – also the switching time of the cams.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6. System settings
Select the system parameter of your cam switch of your CamCon controller here.
6.6.1. Measuring system
Parameter the measuring system of the cam switch here.
6.6.1.1. Select measuring system
You can choose between different preset measuring systems. The most
common are SSI single turn angle encoders with 256, 360, 512, 1000,
1024, 2048, 4096 or 8192 steps or multiturn angle encoders with different
transmissions and triggers, but also two analog SSI converter modules AWA can be selected.
Note:
Should you not be able to select values at the upper resolution range, the cause might be that
there is not enough RAM memory available.
If the measuring system option is not available in the menu, you have to select a "Special measuring
system". See also chapter "6.6.1.6. Configuration of the special measuring system" on page 34 on this
issue.
6.6.1.2. Value Hysteresis
This value is needed to suppress a „shimmy“ of the outputs at fluttering actual values. The exact value
has to be determined by trials, it should nevertheless be always as small as possible or 0. The
hysteresis can be between 0 and ¼ of the total resolution (maximum), it has nevertheless a 125 pulses
maximum.
6.6.1.3. Speed max or measuring system control
The menu option "Speed max." can be used to set the maximum acceptable actual value skip per
cycle, a feature that can be used to control the Measuring System. The needed value can be
calculated from the CamCon’s recent cycle time, the physical resolution or the machine’s speed.
Note:
The resolution must be entered as a physical property. If, for example, a Measuring System
with 4096 pulses is employed and a transmission gear (3600/4096) reduced the displayed
value to 3600 pulses, a resolution of 4096 has to be used in the calculation!
Example: Cycle Time = 0.5ms / Resolution = 360 / Machine Velocity = 180 min -1.
Speed - Max =
Resolution * Machine Velocity
---------------------------------------------------------(60 * 1000)
* Cycle Time + Security Stock
360 * 180 / (60 * 1000) * 0.5 + 5 = 5.54 ≈ 6
The rounded result is entered in the "Speed max." box.
If the CamCon now detects a skip of more than six pulses for the actual value, an error message "IstErr:5" or "Error Number 5" is displayed.
If a zero is entered here, the measuring system control is switched off. The maximum value is 9999
pulses.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.1.4. Electronic Gear Transmission
The option "Transmision - multiplier" and "Transmision - divider" can be used to enter a
transformation factor for the measuring range. This makes it possible to transform the physical
measuring range of e.g. a rotating angle encoder into a visible measuring range for the user. The
standard transmission is set to 1:1.
The measured actual value is then multiplied by the selected factor and then divided by the divisor. The
thereby calculated value is the displayed value.
Example:
A machine moves 1000mm for a full rotation (360 steps) of an angle encoder.
If the value should not be displayed in 360 steps of one degree each it is necessary to set
the transmission to 1000 / 360. Keep in mind that the display will nevertheless not
progress in steps of one mm, as the resolution (360) remains unaffected.
If you would type in 100 / 360, the actual value is calculated down to a range of 100. The
position is then displayed in cm, although a floating decimal is still not possible.
Note:
A negative "Transmision - multiplier" value changes the counter direction or the rotation
oft he Measuring System respectively.
6.6.1.4.1. The Electronic Rotation Direction Switch
The counter direction of the Measuring System can be selected with the "Transmision - multiplier"
(see previous chapter) by changing the algebraic sign.
Note:
After a change of the counter rotation direction, the zero value (offset) has to be adjusted
anew.
6.6.1.5. Actual Value Display Format
Use this option to select the display format for the actual value or the cam programming.
The hash marks are wild cards for the display value. The remaining digits can be used to enter
additional input like the measuring unit (e.g. mm, cm or inch) for linear systems.
If you want to use a decimal point, you could enter it between the hash marks (like this: ###.#mm)
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.1.6. Configuration of the special measuring system
If your Measuring System is not available in the default options, you will have to configure a special
measuring system for the CamCon.
There are nine different special measuring systems available at the moment.
- Name:
When configuring a special measuring system, you can select a name and
description of up to two lines length under "Name:".
6.6.1.6.1. Special measuring system - SSI
The special measuring system SSI is needed if you are running a SSI measuring system with special
parameters (e.g. a SSI encoder with 500 steps).
- Resolution in bits Number of used data bits of the SSI measuring system.
At a resolution of e.g.,. 500 pulses, that makes 9 bits.
- Offset in bits
Note:
Position of the lowest bit (LSB).
For our example, that would be the position of the LSB’s at the ninth position.
Further information can be found in the manual of your Measuring System.
This value has to be at least equal to the "Resolution in bits".
- Capping
Enter the capping of the Gray – Code here.
For our example that would be: ( 512 - 500 ) / 2 = 6.
- SSI-Error bit
Enter the position of the SSI Errorbit here. For standard rotating angle encoders
manufactured by Stegmann the Bit position 14 is needed. This position in the
SSi protocol has always to contain a zero.
If no zero can be detected here (e.g., because the wire broke down), the
CamCon delivers the error message "Pos-Err:2" or "Error Number 2"
respectively.
Note:
6.6.1.6.2. Special measuring system - Parallel
- Resolution
Enter the resolution of the parallel Measuring System here (e.g. 500 pulses).
- Start input
Enter the input number of the lowest value bit (LSB) here. In our example that
would e.g. be the position of the LSB at input #7. At a resolution of 500 pulses, a
nine bit resolution is needed. The CamCon determines the inputs automatically
from the position of the LSB in ascending order. In our example input 7 to 16
would be attributed to the bits of the parallel angel encoder in accordance.
- Mode
The "Mode" option can be used to program the parallel Measuring System. It
can be set to Gray = Graycode or Bin. = Binary code.
Attention:
A parallel binary code should only be used as an exception. Contact the
customer service for this issue.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.1.6.3. Special measuring system - Incremental
- Resolution
Enter the maximum number of pulses here. This value is used as the maximum
resolution for the calculation of the cams. If the unit registers more pulses than
this set maximum, it restarts counting again at zero.
The option "Measuring offset" can be used to switch the movement "System"
to "linear", a counter overflow triggers a "Clear...." or "Error 3" message at the
CamCon. You will have to increase the resolution or to set the actual value to
zero using a preset or clear signal.
- Divisor
The divisor multiplies or divides measured pulses from the Measuring System
with a set factor. The following scalers can be used: "*4", "*2", "*1", "/2", "/4",
"/8", "/16", "/32", "/64", "/128", "/256", "/512".
If, for example, the divisor is set to "*4", an encoder or Measuring System with a
resolution of 500 pulse could transmit up to 2000 pulses to the unit (four times
the resolution).
- Clearemode
Is used to set the additional inputs C1 and C2. You can choose between eight
optional settings:
"C1 & C2"
If input C1 is high and C2 high too, the counter is set to zero.
"/C1 & C2"
If input C1 is low and C2 is high, the counter is set to zero.
"C1 & /C2"
If input C1 is high and C2 is low, the counter is set to zero.
"/C1 & /C2" If input C1 is low and C2 low too, the counter is set to zero.
"C1 : W"
If input C1 is high, the counter is set to zero.
If input C2 is high, no further pulses are counted (Wait).
"/C1 : W"
If input C1 is low, the counter is set to zero.
