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Technical Documentation
Twin Line Cell Controller
Motion controller with Soft-PLC
TLCC
Operating system: 1.1xx
Order no.: 00 9844 111 3216
Release: 1.05, 05.05
A product of:
Berger Lahr GmbH & Co. KG
Breslauer Str. 7
D-77933 Lahr
Tel. +49 (0) 7821 946 01
Fax +49 (0) 7821 946 313 http://www.berger-lahr.de
TLCC
1-2 Twin Line Cell Controller
TLCC
Table of Contents
Table of Contents
Twin Line Cell Controller
Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-3
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . V-3
Product names . . . . . . . . . . . . . . . . . . . . . . . . . V-3
Technical terms . . . . . . . . . . . . . . . . . . . . . . . . V-4
Symbol conventions . . . . . . . . . . . . . . . . . . . . . . V-5
1 The cell controller. . . . . . . . . . . . . . . . . . . . . . . 1-1
Scope of delivery . . . . . . . . . . . . . . . . . . 1-1
Documentation and References . . . . . . . . . . . 1-3
Device overview . . . . . . . . . . . . . . . . . . . 1-4
Connections and extensions . . . . . . . . . . . . 1-5
Directives and norms . . . . . . . . . . . . . . . . 1-6
Declaration of conformity and CE mark. . . . . . 1-6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hazard categories . . . . . . . . . . . . . . . . . . 2-1
Safety notes . . . . . . . . . . . . . . . . . . . . . 2-1
Intended use . . . . . . . . . . . . . . . . . . . . . 2-2
Environmental conditions . . . . . . . . . . . . . 2-2
Intended application . . . . . . . . . . . . . . . 2-2
Qualification of the personnel . . . . . . . . . . . . 2-3
3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mechanical data . . . . . . . . . . . . . . . . . . . 3-1
Electrical data . . . . . . . . . . . . . . . . . . . . 3-2
UL 508C license . . . . . . . . . . . . . . . . . . . 3-2
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Electromagnetic compatibility, EMC . . . . . . . . . 4-1
Mechanical installation . . . . . . . . . . . . . . . 4-3
Open / close device. . . . . . . . . . . . . . . . 4-3
Remove / mount mains module . . . . . . . . . 4-4
Replace EEPROM . . . . . . . . . . . . . . . . 4-5
Replace flash disk . . . . . . . . . . . . . . . . 4-8
Mount the TLCC in the control cabinet . . . . . . 4-9
Electrical installation . . . . . . . . . . . . . . . . . 4-10
Connection of the 24 V power supply . . . . . . 4-10
Connecting the in- and outputs . . . . . . . . . 4-11
Connection to the RS232 interface . . . . . . . 4-12
Connection to the CAN interface . . . . . . . . 4-13
Connection to the Ethernet interface . . . . . . . 4-15
Connection to the Profibus interface of the second field-bus module . . . . . . . . . . . . . 4-16
V-1
Table of Contents TLCC
Connection to the CAN interface of the second field-bus module 4-18
Connection to the RS485 interface of the second field-bus module . . . . . . . . . . . . 4-20
5 Service, Maintenance, and Guarantee . . . . . . . . . . . . 5-1
Service address . . . . . . . . . . . . . . . . . . . 5-1
Shipment, storage and disposal . . . . . . . . . . . 5-2
Replace battery . . . . . . . . . . . . . . . . . . . 5-3
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
V-2 Twin Line Cell Controller
TLCC
Lists
Abbreviations
Product names
Inc
LED
RTS
M
OS
PC
PELV
PLC
Abbreviation
AC
ASCII
DC
I/O
EMC
EC
EU
Meaning
Alternating current
American Standard Code for Information Interchange
Direct current
Input/Output
Electromagnetic compatibility
European Community
European Union
Increments
Light Emitting Diode
Run-time system
Motor
Operating system
Personal computer
Protected Extra Low Voltage
Programmable logic controller
Abbreviation
TLCC
TLDxxx
TLCxxx
CoDeSys
Product term
Twin Line Cell Controller
Twin Line Drive
Twin Line Controller
Controller Development
System
Used term cell controller
Twin Line device
Twin Line device
CoDeSys
Lists
Twin Line Cell Controller V-3
Lists TLCC
Technical terms
Drive solution The drive solution encompasses the drive system with Twin Line device and motor and the line's mechanics firmly attached into the drive chain.
Drive system The drive system encompasses the Twin Line device and the motor.
User units A user unit corresponds to the maximum precision at which a distance, speed or acceleration value can be entered.
CoDeSys Programming tool for developing and testing application programs.
CoDeSys conforms to the IEC 61131-3 norm.
Default values Factors set values that have been set before installation for the Twin Line device's parameters
Input device The input device is the PC with the user software that is connected to the
RS232 or Ethernet interface and used for the installation.
Force Change signal states independently of the hardware switch state in the device, e. g. with the user software. The hardware signals remain unchanged.
High/open Signal state of an input or output signal, in idle state the signal voltage is high; high level.
Increment signals Arc steps of a shaft encoder as rectangular pulse trains. The pulses signal the change of positions.
Internal units Resolution of the high level at which the motor can be positioned.
Internal units are given in increments.
Actual position of the drive system The actual position of the drive system refers to the absolute or relative position of the moving components in the system.
Low/open Signal state of an input or output signal, in idle state the signal voltage is low; low level
Node guarding Monitoring the connection at the RS232 interface or at the field-bus interface
Opto-decoupled Electrical signal transmission with galvanic separation
Parameter Device data and values specified by the user
RS232 interface The RS232 plug-in connection is the communications interface of the
Twin Line device for connecting a PC or the HMI manual control unit.
