Schneider Electric TLCC User Guide

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
00 9844 111 3216, 1.05, 05.05
TLCC
1-2
Twin Line Cell Controller
TLCC
Table of Contents
Table of Contents
Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-3
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . V-3
Product names . . . . . . . . . . . . . . . . . . . . . . . . . V-3
Technical terms . . . . . . . . . . . . . . . . . . . . . . . . V-4
Symbol conventions . . . . . . . . . . . . . . . . . . . . . . V-5
00 9844 111 3216, 1.05, 05.05
1 The cell controller. . . . . . . . . . . . . . . . . . . . . . .
Twin Line Cell Controller
1-1
1.1
Scope of delivery . . . . . . . . . . . . . . . . . .
1-1
1.2
Documentation and References . . . . . . . . . . .
1-3
1.3
Device overview . . . . . . . . . . . . . . . . . . .
1-4
1.4
Connections and extensions
. . . . . . . . . . . .
1-5
1.5
1.5.1
Directives and norms . . . . . . . . . . . . . . . .
Declaration of conformity and CE mark. . . . . .
1-6
1-6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1
Hazard categories . . . . . . . . . . . . . . . . . .
2-1
2.2
Safety notes . . . . . . . . . . . . . . . . . . . . .
2-1
2.3
2.3.1
2.3.2
Intended use . . . . . . . . . . . . . . . . . . . . .
Environmental conditions . . . . . . . . . . . . .
Intended application . . . . . . . . . . . . . . .
2-2
2-2
2-2
2.4
Qualification of the personnel . . . . . . . . . . . .
2-3
3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3.1
Mechanical data . . . . . . . . . . . . . . . . . . .
3-1
3.2
Electrical data . . . . . . . . . . . . . . . . . . . .
3-2
3.3
UL 508C license . . . . . . . . . . . . . . . . . . .
3-2
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4.1
Electromagnetic compatibility, EMC . . . . . . . . .
4-1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
Mechanical installation . . . . . . . . .
Open / close device. . . . . . . . . .
Remove / mount mains module . . .
Replace EEPROM . . . . . . . . . .
Replace flash disk . . . . . . . . . .
Mount the TLCC in the control cabinet
.
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.
4-3
4-3
4-4
4-5
4-8
4-9
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
Electrical installation . . . . . . . . . . . . . .
Connection of the 24 V power supply . . .
Connecting the in- and outputs . . . . . . .
Connection to the RS232 interface . . . . .
Connection to the CAN interface . . . . . .
Connection to the Ethernet interface . . . .
Connection to the Profibus interface of the
second field-bus module . . . . . . . . . .
.
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. . 4-10
. . 4-10
. 4-11
. 4-12
. 4-13
. . 4-15
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. . . 4-16
V-1
Table of Contents
TLCC
4.3.7
4.3.8
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
5.1
Service address . . . . . . . . . . . . . . . . . . . 5-1
5.2
Shipment, storage and disposal . . . . . . . . . . . 5-2
5.3
Replace battery
. . . . . . . . . . . . . . . . . . . 5-3
00 9844 111 3216, 1.05, 05.05
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
V-2
Twin Line Cell Controller
TLCC
Lists
Lists
Abbreviations
Abbreviation
Meaning
AC
Alternating current
ASCII
American Standard Code for Information Interchange
DC
Direct current
I/O
Input/Output
EMC
Electromagnetic compatibility
EC
European Community
EU
European Union
Inc
Increments
LED
Light Emitting Diode
RTS
Run-time system
M
Motor
OS
Operating system
PC
Personal computer
PELV
Protected Extra Low Voltage
PLC
Programmable logic controller
Abbreviation
Product term
Used term
TLCC
Twin Line Cell Controller
cell controller
TLDxxx
Twin Line Drive
Twin Line device
TLCxxx
Twin Line Controller
Twin Line device
CoDeSys
Controller Development
System
CoDeSys
00 9844 111 3216, 1.05, 05.05
Product names
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
Internal units
Arc steps of a shaft encoder as rectangular pulse trains. The pulses
signal the change of positions.
