RECO Inline Counter Terminal R-IB IL CNT. Application Manual SYSTEM200 DOK-CONTRL-R-IL*CNT***-AW02-EN-P

Transcription

1 RECO Inline Counter Terminal R-IB IL CNT Application Manual SYSTEM200

2 About this Documentation Counter Terminal Title RECO Inline Counter Terminal R-IB IL CNT Type of Documentation Application Manual Document Typecode Internal File Reference Document Number, B344-02/EN Purpose of Documentation This documentation describes the commissioning and programming of the module within a Reco Inline station, serves as general information for the module terminals, serves to specify technical data, serves to specify diagrams and formulas. Record of Revisions Description Release Date Notes B344-02/EN 01/02 First English issue Copyright 2001 Rexroth Indramat GmbH Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Rexroth Indramat GmbH Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone +49 (0)93 52/40-0 Tx Fax +49 (0)93 52/ Dept. EP (UK/CH/NH) Note This document has been printed on chlorine-free bleached paper.

3 Counter Terminal Contents I Contents 1 Functional Description of the Terminal Functional Description Features of the Terminal Areas of Usage Design of the Terminal Housing Dimensions Assignment of Terminal Points Diagnostic and Status Indicators Internal Block Diagram Important Directions for use Appropriate Use Introduction Areas of Use and Application Inappropriate Use Safety Instructions for Electric Drives and Controls Introduction Explanations Hazards by Improper Use General Information Protection Against Contact with Electrical Parts Protection Against Electric Shock by Protective Low Voltage (PELV) Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems Mounting and Dismounting Counter Terminals / Connecting Lines Mounting Instructions for Replacing the Terminal Mounting and Dismounting a Terminal Voltage Supply

4 II Contents Counter Terminal 4.4 Connecting Sensors and Actuators Connection Methods for Sensors and Actuators Connecting a 24 V Sensor Connecting a 5 V Sensor Connecting an Actuator Connecting Lines Connecting Unshielded Lines Connecting Shielded Lines via the Shield Connector Process Data Operation Assignment of the Process Data Channel Output Words Input Words Commands used when working with the Counter Terminal Order of the Commands Frequency Measurement Mode Time-Controlled Frequency Measurement Condition-Controlled Frequency Measurement Event Count Mode Time Measurement Mode Pulse Generator Mode "System Settings" Command "Read Firmware Version" Command "Default Start Value" and "Default End Value" Commands "Stop Counter" and "Start counter" Commands "Set Counter to Default Condition" Command "Read Counter" Command" Limit Values and Limits to the Commands Survey of all Commands Examples and Hints Example for Event Counting Example for a Time Measurement with Comparative Conditions Example for a Time Measurement using System Settings Tips for Working with the Counter Terminal Programming, Technical Data and Ordering Information Programming Data Process Data Words Output Data Words for Configuring the Terminal Input Data Words Technical Data Ordering Information

5 Counter Terminal Contents III 9 Glossary List of Figures Index Service & Support Helpdesk Service-Hotline Internet Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities

6 IV Contents Counter Terminal

7 Counter Terminal Functional Description of the Terminal Functional Description of the Terminal 1.1 Functional Description The R-IB IL CNT terminal is a counter terminal designed for use within an inline station. The counter terminal is also simply called a counter. The counter detects and processes fast pulse sequences of sensors. It has a counter input (source), a control input (gate) and a freely configurable switch output that is set independently by the module. Fast reaction times that are independent of the bus and the control system can thereby be achieved. The terminal can be operated in four different modes. These modes are: frequency measurement, event count, time measurement and pulse generator. Sensors with 24 V DC power supply and 5 V DC power supply can be connected at the terminal. The connection output delivers a maximal current of 500 ma. Features of the Terminal # ' % ' ) Fig. 1-1: The R-IB IL CNT terminal with its appropriate connectors 5979a001.eps Event counting: The counting conditions and the output switching condition can be freely selected. Frequency measurement: Time and condition visualisation controlled frequency measurements with gate times (time of the measurement) between 10 ms and 10 s can be made. Time measurement: Comparative conditions can be evaluated using the time measurement. The evaluation result can be outputted by the process data or at the digital output. This allows a targeted reaction to be made if limit values are exceeded or fallen short of.