V-4 Twin Line Cell Controller
TLCC Lists
Symbol conventions
Action symbol " 왘 " The action symbol denotes instructions to be followed step-by-step in the order given. If the device reacts in a notable manner due to an instruction step, then this will be noted following the description of the action. This gives you a direct feedback on the proper execution of an operative step.
Bullet point "
웇
" Bullet points list the individual points of an information group. If a series of operative steps or actions is listed, then the first step to be taken is in the first place.
Menu paths " ⇒ In the Twin Line Control Tool user software an action can be started by
"Menu
⇒
...". For example "File
⇒ menu saves data from the PC memory to the data carrier.
This symbol brings your attention to general topics that provide further information on the device.
This symbol marks text passages that contain information which may need to be further discussed with your local sales partner.
Twin Line Cell Controller V-5
Lists TLCC
V-6 Twin Line Cell Controller
TLCC
1
1.1
The cell controller
Scope of delivery
The cell controller
Bild 1.1
TLCC scope of delivery
Cell controller scope of delivery The scope of delivery of the TLCC Twin Line Cell Controllers includes:
Amount Item
1 Twin Line Cell Controller with RS232, Ethernet and CAN interfaces
Order number
8650 5000 000
6 with additional Profibus-DP interface with two additional Profibus-DP interfaces with Berger Lahr Product Insert
Terminals for I/O connections
8650 5000 004
8650 5000 005
0000 210 2200
왘 Inspect the delivery for completeness.
Save the original packing material in case the device has to be sent back to the manufacturer for a repair or update.
Twin Line Cell Controller 1-1
The cell controller TLCC
Accessories Accessory parts for the cell controller are:
Item
CoDeSys documentation
CoDeSys & TLC 6xx Target & TLCC Target
Field-bus cables for modules
CAN,
RS485
CAN terminal, 9-pin socket
CAN terminal, 9-pin plug
RS232 programming cable 5 m
RS232 programming cable 10 m
Spare part storage battery TLCC
Order number
5920 0000 030
6250 1102 600
6250 1446 yyy
1)
6250 1455 xxx
2)
6250 1518 002
6250 1518 003
6250 1441 050
6250 1441 100
8620 6999 001
1) Cable length yyy: 005, 015, 030, 050: 0.5 m, 1.5 m, 3 m, 5 m;
2) Cable length xxx: 003, 005, 010, 020, 3 m, 5 m, 10 m, 20 m, longer cable lengths available upon request.
1-2 Twin Line Cell Controller
TLCC The cell controller
1.2
Documentation and References
Manuals CoDeSys; Manual on SPS program development with CoDeSys,
German, English
Following installation of the CoDeSys software, the manual can be found in the installation directory.
Device manuals for the Twin Line devices
BERGER LAHR manuals on the field-buses:
CAN
CANOpen
DeviceNet
Profibus-DB
Interbus-S
RS232
RS485
EMC Information and help on installation of and electromagnetic compatible assembly of
BERGER LAHR motor drives, order no.: 9844 1113 075
References Industrial Ethernet, Auf dem Weg zum Industriestandard
Vogel Verlag, Würzburg 2001
ISBN: 3-8259-1910-2
Interessengemeinschaft CAN
(CAN syndicate)
Controller Area Network
Grundlagen, Protokolle, Bausteine, Anwendungen
Konrad Etschberger
Carl Hanser Verlag, München, 2000
ISBN: 3-4461-9431-2
DIN EN 61131
Speicherprogrammierbare Steuerungen (Programmable logic controllers)
CAN in Automation (CiA)
Am Weichselgarten 26
D-91058 Erlangen www.can-cia.de
Twin Line Cell Controller 1-3
The cell controller
1.3
Device overview
TLCC
1-4
Bild 1.2
Twin Line cell controller TLCC
The Twin Line cell controller (TLCC) is a motion controller with an integrated, powerful soft-PLC in a Twin Line casing. The device is "Web enabled" by an integrated Ethernet connection. The possibility to plug in
3 additional communication modules allows this controller to meet all communication requirements. The CoDeSys-PLC libraries, the drive library, and the user interface are identical to the Twin Line TLC6xx power electronics. This eases the change-over from a freely programmable single axis control to multiple axes control.
Primary use The Twin Line cell controller is used primarily in:
Closed production cells that require drive and PLC functions. The cell controller can in part replace conventional PLCs in such production cells.
Applications that require coordinated or independent movements such as pick & place, handling, assembly, verifying.
Applications that need a connection to the corporate network.
Applications that involve a lot of production data.
The PLC and movement functions integrated into the devices are freely programmed using the programming environment CoDeSys according to IEC 61131-3. The RS232 or the Ethernet interface as well as a possible second field-bus interface (CAN bus or Profibus-DP) can be used for transferring the user programs to the device. All IEC 61131-3 programming languages (AWL, KOP, FUP, ST, AS, CFC) can be used for programming. Predefined library functions for programming the TLCC are available for all languages.
There are 32 freely usable, process-capable inputs and 16 outputs that help reduce the number of additional peripheral components, which also keeps the costs down.
Twin Line Cell Controller
TLCC
1.4
Connections and extensions
The cell controller
24V voltage
Ethernet
CAN IN/OUT
Serial interface
RS232
Switch RS232
7-Segment display
16 outputs
8 inputs
Debouncing time 50 µs
24 inputs
Debouncing time 500 µs
Bild 1.3
TLCC overview
24V power supply The 24V power supply line is connected to the 24V connection to supply the device.
Communication interfaces The standard model of the device is equipped with the following communication interfaces:
CANopen for controlling the drive axles.
Ethernet for remote control of the device, i.e. programming of the application, update of the operating system, CoDeSys, application program, and documentation over the TCP/IP protocol. Monitoring all program variables is also possible with a standard Web browser on a dynamic HTML page.