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
Opto-decoupled
Parameter
Electrical signal transmission with galvanic separation
Device data and values specified by the user
The RS232 plug-in connection is the communications interface of the
Twin Line device for connecting a PC or the HMI manual control unit.
00 9844 111 3216, 1.05, 05.05
RS232 interface
Monitoring the connection at the RS232 interface or at the field-bus
interface
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 ⇒menu item ⇒...". For example "File ⇒Save" in the "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.
00 9844 111 3216, 1.05, 05.05
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
TLCC
00 9844 111 3216, 1.05, 05.05
Lists
V-6
Twin Line Cell Controller
TLCC
The cell controller
1
The cell controller
1.1
Scope of delivery
Bild 1.1
Cell controller scope of delivery
TLCC scope of delivery
The scope of delivery of the TLCC Twin Line Cell Controllers includes:
Amount Item
1
Order number
Twin Line Cell Controller with RS232, Ethernet
and CAN interfaces
8650 5000 000
with additional Profibus-DP interface
with two additional Profibus-DP interfaces
8650 5000 004
8650 5000 005
with Berger Lahr Product Insert
6
Terminals for I/O connections
0000 210 2200
왘 Inspect the delivery for completeness.
00 9844 111 3216, 1.05, 05.05
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
Accessories
TLCC
Accessory parts for the cell controller are:
Item
Order number
CoDeSys documentation
5920 0000 030
CoDeSys & TLC 6xx Target & TLCC Target
6250 1102 600
Field-bus cables for modules
CAN,
RS485
6250 1446 yyy 1)
6250 1455 xxx 2)
CAN terminal, 9-pin socket
CAN terminal, 9-pin plug
6250 1518 002
6250 1518 003
RS232 programming cable 5 m
RS232 programming cable 10 m
6250 1441 050
6250 1441 100
Spare part storage battery TLCC
8620 6999 001
00 9844 111 3216, 1.05, 05.05
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
1.2
The cell controller
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
References
Information and help on installation of and electromagnetic compatible
assembly of
BERGER LAHR motor drives, order no.: 9844 1113 075
Industrial Ethernet, Auf dem Weg zum Industriestandard
Vogel Verlag, Würzburg 2001
ISBN: 3-8259-1910-2
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
00 9844 111 3216, 1.05, 05.05
Interessengemeinschaft CAN
(CAN syndicate)
Twin Line Cell Controller
1-3
The cell controller
1.3
TLCC
Device overview
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.
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.
1-4
Twin Line Cell Controller
00 9844 111 3216, 1.05, 05.05
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.
TLCC
1.4
The cell controller
Connections and extensions
24V voltage
Serial interface
RS232
Switch RS232
7-Segment display
16 outputs
Ethernet
8 inputs
Debouncing time 50 µs
CAN IN/OUT
24 inputs
Debouncing time 500 µs
Bild 1.3
24V power supply
Communication interfaces
TLCC overview
The 24V power supply line is connected to the 24V connection to supply
the device.
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
00 9844 111 3216, 1.05, 05.05
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.
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.
00 9844 111 3216, 1.05, 05.05
Declaration of conformity
•
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:
Twin Line Cell Controller
Type:
TLCC
Product number:
04079
appropriate
EC directives:
Applied national
standards and
technical
specifications in
particular:
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:
00 9844 111 3216, 1.05, 05.05
Company stamp:
Date/Signature:
20.03.2003
Name/Department: R. Berner / Location management
Bild 1.4
Twin Line Cell Controller
Conformity according to the EC low-voltage directive
1-7
TLCC
00 9844 111 3216, 1.05, 05.05
The cell controller
1-8
Twin Line Cell Controller
TLCC
Safety
2
Safety
2.1
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.
00 9844 111 3216, 1.05, 05.05
•
Twin Line Cell Controller
2-1
Safety
TLCC
2.3
Intended use
2.3.1
Environmental conditions
Environmental temperature
Transport and storage temperature
Relative humidity
0°C to +50°C
-40°C to +70°C
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:
10
Frequency range:
10Hz to 500Hz
Amplitude of the acceleration:
20m/s2
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/s2
Protection class
2.3.2
IP20
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.
