dc40e-01

dc40e-01
Digital Cam Switch Unit
CamCon DC40
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]
2 rue René Laennec 51500 Taissy France
Fax: 03 26 85 19 08, Tel : 03 26 82 49 29
E-mail:[email protected]
Site web : www.hvssystem.com
Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
For your attention
This instruction manual relates to the CamCon DC40 from 5/2006. 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.
UP-date
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 DC40 and this instruction manual are protected by copyright. All rights are reserved.
Neither the CamCon DC40, 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 - 2009 / File: DC40_E.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: Jan. 09
Page: 2
2 rue René Laennec 51500 Taissy France
Fax: 03 26 85 19 08, Tel : 03 26 82 49 29
E-mail:[email protected]
Site web : www.hvssystem.com
Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
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
3. Installation.......................................................................................................................................... 12
3.1. Dimensions ..................................................................................................................................... 12
4. Electrical connections ........................................................................................................................ 13
4.1. Pin allocation of the CamCon ......................................................................................................... 13
4.1.1. Pin allocation of the analog output............................................................................................... 13
4.1.2. Pin allocation of the SSI measuring system (encoder) ................................................................ 13
4.1.3. Pin allocation of the inputs ........................................................................................................... 14
4.1.4. Pin allocation of the outputs......................................................................................................... 14
4.1.5. Pin allocation of the voltage supply.............................................................................................. 15
4.1.6. Pin allocation of the serial interface ............................................................................................. 15
4.1.6.1. Pin allocation of the serial RS232 interface .............................................................................. 15
4.1.6.2. Pin allocation of the serial RS485 interface .............................................................................. 16
4.2. The encoder.................................................................................................................................... 17
4.3. The outputs ..................................................................................................................................... 17
4.3.1. The 40mA outputs (only CamCon device with aluminium back wall) .......................................... 17
4.3.2. The 500mA outputs ..................................................................................................................... 17
4.4. The inputs ....................................................................................................................................... 18
4.5. Precautionary measures for welding work ...................................................................................... 18
5. Outline of the operator terminal ......................................................................................................... 19
5.1. Frontview CamCon DC40 ............................................................................................................... 19
5.2. The LED - output display ................................................................................................................ 19
5.3. The seven-segment display for position and speed (Standard display) ......................................... 19
5.4. The keyboard .................................................................................................................................. 20
5.4.1. Outline of key functions................................................................................................................ 20
6. Commissioning .................................................................................................................................. 21
6.1. Complete deletion ........................................................................................................................... 21
7. Programming ..................................................................................................................................... 22
7.1. Initialization of the system registers ................................................................................................ 22
7.1.1. User keys for system registers .................................................................................................... 22
7.1.2. The encoder resolution ................................................................................................................ 23
7.1.3. The electronic gear ...................................................................................................................... 23
7.1.4. The actual position hysteresis...................................................................................................... 23
7.1.5. Measuring system control ............................................................................................................ 24
7.1.6. Changing the rotation direction .................................................................................................... 24
7.1.7. The zero point correction ............................................................................................................. 24
7.1.8. The speed factor.......................................................................................................................... 24
7.1.9. Adjusting the range of the speed display ..................................................................................... 25
7.1.10. Accuracy of the speed display ................................................................................................... 25
7.1.11. Display type................................................................................................................................ 26
7.1.12. Setting the cable legth ............................................................................................................... 26
7.1.13. Setting the cycle time................................................................................................................. 26
7.1.14. Number of inputs ....................................................................................................................... 27
7.1.15. Number of outputs ..................................................................................................................... 27
7.1.16. Number of outputs with speed compensation............................................................................ 27
Version: Jan. 09
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
7.1.17. Keyboard lock ............................................................................................................................ 27
7.1.18. Input for error reset .................................................................................................................... 27
7.1.19. Enable input ............................................................................................................................... 27
7.1.20. Setting of the external program selection .................................................................................. 27
7.1.21. Actual position preset or external shifting of the zero point ....................................................... 28
7.1.22. The security or SI output............................................................................................................ 28
7.1.23. The rotation direction or FR output ............................................................................................ 28
7.1.24. The standstill or V0 output ......................................................................................................... 29
7.1.25. The speed hysteresis................................................................................................................. 29
7.1.26. Setting the serial interface ......................................................................................................... 29
7.1.26.0.1. The "Cam-BUS" comunication mode................................................................................... 29
7.1.26.0.2. The "Standard" comunication mode .................................................................................... 29
7.1.26.0.3. Der "Multiuser" Kommunikationsmode ................................................................................ 29
7.1.26.0.4. The "S5 - L1" comunication mode ....................................................................................... 30
7.1.26.0.5. The "3964(R)" comunication mode...................................................................................... 30
7.1.27. Setting of the unit number.......................................................................................................... 30
7.1.28. Selecting the programming mode.............................................................................................. 30
7.1.29. Analog speed-output.................................................................................................................. 30
7.1.29.1. Offset match for analog output 1 ............................................................................................ 30
7.1.29.2. Amplification match for analog output 1.................................................................................. 31
7.2. Delay time or speed-compensation ................................................................................................ 31
7.3. Cam programming in programming mode 0................................................................................... 31
7.3.1. Program selection........................................................................................................................ 31
7.3.2. Output selection ........................................................................................................................... 31
7.3.3. Searching for cams...................................................................................................................... 32
7.3.4. Setting the preset value ............................................................................................................... 32
7.3.5. Shifting the activation point .......................................................................................................... 32
7.3.6. Shifting the deactivation point ...................................................................................................... 32
7.3.7. Leaving cam programming .......................................................................................................... 32
7.3.8. Examples for cam programming in the programming mode 0 .................................................... 33
7.3.8.1. Programming the first cam ....................................................................................................... 33
7.3.8.2. Programming additional cams on an output ............................................................................. 34
7.3.8.3. Deletion of a particular cam ...................................................................................................... 35
7.4. Cam programming in programming mode 1................................................................................... 36
7.4.1. Program selection........................................................................................................................ 36
7.4.2. Output selection ........................................................................................................................... 36
7.4.3. Shifting the activation point .......................................................................................................... 36
7.4.4. Shifting the deactivation point ...................................................................................................... 36
7.4.5. Leaving cam programming .......................................................................................................... 36
7.4.6. Examples for cam programming in the programming mode 1 .................................................... 37
7.4.6.1. Cam programming .................................................................................................................... 37
7.4.6.2. Deletion of cams ....................................................................................................................... 37
8. Outline of operations.......................................................................................................................... 38
8.1. Switching the standard display........................................................................................................ 38
8.2. Initialising the system registers ....................................................................................................... 38
8.3. Delay time programming................................................................................................................. 39
8.4. Cam programming .......................................................................................................................... 39
8.5. Display the unit configuration.......................................................................................................... 40
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
9. Troubleshooting ................................................................................................................................. 41
9.1. Problem: The display remains dark after activation........................................................................ 41
9.2. Problem: The display shows: EE.Err .............................................................................................. 41
9.3. Problem: The display shows: I.Err 1 ............................................................................................... 41
9.4. Problem: The display shows: I.Err 2 ............................................................................................... 41
9.5. Problem: The display shows: I.Err 3 ............................................................................................... 41
9.6. Problem: The display shows: I.Err 5 ............................................................................................... 41
9.7. Problem: An error happens during operation.................................................................................. 42
9.8. Problem : The display shows: A-Err................................................................................................ 42
9.9. Problem: Outputs do not react........................................................................................................ 42
9.10. Problem : The display shows: t1.Err ............................................................................................. 43
9.11. Problem : The display shows: E.Full............................................................................................. 43
10. Calculation EEPROM cam storage.................................................................................................. 44
11. Calculation the RAM storage-requirement for CamCon .................................................................. 45
12. Technical data.................................................................................................................................. 46
13. Key word table ................................................................................................................................. 47
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Fax: 03 26 85 19 08, Tel : 03 26 82 49 29
E-mail:[email protected]
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
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).
*
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: Jan. 09
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Fax: 03 26 85 19 08, Tel : 03 26 82 49 29
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
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 1:
Cam 2:
Cam 3:
Cam 1:
Cam 2:
Cam 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 DC40
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 DC40
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.
Version: Jan. 09
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Fax: 03 26 85 19 08, Tel : 03 26 82 49 29
E-mail:[email protected]
Site web : www.hvssystem.com
Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
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 "7.2. Delay time or 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 "7.2. Delay time or 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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Fax: 03 26 85 19 08, Tel : 03 26 82 49 29
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
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.
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°).
-
Now calculate the delay time, taking into account the
distance and speed difference, using this formula:
Delay time ( in sec. ) =
U/min
Verlauf
Nocke 1
Nocke 2
∆ way (in °) * 60 (sec./min.)