8 ! " * ) 4 + * 6! "! " 4, +! "! " 7! "! " 7 5 7! "! " / 5,! "! "! " 1-2 Functional Description of the Terminal Counter Terminal Areas of Usage Pulse generator: The pulse generator generates square signals with frequencies of 1 khz to 10 khz in 500 Hz steps. The event count and frequency measurement modes deliver a 24 bit test value; the time measurement delivers a 16 bit test value. A link between the source signal and the gate signal can be selected as the counting signal. During operation, a start or end value can be changed without having to stop the counter. An RC filter can be connected at the source and at the gate. This allows mechanical switches to be used. A counter-start command does not have to be issued to start counting. Counting begins immediately when the command for the selection of the operating mode is transmitted. The counter terminal works in process data mode. Event counting Event counting has been designed for unit counting. Example for event counting 1* 1 " * 1* ! # & ' % eps Fig. 1-2: Example configuration for counting separately packed articles Legend: No. Sensor/Actuator Corresponding input/output 1 Valve (control of the flap) Switch output 2 Sensor (control signal) Control input 3 Sensor (count pulse) Counter input In the example shown in Fig. 1-2, e.g. 100 screws should be packaged in a box. The control input (2) releases the counter at the counter input (3) when there are screws in the funnel. Every screw that falls from the funnel into the box triggers a pulse at the counter input. When there are 100 screws in the box, the switch output (1) is set ad the valve closes the funnel. A new box can now be filled.

9 Counter Terminal Functional Description of the Terminal 1-3 Frequency measurement Frequency measurement is suitable for measuring speeds. Time measurement You can use the time measurement option for a most varied range of applications. One example would be to determine the size of a part using the time measurement. This then allows you to determine the differences in size on a conveyor belt using the time differences. You can use the time measurement for measuring speed if you want to react to situations where the limit values are exceeded or fallen short of.. You can, e.g. set the output when a stipulated highest speed has been reached. Note: Please note that when in time measurement mode, you can measure lower speeds than when in frequency measurement mode as the time measurement works with 16-bit test values but the frequency measurement works with 24-bit values. Pulse generator You can generate and output pulse sequences at various frequencies using the pulse generator. 1.2 Design of the Terminal Housing Dimensions Nowadays, small I/O stations are often used in standard switch cabinets with a depth of 80 mm. The design of the Inline terminals allows for use in this type of switchbox. The housing dimensions of a terminal are defined by the dimensions of the electronic socket and of the connector. The electronics base of the terminal is 24.4 mm wide (see Fig. 1-3). Two plugs, each with a width of 12.2 mm are plugged onto this base (see Fig. 1-4). With plugged-on connector, the terminal has a depth of 71.5 mm. The height of the terminal depends on the type of connector used. Either one standard connector and one shielded connector (connector set for the counter terminal), or two standard connectors, can be used on the counter terminal.

10 1-4 Functional Description of the Terminal Counter Terminal Electronic socket % # & # " % " " " ' $ # # Fig. 1-3: Dimensions of the electronics base of the R-IB IL CNT terminal eps Connector ) *! # ' %!! " " " #!! " " " " " & " & # ' % ' ) # 5979a015.eps Fig. 1-4: Connector dimensions Legend: A Shield connector B Standard connector The connector depth is irrelevant as it has no effect on the overall module depth.