00 9844 111 3216, 1.05, 05.05
The cell controller can be integrated into computer networks.
2-2
Twin Line Cell Controller
TLCC
2.4
Safety
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.
00 9844 111 3216, 1.05, 05.05
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
TLCC
00 9844 111 3216, 1.05, 05.05
Safety
2-4
Twin Line Cell Controller
TLCC
Technical data
3
Technical data
3.1
Mechanical data
Weight
Device protection
Dimensions
Assembly distances
Standard TLCC
2.0 kg
Protection class according to DIN EN 60529: 1991
IP 20
Width
Height
Depth
128 mm
212.5 mm
214.5 mm
Front width
125.5 mm
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
Controller
Exiting interfaces
Bus
AMD ELAN SC520-PC104
COM1, CAN, Ethernet
ISA bus connection on base circuit board
00 9844 111 3216, 1.05, 05.05
PC/104 module
Assembly distances, distances in mm
Twin Line Cell Controller
3-1
Technical data
3.2
TLCC
Electrical data
DC/DC converter
Outputs
Input voltage
21 to 28 VDC
Minimum current consumption without outputs
1000 mA
Output voltage
5 VDC ± 5 %
Output current
8 A, maximum 10 A
Overload protection
≥10 A on output side (5 V)
Power loss ride-through
6 s with 1.5 A
Input and output sided voltage monitoring
Power fail input and output
Number
Output voltage
Output current
Inputs
3.3
Number
16
short proof
surge absorber
24 VDC
500 mA
(limited to 500 mA)
32
short proof
filtered
surge absorber
UL 508C license
00 9844 111 3216, 1.05, 05.05
The UL license for the Twin Line cell controller TLCC has been applied
for.
3-2
Twin Line Cell Controller
TLCC
Installation
4
Installation
4.1
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 Good conductivity
through surface contacts
metal parts at broad surfaces, remove paint from
contacting surfaces.
Earth control cabinet, door, and assembly plates
Reduce EMC emission.
with earth tapes or cables that have a cross-section
of more than 10 mm2.
Mount power and control components separately, at Reduces mutual
least 25 cm apart, reduce coupled-in noise of both coupled-in noise.
components by using multiple-earthed separator
plates.
Cables
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.
EMC measures
Effect
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
Avoids capacitive and
inductive coupled-in
noises.
Connect large surfaces of the sheaths of all
Reduce EMC emission.
shielded lines at the control cabinet outlet with cable
clips to the mounting plate.
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.
00 9844 111 3216, 1.05, 05.05
Lay on cable screens flat, use cable clips and tapes. Reduces poor screening
effect of non-flat
connections, reduces
emissions.
Twin Line Cell Controller
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
4-1
Installation
TLCC
Earthing to
star point
Shield on
mounting plate
"Power supply"
Star point
to earthing
System earth
Machine bed
Place shield flat
Keep open cable ends short
Trim shield no more
than 10mm before
first terminal
COM
24V
GND
Earth device by surface
contact to mounting plate
"Network"
Use shielded
network
cables only
Earth signal lines
on plug case
"Signals"
Bild 4.1
EMC measures and division of the control cabinet
00 9844 111 3216, 1.05, 05.05
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
햳
햲
햲
햲
Open / close device and
loosen / attach storage battery connection
00 9844 111 3216, 1.05, 05.05
Bild 4.2
Twin Line Cell Controller
4-3
Installation
4.2.2
TLCC
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
Remove / mount base circuit board
00 9844 111 3216, 1.05, 05.05
Bild 4.3
4-4
Twin Line Cell Controller
TLCC
4.2.3
Installation
Replace EEPROM
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.
Ethernet and data cable
loosen and attach
햲
햳
Loosen / attach Ethernet connection cable
00 9844 111 3216, 1.05, 05.05
Bild 4.4
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.