340-332 * 60
= 40-30 * 360 =
∆ Speed (in rpm.) * 360 (°/turn)
0.133 sec.
-
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.
Version: Jan. 09
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
3. Installation
The unit is inserted into a cutout for front plate installation (see chapter "3.1. Dimensions" on page 12).
Connect the groundig pins on the back of the encasement as well as the cable cover to a grounding
point of the switchboard door in the shortest possible way. All cable connections must be done in a
cold state! The connection cables, e.g. for the measuring system or the serial interface, must be wired
with covers, and the covers have to grounded on both ends. Analog signals must also be wired with
covers, and the covers have to be grounded on one end.
3.1. Dimensions
front door
can be locked
DIGITRONIC
CamCon
cutout as per
Connector input for
the encoder
attachment clip
Fig.: Drawing to aid the installation of CamCon
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Digitronic
Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
4. Electrical connections
Before you begin with wiring, please consult the following chapters: "4.3. The outputs" on page 17,
"4.4. The inputs" on page 18 and "4.2. The encoder" on page 17.
4.1. Pin allocation of the CamCon
CamCon
Fig.: Rearview of the CamCon
4.1.1. Pin allocation of the analog output
Pin
Pin
Pin
1:
2:
3:
0V for the analog output
Analog output 1
Analog output 2
4.1.2. Pin allocation of the SSI measuring system (encoder)
Pin
Pin
Pin
Pin
Pin
Pin
11:
12:
13:
14:
15:
16:
0V for the SSI measuring system
Data A or +
Data B or Clock A or +
Clock B or +24V DC for the SSI measuring system
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Digital Cam Switch Unit
CamCon DC40
4.1.3. Pin allocation of the inputs
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 signal mass for inputs
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
+24V DC voltage supply for inputs 1 - 16
0V signal GND for inputs
Input 9
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Input 16
+24V DC voltage supply for inputs 1 - 16
4.1.4. Pin allocation of the outputs
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 voltage supply for outputs 1 - 16
Output 1
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
Output 8
+24V DC voltage supply for outputs 1 - 16
0V voltage supply for outputs 1 - 16
Output 9 ( )
Output 10 ( )
Output 11 ( )
Output 12 ( )
Output 13 ( )
Output 14 ( )
Output 15 ( )
Output 16 ( )
+24V DC voltage supply for outputs 1 - 16
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Pin
61:
0V voltage supply for outputs 17 - 32
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
62:
63:
64:
65:
66:
67:
68:
69:
70:
71:
72:
73:
74:
75:
76:
77:
78:
79:
80:
Output 17 (I)
Output 18 ( )
Output 19 ( )
Output 20 ( )
Output 21 ( )
Output 22 ( )
Output 23 ( )
Output 24 ( )
+24V DC voltage supply for outputs 17 - 32
0V voltage supply for outputs 17 - 32
Output 25 ( )
Output 26 ( )
Output 27 ( )
Output 28 ( )
Output 29 ( )
Output 30 ( )
Output 31 ( )
Output 32 ( )
+24V DC voltage supply for outputs 17 - 32
Digital Cam Switch Unit
CamCon DC40
4.1.5. Pin allocation of the voltage supply
Pin
Pin
Pin
Pin
81:
82:
83:
84:
Attention:
0V voltage supply for the CPU
0V voltage supply for the CPU
+24V DC voltage supply for the CPU
+24V DC voltage supply for the CPU
Pins 30, 40, 50 and 60 are internally connected.
Pins 1,11, 21, 31, 41, 51, 61, 71, 81, 82 are internally connected.
4.1.6. Pin allocation of the serial interface
You have to specify the type of serial interface of the CamCon with your order (either RS232 or
RS548). The pin allocation depends on the type of interface used.
Please also note: chapter 7.1.26. Setting the serial interface on page 29.
4.1.6.1. Pin allocation of the serial RS232 interface
DSUB 9 socket:
Pin
Pin
Pin
Pin
Pin
1,4
2
3
5
6-9
RS232 interface for PC - connection (maximum cable length 15m)
may not be allocated !!
TxD
RxD
GND
not allocated.
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Digital Cam Switch Unit
CamCon DC40
4.1.6.2. Pin allocation of the serial RS485 interface
DSUB 9 socket:
Pin
Pin
Pin
Pin
Pin
1,4
2
3
5
6-9
CamCon
RS485 interface for PC - connection or linking several devices
(maximum cable length 1000m)
closedown resistors
B (-)
A (+)
Mass
not allocated.
interface converter
PC
CamCon
CamCon
interface converter
PC
CamCon
CamCon
Please note:
With an RS485 interface the connection plugs of the first and the last unit of a
linked chain, pins 1 and 2, as well as pins 3 and 4 have to be bridged to close
off the data and the input cable. Herefore the device has closedown resistors
at pins 1 and 4.
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Digital Cam Switch Unit
CamCon DC40
4.2. The encoder
The encoder is used for getting the actual position, necessary for the cam controller. Only encoders
with an SSI interface can be connected to CamCon DC40. The SSI interface is a common interface for
absolute single and multiturn encoders. The CamCon supplies the measuring system with 24Volt via
this interface. To read the data, CamCon sends a clock signal with an RS422 level to the encoder. The
encoder the answers synchronously with the output (data) of the position in Gray code. The frequency
of the clock signal depends on the length of the cable connecting ecoder and CamCon. The cable
length can be set at the CamCon DC40.
Note: The data protocol corresponds with the Stegmann SSI Norm.
Tp
= clock impulse
Tmono
= mono flop time 25µs
Attention:
Use only a covered double entwired connection cable. The
wiring should not be near power current lines. Ground the
covers at both sides.
4.3. The outputs
The CamCon can have up to 32 short circuit proof outputs, depending on its version. They emit 24Volt
high active signals and are not potentially free. Outputs 1 to 16, as well as outputs 17 to 32 of the unit
have to be supplied with 24Volt, since the supply of the outputs has been divided for a better
distribution.
4.3.1. The 40mA outputs (only CamCon device with aluminium back wall)
If all outputs are activated, not more than 40 mA permanent current in the complete temperature range
should be extracted per output, else the unit will deactivate with an error message. If a higher starting
performance is required, one has to know that the outputs are combined in 4 groups, each group
consisting of 8 outputs. Within each group, 480 mA permanent current at a surrounding temperature of
50°C, and at a surrounding temperature of 25°C even 700mA permanent current is available. This
permanent current can be dirtributed freely within a group, as long as the single output current of 300
mA is not overshot (see chapter "7.1.15. Number of outputs" on page 27).
4.3.2. The 500mA outputs
At a surrounding temperature of 25°C even 500mA permanent current is available for each output. If
your outputs are overloaded or short-circuited the unit will deactivate with an "out-err" message
(see chapter "7.1.15. Number of outputs" on page 27).
Attention: With inductive loads the outputs have to be switched with free wheeling
diodes.
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Digital Cam Switch Unit
CamCon DC40
4.4. The inputs
The CamCon has, concerning each upgrading level, up to 16 inputs. These inputs work with high
externally active 24Volt signals and are not potentially free towards the CPU.
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 "7.1.14. Number of inputs" on page 27, chapter
"7.1.2. The encoder resolution" on page 23, chapter "7.1.20. Setting of the external program selection"
on page 27 and chapter "7.1.17. Keyboard lock" on page 27.
4.5. 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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Digital Cam Switch Unit
CamCon DC40
5. Outline of the operator terminal
.
5.1. Frontview CamCon DC40
DIGITRONIC
CamCon
5.2. The LED - output display
The output display shows the current state of the first 16 outputs (outputs 1-8 and A-H = 9-16), or
outputs I-P = 17-24 and Q-X = 25-32. If a LED is lit, the corresponding output is active. To switch
through the display range, press the
message
(for outputs I-P), or
key. While viewing outputs I-P or I-X, the display shows the
(for outputs I-X).
5.3. The seven-segment display for position and speed (Standard display)
After the activation the seven-segment display always shows the current angular position (when the
encoder is standing still). If the encoder is put into a slow rotation, the display shows the actual
position. With increasing speed, the display switches to display the current speed in rotations/minute.
This switching point is at 5% of the set maximum speed of the analog speed output. Additionally, 5
decimal popints of the 7 segment-display are switched on, while beeing in the current speed mode.
Optimizing the speed display is done during initialisation for the input of system registers (see chapter
7.1. Initialization of the system registers on page 22). This enables psetting a factor to the actual speed
display or to prevent the display from switching from speed to position and vice versa.
Also, you can check the set program number by pressing the
Version: Jan. 09
key, e.g.
.
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Digital Cam Switch Unit
CamCon DC40
5.4. The keyboard
The foil-covered keyboard resists dirt and can be cleaned with solvents. The keys have a pressure
point that can be felt, as well as an accoustic input confirmation. See also chapter 7.1.17. Keyboard
lock on page 27.