11 Counter Terminal Functional Description of the Terminal 1-5 Assignment of Terminal Points The R-IB IL AO/CNT-PLSET connector set has been designed for connecting the lines. It comprises one R-IB IL SCN-6 SHIELD shielded connector and one R-IB IL SCN-8 standard connector. You must use the shielded connector when you use shielded lines. A shielded line must be used when you are connecting sensors at the 5 V counter input and at the 5 V control input. If you are not using a shielded line then you can use two R-IB IL SCN-8 standard connectors.!!!!!!!! " " " " " " " " # ' % ' $ eps Fig. 1-5: Assignment of terminal points

12 1-6 Functional Description of the Terminal Counter Terminal Connector 1 Terminal point Signal Assignment 1.1 S+ Counter input 24 V (source) 2.1 G+ Control input 24 V (gate) 1.2 U INI Sensor voltage +24 V 2.2 U INI Sensor voltage +24 V 1.3 S- Ground for the counter input (source) and the segment voltage 2.3 G- Ground for the control input (gate) and the sensor voltage 1.4 Shield Shield connection (high capacitive resistance at FE) 2.4 Shield Shield connection (high capacitive resistance at FE) S+* Counter input 5 V (source) 2.1 G+* Control input 5 V (gate) OUT GND Output: the terminal points are bridged. Ground for the output: the terminal points are bridged internally. 1.4 FE Functional earth ground (directly to FE) 2.4 FE Functional earth ground (directly to FE) Fig. 1-6: Connector assignment Note: The sensor voltage U INI (protected by short-circuit) is generated from the main voltage U M. The main voltage U M is not used directly at the terminal points of the counter terminal. Diagnostic and Status Indicators 5, / # ' % ' ) % 5979a007.eps Fig. 1-7: Diagnostic and status indicators

13 Counter Terminal Functional Description of the Terminal 1-7 Diagnostics The display of the counter terminal informs you of the following conditions: D LED green Diagnostics On: Local bus is active E Flashing: 0.5 Hz: (at a slow rate) 2 Hz: (at a medium rate) 4 Hz: (at a rapid rate) Off: LED red On: Off: Logic voltage available, local bus not active Logic voltage available, LOCAL BUS active, peripheral fault Logic voltage available; terminal before the flashing terminal failed Terminals after the flashing terminal are not included in the configuration frame Logic voltage not available, LOCAL BUS not active Short-circuit at the sensor supply voltage Short-circuit at connector 1 between terminals 1.2 and 1.3 or between terminals 2.2 and 2.3 No fault Status The state of the input or output can be seen from the corresponding yellow LED: S LED yellow Status of counter input (source) On: Input is set Off: Input is not set G+ LED yellow Status of the control input (gate) On: Input is set Off: Input is not set 1 LED yellow Status of the output On: Output is set Off: Output is not set

14 1-8 Functional Description of the Terminal Counter Terminal Internal Block Diagram * ) ) : 1 " " # ' % ' " eps Fig. 1-8: Internal block diagram of the R-IB IL CNT Legend: Local bus U L+ Data jumper for the local bus Logic voltage U L- Grounded logic voltage U ANA Peripheral equipment supply voltage for analog terminals U M Main voltage +24 V U INI Sensor voltage +24 V; generated from the main voltage U S Segment voltage +24 V OPC Bus protocol chip (bus logic including voltage treatment) 2 Microprocessor Optocoupler Digital input

15 Counter Terminal Functional Description of the Terminal 1-9 Digital output Transistor (output driver) Coupling interface 2 Component with multiplexer, filter and logic 1 Sensor supply voltage with short-circuit protection Ground Functional earth ground Terminal connection Voltage or data jumpers with lateral routing contacts

16 1-10 Functional Description of the Terminal Counter Terminal

17 Counter Terminal Important Directions for use Important Directions for use 2.1 Appropriate Use Introduction Rexroth Indramat products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel. Note: Rexroth Indramat, as manufacturer, is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Rexroth Indramat products, make sure that all the prerequisites for appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the product takes the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation.

18 2-2 Important Directions for use Counter Terminal Areas of Use and Application The RECO Inline system is a decentralized modular fieldbus-coupled input and output system. The RECO Inline system by Rexroth Indramat is intended for the cases of use listed below. Machine tools Transfer systems General automation Note: The RECO Inline system may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant functional descriptions. 2.2 Inappropriate Use The typical fields of application of RECO Inline modules are as follows: Turning machines Milling machines Machining centers General automation The RECO Inline system may only be operated under the assembly, installation and ambient conditions as described here (temperature, system of protection, humidity, EMC requirements, etc.) and in the position specified. Using the RECO Inline system outside of the above-referenced areas of application or under operating conditions other than described in the document and the technical data specified is defined as "inappropriate use". The RECO Inline system may not be used if they are subject to operating conditions that do not meet the above specified ambient conditions. This includes, for example, operation under water, in the case of extreme temperature fluctuations or extreme maximum temperatures or if Rexroth Indramat has not specifically released them for that intended purpose. Please note the specifications outlined in the general Safety Instructions!

