EFAS The new automation control system from Schmersal NEW

Transcription

1 EFAS The new automation control system from Schmersal NEW

2 Introduction Heinz and Philip Schmersal, Managing Directors of the Schmersal Group New solutions to improve production efficiency and machine safety The Schmersal Group, systems and solutions provider for machine safety, provides everything from a single source. We develop individual solutions tailored to your specific application off the back of a comprehensive range of products and services. We follow new technological developments closely and understand the huge challenges that you, as a machine operator or engineer, face as a result of Industry 4.0. To ensure that we provide the best possible support as new digital technologies appear, we are constantly expanding our product range and our expertise. And for the first time, we are now able to offer an automation control in the form of EFAS: Our new EtherCAT Fast Automation System (EFAS): Offers an outstanding variety of modules that can be individually combined. Enables productivity improvements thanks to EtherCAT, which is currently the fastest Ethernet-based field bus system. Can be complemented with our PSC1 safety controller, as a safety separated solution, adjustments to the operational control can be realised with ease. As a reliable partner, we provide support in the design of safe, sustainable and forward-looking production processes. We look forward to working with you! 2

3 Content Introduction Page 2 Content Page 3 EFAS The advantages at a glance Page 4 Description Page 6 EFAS controller and communication modules Page 8 Mini IPC Controller EFAS Controller 113 Page 8 Mini IPC Controller EFAS Controller 116 Page 9 EtherCAT interface module EFAS Extender Page 10 EtherCAT Bus Coupler with Inputs and Outputs EFAS Bus Coupler DI16/DO16 Page 11 Digital EFAS I/O modules Page 12 Digital Input Module EFAS DI16 Page 13 Digital Input and Output Module EFAS DI16/DO16 Page 13 Digital Input Module EFAS DI32 Page 13 Digital Power Output Module EFAS DO8 2A Page 14 Digital Output Module EFAS DO16 Page 14 Digital Relay Output Module EFAS RO8 Page 15 Potential Distributor 2x16 Page 15 Analogue EFAS I/O modules Page 16 Analogue Input Module EFAS AI4-I Page 16 Analogue Input Module EFAS AI8-U Page 16 Analogue Output Module EFAS AO4-UI Page 17 Temperature Input Module EFAS AI4-PT-Ni-TH Page 17 Potential Distributor 2x16 Page 17 Special assemblies Page 18 Cam gear EFAS CAM Control Page 18 Counter Module with two counters EFAS Counter Page 19 Compact Drive Controller EFAS Drive Page 19 3

4 Efficient versatile increased productivity EFAS the advantages at a glance High performance The EtherCAT Fast Automation System (EFAS) from Schmersal allows you to increase productivity in your machines and production lines since EFAS communicates as far as the terminal via the EtherCAT Ethernet field bus with no intermediary bus. Each module is a direct EtherCAT peripheral. All EFAS controllers guarantee extremely high I/O access performance, thus ensuring optimum synchronisation for SPS tasks. Time-synchronous I/O access to EtherCAT slaves is also supported thanks to distributed clocks (DC). Variety of modules The EFAS automation control system offers an exceptional variety of modules which can be individually combined for all kinds of applications. No matter whether you wish to extend an existing CODESYS controller or use the EFAS controller as a separate solution, EFAS offers maximum flexibility for your automation tasks. Special modules tailored to your application allow process signals to be handled with new physical interfaces and application-specific functions to be implemented while achieving cost efficiencies. This delivers optimally customised machine and production line control. 4