5.4.1. Outline of key functions
=
is used to increase the input values by 1 during programming and initialization. Keeping
the key pressed (for about 2 sec.) causes the the values to increase automatically until
released. The speed of the increasing process also increases; this is indicated by a tone
that becomes higher as the speed increases.
You can switch through the output display in the standard display. Here you can switch
through the range of outputs, displayed on the LEDs (only with more than 16 outputs).
=
serves for decreasing of input values by 1 during programming or initialization. Pressing
this key for more than two seconds reduces the input values automatically. The longer this
key is pressed, the faster will the input values reduce. The sound that the unit emits will
become higher to reflect the increase of speed.
By pressing this key for about 2 seconds in the standard display, you can call up a
complete outline of the system registers.
=
initializes the cam programming and switches the input type during the cam programming.
Pressing and releasing this key in the standard display shows the current program
number.
=
starts initialization and selects system registers during the initialization, or displays an
outline of all system registers.
By keeping this key pressed (about 2 sec.) in the standard display, you switch to the input
of the dead time programming
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6. Commissioning
Before activating the device for the first time please check the wiring of the device (siehe Kap. 4.
Electrical connections).
Attention: With induced loads the outputs have to be switched with a freewheeling diode.
Covers or inductivities very close to the device inside the switchboard have to
be switched with a deletion unit as do those that are wired to or influence the
wiring of the device.
After the activation of the CamCon, the device reports with a high pitched tone and the display
message
, i.e. an internal system check starts and the system is run up (e.g. the proof
total of the EEPROM and the EPROM is calculated). This process takes several seconds. After a
successful installation of the system the standard display is shown, i.e. either the current position, the
current speed or an error message is displayed. If the system registers are adjusted to the measuring
system, no error message should be display (with a correct wiring).
After the first activation of the supply voltage, the program memory is in an undefined state. Because of
this you have to start a complete deletion before commissioning
If the complete deletion is finished, you can start with the programming of the CamCon
(see chapter 7. Programming on page 22).
6.1. Complete deletion
1.
Activate the device (supply with voltage, +24V DC).
2.
Wait until the display shows either a number or an error message, e.g.
3.
Press the
key four times.
4.
Press the
key four times.
5.
Press the
key (about 2sec.), until
is displayed.
6.
Press the
key (about 2sec.), until
is displayed.
7.
Release the
.
key.
After a short while the standard display is reactivated. This waiting time depends on the size of the
EEPROM used, since the memory has to be formated. When using a 32k - EEPROM, it increases e.g.
to 2 min. After this, the complete deletion is finished. All cams are erased, and all system registers
have the standard value.
Attention:
Erased memory cannot be restored.
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CamCon DC40
7. Programming
Starting point of the programming is always the standard display (position or speed display).
For your CamCon to be able to function, you have to adjust the system registers of the unit to your
maschine. This is described in the following chapters. If you have entered the inputs of the system
registers, the CamCon is ready for cam programming and should display no further error messages.
7.1. Initialization of the system registers
.
7.1.1. User keys for system registers
In order to be able to program the system registers, the following key sequence must be maintained:
1.
Press the
key four times.
2.
Press the
key four times.
3.
Keep the
key pressed for about 2 seconds, until the display shows
.
To select the different system registers one by one, press the
key once. The selection of the
system registers is only possible in increasing order. If you have somehow skipped a register, you have
to leave the initialization and repeat the entire process. Your previously entered values are still there,
however.
When you reach the last system register e.g.
after pressing the
or
, you leave the initialization
key, and you return to the standard display (position or speed display) mode.
The initialization can be left at any time by pressing the
key, but all changes made are saved.
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Digital Cam Switch Unit
CamCon DC40
7.1.2. The encoder resolution
The display
shows the resolution of the encoder in steps per rotation. The CamCon
operates with a standard encoder with a resolution of 360 steps per rotation. In this case, an
adjustment of the input value is not necessary. Otherwise, CamCon can be adjusted to the encoder
with the
or the
key. You can choose between several set resolutions that all correspond with
common encoders: 256, 360, 512, 1000, 1024, 2048, 4096 and 8192 steps. If values in the high range
of the resolution cannot be adjusted, there is not enough available memory. Should this be the case
you need to upgrade the device by extending the memory.
Please note the chapter 11. Calculation the RAM storage-requirement for !
Attention: If the display shows
instead, a speacial measuring system was activated by
a PC. In this case you can only change the encoder resolution with the PC
Please note ! If the
key is pressed too long (while the display is showing the encoder
resolution), you initiate a complete deletion !
7.1.3. The electronic gear
After having pressed the
key the display shows
. Here the display shows the effective
(the one visible for the user) measuring range of the encoder. Because of this the process with the
electronic gear is a transformation of the measuring range. The standard translation is that of 1:1 , i.e.
at the encoder resolution of 360 steps, the gear is set to
key, you can change this translation.
Example:
. By pressing the
or the
At a full rotation of an encoder with a resolution of 360 steps, a machine covers 1000mm.
the display of the position is no longer in
After the adjustment of the gear to
(angular) degrees, but in mm. The display will no longer change in steps of 1, since the
resolution of the encoder remains unaffected.
If you select e.g.
, the actual position is calculated down to a measuring
range of 100. The position display is now done in cm, but a floating-point representation is
not possible.
7.1.4. The actual position hysteresis
By pressing the
the display shows
. This value is needed to prevent the flashing of the
outputs at unexact acquisition of the actual position. The exact value can only be determined through
experiments, but it should be as low as possible or always 0. By pressing the
or the
key, the
hysteresis can now be set to a value between 0 and 1/4 of the total resolution. The hysteresis can have
a maximum value of 255 impulses.
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CamCon DC40
7.1.5. Measuring system control
By pressing the
the display shows
. This value is needed to prevent the maximum
speed for measuring system control (Impulses per cycle) The value to be entered is calculated from
the actual cycle time of the CamCon, from the physical solution of the measuring systems and the
speed of the machine.
Note: The resolution must be set as a physical value. If e.g. a measuring system with 4096 impulses
is set and the displayed value is transformed to 3600 impulses by the gear, you must set the
"resolution"-value of the formula to 4096.
Example: Cycle time = 0.5ms / solution = 360 / speed of the machine = 180 min -1.
Value =
Resulution * machine speed
* cycle time + safety reserve
60 * 1000
360 * 180
60 * 1000 * 0.5 + 5 = 5.54 ≈ 6
The result is rounded up and entered. If the CamCon now registers an actual value jump of more than
6 impulses, an error message "Pos-Err:5" is created.
If a zero is entered, the control is switched off. The maximum value is 9999 impulses.
7.1.6. Changing the rotation direction
Press the
key and
appears on the display. The message
shows that the
encoder, in respect to the wave of clockwise movement, counts upwards. By pressing the
the
key or
key you can reverse the encoder' s direction of rotation. The display then shows
.
7.1.7. The zero point correction
If you press the
key, the display shows e.g.:
. 123 represents the current angular
position of the encoder. After having positioned the drive to mechanical "0", you can also shift the
current angular position to "0" by pressing the
key or the
electronic zero point coincide. The display shows
key, so that the mechanical and the
.
7.1.8. The speed factor
After pressing the
key, the display shows e.g.:
calculation of the speed. By pressing the
range of 0.000 to 9.999.
or the
. Here you enter the factor for the
key you can in- or decrease this value in the
Normally the speed is displayed through the number of increments or impulses per second. If you want
the speed displayed e.g. in rotations per minute or in the number of pieces per minute, you have to
enter a randomizing factor. This factor is multiplied with the calculated speed value, and that result is
seen on the display.
Example 1:
A rotation encoder with 512 steps supplies 512 increments per minute, which means
that the gear runs with 1 rotation per minute. The CamCon measures 512/60 = 8,533
increments per second.
To receive a display in rotations per minute enter the factor 1/8,533 = 0,117.
Example 2:
A rotation encoder with 360 steps supplies 360 increments per minute, which means
that the gear runs with 1 rotation per minute. The CamCon measures 360/60 = 6
increments per second.
Enter a factor of 1/6 = 0,166 to have the display remain in rotations per second.
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CamCon DC40
7.1.9. Adjusting the range of the speed display
Press the
key, and the display shows e.g.:
. In this system register you enter the
maximum rotation speed of your gear or the speed of the movement. The input serves the adjustment
of the speed display. By pressing the
or the
key, you can set this value in the range of 0 to
9999. This value controls the speed, at which the position display switches to the speed display. This
switching always occurs at 5% of the value entered here, so with 1000 min -1 it switches at 50 min -1.