19 Counter Terminal Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls 3.1 Introduction Read these instructions before the initial startup of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times. Do not attempt to install or start up this equipment without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment, contact your local Rexroth Indramat representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the equipment is resold, rented or transferred or passed on to others, then these safety instructions must be delivered with the equipment. WARNING Improper use of this equipment, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! 3.2 Explanations The safety instructions describe the following degrees of hazard seriousness in compliance with ANSI Z535. The degree of hazard seriousness informs about the consequences resulting from noncompliance with the safety instructions. Warning symbol with signal word Degree of hazard seriousness according to ANSI Death or severe bodily harm will occur. DANGER Death or severe bodily harm may occur. WARNING Bodily harm or material damage may occur. CAUTION Fig. 3-1: Hazard classification (according to ANSI Z535)

20 3-2 Safety Instructions for Electric Drives and Controls Counter Terminal 3.3 Hazards by Improper Use DANGER High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life or bodily harm by electric shock! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to improper handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock or incorrect handling of pressurized systems! Risk of injury due to incorrect handling of batteries! CAUTION

21 Counter Terminal Safety Instructions for Electric Drives and Controls General Information Rexroth Indramat GmbH is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before starting up the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Only persons who are trained and qualified for the use and operation of the equipment may work on this equipment or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the equipment as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and equipment on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Use only safety features and applications that are clearly and explicitly approved in the Project Planning Manual. For example, the following areas of use are not permitted: construction cranes, elevators used for people or freight, devices and vehicles to transport people, medical applications, refinery plants, transport of hazardous goods, nuclear applications, applications sensitive to high frequency, mining, food processing, control of protection equipment (also in a machine). The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Startup of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application.

22 3-4 Safety Instructions for Electric Drives and Controls Counter Terminal Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the documentation "EMC in Drive and Control Systems". The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

23 Counter Terminal Safety Instructions for Electric Drives and Controls Protection Against Contact with Electrical Parts Note: This section refers to equipment and drive components with voltages above 50 Volts. Touching live parts with voltages of 50 Volts and more with bare hands or conductive tools or touching ungrounded housings can be dangerous and cause electric shock. In order to operate electrical equipment, certain parts must unavoidably have dangerous voltages applied to them. DANGER High electrical voltage! Danger to life, severe bodily harm by electric shock! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on high voltage installations. Before switching on power the ground wire must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the ground wire is not permanently connected to the points of the components provided for this purpose. Before working with electrical parts with voltage higher than 50 V, the equipment must be disconnected from the mains voltage or power supply. Make sure the equipment cannot be switched on again unintended. The following should be observed with electrical drive and filter components: Wait five (5) minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (RCD) must not be used on electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device. Electrical components with exposed live parts and uncovered high voltage terminals must be installed in a protective housing, for example, in a control cabinet.

24 3-6 Safety Instructions for Electric Drives and Controls Counter Terminal To be observed with electrical drive and filter components: DANGER High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! Connect the electrical equipment, the housings of all electrical units and motors permanently with the safety conductor at the ground points before power is switched on. Look at the connection diagram. This is even necessary for brief tests. Connect the safety conductor of the electrical equipment always permanently and firmly to the supply mains. Leakage current exceeds 3.5 ma in normal operation. Use a copper conductor with at least 10 mm² cross section over its entire course for this safety conductor connection! Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. Otherwise, high voltages can occur on the housing that lead to electric shock. 3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 0 and 50 Volts on Rexroth Indramat products are protective low voltages designed in accordance with international standards on electrical safety. WARNING High electrical voltage due to wrong connections! Danger to life, bodily harm by electric shock! Only connect equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) to all terminals and clamps with voltages of 0 to 50 Volts. Only electrical circuits may be connected which are safely isolated against high voltage circuits. Safe isolation is achieved, for example, with an isolating transformer, an opto-electronic coupler or when battery-operated.