RS232 for programming the application. By means of a switch the
RS232 interface can be used for accessing other devices as well.
Red switch to the left: RS232 for programming TLCC
Red switch to the right: RS232 freely programmable from applications
Status display The 7-segment display can be freely programmed and therefore be engaged differently by different user applications.
Module slots The device is equipped with a PC/104 module. If needed up to 3 more
PC/104 modules can be added to provide further field-bus connections, such as connections to CANOpen, DeviceNet, Profibus, Interbus,
Modbus or Modbus Standard or for providing further in- and outputs.
Inputs and outputs The 32 inputs and 16 outputs provide the user with many possibilities, because the in- and outputs are freely programmable by the CoDeSys programming environment.
Installation Information on the installation of the cell controller can be found in the
"Installation" chapter on page 4-1.
Twin Line Cell Controller 1-5
The cell controller TLCC
1.5
Directives and norms
1.5.1
Declaration of conformity and CE mark
The EC directives formulate the minimal requirements, especially the safety requirements, of a product and must be observed by all manufacturers and distributors that want to market the product in the member states of the European Union (EU).
The EC directives describe the principle requirements of the product.
The technical details have been specified in harmonised norms; in
Germany they have been implemented in the DIN-EN norms. If no EN norm is available yet for a product area, then current technical norms and regulations apply.
CE mark The declaration of conformity and the CE mark of the product prove that the manufacturer's product conform to the requirements of the relevant
EC directives. The device can be used world-wide.
Machine directive The Twin Line device is not a machine according to the EC machinery
Directive (89/392/EEC). It has no operatively moving parts. The device may be a component of a machine of a system though.
In so far as the rest of the machine complies with the machine directive and a construction according to the EMC test conditions of the manufacturer is available, conformity to the machine directive can be certified.
EMC directive The EC Directive Electromagnetic compatibility (89/336/EEC) is valid for devices that could cause electromagnetic interference or that could be impaired by such interferences.
Compliance with the EMC directive may not be determined until the
Twin Line device has been properly installed into the machine. The
specifications for ensuring the EMC described in "Installation" must be
observed so that the EMC safety of the Twin Line device in the machine or system is guaranteed and so that the device can be put into operation.
Low-voltage directive The EC low-voltage directive (73/23/EEC) states safety requirements for
"electrical equipment" for protection against dangers that might be caused by such devices or that can be caused by outside influences.
The Twin Line device conforms to the EN 50178 norm according to the low-voltage directive and also to the following conditions:
• Protection class IP20
• Degree of fouling 2.
Declaration of conformity The declaration of conformity certifies that the device conforms to the given EC directive. A declaration of conformity according to the EC lowvoltage directive will be issued for the Twin Line device.
1-6 Twin Line Cell Controller
TLCC The cell controller
EC Declaration of Conformity Year 2003
Business Unit Solutions
Maybachstr. 13
D-88094 Oberteuringen
according to EC Machine directive 89/392/EEC, annexe IIA according to EC EMC directive 89/336/EEC according to EC Low-voltage directive 73/23/EEC directives mentioned above have been altered by the CE mark directive 93/68/EEC
Herewith we declare that the machinery designated below, on the basis of its design and construction in the form brought onto the market by us is in accordance with the requirements of the EC Council Directive as mentioned below. If alterations are made to the machinery without prior consultations with us, this declaration becomes invalid.
Name:
Type:
Product number: appropriate
EC directives:
Applied national standards and technical specifications in particular:
Twin Line Cell Controller
TLCC
04079
EC Machine directive 89/392/EEC
EC EMC directive 89/336/EEC
EC Low-voltage directive 73/23/EEC
EN 55011: 1998 + A1: 1999
EN 61131-2: 1994 + A11: 1996 + A12: 2000
EN 61000-4-1: 2000
EN 61000-4-2: 1995
EN 61000-4-3: 1996
EN 61000-4-4: 1995
EN 61000-4-12: 1995
Applied harmonised standards, in particular :
Company stamp:
Date/Signature: 20.03.2003
Name/Department: R. Berner / Location management
Bild 1.4
Conformity according to the EC low-voltage directive
Twin Line Cell Controller 1-7
The cell controller TLCC
1-8 Twin Line Cell Controller
TLCC Safety
2
2.1
Safety
Hazard categories
Safety notes and general topics that provide further information are marked by special symbols in the manual.
Depending on the seriousness of a hazard situation the warnings are divided into three hazard categories. The symbols below signify the danger situation against which they warn.
DANGER!
Signifies a direct danger for persons.
If disregarded, this can lead to serious injuries or even death.
WARNING!
Signifies a perceivable risk.
If disregarded, the danger can lead to serious injuries or even death and destroy the device or parts of the machinery.
CAUTION!
Signifies a hazard.
If disregarded, this can lead to lighter injuries or damage the device or machinery.
2.2
Safety notes
DANGER!
Electric shock from high voltage!
Safety rules when working on electrical systems must be observed:
• Switch the device's power supply off
• Secure the device against being switched on again
• Check that there is no voltage remaining
• Cover or fence off neighbouring system units that are under voltage.
Twin Line Cell Controller 2-1
Safety TLCC
2.3
Intended use
2.3.1
Environmental conditions
Environmental temperature
Transport and storage temperature
0°C to +50°C
-40°C to +70°C
Relative humidity 15% to 85%
(no condensation allowed)
Installation altitude, operation without loss of performance h <1000 m above sea level
Vibrational loading during operation according to DIN IEC 68-2-6
Number of cycles:
Frequency range:
Amplitude of the acceleration:
10
10Hz to 500Hz
20m/s
2
Continuous shock according to DIN IEC 68-2-29
Number of shocks: 1000/direction
(directions: X,Y,Z per pos. and neg. direction, total 6000)
Maximum acceleration: 150m/s
2
Protection class IP20
2.3.2
Intended application
The cell controller is an electrical component used for controlling and regulating various system parts.