5 Efficient versatile increased productivity EFAS the advantages at a glance Increased machine availability Predictive maintenance minimises machine downtimes. That's why the EFAS control integrates several functions which allow convenient on-site diagnosis or remote services to rectify malfunctions rapidly. High resistance to any environmental influences also guarantees high reliability and, consequently, maximum machine availability. Easy programming Control is programmed with CODESYS, a renowned software platform, which allows convenient, practice-oriented project planning for an extensive variety of automation applications. CODESYS unites software creation in IEC programming languages (FBD, LD, IL, ST and SFC), field bus configuration for EtherCAT and CANopen, I/O configuration, the visualisation editor and motion control in a single environment. Extensive debugging and online functions and numerous software add-ons and libraries make programming easier. Plug-ins for an extensive variety of applications and industries allows controls to be customised to the specific work environment. Time-tested safety monitoring Safety-separated: safety functions can be implemented using Schmersal's time-tested PSC1 safety control, which acts separately from EFAS automation control. This ensures that normal operation control can be adapted more easily to individual applications without needing to modify the safety functions and their documentation. The PROTECT PSC1 safety system is just as flexible as EFAS: n Complemented by central and decentralised I/O extension modules where necessary, the two PSC1-C-10 and PSC1-C-100 basic modules ensure optimum adaptation to the system size and connect safety switching components where they are needed. n The universal communication interface is used to communicate with the EFAS control system via EtherCAT. n The universal communication interface also allows secure remote I/O communication and secure cross-communication between PSC1 base devices via SDDC and SMMC Ethernet at the same time. 5

6 Description of EFAS automation control EtherCAT high-performing right up to the terminal A control system can only be as fast as its system bus. EFAS communicates via EtherCAT, currently considered the fastest Ethernet-based field bus system. EtherCAT is setting speed benchmarks with 1,000 I/Os in 30 µs. It links controls with I/O modules, drives and all EtherCAT -based sensors and actuators as rapidly as a central backplane bus. Thanks to its flexible network topology and simple configuration, EtherCAT is eminently suitable for controlling extremely fast processes. EFAS EtherCAT Fast Automation System The universal modular device concept of the EFAS series ensures optimum flexibility to implement tailored machine concepts at a low cost. Schmersal EFAS is a system comprising of I/O extension and special modules to connect process signals and perform special functions in an EtherCAT network. There are a large number of modules available: digital and analogue input and output modules, analogue temperature input modules, integrated drive control systems for steppers or BLDC motors, and modules for fast counting operations and cam switch units. Positioned in a row, these modules together with a high-performance controller or bus coupler form an EFAS block. The bus coupler transforms the external transmission signals, which are available at the ports (Ethernet), into the transfer physics inside the module (LVDS). EtherCAT remains completely intact during this process as do the system voltages generated for the connected modules. Schmersal EFAS Controller As the control head, the EFAS Controller supplies the extension and special modules and operates the internal bus. As the EtherCAT master, it transmits telegrams to write output data and read input data. Other EtherCAT slaves such as modern drive controllers can be connected via a port extender module, making it easy to wire different network topologies such as a star structure. Control heads are programmed with CODESYS V3, tailored to specific requirements with solutions such as SoftMotion (SM). The system can be easily integrated into a modern environment via different standard interfaces, such as an Ethernet Port (LAN). If required, other interface protocols are available such as CANopen, PROFINET and MODBUS TCP as a slave. All EFAS controllers guarantee extremely high I/O access performance, thus ensuring optimum synchronisation for SPS tasks. Time-synchronous I/O access to EtherCAT slaves is also supported thanks to distributed clocks (DC). Motion control The EFAS automation system allows stepper, BLDC and servo motors to be controlled in compliance with CoE/CiA 402 and PLCopen specifications. Single- or multi-axis movements, including flying saws and curve plotters, can be easily and conveniently planned on a standard IEC design interface together with the logic application. The integrated motion controller for stepper or BLDC motors or the 116-SM controller with SoftMotion functions allow you to implement movement functionality using a modular set-up within the CODESYS programming system. The up-and-down line is automatically terminated at the end of the block, so that the next EtherCAT unit can be connected to the bus coupler's second port. 6

7 System architectures with EFAS and PSC1 7

8 EFAS controller and communication modules EFAS controller EFAS controllers are mini IPCs based on ARM with integrated CODESYS PLCs. These are programmed with CODESYS V3. An SD card slot and USB interface enable local storage of process data and exchange of control programs. A digital interrupt input is available for immediate responses to process results. The modular control can be flexibly expanded with EtherCAT I/O modules of series EFAS via the side E-bus connection. Data exchange with other systems is via the integrated industrial Ethernet and RS232 interfaces and an additional CAN/CANopen field bus interface. This simplifies integration of the system into existing control concepts. The use of an EFAS extender module also allows for activation of external EtherCAT slaves. General technical data EFAS controller Interfaces 1 x RS232, 1 x USB 2.0 Network 1 x Ethernet 10/100 MBit/s RJ45 Field bus interface 1 x CAN galvanically isolated EtherCAT internally via E-Bus-Interface, externally via Extender module Integrated I/O 1 x DI interrupt supported Housing (W x H x D) Aluminium, plastic housing 25 x 120 x 90 mm Mounting 35 mm DIN Rail Power supply 24 VDC / ( ) Operating temperature 0 C +55 C Approvals 8