25 Counter Terminal Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of the connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily injury and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation. DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. Unintended machine motion is possible if monitoring devices are disabled, bypassed or not activated. Pay attention to unintended machine motion or other malfunction in any mode of operation. Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: - use safety fences - use safety guards - use protective coverings - install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum, especially if there is a possibility of loose parts flying off. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Safe standstill can be achieved by switching off the power supply contactor or by safe mechanical locking of moving parts.

26 3-8 Safety Instructions for Electric Drives and Controls Counter Terminal Secure vertical axes against falling or dropping after switching off the motor power by, for example: - mechanically securing the vertical axes - adding an external braking/ arrester/ clamping mechanism - ensuring sufficient equilibration of the vertical axes The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety! Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: - maintenance and repair work - cleaning of equipment - long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such equipment cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.

27 Counter Terminal Safety Instructions for Electric Drives and Controls Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated near current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers, hearing aids and metal implants are not permitted to enter the following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a heart pacemaker to enter such an area, then a doctor must be consulted prior to doing so. Heart pacemakers that are already implanted or will be implanted in the future, have a considerable variation in their electrical noise immunity. Therefore there are no rules with general validity. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise, health hazards will occur.

28 3-10 Safety Instructions for Electric Drives and Controls Counter Terminal 3.9 Protection Against Contact with Hot Parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch housing surfaces near sources of heat! Danger of burns! After switching the equipment off, wait at least ten (10) minutes to allow it to cool down before touching it. Do not touch hot parts of the equipment, such as housings with integrated heat sinks and resistors. Danger of burns! 3.10 Protection During Handling and Mounting Under certain conditions, incorrect handling and mounting of parts and components may cause injuries. CAUTION Risk of injury by incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general installation and safety instructions with regard to handling and mounting. Use appropriate mounting and transport equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. For safe protection wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stand under suspended loads. Clean up liquids from the floor immediately to prevent slipping.

29 Counter Terminal Safety Instructions for Electric Drives and Controls Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. CAUTION Risk of injury by incorrect handling! Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization). Never charge non-chargeable batteries (danger of leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Do not damage electrical components installed in the equipment. Note: Be aware of environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose batteries separately from other waste. Observe the legal requirements in the country of installation Protection Against Pressurized Systems Certain motors and drive controllers, corresponding to the information in the respective Project Planning Manual, must be provided with pressurized media, such as compressed air, hydraulic oil, cooling fluid and cooling lubricant supplied by external systems. Incorrect handling of the supply and connections of pressurized systems can lead to injuries or accidents. In these cases, improper handling of external supply systems, supply lines or connections can cause injuries or material damage. CAUTION Danger of injury by incorrect handling of pressurized systems! Do not attempt to disassemble, to open or to cut a pressurized system (danger of explosion). Observe the operation instructions of the respective manufacturer. Before disassembling pressurized systems, release pressure and drain off the fluid or gas. Use suitable protective clothing (for example safety glasses, safety shoes and safety gloves) Remove any fluid that has leaked out onto the floor immediately. Note: Environmental protection and disposal! The media used in the operation of the pressurized system equipment may not be environmentally compatible. Media that are damaging the environment must be disposed separately from normal waste. Observe the legal requirements in the country of installation.

30 3-12 Safety Instructions for Electric Drives and Controls Counter Terminal Notes

31 Counter Terminal Mounting and Dismounting Counter Terminals / Connecting Lines Mounting and Dismounting Counter Terminals / Connecting Lines 4.1 Mounting Instructions for Replacing the Terminal DANGER Do not replace terminals when the station is live! De-energize the entire station before you remove a terminal from the station or before you install a terminal in the station! Reconnect the voltage only after you have completed setup of the entire station. 4.2 Mounting and Dismounting a Terminal The terminal has been designed for operation in a RECO Inline Station. You can set up a RECO Inline station by butt-mounting the individual components. You do not require any tools. When the components are butt-mounted, the potential and bus signal connection between the individual components of the station is established automatically. All Inline terminals are mounted on a 35-mm standard mounting rail. The terminals must be mounted perpendicular to the mounting rail. This ensures simple installation and removal even with confined space conditions. Once the station has been set up, individual terminals can be subsequently replaced by being pulled out or plugged in without any additional tools. Note: The design of an Inline station and the procedures to be used when mounting and dismounting a terminal are described in the user manual "Planning and Installation of the RECO Inline Module Family ".