The cell controller may be used in the described system configuration only with fixed connections in industrial applications.
The cell controller may be started up and put into operation only after proper EMC-compliant installation.
The cell controller has to be mounted into a control cabinet and be firmly attached. It may be operated only with the cables and accessories specified by your local sales partner.
The operator of the system is responsible that the installation and configuration of the PLC as well as the programming is carried out by qualified personnel only.
The cell controller can be integrated into computer networks.
2-2 Twin Line Cell Controller
TLCC Safety
2.4
Qualification of the personnel
Installation and configuration of the TLCC as well as programming with
CoDeSys may be done only by electrical and control system technicians according to IEV 826-09-01 (modified) that know the contents of this manual and are familiar with the CoDeSys development application. The technicians must be able to recognise possible dangers that may be caused by programming, changes of parameter values, and generally by mechanical, electrical, and electronic equipment.
Qualified personnel can judge the assigned tasks based on vocational training, knowledge, and experience and can recognise and avoid possible dangers, or has the same level of knowledge based on many years of experience in a comparable field as following a vocational training.
Qualified persons have to know the valid standards, guidelines and accident prevention regulations that must be observed when operating the device.
Twin Line Cell Controller 2-3
Safety TLCC
2-4 Twin Line Cell Controller
TLCC Technical data
3
3.1
Technical data
Mechanical data
Weight Standard TLCC
Device protection Protection class according to DIN EN 60529: 1991
2.0 kg
IP 20
Dimensions Width 128
Front width 125.5 mm
Assembly distances The ventilation vents on and below the device have to be spaced at least
70 mm from neighbouring devices or walls.
128
83
4 x M5
22,5
70
196
70
Bild 3.1
Assembly distances, distances in mm
PC/104 module Controller
Exiting interfaces
Bus
AMD ELAN SC520-PC104
COM1, CAN, Ethernet
ISA bus connection on base circuit board
Twin Line Cell Controller 3-1
Technical data TLCC
3.2
3.3
Electrical data
DC/DC converter Input voltage
Minimum current consumption without outputs
Output voltage
Output current
Overload protection
Power loss ride-through
Input and output sided voltage monitoring
Power fail input and output
≥
21 to 28 VDC
1000 mA
5 VDC ± 5 %
8 A, maximum 10 A
10 A on output side (5 V)
6 s with 1.5 A
Outputs Number
Output voltage
Output current
Inputs Number
16 short proof surge absorber
24 VDC
500 mA
(limited to 500 mA)
32 short proof filtered surge absorber
UL 508C license
The UL license for the Twin Line cell controller TLCC has been applied for.
3-2 Twin Line Cell Controller
TLCC Installation
4
4.1
Installation
Electromagnetic compatibility, EMC
The cell controller conforms to the requirements of the EC directive on
EMC resistance to jamming and to interference emittance according to
EN 61800-3, when the following measures have been taken during installation.
Control cabinet assembly
EMC measures Effect
Mount onto galvanised or chromed plates, connect metal parts at broad surfaces, remove paint from contacting surfaces.
Good conductivity through surface contacts
Earth control cabinet, door, and assembly plates with earth tapes or cables that have a cross-section of more than 10 mm
2
.
Reduce EMC emission.
Mount power and control components separately, at least 25 cm apart, reduce coupled-in noise of both components by using multiple-earthed separator plates.
Reduces mutual coupled-in noise.
Supplement switching devices such as contactors, relays or solenoid valves with anti-interference combinations or spark arresters (e. g. diodes, varistors, RC elements).
Reduces mutual coupled-in noise.
Cables
EMC measures
Keep cables as short as possible, don't put in any
"safety loops", keep cable layout short from star point in control cabinet to the outside earth connection
Effect
Avoids capacitive and inductive coupled-in noises.
Connect large surfaces of the sheaths of all shielded lines at the control cabinet outlet with cable clips to the mounting plate.
Reduce EMC emission.
Lay out cables distanced from each other:
- signal lines
- 24 V power supply cables
- field-bus and Ethernet cables.
Reduces mutual coupled-in noise, reduces emissions, increases resistance to jamming.
Lay on cable screens flat, use cable clips and tapes. Reduces poor screening effect of non-flat connections, reduces emissions.
Earth large areas of the sheaths of digital signal lines or use sub-D cases.
Avoids interference on control cables, reduces emissions.
Earth cable strands not used of the control lines at both ends of the cable (not motor cable).
Additional shielding effect
Twin Line Cell Controller 4-1
Installation TLCC
Earthing to star point
Shield on mounting plate
System earth
Machine bed
"Power supply"
Star point to earthing
24V
GND
"Network"
Use shielded network cables only
COM
Place shield flat
Keep open cable ends short
Trim shield no more than 10mm before first terminal
Earth device by surface contact to mounting plate
Earth signal lines on plug case
"Signals"
Bild 4.1
EMC measures and division of the control cabinet
WARNING!
Malfunction and danger of injury!
To ensure the functions and the error-free operation of the device the EMC of the cables needs to be guaranteed.
Using unsuited, non-EMC-safe cables can damage the device and cause malfunctions.
4-2 Twin Line Cell Controller
TLCC Installation
4.2
Mechanical installation
4.2.1
Open / close device
왘
Remove the four screws (1) which hold the right side panel.
The panel can be taken off of the device.
왘
Loosen the plug connection (2) that connects the storage battery to the mains module.