9 Mini IPC Controller EFAS Controller 113 Technical data EFAS Controller 113 EFAS-C-113 Part number Processor i.mx28 NXP 454 MHz RAM / non-volatile memory 128 MB / Storage in Flash Drive Internal Flash memory, SD(HC)-card slot Software Operating system: Windows Embedded CE 6.0 Application CODESYS V3 Soft SPS optional with Web Visualisation Power approx. 3 W (@ 24 VDC) Mini IPC Controller EFAS Controller 116 Technical data EFAS Controller 116 Type Schmersal EFAS Controller 116 and 116-SM (SoftMotion) Part number EFAS Controller C EFAS Controller C-116-SM Processor i.mx6 SoloX NXP 1 GHz RAM / non-volatile memory 256 MB / Storage in Flash Drive 256 MB internal Flash memory, SD(HC) card slot Software Operating system: Windows Embedded Compact 2013 / Real-time Linux Application CODESYS V3 Soft SPS optional with Web Visualisation and SoftMotion Power approx. 3.5 W (@ 24 VDC) 9

10 EFAS controller and communication modules EFAS communication modules The current range of communication modules enables communication with decentralised EFAS-I/O modules (remote I/Os) as well as connection of EtherCAT slaves from other manufacturers, such as drives, sensors, valves, etc. Other interface modules area available on request. Technical data Mounting 35 mm DIN Rail Shield connection Directly at module Ambient conditions 0 C +55 C, IP 20, EMC rating Zone B according to EN Approvals EtherCAT interface module EFAS Extender The EFAS extender module enables expansion of the EFAS controller or EFAS IO module blocks with any EtherCAT slaves (decentralised EFAS-I/O modules or devices from other manufacturers). The port extender serves to convert the transfer physics of the internal E-bus (LVDS) to the external EtherCAT network (Ethernet twisted pair). The module can be positioned at the end of the EFAS module block but may also be used at any point downstream of the EFAS controller or a bus coupler. The EFAS extender module also allows EtherCAT slaves to be wired with star topology. Technical data EFAS Extender EFAS-EXT-PORT2 Part number Internal E-Bus 2 x EtherCAT 100 MBit/s LVDS In/Out Field bus connection external 2 x EtherCAT RJ45 Out/Out Module supply via E-Bus Indication LED, assigned to the clamping point locally Housing (W x H x D) Aluminium, plastic, 25 x 120 x 90 mm 10

11 EtherCAT EtherCAT Bus Coupler with Inputs and Outputs EFAS Bus Coupler DI16/DO16 The bus coupler allows the control system to be expanded to include decentralised EFAS-I/O modules. For this to function correctly, the module converts the transfer physics of the external EtherCAT network (Ethernet twisted pair) to the internal E-bus (LVDS) and the voltage generation for connected EFAS/I-O modules. A maximum of 11 I/O modules can be installed at the side of the bus coupler. In addition, the module itself has 16 digital inputs and 16 Digital outputs. Technical data EFAS Bus Coupler DI16/DO16 EFAS-BC-2.0A-DI16-3MS-DO16-0.5A Part number Field bus connection 2 x EtherCAT RJ45 In/Out Expansion modules 100 MBit/s via E-Bus (LVDS) E-Bus supply max. 2 A (approx. 11 Module) Digital inputs 16 x 3 ms input delay Digital outputs 16 x 0.5 A, residual current max. 8 A Module supply 24 VDC ( 20 C +55 C) Indication LED, assigned to the clamping point locally Terminals Spring-loaded plug with mechanical ejection Housing (W x H x D) Aluminium, plastic, 42 x 120 x 90 mm 11