32 4-2 Mounting and Dismounting Counter Terminals / Connecting Lines Counter Terminal 4.3 Voltage Supply The power supply to the terminal is carried out by the voltage jumper. The additional connection of supply voltages is not required. 4.4 Connecting Sensors and Actuators Sensors and the actuator must be connected using the connectors. Connector set R-IB IL AO/CNT-PLSET must be used for the R-IB IL CNT terminal. It comprises a shielded connector and a standard connector. If you use 5 V signals for the sensors then you must use the shielded connector. If you are not using such signals then the connecting lines do not need to be shielded and you can then use two standard connectors. Connect unshielded lines in according with chapter Connecting Unshielded Lines on page 4-6. Connect shielded lines in according with chapter Connecting Shielded Lines using the Shielded Connector on page 4-7. Connection Methods for Sensors and Actuators 24 V sensors The 24 V sensors can be connected in the following ways: 2-wire connection (signal and 24 V) 3-wire connection (signal and GND) 5 V sensors The 5 V sensors can be connected in the following ways: 2-wire connection (signal, GND) with shield and external 5 V supply voltage Actuator You can connect the actuator as a 2-wire connection (signal and GND).

33 Counter Terminal Mounting and Dismounting Counter Terminals / Connecting Lines 4-3 Connecting a 24 V Sensor ) * " 8 1 " 8 # ' % ' ) $ 5979a016.eps Fig. 4-1: Connecting a 24 V sensor (Example: Counter input) Signal Terminal point Meaning S+ 1/1.1 Counter input 24 V (source) U INI 1/1.2 Sensor voltage +24 V S- 1/1.3 Ground for the counter input and the segment voltage FE 1/1.4 Functional earth ground Fig. 4-2: Terminal assignment of terminal with 24 V sensor Two-wire connection Three-wire connection Figure A illustrates the connection of a 2-wire sensor at the 24 V counter input. The sensor signal is supplied to the terminal point S+. The sensor is supplied by the voltage U INI. Figure B illustrates the connection of a 3-wire sensor at the 24 V counter input. The sensor signal is supplied to the terminal point S+. The sensor is supplied via the U INI and S- terminal points. A 24 V sensor at the control input is connected in exactly the same way as a 24 V sensor at the counter input. Observe the terminal assignment of the counter terminal ("Assignment of the Terminal Points" on page 1-4).

34 4-4 Mounting and Dismounting Counter Terminals / Connecting Lines Counter Terminal Connecting a 5 V Sensor # 8, + # ' % ' ) % 5979a017.eps Fig. 4-3: Connecting a 5 V sensor Signal Terminal point Meaning S+* 2/1.1 Counter input 5 V (source) S- 1/1.3 Ground for the counter input and the segment voltage FE 1/1.4 Functional earth ground Fig. 4-4: Terminal assignment of terminal with 5 V sensor Fig. 4-3 illustrates the connection of a 2-wire sensor at the 5 V counter input. The sensor signal is supplied to the terminal point S+*. Ground reference is located at terminal point S-. The sensor is grounded via the FE terminal point of the shielded connector. The 5 V supply for the sensor must be supplied externally. A 5 V sensor at the control input is connected in exactly the same way as a 5 V sensor at the counter input. Observe the terminal assignment of the counter terminal ("Assignment of the Terminal Points" on page 1-4).