햲
햲
햳
햲
햲
Bild 4.2
Open / close device and loosen / attach storage battery connection
Twin Line Cell Controller 4-3
Installation TLCC
4.2.2
Remove / mount mains module
DANGER!
Fire hazard!
Disconnect the storage battery block from the mains module before you remove the mains module from the device. Otherwise there is danger of fire.
WARNING!
Malfunction and damage of components!
Static electricity can damage the mains module. Earth yourself with an earthing wrist strap before you start work on the board.
왘
Remove the four screws (1) which hold the mains module on the case.
왘
Grip the mains module at the light-grey heat sink (2) and pull it straight out of the case.
When reassembling the mains module be sure that you can hear the connector plug on the back end of the mains module snapping into the base circuit board.
햲
햲
햳
햲
Bild 4.3
Remove / mount base circuit board
4-4 Twin Line Cell Controller
TLCC Installation
4.2.3
Replace EEPROM
Ethernet and data cable loosen and attach
Look into the opened case when the PC/104 module is removed and you will see on the upper-right of the base circuit board and diagonally below the battery a square black EEPROM chip that has a bevelled-off, lower left corner.
WARNING!
Malfunction and damage of components!
Static electricity can damage the EEPROM chip and the base circuit board. Earth yourself with an earthing wrist strap before you start work on the board.
왘 Pull off the cable (1) that connects the Ethernet socket on the front of the case to the PC/104 module and the data cable (2) from the
PC/104 module.
햲
햳
Bild 4.4
Loosen / attach Ethernet connection cable
Twin Line Cell Controller 4-5
Installation TLCC
PC/104 module remove / mount
왘 Remove the four screws which hold the PC/104 module to the base circuit board.
왘 Pull the PC/104 module carefully off of the base circuit board.
왘
Carefully loosen the plugs that form the data connection between module and base circuit board.
When remounting the module make sure you attach the data cable plug to the module first before you attach the module onto the base circuit board. There is no room to attach the plugs later.
Bild 4.5
Remove / mount PC/104 module
4-6 Twin Line Cell Controller
TLCC Installation
Replace EEPROM 왘 To remove the EEPROM loosen it carefully with a pair of tweezers.
When you mount the new EEPROM chip make sure that the bevelled corner is on the bottom left and that the little arrow on the chip lines up with the arrow on the chip holder.
Bild 4.6
Replace EEPROM
Twin Line Cell Controller 4-7
Installation TLCC
4.2.4
Replace flash disk
A flash disk is mounted on the base PC/104 module. The operating system (OS) and the run-time system (RTS) are stored on the flash disk.
WARNING!
Malfunction and damage of components!
Static electricity can damage the cards. Earth yourself with an earthing wrist strap before you start work on the cards.
왘
Remove the PC/104 module as described under "PC/104 module remove / mount" on page 4-6.
왘
Remove the screws that hold the flash disk to the module.
왘 Carefully pull off the flash disk.
Be sure that you pull the flash disk off horizontally, otherwise you may bend the pins.
Bild 4.7
Replace flash disk
4-8 Twin Line Cell Controller
TLCC Installation
4.2.5
Mount the TLCC in the control cabinet
Before installation...
왘
Inspect the device for visible outside damage such as dented panels or defective connection terminals. Do not mount damaged devices.
DANGER!
Danger from high voltage, destruction of the device's electronics!
During installation make sure that no loose parts such as strands of wire or mounting components can fall into the device. Loose, conductive parts can endanger persons by voltage divergence or destroy the device by shortcircuiting.
Control cabinet The control cabinet needs to be large enough so that all devices and accessories can be firmly mounted and properly wired according to
EMC requirements.
The warmth generated by operating the device and the components needs to be exhausted by the control cabinet ventilation.
왘
Position the device in the control cabinet so that air heated by other devices, e. g. an external ballast resistor, does not warm the fresh air supply for the device unintentionally.
왘 Mount the device vertically with the mains connection on top.
왘
Attach the device to a galvanised metal plate. The back of the device has to have a good, flat connection to the metal plate.
Paint-coated surfaces act as insulation. Before attaching the device to an enamelled mounting plate, scratch off wide areas of the enamel so that the device has good contact to the earthed mounting plate.
Twin Line Cell Controller 4-9
Installation TLCC
4.3
Electrical installation
WARNING!
Malfunction and danger of injury by interfering with other devices.
Connect device according to EMC requirements. Interfered control signals can cause unintended signal states that cause the device to malfunction.
4.3.1
Connection of the 24 V power supply
왘
Lead 24 V power supply lines via an earthed 24 V
DC
(PELV) to the device.
transformer
L1
L2
L3
N
PE
230V
~
24V
=
+24V
0V
24VDC
24VGND
Eingänge
Bild 4.8
24 V connection to TLCC
1
2
Connectio n
Signal Meaning
24VDC 24 V
DC
power supply
24VGND GND (ground/earth) for 24 V
DC
voltage
• Lay out the 24 V power supply lines to the EMC shield with a distance of at least 20 cm to other lines. Twist 0 V and 24 V supply lines that are more than 2 m long with each other.
• The torque of the terminal screws must be 0.56 – 0.79 Nm (5 - 7
LbIn; valid wire gauge: AWG 30 - 12).
4-10 Twin Line Cell Controller
TLCC Installation
4.3.2
Connecting the in- and outputs
The cell controller is equipped with a total of 32 inputs and 16 outputs.
Of the 32 inputs 8 have a debouncing time of 50 µs and 24 have a debouncing time of 500 µs.