12 Digital EFAS I/O modules Description At 25 mm wide, the digital EFAS-I/O modules are extremely compact. Digital input modules capture the binary signal states of the sensors, which are connected to the EFAS automation system and galvanically isolated from the process level. The digital output modules switch the binary control signals through to the actuators. The actuation and power sides of the modules are separated by optocouplers. The galvanic isolations means that the supply to the outputs can only be switched off via a safety component. The signal state of each channel is indicated by LEDs for on-site diagnostics during commissioning or operation. General technical data, digital EFAS-I/O modules Field bus connection EtherCAT 100 MBit/s E-bus (LVDS) (with potential distributor 2x16 looped through from upstream to downstream module) Mounting 35 mm DIN Rail Indication LED, assigned to the clamping point locally Resistance to vibration/shock in accordance with EN / EN Transient emissions in accordance with EN / EN Protection class/mounting position IP 20 / any Shield connection Directly at module Terminals Spring-loaded plug with mechanical ejection Ambient conditions 0 C +55 C, IP 20, EMC rating Zone B according to EN Housing (W x H x D) Aluminium, plastic, 25 x 120 x 90 mm Approvals 12

13 Digital Input Module EFAS DI16 Technical data Input Module EFAS DI16 EFAS-DI16-1MS Part number Digital inputs 16 x 1 ms input delay Digital Input Module EFAS DI32 Technical data EFAS DI32 EFAS-DI32-1MS Part number Digital inputs 32 x 1 ms input delay Digital Input and Output Module EFAS DI16/DO16 Technical data EFAS DI16/DO16 EFAS-DI16-1MS-DO16-0.5A Part number Digital inputs 16 x 1 ms input delay Digital outputs 16 x 0.5 A, residual current max. 8 A 13

14 Digital EFAS I/O modules Digital Power Output Module EFAS DO8 2A Technical data EFAS DO8 2A EFAS-DO8-2.0A Part number Digital outputs 8 x 2 A, residual current max. 8 A Digital Output Module EFAS DO16 Technical data EFAS DO16 EFAS-DO16-0.5A Part number Digital outputs 16 x 0.5 A, residual current max. 8 A 14

15 Digital Relay Output Module EFAS RO8 The EFAS relay module has 8 relays each with one separated contact. The relay contact is available for voltages up to 24 VDC or 230 VAC and can be used universally for switching devices requiring mains power. It is suitable for machine and apparatus engineering and for building and control technology. The common 24 V power supply to the relay is separate to allow for integration into an emergency-off circuit. A maximum of 5 A ohmic or 2 A inductive load can be switched per output. Technical data Relay Output Module EFAS RO8 EFAS-RO8-230VAC Part number Digital outputs 8 x Relay, NO contact, 24 VDC / 230 VAC, 5 A ohmic / 2 A inductive Potential Distributor 2x16 The EFAS Potential distributor module provides 2 x 16 terminal points for potential distribution and enables the tapping of the voltages without further terminal blocks or wiring work. With the help of the module, the 2- or 3-wire connection can also be implemented with digital I/O modules. The module provides 2 separate potential lines. It distributes the voltage applied to the terminals L1 and L2 potential (optional 0 or 24 VDC) to the terminals 0 to 15 of the corresponding row. Conductor connection for solid conductors can be made without tools using the push-in technique. Technical data Potential Distributor 2x16 EFAS-POTENTIAL-DISTRIBUTOR-2X16 Part number Connections 2 x 16, potential 0 24 V 15