Remove / mount PC/104 module
00 9844 111 3216, 1.05, 05.05
Bild 4.5
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.
Replace EEPROM
00 9844 111 3216, 1.05, 05.05
Bild 4.6
Twin Line Cell Controller
4-7
Installation
4.2.4
TLCC
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.
Replace flash disk
00 9844 111 3216, 1.05, 05.05
Bild 4.7
4-8
Twin Line Cell Controller
TLCC
4.2.5
Installation
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.
00 9844 111 3216, 1.05, 05.05
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
4.3
TLCC
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 VDC transformer
(PELV) to the device.
L1
L2
L3
N
PE
230V
~
+24V
24V
=
0V
24VDC
24VGND
+24V
0V
Eingänge
Bild 4.8
24 V connection to TLCC
Connectio Signal
n
Meaning
1
24VDC
24 VDC power supply
2
24VGND
GND (ground/earth) for 24 VDC 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).
00 9844 111 3216, 1.05, 05.05
•
4-10
Twin Line Cell Controller
TLCC
4.3.2
Installation
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).
OUT
24VDC +
24VGND –
INa
INb
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
16
17
18
19
20
21
22
23
8
9
10
11
12
13
14
15
8
9
10
11
12
13
14
15
24
25
26
27
28
29
30
31
0V
230V
~
+24V
+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
00 9844 111 3216, 1.05, 05.05
24 inputs
Debouncing time 500 µs
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
Twin Line Cell Controller
All outputs have an output voltage of 24 VDC and a maximum output
current of 500 mA.
4-11
Installation
4.3.3
TLCC
Connection to the RS232 interface
connection
The RS232 interface with sub-D socket, 9-pin with M3 fastening is wired
1:1 to the PC.
Plug
9
6
Socket
Plug
Socket
5
GND
1
RxD
TxD
TxD
RxD
1
GND
5
14
6
1
1
6
6
9
9
1
TxD
RxD
GND
5
9
on Twin Line
socket
on Twin Line
socket
5
on PC plug
25
13
on PC plug
Pin
Signal
Pair
Meaning
I/O
1
–
–
not used
–
2
TxD
1
Transmitted data to input device
O
3
RxD
1
Received serial data from input device
I
4
–
2
not used
–
5
GND
2
Ground/earth
–
6
–
–
not used
–
7
–
–
not used
–
8
–
–
not used
–
9
–
–
not used
–
•
Shielded cable
•
Cable length 15 metres maximum
•
Minimum cross-section of the signal wires 0.25 mm2 for supply
voltage and earth wire 0.5 mm2
•
Shield earthed at both ends.
Cable specifications
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
00 9844 111 3216, 1.05, 05.05
Bild 4.11 Cable for the RS232 interface to the PC
View: Solder side, cable plug
TLCC
4.3.4
Installation
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.
1
GND
6
9
-
CAN_LOW
CAN_HIGH
GND
-
5
-
9
5
-
-
GND
CAN_HIGH
GND
-
-
CAN_LOW
6
2
7
3
-
-
6
1
Bild 4.12 Interface connections of the field-bus module with plug and socket
Pin
Signal
Pair
Meaning
I/O
1
–
1
not used
–
6
GND
1
Ground/earth
–
2
CAN_LOW
2
Data line, inverted
I/O
7
CAN_HIGH
2
Data line
I/O
3
GND
3
Ground/earth
–
8
–
3
not used
–
4
–
–
not used
–
9
–
–
not used
–
5
–
–
not used
–
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 mm2
•
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.
00 9844 111 3216, 1.05, 05.05
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 mm2, over 200 m length:
20 mm2.
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
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.
00 9844 111 3216, 1.05, 05.05
Field-bus manual
Terminating resistors of 120 Ω have to be attached to both ends of the
bus.
4-14
Twin Line Cell Controller
TLCC
4.3.5
Installation
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+
TDRD+
RD-
8
Bild 4.13 Interface connection of the Ethernet module (socket)
Pin
Signal
Pair
Meaning
I/O
1
TD+
1
Transmit data
O
2
TD–
1
Transmit data
O
3
RD+
2
Receive data
I
4
–
–
not used
–
5
–
–
not used
–
6
RD–
2
Receive data
I
7
–
–
not used
–
8
–
–
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.