If input C2 is high, no further pulses are counted (Wait).
"C1 or C2" The counter is set to zero if C1 is high or C2 switches from low to high.
"C1 or C2". The counter is set to zero if C1 high or C2 switches from high to low.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.1.6.4. Special measuring system - Multi
This Measuring System is needed to use a multiturn turn-encoder (4096*4096 with 24Bit) with a nonbinary number of revolutions.
If e.g. the encoder at the shaft revolves more than one turn, but your machine just operates in a single
step or product.
- Resolution
Total resolution of the Measuring System at the CamCon used to calculate the
cams.
- Turns
Multiplier for the factor of revolutions at the encoder’s shaft.
- Turn - divisor
Divisor for the factor of revolutions at the encoder’s shaft.
Example 1:
Using a rotary disc with a 3 to 1 transmission gear, at which the encoder turns three
times per one revolution of the disc. These three revolutions correspond to 360
pulses (360 degrees).
The following presets are required:
"Resolution" = 360 / "Turns" = 3 / "Turn - divisor" = 1.
Example 2:
Using a rotary disc with a 12.5 to 1 gear transmission gear. The encoder turns 12.5
times with each revolution of the disc shaft. These 12.5 rotations would now
correspond to 3600 pulses (360.0 degrees).
The following presets are required:
"Resolution" = 3600 / "Turns" = 25 / "Turn - divisor" = 2.
Attention:
This Measuring System works only in combination with a multiturn angle encoder with
a resolution of 4096 x 4096 pulses(Type: AAG66107 or AAG626).
Note:
Never turn the encoder more than 512 times without power supply, otherwise the
preset zero is lost.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.1.6.5. Special Measuring System - PLL
The PLL Measuring system (Phase - Lock - Loop) determines
the position by interpolation of a single pulse over time (like a
photo cell or limit switch).
If e.g. a rotating disk is equipped with an initiator and you want
to measure the recent position at a certain, constant speed
without having to install a second Measuring System the PLL is
a good solution.
- Impulses per signal
Enter the number of steps between
each pulse.
- No. of imp.f. one rev. If one rotation triggers several pulses
you can enter their number here.
Note:
The number of pulses that the CamCon uses to calculate the cams is the result of a
multiplication of this two menu points (e.g. 360*10 = 3600 pulses).
- Impuls - input
Set the input number for the initiator pulse
- Clear - input
Input number for the clear – signal used to set the zero value
- Error - window
If a step error or a departure bigger than the preset value in the error window
is detected, the unit switches into the asynchronous mode and switches the
"Synchron - output" off.
- Synchron - output
Cam output number for a synchronous state of operations. This output is
active as long as the PLL Measuring System is running in the synchronous
mode or within the "Error - window" respectively.
6.6.1.6.6. Special measuring system - Timer
The timer ways simulator helps to create actual time values or ways without a hardware system, on
time basis. The cam switch works similar to the control program of e.g. a washing machine or a time
relay control.
- Resolution
Enter the number of steps that the CamCon shall use to calculate the cams
(Total Time).
- Time per step in ms
Time delay between the single steps in milli seconds (ms).
- Stop - input
Used to release the timer system. A high signal at this input sets the timer
off, a low signal stops it. If you do not want or need a stop input, just enter „0“
in here.
- Clear - input
A high signal at this input resets the timer to „0“ or halts it at „0“. If you do not
want or need a clear input, just enter „0“ here.
Example:
If the option "Time per step in ms" is set to 5 and a "Resolution" of 1000 is
defined, the total running time will be 5 seconds (5ms x 1000 steps = 5 seconds).
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.1.6.7. Special measuring system - AG615
The AG615 - Single - Multiturn – Measuring System creates a multiturn Measuring System from an
AAG615 - 8192 Singleturn - Unit.
- Resolution
Set the resolution that the CamCon shall display per turn (e.g. 360).
- Turns
Set the number of uses or revolutions that the CamCon shall create (e.g. 5).
The results are several revolutions or uses of the CamCon with each turn of the AAG615.
Example:
At a value of 5 * 360 the CamCon counts from 0 up to 359 five times if the AAG615
- 8192 encoder rotates once at the shaft.
6.6.1.6.8. Special measuring system - SIM
The SIM – Measuring system (Simulator) helps to create actual values from time basis without the
need for an additional measuring system. Compared to the timer Measuring system, a higher speed is
possible.
- Resolution
Enter the number of steps that the CamCon shall use to calculate the cams (e.g.
5000).
- Increment per sec. Enter the speed or the pulses per second here (e.g. 1000).
- Stop - input
Used to release the timer system. A high signal at this input sets the SIM timer
off, a low signal stops it. If you do not want nor need a stop input, just enter „0“
here.
- Clear - input
A high signal at this input resets the SIM timer to „0“ or halts it at „0“. If you do
not want nor need a clear input, just enter „0“ here.
Example:
At a resolution of 5000 and a speed of 1000 pulses/second a velocity of 5000 is
simulated.
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.1.6.9. Special measuring system - HIPER
This Special measuring system is used if the CamCon is equipped with an incremental Measuring
System input and an uneven gear transmission is likely to cause an error overflow (roll over function).
- Multiplier
Enter the multiplier for the gear transmission.
- Divisor
Enter the divisor for the gear transmission (e.g. 5 / 7).
Note:
- Resolution
Each edge change is counted = quadrupling.
Enter the maximum needed number of pulses here. This value is the maximum
resolution used for the calculation of the cams.
If the unit registers more pulses than this set maximum, it restarts counting
again at zero.
The option "Measuring offset" can be used to switch the movement "System"
to "linear", a counter overflow triggers a "Clear...." or "Error 3" message at the
CamCon. You will have to increase the resolution or to set the actual value to
zero using a preset or clear signal.
- Clearemode:
Is used to set the additional inputs C1 and C2. You can choose between eight
optional settings:
"C1 & C2"
If input C1 is high and C2 high too, the counter is set to zero.
"/C1 & C2"
If input C1 is low and C2 is high, the counter is set to zero.
"C1 & /C2"
If input C1 is high and C2 is low, the counter is set to zero.
"/C1 & /C2" If input C1 is low and C2 low too, the counter is set to zero.
"C1 : W"
If input C1 is high, the counter is set to zero.
If input C2 is high, no further pulses are counted (Wait).
"/C1 : W"
If input C1 is low, the counter is set to zero.
If input C2 is high, no further pulses are counted (Wait).
"C1 or C2" The counter is set to zero if C1 is high or C2 switches from low to high.
"C1 or C2". The counter is set to zero if C1 high or C2 switches from high to low.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
6.6.2. Measuring offset
Movement - "System" = Rotatory (standard)
Movement - "System" = inear
- System:
Can be used to select the controlled system: Either rotatory (like packaging
machines, trimmers or eccentric presses) or a linear system like a
positioning unit or a toggle press.
- Offset:
The offset is subtracted from the physical actual value, thus giving you the
possibility to shift the zero value.
Note:
- Start position:
Hint:
- End position:
If the "System" is set to linear and the direction of rotation is set to negative,
the "Offset" value has to be below zero (e.g. -359). See also chapter
"6.6.1.4.1. The Electronic Rotation Direction Switch".