16 Analogue EFAS I/O modules Description Compact I/O modules for analogue signals with only 25 mm width. The input and output modules have 4 to 8 individually parametrisable inputs or outputs. Each input and output channel can be easily configured with CODESYS via CoE (the CAN application protocol over EtherCAT ) to the corresponding value range and the requisite parameters configured from the process map. The channels are digitised with a resolution of 12 or 13 Bit (inputs) and 16 Bit (outputs) and are galvanically isolated. The signal state of each channel is indicated by the LEDs assigned to the clamps. Thanks to the channel-based configuration, the variety of modules within a system can be reduced considerably. General technical data, analogue EFAS-I/O modules Field bus connection EtherCAT 100 MBit/s via E-Bus (LVDS) Mounting 35 mm DIN Rail Terminals Spring-loaded plug with mechanical ejection Indication LED, assigned to the clamping point locally Shield connection Directly at module Ambient conditions 0 C +55 C, IP 20, EMC rating Zone B according to EN Housing (W x H x D) Aluminium, plastic, 25 x 120 x 90 mm Approvals Analogue Input Module EFAS AI4-I Signals in the value range 0 to 20 ma or 4 to 20 ma can be processed with the Al4-I module. The current inputs can be used both for connection of passive as well as active current sensors. Technical data Input Module AI4-I EFAS-AI4-S-I-12BIT-COE Part number Analogue inputs 4 x current input 0 20 ma or 4 20 ma, 12 Bit, CoE Analogue Input Module EFAS AI8-U With the Al8-U module, the voltage inputs can be used differentially (max. 4 x 2 inputs) or single-ended (max. 8 inputs). Technical data Input Module AI8-U EFAS-AI8-SD-U-13BIT-COE Part number Analogue inputs 4 (differential) or 8 (single-ended) 0 10 V or ± 10 V, 13 Bit, CoE 16

17 Analogue Output Module EFAS AO4-UI The analogue output module AO 4-UI allows different current and voltage ranges to be adjusted. It generates signals over 4 channels in ranges 0 to 20 ma, 4 to 20 ma, 0 to 24 ma, 0 to 10 V and ±10 V. Technical data Output Module AO4 EFAS-AI4-S-I-12BIT-COE, Part number Analogue outputs 4 x either 0 10 V, ± 10 V, 0 20 ma, 4 20 ma or 0 24 ma, 16 Bit, CoE Temperature Input Module EFAS AI4-PT-NI-TH The analogue EFAS module Al4-PT/NI/Thermo has 4 individually parameterisable, galvanically isolated channels. The temperature inputs enable direction connection of resistance sensors and thermocouples. A microprocessor implements linearisation over the entire temperature range. For special temperature range requirements, customer-specific specifications can also be realised on request. Technical data Temperature Input Module AI4-PT/NI/Thermo EFAS-AI4-PT-NI-TH-16BIT-COE Part number Temperature Inputs Optional millivolt encoder, Pt100, Pt1000, Ni100, Ni1000 (DIN 43760) or thermocouple Resolution 16 Bit Potential Distributor 2x16 The EFAS Potential distributor module provides 2 x 16 terminal points for potential distribution and enables the tapping of the voltages without further terminal blocks or wiring work. With the help of the module, the 2- or 3-wire connection can also be implemented with digital I/O modules. The module provides 2 separate potential lines. It distributes the voltage applied to the terminals L1 and L2 potential (optional 0 or 24 VDC) to the terminals 0 to 15 of the corresponding row. Conductor connection for solid conductors can be made without tools using the push-in technique. Technical data Potential Distributor 2x16 EFAS-POTENTIAL-DISTRIBUTOR-2X16 Part number Connections 2 x 16, potential 0 24 V 17

18 Special assemblies Description Special assemblies expand the standard function and power range of the EFAS system to include assemblies for special applications. General technical data, special assemblies Field bus connection EtherCAT 100 MBit/s via E-Bus (LVDS) Mounting 35 mm DIN Rail Indication LED, assigned to the clamping point locally Shield connection Directly at module Terminals Spring-loaded plug with mechanical ejection Ambient conditions 0 C +55 C, IP 20, EMC rating Zone B according to EN Housing (W x H x D) Aluminium, plastic, 25 x 120 x 90 mm Approvals Cam gear EFAS CAM control The EFAS CAM control cam gear can be used as an autarchic or networked system solution and is often used in machines and special machinery where cyclic, recurring processes need to be controlled at higher speeds on a position-dependent basis. The EFAS CAM control receives the actual values from a shaft encoder and controls the functions of the machine according to the switching points parametrised by the user, where applicable taking into account any delay times. Time-dependent switching of outputs is also possible, as well as use of a single encoder via EtherCAT for synchronised control of multiple CAM control modules. EFAS CAM-Creator software is used to parametrise the cam functions. Technical data EFAS CAM Control EFAS-CAM Part number CAM tracks (outputs) 24 x 0.5 A (dead time compensation 1 up to 5000 ms) + 8 software tracks, 8 cams / track Total output current Itot 4.5 A Inputs 1 x 24 VDC, 1 ms, 4 x 24 VDC or 0 10 V (parametrisable) Encoder interface Incremental 24V DC, A, B, Ref., Absolute encoder via CANopen or EtherCAT CAM programs 32 Cycle time 20 µs Max. speed 1000 rpm (@ resolution 1 ) 18