If your device has an analog output, through which an analog signal is emitted, that is proportional to
the speed, this value is used for the calculation of the output voltage. An input of e.g.: 1000 min -1
means that at +/-1000 min -1 the analog output voltage has reached its maximum value (100%) of
+/-10V.
7.1.10. Accuracy of the speed display
By pressing the
key, the display shows e.g.:
. During operations the speed display usually
fluctuates a little. These fluctuations are accounted for in the measuring priciple for the speed, since it
is a scanning system. In this system register you can limit these fluctuations to a maximum value. It is
a damping through a low pass that results in a smoothing of the display, which means that an
averaging process is put into operation. The lower the input value is, the quieter is the speed display. In
practice, you will always find a compromise between the dynamics of the display and its readability. By
pressing the
or the
key, this value can be set from 0.01 to 9.99.
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Digital Cam Switch Unit
CamCon DC40
7.1.11. Display type
By pressing the
key, the display shows e.g.:
. If you do not want your display to switch
at 5% of the maximum speed value, you can set this option in this system register by pressing the
or the
key. You can choose among three display types.
When the speed value reaches 5% of the maximum rotation value, the position
display switches automatically to the speed display.
The display only shows the speed.
The display only shows the position.
key again makes the display show e.g.:
Pressing the
. In this system register you can
set an input, with which the display can be switched from speed display to position display. With the
key or the
key, you can select the desired input number. You can only select this option, if you
chose the display types
or
. Activating an input signal e.g. with the
display type switches the display to the speed display. If no inputs are available, this
function is not possible.
7.1.12. Setting the cable legth
Press the
key; the display shows
. Using the keys
and
you can set the
conduction length between the encoder and the CamCon, in meters. This is necessary, since the cable
length determines the maximum possible speed of serial data transmission. The larger the set cable
length, the larger is the cycle time of the transmission and the slower is the data traffic. The cable
length can be set to a maximum of 1000m.
Attention: With cables exceeding 300m in length, use an encoder that is adjusted
correspondingly.
7.1.13. Setting the cycle time
Press the
key again and the display shows
. This indicates that the device is operating with
the shortest possible cycle time. Using the keys
and
you can change this cycle time, e.g. when
you are programming a large number of outputs with delay time or with a high encoder resolution and
need longer single delay times. These depend on the available memory and the cycle time (see
chapter 11. Calculation the RAM storage-requirement for). A noticable change occurs only when the
set value lies above the current cycle time.
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Digital Cam Switch Unit
CamCon DC40
7.1.14. Number of inputs
By pressing the key
, the display shows e.g.:
. Here you enter the number of inputs of
the cam switch unit. You can modify the input number with the keys
and
. The CamCon DC40
can manage a maximum of 16 inputs. The number of inputs should always excactly meet the number
of electrcal inputs since the CamCon's short-circuit-detection reacts ocxorresponding to the number of
inputs.
7.1.15. Number of outputs
By pressing the
key, the display shows e.g.:
. Here you can enter the number of
outputs of the CamCon. You can modify this value with the keys
manage 8,16,24 or 32 outputs.
and
. The CamCon DC40 can
7.1.16. Number of outputs with speed compensation
By pressing the
key, the display shows e.g.:
. Here you can enter the number of
outputs (of the CamCon) with dead time compensation. This value can also be modified with the keys
and
.
7.1.17. Keyboard lock
By pressing the
key, the display shows e.g.:
. Here you may define an input that locks
the keyboard to prevent unauthorized programming. You can enter the input for the keyboard lock with
the
and
keys. A zero means the keyboard cannot be locked. This function is only possible if an
input is available.
7.1.18. Input for error reset
With the positive edge (+24V DC) on this input e.g.:
and 5 but not an "Out-Error".
, the CamCon resets an Pos-Err:1,2,3
7.1.19. Enable input
By pressing the
key, the display shows e.g.:
Here you may define an input that lock or
unlock and/or enable the outputs. A signal of +24V DC on this input enable the cam output, a signal of
0V lock and/or disenable the outputs. If the input number is "0", this function is switch off and the
outputs are always enabled.
7.1.20. Setting of the external program selection
By pressing the
key, the display shows e.g.:
. Here you can set the number of programs
you can select externally. You can modify the number of programs with the keys
DC40 offers you the possibility to manage up to 999 programs.
and
. CamCon
By pressing the
key, the display shows e.g.:
. In this system register you have to define
an input, used as a take-over-impulse. It has to be selected with regard to the fact that there have to be
enough free inputs to be able to send the program number. The program number is a binary number,
which is sent at the inputs after the take-over-impulse, whereas the LSB is the input after the takeover-impulse. Thus the inputs for the program selection are flexible. By pressing the
or the
you can now set the desired input number. This input is only possible if an input is available.
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Digital Cam Switch Unit
CamCon DC40
7.1.21. Actual position preset or external shifting of the zero point
By pressing the
key, the display shows e.g.:
. Here you have the possibility to set the
actual position to a previously set value (Preset) by activating an input. By setting the preset value to
zero, you can generate an external zero signal, e.g. to synchronize the position of the maschine with
the actual position of the CamCon DC40. You can set the desired preset with the
and the
You then enter the input of the input number that activates the preset by pressing the
display shows e.g.:
. Enter the desired input number with the keys
and
are available, this input, as well as the preset function, is not possible. By pressing the
you enter the input of the preset type. The display now shows e.g.:
between the two preset types with keys
and
key.
key. The
. If no inputs
key again,
. You can choose
. There are two options available:
"RAM" storage.
The preset value is only copied into the RAM memory of the device, so after
switching the device off and activating it again, your preset value will be gone.
"EEPROM" storage.
The preset value is copied into the RAM memory as well as the EEPROM memory
of the CamCon, protecting the value from voltage failures
Attention:
Storage in the EEPROM memory should only be used, if you activation of the preset
does not occur often and is absolutly necessary. This is because an EEPROM only
has a limited number of writing cycles (100000). Exceeding this maximum number of
writing cycles leads to the destruction of the EEPROM and loss of the program data.
7.1.22. The security or SI output
To be able to watch over the CamCon, e.g. during short cuircuits at the output channels or at errors
with the calculation of the actual position, you have the possibility to program a cam for a specific
output, that means this output is active for all angular positions. After pressing the
, the display
shows the message
. By pressing the
or the
key, you can select an output number,
that will function as an SI output. A '0' means, that no security output has been programmed.
Please note:
The SI output is reset for a short time at program changes.
7.1.23. The rotation direction or FR output
By pressing the
key, the display shows e.g.:
. Here you can select an output that displays
the direction of the encoder rotation. You can select the output number with the keys
and
. The
output is activated at a positive rotation direction and deactivated with a negative rotation direction. If
this value is set to '0', there is no FR ( forwards - reverse ) output.
(see also chapter 7.1.25. The speed hysteresis on page 29)
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Digital Cam Switch Unit
CamCon DC40
7.1.24. The standstill or V0 output
By pressing the
key, the display shows e.g.:
. Here you can select an output that is active
while the encoder is moving and deactivates when the encoder stops. You can select the output
number with the keys
and
. The output is activated at a positive rotation direction and
deactivated with a negative rotation direction. If this value is set to '0', there is no V0 output. (see
alsochapter 7.1.25. The speed hysteresis below)
7.1.25. The speed hysteresis
To be able to used the option of the rotation direction control, you have to set the hysteresis. This value
is needed to prevent the flashing of the outputs at small changes in speed. The exact value can only
be determined through experiments, but it should be as small as possible.
By pressing the
the keys
and
key, the display shows e.g.:
. You can enter the hysteresis value with
.
7.1.26. Setting the serial interface
After the
key was pressed, the display shows e.g.:
. By pressing the
and/or
keys you are able to select the serial interface's comuication mode. You are able to choose between 4
modes of operation, these are: 1. = "Cam-BUS", 2. = "Standard", 3. = "Multiuser" and 4. = "S5-L1". If a
particular mode was set, you ahve ensure yourself of the fact that every device with which a contact
shall be established, also supports the selected comunication mode. Please regard that you have the
possibility to select the type of interface in your order chosing between RS232 or RS485. All four
comunication modes work as well in the RS232 point-to-point comunication as in the 485 BUS
comunication. See also chapter 4.1.6.2. Pin allocation of the serial RS485 interface on page 16 and
chapter 7.1.27. Setting of the unit number on page 30 as well as chapter 4.1.6.1. Pin allocation of the
serial RS232 interface on page 15.
Note: The Ser.Mode is set to "Multiuser" and the devicenumber to "0" by the factory.
7.1.26.0.1. The "Cam-BUS" comunication mode
You have to select this setting, if you have to program or display one or several
devices from several different locations through an RS485 interface (e.g. via programming device type:
DC51/T4 and daughter display CD10).