Six connection terminals for the in- and outputs are supplied with the device. The maximum cable diameter is 1.5 mm² (AWG 28 - 12), the valid torque for attracting the screw in the connection terminal 0.22 –
0.45 Nm (2-4 LbIn).
24VDC
24VGND
+
–
OUT
6
7
4
5
2
3
0
1
INa
6
7
4
5
2
3
0
1
INb
20
21
22
23
16
17
18
19
12
13
14
15
10
11
8
9
12
13
14
15
10
11
8
9
28
29
30
31
24
25
26
27
230V
~
24V
=
0V
+24V
+24V
0V
Bild 4.9
Inputs and outputs wiring
Inputs
The input's power supply source has to be the same as the device's so that the same reference potential for earth
(GRD) is available.
16 outputs
8 inputs
Debouncing time 50 µs
24 inputs
Debouncing time 500 µs
Twin Line Cell Controller
Bild 4.10 Inputs with different debouncing times
The inputs with 50µs are intended for applications in which very quick reactions are required following input signals.
Outputs All outputs have an output voltage of 24 VDC and a maximum output current of 500 mA.
4-11
Installation TLCC
4.3.3
Connection to the RS232 interface
6
9 connection The RS232 interface with sub-D socket, 9-pin with M3 fastening is wired
1:1 to the PC.
Plug Socket Plug Socket
5
GND
RxD
TxD
1
1
TxD
RxD
GND
5
6
9
14
1
1
TxD
RxD
GND
5
6
9
6
9
1
5 on Twin Line socket on Twin Line socket on PC plug
6
7
4
5
8
9
2
3
Pin Signal
1 –
TxD
RxD
–
GND
–
–
–
–
25 on PC plug
13
Bild 4.11 Cable for the RS232 interface to the PC
View: Solder side, cable plug
–
–
2
2
–
–
1
1
Pair Meaning
– not used
Transmitted data to input device
Received serial data from input device not used
Ground/earth not used not used not used not used
–
–
–
–
–
–
I/O
–
I
O
Cable specifications • Shielded cable
• Cable length 15 metres maximum
• Minimum cross-section of the signal wires 0.25 mm
2
for supply voltage and earth wire 0.5 mm
2
• Shield earthed at both ends.
Function User programs are transferred from the PC to the cell controller through the the serial RS232 interface. Connect a PC here that has the
CoDeSys programmer suite.
The RS232 interface cannot be used to network several devices.
4-12 Twin Line Cell Controller
TLCC Installation
4.3.4
Connection to the CAN interface
Interface The CAN interface is equipped with a sub-D plug and a sub-D socket; both 9-pin with UNC fastening. The pin assignment is identical for both interface connections.
GND
CAN_HIGH
6
-
-
9
1
-
CAN_LOW
-
GND
5
-
CAN_HIGH
GND
-
-
9
6
1
5
-
-
-
GND
CAN_LOW
6
-
2
7
3
-
8
4
7
3
9
5
6
2
Pin Signal
1 –
GND
CAN_LOW
CAN_HIGH
GND
–
–
–
–
Bild 4.12 Interface connections of the field-bus module with plug and socket
3
–
2
3
–
–
1
2
Pair Meaning
1 not used
Ground/earth
Data line, inverted
Data line
Ground/earth not used not used not used not used
–
–
–
–
I/O
–
I/O
–
–
I/O
On devices that have a cover the cable needs to be led away downwards from the connection.
Cable specifications • Shielded cable
• Minimum cross-section of the signal wires 0.14 mm
2
• Twisted-pair lines
• Shield earthed at both ends
• Maximum length depends on the number of users, baud rate, and signal propagation delay. The higher the baud rates the shorter the bus cable has to be.
Guide values: 40 m with 1 MBit/s, 500 m with 100 kBit/s.
As a protection against interference, the shielding of digital cables is connected at both ends. Potential differences can cause undesirable currents on the shields and have to be prevented by potential equalisation lines: cable crosssection up to 200 m length: 16 mm
2
, over 200 m length:
20 mm
2
.
Twin Line Cell Controller 4-13
Installation TLCC
Function Using the CAN interface the cell controller can be connected to the following networks:
• CAN-Bus
• CANOpen.
As a slave the cell controller receives data and commands from a superior bus user; the master. As an acknowledgement the control sends back to the master information on the status of for example the device and operation. The data exchange is conducted by a special communication protocol.
As a CANOpen master the cell controller sends data and commands to subordinate bus users; the slaves. The data exchange is conducted by a special communication protocol.
Each device in the network can be identified by a unique, settable node address.
Terminators Terminating resistors of 120 Ω have to be attached to both ends of the bus.
Field-bus manual Integrating a Twin Line device into the field-bus is described in the respective field-bus manual in the chapters on installation and start-up.
4-14 Twin Line Cell Controller
TLCC Installation
4.3.5
Connection to the Ethernet interface
Interface The Ethernet interface with RJ45 socket is wired to the PC with a crossover cable or a data cable from the network.
1 TD+
TD-
RD+
RD-
8
6
7
4
5
8
2
3
Pin Signal
1 TD+
TD–
RD+
–
–
RD–
–
–
Bild 4.13 Interface connection of the Ethernet module (socket)
2
–
–
–
–
1
2
Pair Meaning
1 Transmit data
Transmit data
Receive data not used not used
Receive data not used not used
On devices that have a cover the cable needs to be led away downwards from the connection.
Cable specifications • Shielded cable
• Twisted-pair lines
• Maximum length for 10BaseT Ethernet: segment: max. 100 m total network: max. 2500 m
A network segment is a cable in the most simple case. In a more complex network all ports of a hub form a network segment.
Function User programs are transferred from the PC to the cell controller through the Ethernet interface. Connect a PC here that has the CoDeSys programmer suite.