Here you can set a start value if your "System" is set to linear. From this
value on the cam values will start.
You can also use negative values.
This value changes automatically if the "System" is set to linear and the
"Start position" or the resolution is changed. This value is always the
highest possible programmable cam value and cannot be changed.
Attention:
If the start or end value is overrun, the CamCon switches of, displaying an
error message "Pos-Err 3" or "Error: 3".
- Preset value:
This value can be used in both the „rotatory“ as well as in the „linear“
condition to set a physical value to a new, preset value by adding an input
(positive edge).
You could e.g. set the preset value to zero to create an external zero signal
which can be used to synchronise a machine.
- Preset input no.:
Enter the number of the input that sets the preset value as an actual value
once it’s triggered by a positive edge.
- Pr. value store typ:
This option is used to determine whether a saved preset is tolerant against
power failures.
Using the "RAM" – memory loses the preset every time the device is
switched off and on again.
"EEPROM" – saving copies the preset from the RAM into the EEPROM
memory to make it robust against power shortages.
Attention:
The EEPROM memory should only be used if the preset is rarely triggered and
absolutely necessary, since the number of writing turns into the EEPROM memory is
limited (to about 100000 cycles). After that, the EEPROM is ultimately damaged and
the CamCon’s programming data is lost.
Note:
The Preset Input will be read in in real time from software date 21.5.2002 on.
Therefore it can be synchronised with a machine.
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Digital Cam Switch Unit
CamCon DC190
6.6.3. Speed
This menu is used to set the CamCon’s speed display according to the turning speed of your machine.
You can e.g. alter the displayed speed by several factors or adjust a dampening to prevent a fluttering
of the display.
- Speed factor:
Usually the measured speed is displayed in pulses/second. If you want to
use another unit like e.g. revolutions/min, a calculating factor has to be
set here.
Example 1: A rotating angle encoder with 512 steps delivers 512 increments per minute,
indicating a speed of one turn per minute. The CamCon measures 512/60 =
8.533 pulses/second. To set the display to revolutions/minute, a factor of
1/8.533 has to be used.
Example 2: A rotating angle encoder with 360 steps delivers 360 increments per minute,
indicating a speed of one turn per minute. The CamCon measures 360/60 = 6
pulses/second. To set the display to revolutions/minute, a factor of
1 / 6 = 0,16666 is required.
Note:
This factor is affected by the electronic gear transmission. See also chapter
"6.6.1.4. Electronic Gear Transmission".
- Speed display format:
Set the display format for the speed display here.
The hash characters are wildcards for the display value. If e.g. the value
is smaller than 1000, only three characters are needed – enter three hash
characters. If you need a decimal, simply add it between the hashes (e.g.
###.# rev/min).
- 100% Speed value:
This menu point is used to set the maximum speed value of your plant.
It is used to adjust the speed display: if e.g. an analog speed output is
used, this value indicates the point where the analog value reaches its
maximum.
Note:
The endpoint of the bar chart for a CamCon DC50/51 or CD/CT10
terminal display is also affected by this value, as is the 5% trigger
threshold of the position to the speed display (if the "Display" menu is
set to "Automatic").
- Accuracy of speed display: A smaller value dampens the display speed making it less affected by
fluttering values (thus increasing the accuracy).
This dampening uses a deep pass to level the display, resulting in a
more “average” display value. The smaller the set value, the more
stable the display will be. It is therefore practical to decide for a
compromise between dynamic and readability.
Hinweis:
Both these values affect the speed value that a PLC Backplane, like an S7 or
ControlLogix or a C16/ P delivers to an attached PLC.
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- Display:
Digital Cam Switch Unit
CamCon DC190
This is only necessary when using a CamCon DC50/51 or CD/CT10
terminal display. You can choose between three modes:
"automatic"
If a 5% (of the set 100% turning speed) input threshold is passed, the
position display switches to a speed display, with the bar chart
representing the speed in percent.
"speed"
The bar chart only display the speed (not the position) in percent of a
set 100% maximum speed.
"position"
The display only indicates the position. The bar now displays the
position between start (0%) and end 100%): e.g. 0% = 0 degree / 50%
= 180 degree / 99% = 359 degree).
- Switching input:
If you set the "Display" option to "speed" or "position", you can use
the input number of the CamCon that switches the display of the
CamCon DC50/51 or CD/CT10 terminal display.
If the input is not active, the set display mode ("speed" or "position") is
always displayed. The switching from one to another can be triggered
by an input signal
6.6.4. Cable length
- Cable length:
Here you can enter the length of the cable that connects the SSI Measuring
System with the CamCon.
This is necessary, since the length of the wiring directly influences the speed
of data transmissions: The longer the cable is, the slower the transmission
and the bigger the cycle time will be.
Note:
If you use the „external Interface“ for an I/O- expansion and the cable of the
SSI Measuring System is shorter than the one between the I/O-modules (e.g.
DC91 or AWA) and the CamCon, you have to enter the length of the longest
cable (in meters).
! Attention !
Cables with more than 300 meter length require a specially configured SSI
Measuring System as well as I/O-expansion modules with changed mono-floptimes.
- max. DTC:
Displays the maximum possible Speed Time compensation value of the unit.
- Cycletime:
As a standard CamCon works with the shortest possible cycle time if you set
this value to zero.
The cycle time can, nevertheless, be shortened or increased, which is
necessary to e.g. you use a Measuring System that can only read the SSI
data once in a specific time (e.g. an ultrasonic sensor) or the CamCon’s
RAM memory would otherwise not be sufficient.
- Actual cycle time:
Note:
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Used to display the current cycle time of the CamCon.
Using the Digisoft 2000 program "Offline", this value is always"55.555ms".
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Digital Cam Switch Unit
CamCon DC190
6.6.5. Special outputs
The special outputs are divided into analog and digital signals:
6.6.5.1. Special outputs digital
- Safty output/RUN-Control:
To have the possibility to control the CamCon even in cases of short circuits in
the control channels or errors of the Measuring System, a rotating cam can be
programmed for a single cam output. This output is only switched of if an error
occurs and can therefore be used as a safety output.
If the programming changes, the safety output will be reset. See also chapter
"6.6.6. System upgrading" on page 47.
A "0" in the input box means that no safety output has been programmed.
- Send position
The CamCon provides the opportunity to put the actual value directly and in
real time onto the outputs.
This option is used for devices like the DC300 or the 1756-DICAM as well as
for the Profibus configuration CP16/P to have the actual value in real time
available for a PLC.
You can choose between four different settings:
"no"
= Actual value is not put out.
"Gray"
= Actual value is put out as a gray code on the outputs (physical value).
"Binary" = Actual value is put out in binary code for a DC300, 1756-DICAM and CP16/P.
(displayed value includes factor, offset and direction of turn).
"Exp."
= Actual value is put out as a gray code only with CamCon DC115 for a Master Slave - Connection.
With this function, the lowest value bit is counted first the others follow later
(actual value of 32 bits) behind the last defined output.
Example 1:
Example 2:
- Direction output:
For a CamCon with e.g. 32 hardware outputs, this is output 33. If the actual
value shall be available at the 24V-outputs, the number of defined hardware
outputs has to be reduced to e.g. 16, to have the first 16 Bit of the actual value
on outputs 17-24.