Attention: All devices using this setting (as well as the PC) have to be equiped with an RS485
interface and a software from at least August 1996 or later
7.1.26.0.2. The "Standard" comunication mode
Standard operation commences only in connection with an interface of the type RS232
and is a point to point communication, i.e. you can only connect a maximum of 2 devices ( DC40 to the
PC ). Because there is not protocol safeguarding in this mode, it should only be used for testing
purposes.
7.1.26.0.3. Der "Multiuser" Kommunikationsmode
This setting only works in connection with an RS485 interface. Unlike the "Cam-BUS"
mode, it is "not" possible to run several display devices
(e.g. progr. device type: DC51/T4 and daughter display CD10) and several PCs at the RS485 BUS
(factory-preset).
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Digital Cam Switch Unit
CamCon DC40
7.1.26.0.4. The "S5 - L1" comunication mode
This setting is necessary to connect the CamCon to a Siemens S5 PLC with L1 BUS.
This is a so-called point to point communication, which means that only the CamCon and the Siemens
S5 CPU can be connected to each other. If ypou want to save the CamCon's data at a PC, the
connection to the S5 CPU has to be interrupted. To the S5 - L1 comunicationmode a connection-set
with TTY-cable, handling component and manual can be ordered (Order No. PC40/S5-L1).
Attention: The interface type has to be specified with your order of the CamCon.
7.1.26.0.5. The "3964(R)" comunication mode
This setting is necessary, if you want to program the CamCon device via the serial
interface with an RK512 procedure. This is a so-called point to point communication. A manual with the
order No. H-RK512e is avaiable for this procedure.
7.1.27. Setting of the unit number
In the Cam-BUS, Multiuser and S5-L1 modes, you have assign unit numbers to all devices linked. After
having pressed the
key, the display shows e.g.:
. You can select a number between 0
and 63 with the
and
keys. Each unit number may only be assigned once, so it is necessary to
speratly select the unit number and the communication mode for every device before connecting the
serial interfaces.
7.1.28. Selecting the programming mode
After having pressed the
key, the display shows e.g.:
. Here you can set the mode for
the cam programming. By using the
or the
key, you switch from programming mode 0 into
programming mode 1. Programming mode 1 is easier to use than programming mode 0, but it is not
possible to program several cams on a single output in programming mode 1.
7.1.29. Analog speed-output
After having pressed the
key, the display shows e.g.:
. Here you can define an analog
speed-output for version 38 or later (requiring aditional analog hardware). By pressing the keys
and
the analog speed output is switched on (=1) - respective off (=0). If it is switched on, the analog
output has to be equalized as shown in the following chapters.
7.1.29.1. Offset match for analog output 1
Note:
This is not longer necessary or possible with the device edition DC40/S5..
Press the
key for about two seconds, until the display shows
. In this configuration, you
are able to eveluate the zero-point of analog-ouput 1. Connect a voltmeter to analog output 1and
correct the voltage using the
possible.
and
key, until the voltmeter displays a value as exact to 0V as
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Digital Cam Switch Unit
CamCon DC40
7.1.29.2. Amplification match for analog output 1
Note:
This is not longer necessary or possible with devices edition DC40/S5..
key for a short time, the display shows e.g.:
. Here you can
After having pressed the
enter (or match) the amplification factor for analog output 1. The maximum of analog output voltage is
±10V. If you desire a shorter voltage range, you can adjust maximum voltage with the
and
keys.
In this setting the CamCon already offers the maximum of positive output voltage. For adjustments,
connect a voltmeter to analog output 1, and use the two keys until the measuring device shows the
correct voltage.
Please note:
An adjustment of the speed display via the amplification match is not recommendable !
see chapter "7.1.9. Adjusting the range of the speed display" on page 25.
7.2. Delay time or speed-compensation
Keeping the
key pressed (for about 2 sec.) in the standard mode lets the display show
. Here you can enter the delay time for output 1 in the range of 0ms to 999ms. By pressing
the
key or the
key, you can change this value in steps of 1 ms. By pressing the
key shortly,
you can proceed to the next output, and so on. The display shows e.g.
. This way you can
enter time factors for every single output, so that they are (de)activated earlier. If you have already
configured an output as a SI-output, it is no longer possible to enter a dead time for this output. You
can abort the programming of the dead time compensation at all times by pressing the
key.
7.3. Cam programming in programming mode 0
.
7.3.1. Program selection
The cam programming and the program selection are initiated as follows:
Press the
key for about 2 seconds, until the display shows e.g.:
.
indicates
key or the
key you have the possibility
that e.g. program 0 is currently selected. By pressing the
to select a program number from 0 to 999. When the desired program number is set, you can exit the
'Cam programming' mode by pressing the
By pressing the
key.
key you can check the selected program number; the display shows
.
7.3.2. Output selection
To initiate cam programming press the
the display shows e.g.:
key during the program selection for about 2 seconds, until
. This indicates that there is no programmed cam on output 1 in the
'Output selection' mode. By pressing the
key or the
key you can now select the output on which
you want to program cams. Automatically scrolling through the the outputs during output selection is
not possible.
If you already selected an output as a special output, you cannot program any cams on this output.
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Digital Cam Switch Unit
CamCon DC40
7.3.3. Searching for cams
By pressing the
key you leave the 'Output selection' mode
search'
. In the 'Cam search' mode
and enter the mode 'Cam
you can search for the cam activation
key. Every time the
key is pressed, CamCon searches the memory for
points by pressing the
activation points of the cams on the corresponding output. If no cam has been programmed,
is displayed.
7.3.4. Setting the preset value
You leave the 'Cam search' mode
and enter the 'Preset' mode
by pressing the
key. By pressing the
or the
key you can now select a value, e.g. 100. This value is the
originator from which cams may either be reconstructed or erased by changing the activation and the
deactivation points.
7.3.5. Shifting the activation point
By pressing the
key you leave the 'Preset' mode
. A pressing of the
key or the
done according to the following system:
A short single pressing of the
and enter the 'Activation point' mode
key shifts the activation point by one step. This is
key will erase the activation point at the previously displayed preset
value, e.g. 100, and then the preset value is increased by 1, e.g. to 101. A short pressing of the
will lower the preset value (100 in our example) by 1 and then set a new activation point at 99.
key
7.3.6. Shifting the deactivation point
Pressing the
key once more leads you from the 'Activation point' mode
'Deactivation point' mode
into the
. CamCon will first search for the deactivation point of the current
). By pressing the
or the
cam (e.g.:
This is done according to the following system:
A single short pressing of the
key the deactivation point is shifted by one step.
key will set a new switching point at the previously displayed preset
value, e.g. 100. Then the preset value is increased by one, e.g. to 101. A short pressing of the
key
will lower the preset value, e.g. 100, by 1 and then delete the switching point 99. The new deactivation
point is then 99. A further pressing of the
key brings you back to the 'Output selection' mode
.
7.3.7. Leaving cam programming
No matter in which programming mode you are, you can always leave cam programming by pressing
the
key and return to the standard display.
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Digital Cam Switch Unit
CamCon DC40
7.3.8. Examples for cam programming in the programming mode 0
.
7.3.8.1. Programming the first cam
Task:
After a complete deletion of the program memory and a successful initialization of the system, a cam
shall be programmed in program 0 for output 2 from 100 to 200.
Solution:
1.
Press the
key (for about 2 sec.), until you enter the 'Program selection' mode:
2.
Press the
key, you enter the "programing mode"
3.
Press the
key to select output 2,
4.
Press the
key, you enter the 'Cam search' mode
5.
Press the
key, for the input of the preselection
6.
Press the
key and keep it pressed until
7.
If you have released the
the
or the
.
.
is displayed.
key too early or too late, you can adjust the preselection to 100 with
key.
Press the
key, the activation point is displayed.
9.
Press the
key to program the deactivation point.
CAUTION!
.
.
8.
10. Press the
key and keep it pressed until the display shows
Do not keep the key pressed too long. It is best to keep the
and then adjust to 200 step by step.
11. Press the
.
.
key pressed until 190
key. You return to the standard display.
Please Note:
When programming the activation and the deactivation points you are working "on line", i.e. if you keep
the
key pressed for too long, the cam will be programmed too long. Although you can correct this
subsequently with the
key, the range between the desired end of the cam and cams entered in
excess is erased. All cams already programmed in this range are lost.
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Digital Cam Switch Unit
CamCon DC40
7.3.8.2. Programming additional cams on an output
Task:
A cam shall be programmed in program 0, on output 2 from 300 to 330 in addition to an already
existing cam, e.g. from 100 to 200.
Solution:
1.
Press the
key (for about 2 sec.), until you enter the 'Program selection' mode:
2.
Press the
key, you enter the 'progrming' mode
3.
key to select output 2,
Press the
already programmed cam.
4.