Data can be exchanged over the network between the controls. An OPC server is additionally delivered with the TLCC's software package to make the data exchange possible.
Each device in the Ethernet network can be identified by a unique, settable IP address.
I
–
–
–
–
I/O
O
I
O
Twin Line Cell Controller 4-15
Installation TLCC
4.3.6
Connection to the Profibus interface of the second field-bus module
Interface The Profibus-DP module is equipped with a sub-D plug, 9-pin with UNC fastening.
A_LT
-
5VDC
-
9
6
5
-
GND
RTS
-
B_LT
1
4
-
5
6
-
3
8
8
4
7
3
9
5
6
2
Pin Signal
1 -
-
5VDC
-
-
B_LT
A_LT
RTS
GND
Bild 4.14 Interface connections of the field-bus module
-
-
-
-
-
-
-
-
-
Colour
-
2
3
-
2
-
1
Pair Meaning
1 not used
3
Power supply, max. 10 mA for circuit termination not used not used
Data line, inverted
Data line
Request to send not used
Ground/earth
Cable specifications for connection to a bus terminal
A bus terminal forms the docking point to the Profibus. The data lines between module and bus terminal are wired 1:1.
Minimum wire connections are the terminals A_LT and B_LT to the A and B wires in the network.
On devices that have a cover the cable needs to be led down from the connection.
• Shielded cable
• Minimum cross-section of the signal wires 0.14 mm
2
• Twisted-pair lines
• Shield earthed at both ends
• Maximum length 100 metres
As a protection against interference, the shielding of digital cables is connected at both ends. Potential differences can cause undesirable currents on the shields and have to be prevented by potential equalisation lines: cable cross-section up to 200 m length: 16 mm
2
, over 200 m length: 20 mm
2
.
-
-
-
I/O
I/O
O
-
I/O
-
O
4-16 Twin Line Cell Controller
TLCC Installation
Function Using the Profibus-DP field-bus module, the cell controller can be connected as a slave to a Profibus-DP network.
The cell controller receives data and commands from a superior bus user; the master. As an acknowledgement the control sends back to the master information on the status of for example the device and operation. The data exchange is conducted by a special communication protocol.
The data is exchanged in cycles between master and slave. Each device in the network can be identified by a unique, settable device address.
Baud rate The baud rate depends on the transmission rate of the master.
Field-bus manual Integrating a Twin Line device into the field-bus is described in the respective field-bus manual in the chapters on installation and start-up.
Twin Line Cell Controller 4-17
Installation TLCC
4.3.7
Connection to the CAN interface of the second field-bus module
Interface The CAN module is equipped with a sub-D plug and a sub-D socket; both 9-pin with UNC fastening. The pin assignment is identical for both interface connections.
GND
CAN_HIGH
6
-
-
9
1
-
-
CAN_LOW
-
GND
5
CAN_HIGH
GND
-
-
9
6
1
5
-
-
-
GND
CAN_LOW
-
6
2
7
3
-
8
4
7
3
9
5
6
2
Pin Signal
1 –
GND
CAN_LOW
CAN_HIGH
GND
–
–
–
–
Bild 4.15 Interface connections of the field-bus module with plug and socket
3
–
2
3
–
–
1
2
Pair Meaning
1 not used
Ground/earth
Data line, inverted
Data line
Ground/earth not used not used not used not used
–
–
–
–
I/O
–
I/O
–
–
I/O
On devices that have a cover the cable needs to be led away downwards from the connection.
Cable specifications • Shielded cable
• Minimum cross-section of the signal wires 0.14 mm
2
• Twisted-pair lines
• Shield earthed at both ends
• Maximum length depends on the number of users, baud rate, and signal propagation delay. The higher the baud rates the shorter the bus cable has to be.
Guide values: 40 m with 1 MBit/s, 500 m with 100 kBit/s.
As a protection against interference, the shielding of digital cables is connected at both ends. Potential differences can cause undesirable currents on the shields and have to be prevented by potential equalisation lines: cable crosssection up to 200 m length: 16 mm
2
, over 200 m length:
20 mm
2
.
4-18 Twin Line Cell Controller
TLCC Installation
Function Using the CAN interface the cell controller can be connected to the following networks:
• CAN-Bus
• CANOpen.
As a slave the cell controller receives data and commands from a superior bus user; the master. As an acknowledgement the control sends back to the master information on the status of for example the device and operation. The data exchange is conducted by a special communication protocol.
As a CANOpen master the cell controller sends data and commands to subordinate bus users; the slaves. The data exchange is conducted by a special communication protocol.
Each device in the network can be identified by a unique, settable node address.
Terminators Terminating resistors of 120 Ω have to be attached to both ends of the bus.
Field-bus manual Integrating a Twin Line device into the field-bus is described in the respective field-bus manual in the chapters on installation and start-up.
Twin Line Cell Controller 4-19
Installation TLCC
4.3.8
Connection to the RS485 interface of the second field-bus module
Interface The RS485 module is equipped with a sub-D plug and a sub-D socket; both 9-pin with M3 fastening. The pin assignment is identical for both interface connections.
5
SGND
RxD
TxD
GND
12VDC
1
9
6
RxD
TxD
GND
12VDC
12VDC
GND
TxD
RxD
SGND
5
1
6
9
12VDC
GND
TxD
RxD
8
3
9
4
5
1
2
6
7
3
9
7
8
4
5
2
6
Pin Signal
1 12VDC
GND
12VDC
GND
TxD
TxD
RxD
RxD
SGND
Bild 4.16 Interface connections of the field-bus module
Colour white brown green yellow pink grey red blue black -
3
4
2
3
1
2
Pair Meaning
1 Supply voltage
4
Earth for supply voltage 12 VDC
Supply voltage
Earth for supply voltage 12 VDC
Transmitted data
Transmitted data, inverted
Received data
Received data, inverted
Ground/earth
Only one of the voltage outputs 12 VDC of the two sub-D connections may be loaded with a maximum of 150 mA current.