For a CamCon DC300 or 1756-DICAM with 24b hardware outputs and 16
virtual inputs via the back plane this is e.g. the virtual backplane output 41.
You can set a cam output that displays the direction of the machine’s
movement or rotation.
For a positive movement or rotation, the cam output is switched on, for a
negative it is switched off.
Note:
If the direction of movement changes, the output can only be switched if the
threshold set in "Direction hysteresis" is exceeded.
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- Move detection output:
Digital Cam Switch Unit
CamCon DC190
Use to set an output for the indication of movement.
The output is switched if the threshold set in "Direction
hysteresis" is exceeded in positive or negative direction.
- Direction hysteresis:
Set the threshold speed for the "Direction output" – and the
"Move detection output" here.
To be able to use the "Direction output" – and/or the "Direction
output" correctly, you have to set a threshold value at which the
movement is indicated or the cam output switches.
- Hysteresis of move d. output: Used to dampen a fluttering of the Move detection output for small
velocity changes.
You can use values between 0 and 99% of the "Direction
hysteresis".
Example:
If the "Direction hysteresis" threshold is set to e.g. 10rev/min and
this value is set to 50%, the output switches on at a number of
revolutions of 15 rev/min, and off again on 5 rev/min.
Note:
Only available for CamCon firmware version 3/2006 or higher.
6.6.5.2. Special outputs analog
- Speed analog:
With this function activated (set to "Yes"), the CamCon displays the
measured speed at the outputs.
It is therefore possible to provide speed data in real time for a
CamCon DC300, 1756 DICAM or Profibus CP16/P.
The speed is displayed as a 16 bit value behind the last defined output
and shifts if the option "Send position" is set, between the 32Bit
actual value and the last defined output.
Example:
Note:
32 "normal" outputs + speed (16Bit) + actual value (32Bit) = 80 Bits.
Also in this case not available hardware outputs are set as virtual
outputs to the back plane of the PLC.
Since the measured actual value is in most cases smaller than 16 Bit, the
higher bits can be ignored.
The 16 Bit speed value is already formatted by the "100% Speed
value" to be usable for a CamCon DAC16 digital analog converter.
Once the measured speed reaches the set value of 100%, a DAC16
with voltage output gives +10V or 20mA for a power output. At 0%
velocity, e.g. 0V or 10mA and for -100% = -10V or 0mA could be
displayed.
Note for S7, CLX and CP16: If the value is transmitted digitally via the back plane or a CP16/P/IO
into the PLC, the DAC16 formatting has to be removed or calculated
out. At 0% speed a value of 32768 and for 100% speed 65535 is
displayed. Therefore, you have to first subtract 32768 and then scale
up to 100%.
Note:
The CamCon DC51 can be purchased with integrated analog outputs. For this option,
the analog value can be displayed at the first analog output (clamp 2).
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- Analog Cam:
Digital Cam Switch Unit
CamCon DC190
The CamCon can display cams not only as digital 24Volt outputs but also
create position sensitive „analog cams“. Select Select the number of analog
cams that the CamCon shall use (from 0 = none to a maximum of 14).
In most cases, this directly corresponds to the number of analog hardware
outputs.
Note:
If the option "Speed analog" is set to "Yes", the first analog output is used to
indicate the speed.
6.6.5.2.1. Analog cam configuring
- Nb.:
Choose the cam you want to configure or program.
- Format:
Select the desired input format. The hash characters are wildcards for the
actual numerical value.
It is possible to use percent ("####.##%" (Standard)), voltage "###.###V",
pressure in bar "#.###mbar", in Ampere "##.###mA" or in any individual unit.
- Minimum:
Used to set the minimum input value (e.g. -100.00% or -10.00V).
This value is the threshold from which on the minimum value of the analog
output is displayed and used as a reference for the input.
- Maximum:
Used to set the maximum input value (e.g. 100.00% or 10.00V).
This value is the threshold from which on the maximum value of the analog
output is displayed and used as a reference for the input.
Note:
The CamCon always uses 16 Bit values for its analog cams that are compatible to
the CamCon DAC16 - D/A - converter.
This means that the smallest binary value (“0”) at the DAC16 corresponds to the
smallest analog value of -10Volt or 0 respectively 4mA. The biggest binary value
of 65535 corresponds to the biggest analog value of +10V or 20mA.
Example 1:
If the minimum is set to -100.00% and the maximum set to +100.00%, a
programmed analog value of -50% triggers a voltage output of -5V or a power
output of 5mA.
Example 2:
A minimum of 0 and a maximum value of 50, result in a programmed analog
value of 25 with an output voltage of 0V or 10mA current respectively.
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- Disable input:
Digital Cam Switch Unit
CamCon DC190
The output of the analog cam value can be frozen by setting an input to a
specific value.
For this purpose enter the number of the input that shall be used to set the
corresponding analog value to the "Disable value".
- Disable value:
Enter the value that shall be displayed if the "Disable input" is active.
This value must not be above the maximum or below the minimum value!
Note:
- Interpolation:
If no cam is programmed fort he used analog output, the "Disable value" is
used as a default value.
If this option is set to "On", the CamCon interpolates the programmed values
from interpolation point to interpolation point to form a smooth curve.
Interpolation = "Off"
Interpolation = "On"
+10V
0°
+10V
90°
180°
270°
-10V
360°
0°
90°
180°
270°
360°
-10V
- Factor:
Enter a multiplier factor in percent. If you use e.g. a value of 200%, an input of
10 mA would be displayed as 20mA. An input of 20mA for a 200% factor would
nevertheless cause an overflow.
- Offset:
Use this option to set an Offset.
An offset of e.g. 5mA has an input of 10mA displayed as 15mA.
6.6.5.2.2. Programming analog cams
The lower section of the analog cam input is used to program the actual analog cams:
Therefore, each interpolation point (e.g. 180°) is attributed to an analog value (e.g. 9.99V).
The interpolation points can be deleted (DEL), all deleted (Edit) or attributed to new values.
They are displayed in a rising order.
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Digital Cam Switch Unit
CamCon DC190
6.6.6. System upgrading
- physical inputs:
Display the number of available physical inputs that are configured in the
"Configure hardware" Menu.
- physical outputs:
Display the number of available outputs that are configured in the
"Configure hardware" Menu.
Note:
If the "PLC - Logic - Module" is switched on, this menu is used to set the
software in- and outputs (P. and N.) for the cam switch module.
- Inputs:
Used to define the number of inputs (P) for the cam switch.
- Outputs:
Used to define the number of outputs or cam tracks (P) for the cam
switch.
- DTC Outputs:
Used to define the number of cam tracks that use Delay Time
compensation.
This value should not be more than the number of absolutely
necessary outputs to save cycle time and memory space.
- NLDTC (not linear SC):
Enter here the number of available "Non – Linear – Speed
compensation Values" that you want to have must be set. The
maximum number is 246.
Try to keep this value as small as possible to save valuable
memory space!
The "used:” window displays the number of configured NLDTC.
- Key - lock - input:
When using a CamCon DC50/51 terminal display, you can select
an input number at which a Signal (+24V DC) triggers a keyboard
lock.