Press the
key, you enter the 'Cam search' mode
5.
Press the
key for the input of the preselection
6.
Press the
key and keep it pressed until
7.
If you have released the
the
or the
. The display also shows the begin of the
.
.
appears on the display.
key.
Press the
key, the activation point is displayed.
9.
Press the
key to program the deactivation point.
CAUTION!
.
key too early or too late, you can adjust the preselection to 300 with
8.
10. Press the
key and keep it pressed until
is displayed.
Do not keep the key pressed too long. It is best to keep the
and then adjust to 330 step by step.
11. Press the
.
key pressed until 320
key. You return to the standard display.
Please Note:
When programming the activation and the deactivation points you are programming "on line", i.e. if you
keep the
key pressed for too long, the cam will be programmed too long. Although you can correct
this subsequently with the
key, the range between the desired end of the cam and cams entered in
excess is erased. All cams already programmed in this range are lost.
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Digital Cam Switch Unit
CamCon DC40
7.3.8.3. Deletion of a particular cam
Task:
You want to delete the cam from 300 to 330 in program 0, on output 2.
Solution:
1.
Press the
key (for about 2 sec.), until you enter the 'Program selection' mode:
2.
Press the
key, you enter the 'programing' mode
3.
Press the
key to select output 2,
4.
Press the
key, you enter the 'Cam search' mode
5.
Press the
key, the device searches for the start of the next cam.
6.
Press the
key. The preselection
7.
Press the
key to program the activation point. The display shows
8.
Press the
key and keep it pressed until the display shows
CAUTION!
9.
Please Note:
.
. The start of the first cam found is displayed.
.
is displayed.
is displayed.
Do not keep the key pressed too long. It is best to keep the
and then adjust to 330 step by step.
Press the
.
.
.
key pressed until 320
key. You return to the standard display.
By shifting the cam activation point to the cam deactivation point the programmed cam
is deleted. By shifting the activation point beyond the deactivation point deletes the
range after the cam (e.g. from 330 to 350). All cams programmed in this range are
deleted. A new cam will be placed between 330 and 350 when you move the activation
point back to the desired position of 330 !
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Digital Cam Switch Unit
CamCon DC40
7.4. Cam programming in programming mode 1
.
7.4.1. Program selection
The cam programming and the program selection are initiated as follows:
Press the
key for about 2 seconds, until the display shows e.g.:
.
indicates
that e.g. program 0 is currently selected. By pressing the
key or the
key you have the possibility
to select a program from 0 to the highest program number (configured in the plant). When the desired
program number is set, you can exit the 'Cam programming' mode by pressing the
key.
7.4.2. Output selection
key during program selection, you enter the mode of the cam programming. The
If you press the
display shows e.g.
. This indicates that no cam has been programmed on output 1 in the
'Output selection' mode. By pressing the
you want to program cams.
key or the
key you can now select the output on which
7.4.3. Shifting the activation point
By pressing the
key you leave the 'Output selection' mode
point' mode
. A pressing of the
key or the
This is done according to the following system:
A short single pressing of the
and enter the 'Activation
key shifts the activation point by one step.
key will erase the activation point at the previously displayed preset
value, e.g. 100, and then the preset value is increased by 1, e.g. to 101. A short pressing of the
key
will lower the preset value (100 in our example) by 1 and then set a new activation point at e.g. 99.
7.4.4. Shifting the deactivation point
Pressing the
key once more leads you from the 'Activation point' mode
'Deactivation point' mode
into the
. CamCon will first search for the deactivation point of the current
cam (e.g.:
). By pressing the
or the
This is done according to the following system:
A single short pressing of the
key the deactivation point is shifted by one step.
key will set a new switching point at the previously displayed preset
key
value, e.g. 100. Then the preset value is increased by one, e.g. to 101. A short pressing of the
will lower the preset value, e.g. 100, by 1 and then delete the switching point 99. The new deactivation
point is then 99. A further pressing of the
key brings you back to the 'Output selection' mode. If no
cam has been programmed, the display shows
again.
7.4.5. Leaving cam programming
No matter in which programming mode you are, you can always leave cam programming by pressing
the
key. The standard display appears
.
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Digital Cam Switch Unit
CamCon DC40
7.4.6. Examples for cam programming in the programming mode 1
.
7.4.6.1. Cam programming
Task:
After a complete deletion of the program memory and a successful initialization of the system, a cam
shall be programmed in program 0 for output 2 from 100 to 200.
Solution:
1.
Press the
key (for about 2 sec.), until you enter the 'Program selection' mode:
2.
Press the
key, you enter the 'programming' mode
3.
Press the
key to select output 2,
4.
Press the
key for the programming of the activation point
5.
Press the
key and keep it pressed until
6.
If you released the
or the
.
.
.
.
is displayed.
key too early or too late, you can adjust the preselection to 100 with the
key.
7.
Press the
key to program the deactivation point.
8.
Press the
key and keep it pressed until the display shows
9.
If you have released the
with the
10. Press the
or the
.
key too early or too late, you can adjust the deactivation point to 200
key.
key. You return to the standard display.
7.4.6.2. Deletion of cams
Task:
You want to delete the cam 100 to 200 on output 2 in program 0.
Solution:
1.
Press the
key (for about 2 sec.), until you enter the 'Program selection' mode:
2.
Press the
key, you enter the 'Output selection' mode
3.
Press the
key to select output 2,
4.
Press the
key to program the activation point. The display shows
5.
Press the
key and keep it pressed until
6.
If you released the
.
.
. The start of the found cam is displayed.
.
is displayed.
key too early, shift the deactivation point to 200 by repeatedly pressing the
key. If you released the
key too late, do not correct it ! The cam is then already erased.
Shifting the activation point backwards programs a new cam in consequence. This cam should be
deleted.
7.
Press the
key. You return to the standard display.
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Digital Cam Switch Unit
CamCon DC40
8. Outline of operations
.
8.1. Switching the standard display
Press the
key
Display of the output channels I-X
8.2. Initialising the system registers
Standard display position/speed (min -1)
Press the
key 4 times
User key for system registers
Press the
key 4 times
User key for system registers
Hold the
key (2 sec).
Encoder resolution physically
Press the
key
Encoder resolution desired.
Press the
key
Actual position hysteresis
Press the
key
Measuring system control
Press the
key
Encoder rotation direction change
Press the
key
Zero point correctionr
Press the
key
Speed factor
Press the
key
Range adjustment of the speed display
Press the
key
Accuracy of the speed display
Press the
key
Display type
Press the
key
Input of the display change
Press the
key
Encoder cable length of the SSI interface
Press the
key
Preset Cycle time
Press the
key
Number of inputs
Press the
key
Number of outputs
Press the
key
Number of outputs with speed compensation
Press the
key
Input of the keyboard lock
Press the
key
Input for error reset
Press the
key
Enable input for the outputs
Press the
key
Number of inputs for external program selection
Press the
key
Take-over input for external program selection
Press the
key
Value for actual position preset
Press the
key
Input for triggering the actual position preset
Press the
key
Storage of the actual position preset
Press the
key
Security output (Cycle cam)
Press the
key
Rotation direction output
Press the
key
Standstill output
Press the
key
Speed hysteresis
Press the
key
Communication protocol of the serial interface
Press the
key
Unit number
Press the
key
Programming mode
Press the
key
Analog output (software version V38)
Press the
key
Return to standard display
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CamCon DC40
8.3. Delay time programming
Standard display
Press the
key (about 2 sec.)
speed compensation for output 1
Press the
key shortly
Switch forward to output 2
Press the
key shortly
Return to standard display
8.4. Cam programming
Standard display
Press the
key (about 2 sec.)
Program selection
Press the
key shortly
Output selection
Press the
only)
key shortly
Searching for cam activation point (Mode 0
Press the
key shortly
Enter preset position (Mode 0 only)
Press the
key shortly
Shifting the activation point
Press the
point
key shortly
Searching for and shifting the deactivation
Press the
key shortly
Output selection
Press the
key shortly
Select next output
Press the
key shortly
Select previous output
Press the
key shortly
Return to the standard display
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Digital Cam Switch Unit
CamCon DC40
8.5. Display the unit configuration
Standard display (position/speed)
Hold the
key (2 sec)
Software version (Date 10.01.94 or 04)
Press the
key
Number of free cams
Press the
key
Maximum speed compensation in ms
Press the
key
RAM size in kByte
Press the
key
Size of serial EPROM in kByte
Press the
key
Size of parallel EEPROM in kByte
Press the
key
Encoder resolution physically
Press the
key
Encoder resolution desired.