Cable specifications • Shielded cable
• Minimum cross-section of the signal wires 0.14 mm
2
• Twisted-pair lines
• Shield earthed at both ends
• Maximum length 400 metres.
On devices that have a cover the cable needs to be led down from the connection.
As a protection against interference, the shielding of digital cables is connected at both ends. Potential differences can cause undesirable currents on the shields and have to be prevented by potential equalisation lines: cable cross-section up to 200 m length: 16 mm
2
, over
200 m length: 20 mm
2
.
-
I
O
O
I
O
I/O
O
O
O
4-20 Twin Line Cell Controller
TLCC Installation
Function Using the RS485 field-bus module, the Leistungselektronik can be connected as a slave to a serial bus.
The Leistungselektronik receives data and commands from a superior bus user; the master. As an acknowledgement the control sends status information back to the master. The data exchange is conducted by a special communication protocol.
Each device in the network can be identified by a unique, settable device address.
Field-bus manual Integrating a Twin Line device into the field-bus is described in the respective field-bus manual in the chapters on installation and start-up.
Twin Line Cell Controller 4-21
Installation TLCC
4-22 Twin Line Cell Controller
TLCC Service, Maintenance, and Guarantee
5
5.1
Service, Maintenance, and Guarantee
Service address
Contact your local sales partner if you have questions or problems. He will inform you which service centre is nearest to you.
Maintenance The Twin Line device is maintenance-free
왘 Check the filter of the control cabinet's ventilation regularly. The inspection interval depends on the environmental conditions of the location.
Have repairs on the device carried out by your local sales representative only. This sustains the guarantee of the safety of the device during operation.
Guarantee If accessories are used that have not been recommended by the manufacturer, claims for guarantee expire.
Twin Line Cell Controller 5-1
Service, Maintenance, and Guarantee TLCC
5.2
Shipment, storage and disposal
removal 왘 Make note of the device's settings and save the user programs that where made with the CoDeSys programmer suite.
왘 Switch off the device.
왘
Disconnect the device from the 24V power supply.
왘 Mark all the connections to the device.
왘
Pull off the interface plugs.
왘 Dismantle the device from the control cabinet.
Shipment The device may be transported only if it is well padded. Use the original packaging for shipping.
Storage Store the device only under the specified, allowed environmental conditions for room temperature and humidity.
Protect the device against dust and dirt.
Disposal The cell controller consists of various materials that can be reused or recycled separately.
For recycling dismantle the device into the following components:
• case, screws, and clamps for iron recycling
• cables for copper recycling
• plugs and cover for plastic recycling
The circuit boards and the electronics need to be recycled separately according to valid environment protection laws. These components need to be treated as special waste.
5-2 Twin Line Cell Controller
TLCC
5.3
Replace battery
Service, Maintenance, and Guarantee
DANGER!
Damage of components.
Carry out all tasks at the open Cell Controller at an ESDsafe work site.
Make sure that while working on the Cell Controller no dangerous leakage current can occur.
CAUTION!
If the storage battery is defective, data can be lost when the
TLCC is switched off.
Make sure that following a storage battery exchange, all data is complete and valid before you put the system back into operation.
왘 Loosen the 4 screws (1) that hold the right side panel.
왘
Take off the right cover (2): The battery is located on the removed case cover.
햲
햲
햳
Bild 5.1
Cell Controller case
햲
햲
Twin Line Cell Controller 5-3
Service, Maintenance, and Guarantee
왘 Replace the complete case wall and the storage battery.
TLCC
Bild 5.2
Right case wall with storage battery
왘
Connect the storage battery.
왘 Put the cover back on the Cell Controller and attach it with the
4 screws. Tighten the screws.
왘 Mount the Cell Controller back into the control cabinet and reconnect all connections.
5-4 Twin Line Cell Controller
TLCC
Index
Twin Line Cell Controller
Numerics
24V power supply
7-segment display, see status display
A accessories
Scope of delivery
assembly
assembly distances
B battery replacement
C
CAN interface
CE mark
CoDeSys
communication interfaces
connections
control cabinet
control cabinet, assembly
D declaration of conformity
device overview
device protection
dimensions
disposal
documentation
E
EC directives
EEPROM, replace
EMC directive
environmental conditions
Ethernet cable, mount
Ethernet interface
extensions
F field-bus interfaces
flash disk, replace
G guarantee
H hazard categories
I inputs
Inputs connection
installation
intended application
Index
A-1
Index
A-2
TLCC
M mains connection
24 V power supply connection
mains module, mount
maintenance
module slots
modules
Signal cables for
O outputs
P
PC connection
PC/104 module, mount
personnel qualification
power supply
primary use
Profibus-DP interface
protection class
Q qualification of the personnel
R references
Removal
replacing battery
RS232 interface
RS485 interface
S safety notes
second field-bus module
Serial interface
service address
shipment
status display
storage
T
TLCC
24 V connection wiring
assembly distances
close
control cabinet, assembly
EEPROM, replace
Ethernet cable, mount
flash disk, replace
mains module, mount
open
overview
PC/104 module, mount
Twin Line Cell Controller
TLCC
Twin Line Cell Controller
24 V connection wiring
assembly distances
close
control cabinet, assembly
EEPROM, replace
Ethernet cable, mount
flash disk, replace
mains module, mount
open
overview
PC/104 module, mount
W weight
Index
Twin Line Cell Controller A-3
Index TLCC
A-4 Twin Line Cell Controller
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