00 9844 111 3216, 1.05, 05.05
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.
Twin Line Cell Controller
4-15
Installation
4.3.6
TLCC
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.
9
5
-
RTS
A_LT
B_LT
5VDC
6
3
8
4
5
GND
6
1
-
Bild 4.14 Interface connections of the field-bus module
Pin
Signal
Colour
Pair
Meaning
I/O
1
-
-
1
not used
-
6
5VDC
-
1
Power supply, max. 10 mA for circuit termination
O
2
-
-
-
not used
-
7
-
-
-
not used
-
3
B_LT
-
2
Data line, inverted
I/O
8
A_LT
-
2
Data line
I/O
4
RTS
-
3
Request to send
O
9
-
-
3
not used
-
5
GND
-
-
Ground/earth
-
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.
Cable specifications for connection
to a bus terminal
•
Shielded cable
•
Minimum cross-section of the signal wires 0.14 mm2
•
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 mm2, over 200
m length: 20 mm2 .
4-16
Twin Line Cell Controller
00 9844 111 3216, 1.05, 05.05
On devices that have a cover the cable needs to be led down from the
connection.
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
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.
00 9844 111 3216, 1.05, 05.05
Field-bus manual
The baud rate depends on the transmission rate of the master.
Twin Line Cell Controller
4-17
Installation
4.3.7
TLCC
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.
1
GND
6
9
-
CAN_LOW
CAN_HIGH
GND
-
5
-
9
5
-
-
GND
CAN_HIGH
GND
-
-
CAN_LOW
6
2
7
3
-
-
6
1
Bild 4.15 Interface connections of the field-bus module with plug and socket
Pin
Signal
Pair
Meaning
I/O
1
–
1
not used
–
6
GND
1
Ground/earth
–
2
CAN_LOW
2
Data line, inverted
I/O
7
CAN_HIGH
2
Data line
I/O
3
GND
3
Ground/earth
–
8
–
3
not used
–
4
–
–
not used
–
9
–
–
not used
–
5
–
–
not used
–
Cable specifications
•
Shielded cable
•
Minimum cross-section of the signal wires 0.14 mm2
•
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 mm2, over 200 m length:
20 mm2.
4-18
Twin Line Cell Controller
00 9844 111 3216, 1.05, 05.05
On devices that have a cover the cable needs to be led away downwards
from the connection.
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
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.
00 9844 111 3216, 1.05, 05.05
Field-bus manual
Terminating resistors of 120 Ω have to be attached to both ends of the
bus.
Twin Line Cell Controller
4-19
Installation
4.3.8
TLCC
Connection to the RS485 interface of the second field-bus module
Interface
SGND
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
9
RxD
6
TxD
RxD
12VDC
SGND
1
12VDC
GND
TxD
GND
GND
6
GND
TxD
TxD
12VDC
1
12VDC
RxD
9
RxD
5
1
2
6
7
8
3
9
4
5
Bild 4.16 Interface connections of the field-bus module
Pin
Signal
Colour
Pair
Meaning
I/O
1
12VDC
white
1
Supply voltage
O
2
GND
brown
1
Earth for supply voltage 12 VDC
O
6
12VDC
green
2
Supply voltage
O
7
GND
yellow
2
Earth for supply voltage 12 VDC
O
8
TxD
pink
3
Transmitted data
O
3
TxD
grey
3
Transmitted data, inverted
O
9
RxD
red
4
Received data
I
4
RxD
blue
4
Received data, inverted
I
5
SGND
black
-
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 mm2
•
Twisted-pair lines
•
Shield earthed at both ends
•
Maximum length 400 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 mm2, over
200 m length: 20 mm2.
4-20
Twin Line Cell Controller
00 9844 111 3216, 1.05, 05.05
On devices that have a cover the cable needs to be led down from the
connection.