35 Counter Terminal Mounting and Dismounting Counter Terminals / Connecting Lines 4-5 Connecting an Actuator 7 6 /, 7 6 Fig. 4-5: Connecting an actuator # ' % ' eps Signal Terminal point Meaning OUT1 2/2.2 Output GND 2/2.3 Ground reference for the output Fig. 4-6: Terminal assignment: Connecting an actuator Fig. 4-5 illustrates the connection of an actuator. The actuator is supplied with voltage by the output OUT1. The load is switched directly via the output. DANGER Observe correct ampacity! The maximal ampacity of the output of 500 ma must not be exceeded. If this is not observed, then the output switches off in case of overload.

36 1 F EC EJ= 4-6 Mounting and Dismounting Counter Terminals / Connecting Lines Counter Terminal 4.5 Connecting Lines Connecting Unshielded Lines When using the R-IB IL CNT terminal within an Inline station, both shielded and unshielded connecting lines can be used. Connect the lines for peripheral equipment via tension spring connection points. This allows lines with a connection cross-section of 0.2 mm 2 to 1.5 mm 2 (AWG 24-16) to be connected. # ' % ' eps Fig. 4-7: Connecting unshielded lines Wire the connectors as required according to your application. Note: The connection assignment is listed in "Assignment of Terminal Points" on page 1-5. Proceed as follows to wire the connectors: Strip the line to a length of 8 mm. The Inline wiring is provided without connector sleeves. However, connector sleeves may be used, if desired. In this case, the connector sleeves must be properly crimped. Push a screw driver so far into the operating vertical raceway of the corresponding terminal point (Fig. 4-7, 1) that you are able to put the conductor into the opening of the spring. Rexroth Indramat recommends the screwdriver SFZ x 3.5 (in preparation). Insert the conductor (Fig. 4-7, 2). Pull the screwdriver out of the opening. This fixes the conductor. We recommend you label both the cores and the terminal points after completed installation (see the user manual "Planning and Installing the Inline Module Family").

37 Counter Terminal Mounting and Dismounting Counter Terminals / Connecting Lines 4-7 Connecting Shielded Lines via the Shield Connector ) * # # ' = &! +, -... # ' % ' # eps Fig. 4-8: Connecting the shield on the shielded connector Shielded lines must be used exclusively when you are connecting sensors at the 5 V counter input and at the 5 V control input. Connection at the 5 V counter input is described here. This input must be wired as follows in accordance to the connector assignment in chapter "Assignment of Terminal Points" on page 1-5: Proceed as follows (compare Fig. 4-8) : Counter input 5 V Connector 2 Terminal point 1.1 GND counter input Connector 1 Terminal point 1.3 Shield Connector 1 Shield connection

38 4-8 Mounting and Dismounting Counter Terminals / Connecting Lines Counter Terminal Stripping the lines Strip the outer sheath of the line to the desired length (a). (A) Select the length (a) is such a way that you are also able to easily connect the line to connector 2. The desired length (a) also depends on whether you intend to lay the cores between the connection point and shield connection in a generous or a tight arrangement. Shorten the braided screen to 15 mm. (A) Place the braided screen around the outer sheath. (B) Remove the protective foil. Strip the cores for 8 mm. (B) Note: The Inline wiring is provided without connector sleeves. However, connector sleeves may be used, if desired. In this case, the connector sleeves must be properly crimped. Wiring the connectors Push a screw driver so far into the operating vertical raceway of the corresponding terminal point (Fig. 4-8 on page 4-7, 1) that you are able to put the conductor into the opening of the spring. Rexroth Indramat recommends the screwdriver SFZ x 3.5 (in preparation). Insert the conductor (Fig. 4-8 on page 4-7, 2). Pull the screwdriver out of the opening. This fixes the conductor. Note: The connector assignment is listed in chapter "Assignment of Terminal Points" on page 1-5. Connecting the shield Open the shield connector. (C) Check the alignment of the shield clip in the shield connection (see Fig. 4-8). Place the line including surrounding braided screen in the shield connector. (D) Close the shield connector. (E) Tighten the screws on the shield connector using a screwdriver. (F1) Fix the second conductor to connector 2. (F2)