If the selected input is set to "0" the keyboard lock is inactive
- Error quit input:
A positive edge (+24V DC) at the selected input acknowledges an
error message at displayed at the CamCon ("Pos - Error": 1,2,3
and 5).
Note:
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An "Output - Error" or "Error: 4" can nevertheless not be
acknowledged.
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- Enable - input:
Digital Cam Switch Unit
CamCon DC190
A Signal (+24V DC) at the selected input enables the cam outputs. A 0V DC
signal locks them, respectively.
If this input is set to "0", the enable function is switched of and the cam
outputs are always available.
Note:
With the PLC - Logic - Module switched on, not the outputs („O“) but the cam
outs („N“) are locked or enabled.
Attention:
A CamCon with a direct PLC connection via a CP16 or CP340 or a CamCon
DC300 and a 1756-DICAM should always have the enable function set to
zero (switched of), as the PLC already provides a similar function.
- Strob input of ...:
The CamCon provides the possibility to use 24V inputs to switch between
programs and program numbers.
For this purpose select an input number for the switch or takeover pulse.
A 24 Volt pulse at this input selects the chosen program number. The pulse
must be at least 20ms behind the program number and have a length of
100ms or more.
If this input is set to "0" the external program selection is switched off.
- Nmb. of prg. ...:
Select the number of programs that can be switched with the 24V inputs.
This number depends on the number of available inputs: The program
number is set as a binary number after the switch pulse at the inputs, with
the lowest bit at the input being the switching pulse. This allows for a shifting
of the program selection inputs.
Example 1: For 8 available inputs a maximum of 128 programs (0 to 127) can be
selected, if the switching pulse is configured for input 1.
Example 2: For 8 available inputs a maximum of 8 programs (0..7) ) can be selected, if
the switching pulse is configured for input 5, since e.g. inputs 1 to 4 are used
for other functions.
- Typ of .. selection:
"slow"
A change of the program can be done on three different ways:
The selected program builds up cam by cam.
This program change does not require additional RAM memory space, but
can cause problems if a program switch occurs while the machinery is
operating at full capacity.
The CamCon’s safety or RUN - control output is switched off for a short time
for this option.
"direct"
The RAM memory is used to build up the program cam by cam. The switch
itself occurs swiftly.
This option requires the double RAM memory’s space but does not leave a
cam output undefined.
The CamCon’s safety or RUN - control output is not switched off for a short
time for this option.
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"by actual value"
Digital Cam Switch Unit
CamCon DC190
This option uses the RAM memory to build up the program cam by cam. The
unit then waits until a certain actual value is reached to trigger a program
change.
Also this option requires the double RAM memory’s space but does not leave
any output undefined.
The CamCon’s safety or RUN - control output is not switched off for a short
time for this option.
- Actual value:
This box is used to define the actual value for the switching point if the
program selection mode is set to "by actual value".
6.6.7. Masterprogram
The CamCon can be used to define global (transprogram and transproduct) machine/plant cams.
This can be necessary if your machine is used to process different products that have only little
differences in the cam programming and helps to save memory space in the EEPROM, as the cams
are product depended and do not have to be programmed multiple times.
- Mastermodul:
If you want to use the master program option, switch it to "ON".
- Programm No.:
Enter a program number at which the master cam shall be saved.
You can use any number between 0 and 32767, but we recommend using
either 0 or 32767.
- Output 1 - n:
Select cam outputs that shall be used as master cams.
Example:
If the master program cam is set to 32767 and uses output 1, a cam that
uses program 32767 and output 1 is used even if the automatic program is
switched to 0. The cam programmed for program 0 is ignored.
Note:
Programing the master cam is done in a similar fashion to the „normal“
cams. See also "Cam programing".
If you do not use the master program, this is selected automatically for the
input (any recent program is switched off).
Here you can change the desired master cam.
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Digital Cam Switch Unit
CamCon DC190
6.7. Configuration menu
You can order the CamCon cam controller with different hardware configuration, interfaces and
options.
This menu is used to define the hardware configuration and to set the device parameters of the
CamCon.
6.7.1. Configure hardware
- physical inputs:
Enter the number of physical cams of the CamCon and any possible I/O
expansion set at the „external interface“.
The number of inputs always has to be equal to the number of available
inputs as the unit detects overloads and short circuits via the inputs.
Example 1:
For a CamCon DC16 with a DC16/IO expansion module, this number has
to be set to 24.
Example 2:
For a CamCon DC190 with a DC16/IO expansion module at the "external
interface" this value has to equal to 32.
- physical outputs:
Note f. S7 and CLX:
Enter the used number of physical outputs here.
The number of outputs should not surpass the number of electric outputs
as a maximum. It can, nevertheless be raised to up to 64 (CamCon
DC300) or 200 (1756-DICAM). These outputs are then only transferred
virtually via the back plane of the PLC without the need for additional
hardware (e.g. a DC16I/O).
Example 1:
For a CamCon DC16 with a DC16/IO expansion module this value has to
be set to 32.
Example 2:
For a CamCon DC190 with a DC16/IO expansion module module at the
"external interface module this value has to be set to 48.
Note:
If you want to use a speed or actual value display at the outputs, the
output number decreases by the corresponding number of bits.
16Bit for a speed display and another 16 (if necessary 32Bit) for the
display of the measured value.
See also chapter "6.6.5.1. Special outputs digital" on page 43 and
"6.6.5.2. Special outputs analog" on page 44.
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- CP-Typ:
Digital Cam Switch Unit
CamCon DC190
If a CP16 Profibus Module (Order No.: CP16/P/IO) is attached at the unit’s "external
interface", set this parameter to "CP16/P/IO".
The menu will change then so that you can set the following parameter:
- Slave adress:
Set also the desired Profibus DP address here.
- CP inputs:
In addition to the CamCom’s physical inputs the CP16 can simulate inputs
that are controlled by a PLC (e.g. PLC outputs).
Enter the number of desired simulated CamCon inputs here. The sum of
physical and simulated inputs may only be 248.
Attention:
These simulated inputs must not be directly read out at the cam switch or the
PLC - Logic - Module as they are not defined in the communication setup
between the CP16 and the CamCon.
This inputs (I) must be connected to the speciality outputs of the S005 Bit of the
PLC - Logic - Module with an AND – connection, since they are set to 1 for a
successful communication.
- CP outputs:
Just as with the inputs, an additional number of hardware outputs can be
simulated. These are the read out by the PLC as inputs.
Enter the number of desired simulated CamCon outputs here. The sum of
physical and CP outputs may only be 200 (maximum).
More on the function and configuration of the C16 can be found in the device’s manual.
6.7.1.1. Advanced hardware configure
To have the CamCon meet the rising requirements for flexibility, an advanced hardware configuration
was introduced.
This option can be used to adapt a complex PLC Logic Module Program to several different CamCon
hardware option. If a program was originally written for a DC16 with 8 in - and 16 outputs, the same
program must be adapted for the use with a CamCon DC190 with 16 in - and 32 outputs.
With this function it is possible to change the position of in- and outputs or the allocation of backplane
data at a CamCon DC300 or 1756-DICAM to expand the programming flexibly and without the need for
totally new programming in the S7 or CLX.
The advanced hardware configuration is currently available for three interfaces of the unit:
-
for the "external interface" or the CamCon hardware in – and outputs if a CamCon with "X"
Option (external interface) and I/O expansion like e.g. a DC16 IO, DC91/92 IO, DA - or AD –
Converter is used.