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.
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.
00 9844 111 3216, 1.05, 05.05
Field-bus manual
Twin Line Cell Controller
4-21
TLCC
00 9844 111 3216, 1.05, 05.05
Installation
4-22
Twin Line Cell Controller
TLCC
Service, Maintenance, and Guarantee
5
Service, Maintenance, and Guarantee
5.1
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.
If accessories are used that have not been recommended by the manufacturer, claims for guarantee expire.
00 9844 111 3216, 1.05, 05.05
Guarantee
Twin Line Cell Controller
5-1
Service, Maintenance, and Guarantee
5.2
TLCC
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
00 9844 111 3216, 1.05, 05.05
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
Service, Maintenance, and Guarantee
Replace battery
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
햳
햲
햲
햲
Cell Controller case
00 9844 111 3216, 1.05, 05.05
Bild 5.1
Twin Line Cell Controller
5-3
Service, Maintenance, and Guarantee
TLCC
왘 Replace the complete case wall and the storage battery.
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.
00 9844 111 3216, 1.05, 05.05
왘 Mount the Cell Controller back into the control cabinet and reconnect all connections.
5-4
Twin Line Cell Controller
TLCC
Index
Index
Numerics
24V power supply 1-5
7-segment display, see status display
A
accessories
Scope of delivery 1-2
assembly 4-1
assembly distances 3-1
B
battery replacement 5-3
C
CAN interface 1-5, 4-13, 4-18
CE mark 1-6
CoDeSys 1-3, 2-3
communication interfaces 1-5
connections 1-5
control cabinet 4-9
control cabinet, assembly 4-9
D
declaration of conformity 1-6
device overview 1-4
device protection 3-1
dimensions 3-1
disposal 5-2
documentation 1-3
E
EC directives 1-6
EEPROM, replace 4-5
EMC directive 1-6
environmental conditions 2-2
Ethernet cable, mount 4-5
Ethernet interface 1-5, 4-15
extensions 1-5
F
field-bus interfaces 1-5
flash disk, replace 4-8
00 9844 111 3216, 1.05, 05.05
G
guarantee 5-1
H
hazard categories 2-1
I
inputs 1-5
Inputs connection 4-11
installation 4-1
intended application 2-2
Twin Line Cell Controller
A-1
Index
TLCC
M
mains connection
24 V power supply connection 4-10
mains module, mount 4-4
maintenance 5-1
module slots 1-5
modules
Signal cables for 1-2
O
outputs 1-5
P
PC connection 4-12
PC/104 module, mount 4-6
personnel
qualification 2-3
power supply 1-5
primary use 1-4
Profibus-DP interface 4-16
protection class 3-1
Q
qualification of the personnel 2-3
R
references 1-3
Removal 5-2
replacing battery 5-3
RS232 interface 1-5, 4-12
RS485 interface 4-20
S
safety notes 2-1
second field-bus module 4-16, 4-18, 4-20
Serial interface 1-5
service address 5-1
shipment 5-2
status display 1-5
storage 5-2
A-2
00 9844 111 3216, 1.05, 05.05
T
TLCC
24 V connection wiring 4-10
assembly distances 3-1
close 4-3
control cabinet, assembly 4-9
EEPROM, replace 4-5
Ethernet cable, mount 4-5
flash disk, replace 4-8
mains module, mount 4-4
open 4-3
overview 1-5
PC/104 module, mount 4-6
Twin Line Cell Controller
TLCC
Index
Twin Line Cell Controller
24 V connection wiring 4-10
assembly distances 3-1
close 4-3
control cabinet, assembly 4-9
EEPROM, replace 4-5
Ethernet cable, mount 4-5
flash disk, replace 4-8
mains module, mount 4-4
open 4-3
overview 1-5
PC/104 module, mount 4-6
00 9844 111 3216, 1.05, 05.05
W
weight 3-1
Twin Line Cell Controller
A-3
TLCC
00 9844 111 3216, 1.05, 05.05
Index
A-4
Twin Line Cell Controller

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