39 Counter Terminal Mounting and Dismounting Counter Terminals / Connecting Lines 4-9 Shield clip The shield clip (a in Fig. 4-8, 2) in the shield connector can be used according to the line cross-section. With thicker lines, the bulging of the clip must be directed away from the line (Fig. 4-8, 2) With thinner lines, the bulging of the clip must be directed facing the line (Fig. 4-8, 6) If you need to change the direction of the shield clip, proceed as follows according to : Open the housing of the shield connector (1). When delivered, the shield connector is intended for the connection of thicker lines (2). Remove the clip (3), turn the clip according to the cross-section of the line used (4), and fit the clip (5). (5) Figure 6 illustrates the clip if a thin line is used. =! " # $ # # ) $ & 5520a068.eps Fig. 4-9: Aligning the shield clip

40 4-10 Mounting and Dismounting Counter Terminals / Connecting Lines Counter Terminal

41 Counter Terminal Process Data Operation Process Data Operation The counter terminal is configured, controlled and read via process data. 5.1 Assignment of the Process Data Channel The process picture of the counter terminal on the BUS ring is comprised of two data words. DANGER Observe the correct data consistency! Make sure there is a data consistency of two words otherwise the values may be incorrectly interpreted! In this regard, observe the instructions in chapter "Tips for Working with the Counter Terminal" on page 7-9. Controller board Output (memory) area Input (memory) area INTERBUS Input/output IB IL CNT Register Process data channel eps Fig. 5-1: Process picture in the input/output (memory) area of your interface module The data word is in the process data memory area on your interface module. This memory area represents a process picture of your entire application, i.e. your bus construction. You assign the addresses via the physical or logical addressing of the interface module. The process data (memory) area consists of an output (memory) area and an input (memory) area. Both memory areas do not necessarily have to be different.

42 5-2 Process Data Operation Counter Terminal Definition: Data flow of the output data: Data flow of the input data: From the interface module to the terminal From the terminal to the interface module 5.2 Output Words You configure and control the R-IB IL CNT terminal via various commands that are transmitted via the two output words. You transmit the command code via the output word and, when so required, the corresponding parameters from the interface module to the terminal. If no parameters are required then the assignment of the parameter bit is irrelevant. Process data word 0 Process data word 1 MSB LSB Parameter MSB LSB Command code Parameter Fig. 5-2: Assignment of output words eps The possible command codes are listed in chapter 6, "Commands used when working with the Counter Terminal".

43 Counter Terminal Process Data Operation Input Words Two input words are assigned to the R-IB IL CNT terminal. If any command apart from the "read counter" command has been issued then the command code and (if it exists) the corresponding parameter are mapped (mirrored) in the input words at the same position as that of the output word. If parameter word 1 is not required then its assignment is irrelevant. In this case, it does not mirror the assignment of output word 1. A fault bit is set in bit 15 of input word 0 if one of the following causes occurs: The terminal has not yet been configured; There is in invalid parameter in the setting of the operating mode; The counter is read without an operating mode being set; A reserved bit has been set. Process data word 0 Pr ocess data word 1 MSB LSB Mirroring of data wor d MSB LSB Mirr oring of command code Fault bit Parameter eps Fig. 5-3: Assignment of input words (except when after Read Counter)

44 5-4 Process Data Operation Counter Terminal Reading the counter Process data word 0 After issuing the "read counter" command, the command code (00000 bin ) is mirrored in bits 15 to 10 of input word 0. The status of the control input (gate) is shown in bit 9. The status of the output (out) or the result of the evaluation of a comparative condition is displayed in bit 8 (exceeding or falling below of limit values, see Fig. 6-18: Comparative conditions on page 6-10). Bits 7 to 0 of input word 0 and input word 1 contain the results of the count that has been made. A 16-bit value (in time measurement mode) is displayed in input word 1. Bits 7 to 0 of input word 0 are thereby not assigned. A 24-Bit value (in frequency measurement and event count mode) is displayed in the result bit of input words 0 and 1. Process data word 1 MSB LSB Result (counter) MSB LSB bin Gate Out Result (counter) 5979A a018.eps Fig. 5-4: Assignment of input words after Read Counter