Press the
key
Actual position hysteresis
Press the
key
Measuring system control
Press the
key
Encoder Rotation direction change
Press the
key
Speed factor
Press the
key
Range adjustment of the speed display
Press the
key
Accuracy of the speed display
Press the
key
Display type
Press the
key
Input of the display change
Press the
key
Encoder cable length of the SSI interface
Press the
key
Cycle time in µs
Press the
key
Number of inputs
Press the
key
Number of outputs
Press the
key
Number of outputs with speed compensation
Press the
key
Input for the keyboard lock
Press the
key
Input for error reset
Press the
key
Enable input for the outputs
Press the
key
Number of inputs for external program selection
Press the
key
Take-over input for external program selection
Press the
key
Value for the actual position preset
Press the
key
Input for triggering the actual position preset
Press the
key
Storage of the actual position preset
Press the
key
Security output (Cycle cam)
Press the
key
Rotation direction output
Press the
key
Standstill output
Press the
key
Speed hysteresis
Press the
key
Communication protocol of the serial interface
Press the
key
Unit number
Press the
key
Options
Press the
key
Programming mode
Press the
key
Analog output
Press the
key
Return to standard display
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Digital Cam Switch Unit
CamCon DC40
9. Troubleshooting
...
9.1. Problem: The display remains dark after activation
Possible cause:
The wiring is probably not correct.
Solution:
Check the wiring.
9.2. Problem: The display shows: EE.Err
Possible cause:
The EEPROM's data wsas erased or damaged by malfunctions. One of the present data storage
medias (EEPROM or EPROM) was renewed or is defect.
Solution:
By pressing the
key, all data is erased. During the deletion process the display shows
Please contact your customer's service.
.
9.3. Problem: The display shows: I.Err 1
Possible cause:
The encoder is connected incorrectly.
Solution:
Check the wiring to the encoder, concerning the manual. When the error is corrected, press the
key to clear the error message.
9.4. Problem: The display shows: I.Err 2
Possible cause:
The encoder is not connected or connected incorrectly
Solution:
Check the wiring to the encoder or the input of the encoders resolution. Regard also the encoder's
manual. When the error is corrected, press the
key to clear the error message.
9.5. Problem: The display shows: I.Err 3
Possible cause:
The encoder resolution of the connected encoder is not the encoder resolution set at the device.
Solution:
Check the input of the encoder resolution and the set cable length. Regard also the encoder's manual.
When the error is corrected, press the
key to clear the error message.
9.6. Problem: The display shows: I.Err 5
Possible cause:
Measuring system control has triggert. The CamCon detected an inadmissible step of the actual value.
The measuring system is possibly wrong.
Solution:
Test the input of the measuring system's preset and the set cable length, or increase the admissive
actual value steps. See also chapter "7.1.5. Measuring system control" on page 24 and regard the
measuring system's manual. When theerror is corrected, press the
Version: Jan. 09
key to clear the error message.
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Digital Cam Switch Unit
CamCon DC40
9.7. Problem: An error happens during operation.
The display shows:
I.Err 1, I.Err 2, I.Err 3 or I.Err 5.
Possible cause:
The encoder'Äs connection cable or the encoder itself is defect. A cable without shielding or twin wiring
was used. Also the popsition of the connection cable, e.g. next to a strong electro-magnetic
interferance point (e.g. high-voltage cable, motor-cable) can cause an I-Error.
Solution:
Check the encoder's wiring or the change the encoder device. Build up covers or lay the connectioncable elsewhere. Please also regard the encoders manual.
When theerror is corrected, press the
key to clear the error message.
9.8. Problem : The display shows: A-Err
Possible cause:
Your outputs are overloaded or have short circuited. Check the wiring and connected power, as well as
possible inductive loads that are operated without a free wheel or a deletion unit.
The number of entered inputs is not correct.
At an external interface module (e.g. DC91/IO or DC16/IO) the power supply failed.
Solution:
Check the wiring and the connection-cable as well as possible inductive loads, which are run without a
free wheel or a deletion unit.
See chapter 4.3. The outputs on page 17.
See chapter 7.1.14. Number of inputs on page 27.
When the error is corrected, press the
message
key to clear the error message. During this time the
appears for a short time. CamCon tries to reset the outputs during this time.
Attention: Infavourable cable routing can lead to the deactivation of the outputs, since it
builds up a potential that is redirected into the outputs at the closing of a
contact. With induced loads the outputs have to be switched with a
freewheeling diode. Covers or inductivities very close to the device inside the
switchboard have to be switched with a deletion unit as do those that are wired to or
influence the wiring of the device.
9.9. Problem: Outputs do not react
Possible cause:
An error message is displyed.
No power supply is connected to the outputs.
The enable input is not aktiv.
The controll - inputs of the CamCon are locked by an S5 or an S5L1 respective 3964r interface.
Solution:
Check the displayed error-message.
Connect the power supply.
Enable ths Outputs with the enable input, see also chapter 7.1.19. Enable input on page 27
Un-lock the controll-inputs.
See also the S5-L1-coupling's manual.
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
9.10. Problem : The display shows: t1.Err
Possible cause:
Every change in the system setting influences the available memory. Your changes of the system
parameters (e.g. increasing the encoder resolution) have shifted an already programmed speed
compensation above the memory range. At every further pressing of a key, the display shows output
numbers concerned.
Solution:
This error can be recovered by changing the corresponding speed compensation or increasing the
cycle time.
Please also regard chapter 11. Calculation the RAM storage-requirement for on page 45.
9.11. Problem : The display shows: E.Full
Possible cause:
Too little memory in the EEPROM available for cam programming
Solution:
Please contact your customer service. Also, read the chapter 10. Calculation EEPROM cam storage
on page 44.
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Digital Cam Switch Unit
CamCon DC40
10. Calculation EEPROM cam storage
In the CamCon you have the opportunity to extend the EEPROM Cam storage. The storage space
required for programming is influenced by the following factors:
1. Basic requirement
2. Per cam
3. Per set delay time for Speed Compensation
4. Per name for an output
5. Per set key / code
6. For a special measuring system
7. For direct or ”actual” program selection
8. Per set program name
9. Per line of the OP function
= 256 Bytes
= 12 Bytes
= 12 Bytes
= 24 Bytes
= 66 Bytes
= 66 Bytes
= 12 Bytes
= 48 Bytes
= 72 Bytes
The value is generated by the CamCon with the following formula:
Storage requirements in Bytes
Example 1:
=
+
+
+
+
+
+
+
+
Basic needs
Number of cams * 12
Number of delay times for Speed Compensation * 12
Number of output names * 24
Number of user keys * 66
66 when the special measuring system is available.
12 when "on Pos" program selection is set.
48 * number of set program names.
72 * number of set lines of the OP function.
The Cam Switch Unit is supposed to have 8 Programs each with 16 cams and Speed
Compensation for 16 outputs.
Storage requirement in Bytes = 256 Bytes + ( 8 Programs * 16 * 12 Bytes ) + ( 16 * 12 Bytes )
Storage requirement = 1984 Bytes
Example 2:
The Cam Switch Unit is supposed to have 20 programs each with 16 cams and 16
delay times for Speed Compensation.
Storage requirement in Bytes
=
+
+
+
+
256 Bytes
( 20 Programs * 16 * 12 Bytes )
( 16 TZK * 12 Bytes )
( 16 Output names * 24 Bytes )
( 1 User keys * 66 Bytes )
Storage requirement = 4738 Bytes
Warning:
Through alterations in the storage structure of the CamCon software, the extent to
which storage capacity is used up can differ from software version to software version!
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Digital Cam Switch Unit
CamCon DC40
11. Calculation the RAM storage-requirement for CamCon
The required RAM-main storage (not similar to the constand value - Camstorage or the EEPROM)
depends on 7 factors:
1. Standard consumption
2. Number of outputs
3. Cycle time
4. Actual value/measuring system
resolution
5. Maximal Speed-compensation
6. Mode of program selection
(approximately 100000 Byte)
( 8 to 200 in steps of 8 outputs).
(displayed in miliseconds).
(displayed in impulses)
( 0 to 9999.9 in steps of 100 microseconds).
(the double ammount of storage is required ).
( See also chapter "7.4.1. Program selection" on page
36).
( EE-Prom - storage size in Byte for Cache ).
7. Size of the EE-Prom storage
The RAM - storage requirement is calculated by the following formula:
storage requirement in Bytes =
standard consumption +
Number of outputs * IActual value resolution.* ( 2 If program Mode not slow )
+
8
max. delay-time * 4
+ EE-Prom size
cycletime
Example 1:
The camswitch with a resolution of 360°, an EE-Promstorage of 32kByte, 16 outputs, a
speed-compensation of 1000ms and a cycletime of 250µs needs:
Storage requirement in Bytes = 100000 +
16 * 360
1000 * 4
+ 0.250 + 32768
8
Storage requirement in Bytes = 100000 + 720 + 16000 + 32768
Storage requirement in Bytes = 149488 = ca. 150kByte
Example 2:
The camswitch with a resolution of 8192°, an EE-Promstorage of 48kByte, 64 outputs,
a speed-compensation of 500ms and a cycletime of 250µs, needs:
64 * 8182
500 * 4
+ 0.250 + 49152
8
Storage requirement in Bytes = 100000 + 65536 + 8000 + 49152
Storage requirement in Bytes = 100000 +
Storage requirement in Bytes = 222688 = ca. 220kByte
Note:
If the required RAM - storage requirement greater than the CamCons total ammount of
storage, you need to reduce the measuring system's resolution.