-
for virtual in- and outputs via a back plane bus of the CamCon Plugin series of a DC300 and
1756 - DICAM.
-
for a FAST - Ethernet I/O or Ethercat – interface of a DC190.
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Digital Cam Switch Unit
CamCon DC190
6.7.1.1.1. Advanced hardware configuration for CamCon and external interface
For the advanced - hardware – configuration of an external interface a software module called I/ORouter is used.
It is a modular system beginning with a module 1. (first) and a number of n further modules.
To activate the I/O router select a Cam Con basic unit for the first module (e.g. a DC190) to be used.
To switch it off (and delete all (!) entries) it is sufficient to set the basic device to "EMTPY" in the first
module and press the OK button.
Depending on the type CamCon or module you can now address inputs and outputs, e.g. the hardware
outputs of a module to the corresponding in- and outputs of a CamCon.
Note:
To activate virtual outputs (which do not have a hardware structure), devices like a
CamCon DC300 and 1756-DICAM use the "Standard/O" module.
6.7.1.1.2. Back - Plan - Router Configuration
This option is only available if you selected a DC300 or 1756-DICAM as the basic module of the I/O
router.
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Digital Cam Switch Unit
CamCon DC190
6.7.1.1.3. Ethercat hardware configuration
This option is only available if you have selected the basic module DC190 in the first module of the I/O
router.
It is used to select and configure the FAST - Ethernet I/O or Ethercat – interface of the CamCon
DC190.
The FAST Ethernet I/O interface is, just as the I/O router, a modular system, beginning with the first
module, the FAST Ethernet I/O basic module (like e.g. a Beckhoff EK1100) and n other modules (e.g.
ET2004 = quadruple output module or ET1014 = quadruple input module as well as a Bus – terminal module (e.g. Beckhoff EL9010).
Depending on the selected basic module you can now define the configuration of the module line and
the connection or the routing of in- and outputs.
Note:
Inputs that are defined here that are connected to the I/O router will be OR connected.
The outputs can be selected more than once – it is e.g. possible to define the output 1 for
the second and fourth module.
Online:
If you are connected with the CamCon DC190 and a FAST Ethernet I/O System is
attached, the module configuration can be created automatically by clicking the "EtherCat
table synchronization".
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Digital Cam Switch Unit
CamCon DC190
6.7.2. PLC configuration
The PLC - logic - module of the CamCon combines the hardware - in - and outputs to the internal Cam
controller software. This connection is virtual in - and outputs of the PLC - Logic - Module realized. By
this technique it is possible, all activities of the cam controller of PLC logic module to change, and to
control.
In this menu, the PLC - logic - module is switched "on", "off" or to configure.
6.7.3. Key allocation
Entries in this menu are only necessary for the classical CamCon devices with the CamCon
Programming interface can be operated or when an external terminal via RS232 or RS485 connected
(eg DC51 or DC51 DC190 with Terminal / T [2/4]).
In this menu, the access permissions of the user key are defined.
Users are identified only by entering the key. The name is just for the Key Management and is not used
in the CamCon system. The respective rights and permissions by clicking on the button "Edit" or open
the next menu.
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Digital Cam Switch Unit
CamCon DC190
6.7.4. Unit Configuration
In this menu, the device can be completely deleted, and the serial port, and various special parameters
can adjusted.
7. PLC - Logic - Module programming
The PLC - Logic - Module of the CamCon will programmed in this menu.
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CamCon DC190
8. Error messages and removal of errors (FAQ)
The error messages appear on the standard display or in CamCon DC16, 90, 115, 190, 300 and 1756DICAM without a display of their own through the status LED or status bits.
The drawings below shows the error message appearing.
Device with LC - Display (e.g.Pos-Err:3)
Device via Digisoft 2000 or WEB (e.g.Pos-Err: 2)
9.1 Problem: Display shows "No contact to unit: XX".
Possible causes:
The wiring is probably not correct, no device with the selected unit number is on the BUS or the setting
of the 'Ser.Mode' is wrong.
Solution:
Check the wiring and the configuration of the serial interface.
See chapter "4.2.1. PIN - Allocation of the Serial Interface RS232" on page 16 and chapter "6.7.4. Unit
Configuration" on page 55.
8.2. Problem: "Pos - Err:1" respectively error number 1.
Possible causes:
The measuring system has not been correctly connected.
Solution:
Please check the wiring to the measuring system. Please consult the instruction manual to the
measuring system.
If the error is eliminated, the error-message can be deleted by pressing
8.3. Problem: "Pos - Err:2" respectively error number 2.
Possible causes:
The measuring system is faulty or not connected.
The setting of the error bits in the special measuring system setting is not correct.
Solution:
Check the wiring to the measuring system.
Check the inputs of the measuring system resolution.
Consult the instruction manual of your measuring system.
If the error is eliminated, the error-message can be deleted by pressing
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Digital Cam Switch Unit
CamCon DC190
8.4. Problem: "Pos - Err:3" respectively error number 3.
Possible causes:
The resolution of the connected measuring system is not in accord with the input resolution. The
measuring system is faulty. The actual value is outside the range which was entered in the menu path
setting for linear systems. See Chapter "6.6.2. Measuring offset" on page 40. If an incremental
measuring system is set, then this report is an alternative for the message "Clear...".
Solution:
Check the input of the measuring system setting, the offset value and the cable length setting.
Consult the instruction manual of your measuring system.
Consult Chapter "Problem: Clear...".
If the error is eliminated, the error-message can be deleted by pressing
8.5. Problem: "Pos - Err:5" respectively error number 5.
Possible causes:
The measuring system control is activated. The CamCon has registered a large unacceptable actual
value jump. The measuring system is possibly faulty.
Solution:
Check the input of the measuring system setting and of the setting of the cable length or increase the
permitted actual value jump. Consult Chapter "6.6.1.3. Speed max or measuring system control" on
page 32. Consult the instruction manual of your measuring system.
If the error is eliminated, the error-message can be deleted by pressing
8.6. Problem: An "Pos-Error:" occurs during operation.
The monitor displays "Pos-Err:1", "Pos-Err:2", "Pos-Err:3" or "Pos-Err:5".
Possible causes:
The connection cable of the measuring system or the measuring system itself is defective. A cable
without screening or without dual strand was used. The laying of a connection cable in the vicinity of a
strong electromagnetic source of interference (e.g. high voltage cable, motor cable) can lead to an pos
error.
Solution:
Check the wiring to the measuring system. Replace the measuring system.
Take measures for screening.
Lay the connection lead in another location.
Consult the instruction manual of your measuring system.
If the error is eliminated, the error-message can be deleted by pressing
8.7. Problem: "RAM-Full" = RAM memoryis full.
Possible causes:
The resolution of the measuring system is too large.
The number of outputs is too high.
The number of Speed Compensated outputs is too high.
Solution:
Check the input of the measuring system setting.
Reduce the measuring system resolution.
Reduce the number of Speed Compensated outputs.
Please contact your customer service representative if you require a RAM memory extension.
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Digital Cam Switch Unit
CamCon DC190
8.8. Problem: The EEProm memory is full.
Cause:
Too little memory space available in the EEPROM for the storage process.