19 Counter Module with two counters EFAS Counter The EFAS Counter module counts binary pulses and transmits the meter readings electrically isolated to the master control. Two counters are available with multiple counter modes and a higher counting frequency. The module can operate as A-B-Ref or forward/backward counter. It can be switched between single and multiple evaluation of the encoder signals. The digital inputs and output are used as a digital I/O in normal operation. With corresponding configuration, the output can also be controlled by a counter or input signals can be used to delete, initialise or freeze the counter status. Technical data EFAS Counter EFAS-CNT2-5V-24V Part number Counter input 2 x A/B/Ref, RS422 / 24 VDC: 200 khz Digital inputs 8 x 24 VDC 1 ms Digital outputs 2 x 24 VDC 2 A Compact Drive Controller EFAS Drive This extremely compact drive controller is the general-purpose solution for both, stepper motors and brushless DC motors (BLDC). Magnetic field-oriented vector control with encoder feedback and sine commutation ensure high dynamics, high efficiency, very smooth running and low running noise, especially when stepper motors are used. During operation, step errors during travel are corrected and load angle errors are compensated within one full step. By constantly monitoring the motor current, the controller only supplies as much current as necessary, resulting in high energy efficiency. The module can be configured via the integrated web server from any PC with Ethernet connection and web browser without any further software installation. Technical data EFAS CAM Control EFAS-DC-STEPPER-BLDC Part number Motor type 2 Phase Stepper motor or Brushless DC motor Power supply Electronic 24 VDC, motor VDC (culus V DC) Rated current 5 A (culus: max 55 C, VDC / 4 48 VDC) Peak current Stepper motor: 10 A / Brushless DC motor: 15 A Incremental encoder 5 V / 24 V (A, /A, B, /B, Z, /Z) Hall sensor 24 V (H1, H2, H3) or 3 additional zero-switching digital inputs Digital inputs 5 x 1 ms (configurable, reference, limit or release switch) Digital outputs 1 x 0.5 A (brake output or standard output) 19

20 The Schmersal Group In the demanding field of machine safety, the owner-managed Schmersal Group is one of the international market leaders. The company, which was founded in 1945, has a workforce of about 2000 people and seven manufacturing sites on three continents along with its own companies and sales partners in more than 60 countries. Customers of the Schmersal Group include global players from the area of mechanical engineering and plant manufacturing as well as operators of machinery. They profit from the company s extensive expertise as a provider of systems and solutions for machine safety. Furthermore, Schmersal specialises in various areas including food & beverage, packaging, machine tools, lift switchgear, heavy industry and automotive. A major contribution to the systems and solutions offered by the Schmersal Group is made by tec.nicum with its comprehensive range of services: certified Functional Safety Engineers advise machinery manufacturers and machinery operators in all aspects relating to machinery and occupational safety and do so with product and manufacturer neutrality. Furthermore, they design and realise complex solutions for safety around the world in close collaboration with the clients. Safety Products Safety Systems Safety Services Safety switches and sensors, solenoid interlocks Safety controllers and safety relay modules, safety bus systems Optoelectronic and tactile safety devices Automation technology: position switches, proximity switches Complete solutions for safeguarding hazard areas Individual parametrisation and programming of safety controllers Tailor-made safety technology be it for individual machines or a complex production line Industry-specific safety solutions tec.nicum academy Seminars and training tec.nicum consulting Consultancy services tec.nicum engineering Design and technical planning tec.nicum integration Execution and installation The details and data referred to have been carefully checked. Subject to technical amendments and errors. * # / L+W / / Teile-Nr / EN / Ausgabe 01