Attention: Changings in the storage-structure of the CamCon software the storage requirement can
alternate at different software-versions!
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Digital Cam Switch Unit
CamCon DC40
12. Technical data
Multi functionaal display for programming ............... 7- segment, 5 digits, 13mm
Number of outputs ................................................... 8, 16, 24, 32.
Analog output........................................................... for speed display (optional).
Display of the output states...................................... one LED for each of 16 outputs, can be switched to
another 16 outputs
Number of programmable cams .............................. 150, optionally 600, 2500, 3700 or 10500, as per
size of the EEPROM
Number of programs................................................ 999
Cycle time ( switching speed ) ................................. from 100µs on, is adjusted according to the needs
(optimized)
Dead time compensation (DTC) .............................. can be adjusted separately for each output
Adjustment range of the DTC .................................. 0 up to 999ms, differs with encoder type and
memory
Accuracy of the DTC................................................ +0 to -1 steps
Encoder input........................................................... synchronous serial (SSI), parallel data input, gray
coded
Measuring system SSI ............................................ AAG6007 (standard) AAG612-2048, AAG6124096, AAG612-8192, AAG626 oder AAG66107.
Zero point correction ................................................ electronic adjustment by CamCon
Rotation direction of the encoder ............................. is programmed by CamCon
Length of the connection cable
between the encoder and CamCon ......................... 300 m
Data security / storage ............................................. EEPROM
Supply voltage.......................................................... 24V DC ± 20 %
Encoder supply ........................................................ 24V DC through the supply voltage of the CamCon
Current absorbtion ................................................... 300mA without encoder and outputs
Output voltage.......................................................... +24V DC, plus-switching
Output current .......................................................... 500mA per output, short circuit proof permanent
current (see chapter 4.3. The outputs)
Connections for:
Encoder.................................................................... through plug block pins
Voltage supply.......................................................... through plug block pins
Cam outputs ............................................................ through plug block pins
Operating temperature............................................. 0°C to +55°C
Cover type for:
Front plate / full sight gate........................................ IP 67 / IP 55
Cabinet..................................................................... IP 54
Dimensions .............................................................. see fig. page 12
Front gate part ......................................................... 138+1 x 138+1mm
Cabinet (switch plate cabinet by DIN 43700) ........... 144 x 144 x 63mm (WxHxD)
Cover of front plate .................................................. Full-sight gate, can be locked with security
key(optional).
Weight...................................................................... about 1000g
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Digital Cam Switch Unit
CamCon DC40
13. Key word table
3964(R) .................................................................................................................................................. 30
Activation point, Shifting................................................................................................................... 32; 36
Actual position preset............................................................................................................................. 28
Amplification match for the analog outputs............................................................................................ 31
brake functions ...................................................................................................................................... 11
Cable covers .......................................................................................................................................... 12
Cable length, Setting.............................................................................................................................. 26
Cam programming ..................................................................................................................... 31; 36; 39
Cam programming additional, Examples............................................................................................... 34
Cam programming, Examples ............................................................................................................... 33
Cam-BUS............................................................................................................................................... 29
CE ............................................................................................................................................................ 2
centre pressure...................................................................................................................................... 11
Commissioning ...................................................................................................................................... 21
Complete deletion .................................................................................................................................. 21
comunication mode................................................................................................................................ 29
Connections, electrical........................................................................................................................... 13
Cycle time, Setting ................................................................................................................................. 26
Deactivation point, Shifting .............................................................................................................. 32; 36
delay time............................................................................................................................................... 31
Delay time compensation, Effects ........................................................................................................... 8
Delay time, Calculation .......................................................................................................................... 10
Delay time, Programming ...................................................................................................................... 39
Dimensions ............................................................................................................................................ 12
Display ................................................................................................................................................... 19
Display type............................................................................................................................................ 26
EEPROM cam storage, Calculation....................................................................................................... 44
EEPROM, error...................................................................................................................................... 41
Enable, Input.......................................................................................................................................... 27
Encoder.................................................................................................................................................. 17
Encoder resolution ................................................................................................................................. 23
Error Reset, Input................................................................................................................................... 27
FR output ............................................................................................................................................... 28
Gear, Electronic ..................................................................................................................................... 23
Grounding pins....................................................................................................................................... 12
Hysteresis, Actual value......................................................................................................................... 23
Hysteresis, Speed.................................................................................................................................. 29
I.Err. ....................................................................................................................................................... 41
Initialization, System registers ............................................................................................................... 22
Input wiring............................................................................................................................................. 18
Inputs, In general ................................................................................................................................... 18
Inputs, Number ...................................................................................................................................... 27
Installation.............................................................................................................................................. 12
Installation procedures........................................................................................................................... 12
Keyboard................................................................................................................................................ 20
Keyboard lock ........................................................................................................................................ 27
Leaving cam programming .................................................................................................................... 32
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Digital Cam Switch Unit
CamCon DC40
LED - output display............................................................................................................................... 19
Measuring system control ...................................................................................................................... 24
millenium.................................................................................................................................................. 2
Multiuser ................................................................................................................................................ 29
O-Err. ..................................................................................................................................................... 41
Offset match for the analog outputs ...................................................................................................... 30
Operation, Outline.................................................................................................................................. 38
Operator terminal, Outline ..................................................................................................................... 19
Output selection ............................................................................................................................... 31; 36
Output, analog speed-output ................................................................................................................. 30
Output, lock............................................................................................................................................ 27
Outputs .................................................................................................................................................. 17
Outputs, 40mA....................................................................................................................................... 17
Outputs, 500mA..................................................................................................................................... 17
Outputs, Number ................................................................................................................................... 27
Outputs, speed compensated, Number ................................................................................................. 27
PDF - File................................................................................................................................................. 2
Pin allocation.......................................................................................................................................... 13
Pin allocation, Analog output ................................................................................................................. 13
Pin allocation, Inputs.............................................................................................................................. 14
Pin allocation, Outputs ........................................................................................................................... 14
Pin allocation, SSI measuring system.................................................................................................... 13
Pin allocation, Voltage supply ................................................................................................................ 15
Preset..................................................................................................................................................... 28
Preset value, Setting.............................................................................................................................. 32
Program selection............................................................................................................................ 31; 36
Program selection, External................................................................................................................... 27
Programming ......................................................................................................................................... 22
programming mode 1, Examples........................................................................................................... 37
Programming mode, Selection .............................................................................................................. 30
RAM, storage requirement, calculation.................................................................................................. 45
Range adjustment, Speed display ......................................................................................................... 25
RK512 Prozedur, serial.......................................................................................................................... 30
Rotation direction output ........................................................................................................................ 28
Rotation direction, Switching.................................................................................................................. 24
S5 - L1 ................................................................................................................................................... 30
Searching for cams................................................................................................................................ 32
Security output ....................................................................................................................................... 28
Ser.mode ............................................................................................................................................... 29
Serial interface ....................................................................................................................................... 15
Serial interface RS232 ........................................................................................................................... 15
Serial interface RS485 ........................................................................................................................... 16
Serial interface, setting .......................................................................................................................... 29
SI output................................................................................................................................................. 28
Speed compensated outputs, Number .................................................................................................. 27
Speed compensation ............................................................................................................................. 31
Speed Compensation, Effects ................................................................................................................. 8
Speed display, Accuracy........................................................................................................................ 25
Speed factor........................................................................................................................................... 24
Standard ................................................................................................................................................ 29
Standard display, Switching ................................................................................................................... 38
Standstill output ..................................................................................................................................... 29
System registers, initialising................................................................................................................... 38
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Automationsanlagen GmbH
Digital Cam Switch Unit
CamCon DC40
Table of contents ..................................................................................................................................... 3
Technical data........................................................................................................................................ 46
Troubleshooting ..................................................................................................................................... 41
Unit configuration, Display ..................................................................................................................... 40
Unit number, Setting .............................................................................................................................. 30
UP - Date ................................................................................................................................................. 2
User keys ............................................................................................................................................... 22
Welding operations, Safety precautions ................................................................................................ 18
Y2K .......................................................................................................................................................... 2
Zero point correction .............................................................................................................................. 24
Zero point, External shifting ................................................................................................................... 28
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