Solution:
Please contact your customer service representative if you require an EEProm storage extension.
Also consult Chapter "9. Technical Data on page 60.
8.9. Problem: Outputs will not activate
Possible causes:
An error message is active. The outputs are not connected to power supply. A programed Cam is to
short or gets to short by increasing rotation speed. The enable - Input is not set.
Solution:
Check the error message.Program a longer Cam. A Cam with delay-time/speed-compensation must at
least have the length of two steps.
Enable Outputs at the enable-Input, see also chapter 6.6.6. System upgrading on page 47
Enable the outputs through the S5 PLC. Consult your handbook for the S5-L1 linkage.
8.10. Problem: "Out - Error" respectively error number 4.
Possible causes:
Your outputs are overloaded or short-circuited. Check the wiring and the connection output as well as
possible inductive loads which have no zero setting or are driven by a cancellation component.
The number of set inputs is not correct.
Power failure at an external interface module (e.g. DC91/IO or DC16/IO).
Solution:
See chapter "4.7. Outputs" on page 24.
See chapter "6.6.6. System upgrading" on page 47.
See chapter "6.7.1. Configure hardware" on page 50.
If the error is eliminated, the error-message can be deleted by pressing
Here the attempt to reset outputs is done
Warning:
Wires crossing behind the outputs, if the cables leading towards the switchOFF of the outputs are in an awkward position, can lead to a switch-OFF of the
outputs, since in an open situation a potential is built up which, when the
contacts are closed, is led back into the outputs.
In inductive loads the outputs must be organised with a flywheeling diode. Protection or
induction in the switch cabinet in the immediate vicinity of the device or due to their wiring
have an effect on the device or its wiring and must be organised with cancellation
components.
8.11. Problem: Error in the EEPROM respectively error number 255.
Possible causes:
The data of the EEPROM was changed or destroyed by interference.
One of the existing data carriers (EEPROM or EPROM) was renewed or is defective.
The power supply was switched OFF during alteration of the data.
Solution:
Press
for yes and then the
key. All data will be erased and must be re-entered.
Should these errors occur repeatedly, please contact your customer service.
8.12. Problem: "Error ???"
Possible causes:
An unpredictable error has occurred.
Solution:
Please contact your customer service.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
8.13. Problem: "Clear...." respectively error number 3
Cause:
The CamCon is waiting for the arrival of the Clear signal in an incremental measuring system.
Solution:
Set the Clear signal ON or activate an actual value Preset. The result is the immediate release of the
Cam Switch Unit.
Note:
The incremental measuring system is only available as an option for CamCon DC16,
DC50/51, DC115, DC190, DC300 and CamCon 1756-DICAM.
See chapter "6.6.1.6.3. Special measuring system - Incremental" on page 35.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
9. Technical Data
Display ................................................................ a status LED for the in- and outputs (48) each,
5 status LEDs for the power supply,
3 LEDs for the operation mode,
2 Ethernet and 2 EtherCAT Status LEDs
Interfaces ............................................................ Ethernet, EtherCAT, Digitronic external Interface,
RS232 or RS485 and SSI or 24V HTL
Number of outputs .............................................. 32, expendable to 248 outputs when using an external
interface or EtherCAT
Number of inputs................................................. 16, expendable to 248 inputs when using an external
interface or EtherCAT
Number of cam tracks......................................... 200
Number of programmable cams ......................... around 65000 cam
Memory ............................................................... Flash and F-RAM
Number of programms........................................ 32768
Cycle time, (switching speed) ............................. from 80µs, configured as needed (optimized)
Speed compensation (DTC) ............................... individual for each output, corresponding to the
Measuring System and memory available
Configuration range of DTC ................................ -9999.9 to 9999.9ms, corresponding to the Measuring
System and memory available
Measuring System - Inputs ................................. 2 x synchronous serial (SSI) gray encoded,
optional one or two incremental inputs (HTL),
parallel input or other kinds of input
Measuring System Resolution ........................... 360 steps (Standard), otherwise configured according
to the Measuring System and memory available
Measuring System (SSI) ..................................... AAG60007, AAG612-2048, AAG612-4096,
AAG612-8192, AAG626 or AAG66107
SSI – Tact rate (abhängig von der Kabellänge) .. 0 - 9m = 781kHz / 10 - 56m = 390kHz
57 - 149m = 195kHz / 150 - 1000m = 98kHz
Measuring System (incremental) ........................ ADG60/24/500 or any other 24V 90° pulse signals
Border Frequency of the incremental Input......... approx. 100kHz
Level of the incremental Input............................. 24V PNP (HTL only)
Zero point correction for the Measuring System . programmed in the CamCon
Rotation direction of the Measuring System ....... programmed in the CamCon
Length of cable between Measuring Systems
and CamCon....................................................... for SSI up to max. 300m (optional up to 1000m)
Power supply....................................................... 24V DC ±20 %
Measuring System – supply voltage ................... with 24V DC via supply voltage of the unit
Power consumption ............................................ 200mA without Measuring System or outputs and load
Output voltage..................................................... 24V DC, plus switching (PNP)
Output current ..................................................... 0,5A per output, 100%ED, short circuit proof
Programing ......................................................... via Ethernet with WEB Browser,
Digitronic DIGISOFT 2000 Programm,
CamCon DC50/51 Terminal
or CamCon CT10 Terminal.
Connections for:
Measuring System .............................................. screw clamps IP20
Power supply....................................................... screw clamps IP20
Cam outputs........................................................ screw clamps IP20
Mounting ............................................................. simple Snap-On mounting on symmetrical carrier rail
(EN 50 022), can be mounted in a row
Dismounting ........................................................ durch Zurückziehen des Schnappriegels
Dimensions ......................................................... (see chapter "3.1. Dimension" on page 13)
Protection ............................................................ corresponds to IP20
Working Temperature ......................................... 0°C ... + 55° C
Weight................................................................. ca. 820g
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
10. Index
Actual value............................................................................................................................................ 40
Actual Value Display Format.................................................................................................................. 33
Analog cams, configuring....................................................................................................................... 45
Analog measuring system input............................................................................................................. 22
Analog, cam programming..................................................................................................................... 46
Analog, speed ........................................................................................................................................ 44
Back - Plan - Router............................................................................................................................... 52
brake functions....................................................................................................................................... 11
Cable covering ....................................................................................................................................... 13
Cable length ........................................................................................................................................... 42
Cam programming ................................................................................................................................. 30
CamCon, option ..................................................................................................................................... 29
CE ............................................................................................................................................................ 2
centre pressure ...................................................................................................................................... 11
Clear mode ............................................................................................................................................ 35
Clear....................................................................................................................................................... 59
Commissioning ...................................................................................................................................... 26
Configuration, Ethercat .......................................................................................................................... 53
Connections, electrical ........................................................................................................................... 14
CP inputs................................................................................................................................................ 51
CP outputs ............................................................................................................................................. 51
CP16 Module ......................................................................................................................................... 51
Cycle time .............................................................................................................................................. 42
Cycle time, default.................................................................................................................................. 42
Delay time compensation, Effects............................................................................................................ 8
delay time for Speed Compensation, separate for switch-ON and switch-OFF points.......................... 12
Delay time, Calculation .......................................................................................................................... 10
Dimensions ............................................................................................................................................ 13
DIP - Switch ........................................................................................................................................... 18
Direction output ...................................................................................................................................... 43
Direction Switch ..................................................................................................................................... 33
Direction, hysteresis............................................................................................................................... 44
DP Address ............................................................................................................................................ 51
EEProm storage is full ........................................................................................................................... 58
EEPROM, Error...................................................................................................................................... 58
Enable, input .......................................................................................................................................... 48
Entering cams ........................................................................................................................................ 30
Error acknowledge, input ....................................................................................................................... 47
Error messages...................................................................................................................................... 56
Ethercat.................................................................................................................................................. 53
External interface ................................................................................................................................... 18
Externel interface, adcanced configure.................................................................................................. 52
Grounding connections .......................................................................................................................... 13
Hardware Advanced configuration ......................................................................................................... 51
Hardware, configuration ......................................................................................................................... 50
HIPER - Special measuring system ....................................................................................................... 39
Hiperface................................................................................................................................................ 22
Hysteresis, Actual Value ........................................................................................................................ 32
I/O - Router ............................................................................................................................................ 52
Incremental ............................................................................................................................................ 39
Incremental measuring system input ..................................................................................................... 21
Input wiring............................................................................................................................................. 24
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
Inputs, general ....................................................................................................................................... 24
Inputs, Hardware, configure................................................................................................................... 50
Installation .............................................................................................................................................. 13
IP - Address ........................................................................................................................................... 26
Key allocation ......................................................................................................................................... 54
Keyboard - lock - input ........................................................................................................................... 47
Linear ..................................................................................................................................................... 40
Main menu ............................................................................................................................................. 29
Master cams .......................................................................................................................................... 49
Master program...................................................................................................................................... 49
Measuring offset .................................................................................................................................... 40
Measuring system .................................................................................................................................. 32
Measuring System Control..................................................................................................................... 32
Measuring system incremental .............................................................................................................. 35
Measuring system, General information ................................................................................................ 20
millenium .................................................................................................................................................. 2
Move detection output............................................................................................................................ 44
Move detection, Hysteresis .................................................................................................................... 44
Moving, detection ................................................................................................................................... 44
NLDTC ................................................................................................................................................... 47
NLT .................................................................................................................................................. 12; 31
No contact to unit XX ............................................................................................................................. 56
Offset ..................................................................................................................................................... 40
Out - Error .............................................................................................................................................. 58
Outputs, additional ................................................................................................................................. 51
Outputs, general..................................................................................................................................... 24
Outputs, Hardware, configure ................................................................................................................ 50
Outputs, lock .......................................................................................................................................... 48
Parallel measuring system input ............................................................................................................ 20
Password ............................................................................................................................................... 27
PDF - File ................................................................................................................................................. 2
Pin allocation.......................................................................................................................................... 14
Pin allocation, 1. SSI measuring system................................................................................................ 14
Pin allocation, 2. incremental measuring system................................................................................... 14
Pin allocation, 2. SSI measuring system................................................................................................ 14
Pin allocation, EtherCat interface........................................................................................................... 19
Pin allocation, Ethernet interface ........................................................................................................... 19
Pin allocation, external interface ............................................................................................................ 18
Pin allocation, incremental measuring system....................................................................................... 14
Pin allocation, Inputs 1-16...................................................................................................................... 15
Pin allocation, Output 1-16..................................................................................................................... 15
Pin allocation, Output 17-32................................................................................................................... 16
Pin allocation, power supply................................................................................................................... 14
Pin allocation, Serial Interface................................................................................................................ 16
Pin allocation, Serial Interface RS232.................................................................................................... 16
Pin allocation, Serial Interface RS485.................................................................................................... 17
Plant cams ............................................................................................................................................. 49
Plant program ........................................................................................................................................ 49
PLC - modul - configuration ................................................................................................................... 54
PLC - Module - programming................................................................................................................. 55
PLL measuring system input.................................................................................................................. 23
Pos - Err 1 .............................................................................................................................................. 56
Pos - Err 2 .............................................................................................................................................. 56
Pos - Err 3 .............................................................................................................................................. 57
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
Pos - Err 5 .............................................................................................................................................. 57
Preset..................................................................................................................................................... 40
Profibus .................................................................................................................................................. 51
programm selection, external................................................................................................................. 48
programm selection, mode .................................................................................................................... 48
Project data ............................................................................................................................................ 29
Proxy ...................................................................................................................................................... 27
RAM-Full ................................................................................................................................................ 57
Roll - Over .............................................................................................................................................. 39
Rotatory.................................................................................................................................................. 40
Router, I/O.............................................................................................................................................. 52
RS232 as a measuring system .............................................................................................................. 23
RUN-Control........................................................................................................................................... 43
Safty output ............................................................................................................................................ 43
Select measuring system ....................................................................................................................... 32
Send actual value................................................................................................................................... 43
SIM, Special measuring system, Simulator ........................................................................................... 38
Simulation .............................................................................................................................................. 30
Special measuring system ..................................................................................................................... 34
Special measuring system - AG615....................................................................................................... 38
Special measuring system - Multi with gear........................................................................................... 36
Special measuring system - PLL ........................................................................................................... 37
Special measuring system - SSI ............................................................................................................ 34
Special measuring system Timer........................................................................................................... 37
Special outputs....................................................................................................................................... 43
Special outputs, analog.......................................................................................................................... 44
Special outputs, digital ........................................................................................................................... 43
Speed..................................................................................................................................................... 41
Speed analog ......................................................................................................................................... 44
Speed Compensation, Effects ................................................................................................................. 8
Speed compensation, entering .............................................................................................................. 31
Speed compensation, nmb. of outputs .................................................................................................. 47
Speed compensation, non linear ........................................................................................................... 31
Speed Compensation, not linear............................................................................................................ 12
Speed compensation, not linear ............................................................................................................ 47
Speed display format ............................................................................................................................. 41
Speed display, accuracy ........................................................................................................................ 41
Speed factor........................................................................................................................................... 41
Speed-Max............................................................................................................................................. 32
SSI measuring system input .................................................................................................................. 20
Status Display ........................................................................................................................................ 25
Statusdisplay.......................................................................................................................................... 29
System settings...................................................................................................................................... 32
System upgrading .................................................................................................................................. 47
Table of contents ..................................................................................................................................... 3
Technical Data ....................................................................................................................................... 60
Term....................................................................................................................................................... 18
Terminal Resistors, Serial Interface RS485........................................................................................... 18
The status LED ...................................................................................................................................... 26
Time -Cam ............................................................................................................................................. 12
Timer...................................................................................................................................................... 37
Timer as a measuring system................................................................................................................ 23
total deletion........................................................................................................................................... 28
Transmission, electronic gear ................................................................................................................ 33
Unit Configuration .................................................................................................................................. 55
Update...................................................................................................................................................... 2
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC190
User........................................................................................................................................................ 27
V-Max..................................................................................................................................................... 32
Welding operations, Safety precautions ................................................................................................ 24
Y2K .......................................................................................................................................................... 2
Zero point move ..................................................................................................................................... 40
Zero point move, extern ......................................................................................................................... 40
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