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Pleiger Elektronik GmbH & Co. KG Fon +49 2324 398 333 D-58456 Witten Im Hammertal 51 Fax +49 2324 398 389 www.pleiger-elektronik.de [email protected] PCM Pleiger Control Modules PCM Series CM3 manual -version 2013-07 - subject to modification - Manual Modul EHS Control Module IO 8/8/4 IO Module RK 16/8 Relay Card CCM Conti Control Module BI Bus Interface

Transcript of PCM - Handbuch · 2019. 5. 10. · PCM Pleiger Elektronik GmbH & Co. KG Fon +49 2324 398 333 3 / 40...

Page 1: PCM - Handbuch · 2019. 5. 10. · PCM Pleiger Elektronik GmbH & Co. KG Fon +49 2324 398 333 3 / 40 PCM Series CM3 manual -version 2013-07 2 Overview The system consists of the components:

Pleiger Elektronik GmbH & Co. KG Fon +49 2324 398 333 D-58456 Witten ● Im Hammertal 51 Fax +49 2324 398 389 www.pleiger-elektronik.de [email protected]

PCM

Pleiger Control Modules

PCM Series CM3

manual -version 2013-07 - subject to modification -

Manual

• Modul EHS Control Module

• IO 8/8/4 IO Module

• RK 16/8 Relay Card

• CCM Conti Control Module

• BI Bus Interface

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PCM

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PCM Series CM3 manual -version 2013-07

Contents

1 General information .................................................................................. 1 1.1 Transportation and storage instructions ........................................................................... 1 1.2 Installation and electrical connection ................................................................................ 1 1.3 Intervention into the component ........................................................................................ 1 1.4 Intended use ........................................................................................................................ 1 1.5 Not intended use ................................................................................................................. 1 1.6 Use in safety related vital functions................................................................................... 1 1.7 Certificates and Approvals ................................................................................................ 2

2 Overview .................................................................................................... 3

2.1 Assembly ............................................................................................................................. 3

3 EHS control module CM3 ......................................................................... 4 3.1 Operation ............................................................................................................................. 4 3.2 Control functions ................................................................................................................ 5

3.2.1 Types of actuators ........................................................................................................... 5 3.2.2 Operation modes of the actuators .................................................................................... 6

3.3 Adjusting the operating time .............................................................................................. 7 3.3.1 Calibration of the operating time ...................................................................................... 7

3.4 Extended operation modes ................................................................................................ 7 3.4.1 Mimic wire break detection (article numbers 9341100160 / 170 only) .............................. 7 3.4.2 Extended operation mode set-up ..................................................................................... 8 3.4.3 Displaying extended operation modes ............................................................................. 8

3.5 Start reports and self-test ................................................................................................... 8 3.6 Alarm output ........................................................................................................................ 9 3.7 Lamp test ............................................................................................................................. 9 3.8 Placing commands .............................................................................................................. 9 3.9 Terminal assignment .......................................................................................................... 9 3.10 Technical data ................................................................................................................... 10 3.11 Connecting Ex-Type actuators ......................................................................................... 10

4 Input/output module IO 8/8/4 .................................................................. 11 4.1 Displays ............................................................................................................................. 11

4.1.1 Start messages and self-test .......................................................................................... 11 4.1.2 Lamp test ....................................................................................................................... 11

4.2 Adjusting the address ....................................................................................................... 12 4.3 Terminal assignment ........................................................................................................ 12 4.4 Technical data ................................................................................................................... 13

5 Relay Module RK 16/8 ............................................................................. 14 5.1 Indication ........................................................................................................................... 14 5.2 Operation ........................................................................................................................... 14 5.3 Jumper B1 ......................................................................................................................... 14 5.4 Counter function ............................................................................................................... 14 5.5 Technical Data ................................................................................................................... 15 5.6 Terminal assignment ........................................................................................................ 15

6 Conti Control Module CCM ..................................................................... 16 6.1 Operation ........................................................................................................................... 16

6.1.1 Status LED..................................................................................................................... 16 6.1.2 Position measurement ................................................................................................... 17 6.1.3 Position indication .......................................................................................................... 17

6.2 Calibration ......................................................................................................................... 17 6.3 Extended Operation Modes .............................................................................................. 18 6.4 Start reports and self test ................................................................................................. 18

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6.5 Alarm output ...................................................................................................................... 18 6.6 Lamp Test .......................................................................................................................... 18 6.7 Placing commands ............................................................................................................ 18 6.8 Analog Position Signal ..................................................................................................... 19 6.9 Behaviour in case of black out ......................................................................................... 19 6.10 Terminals ........................................................................................................................... 19 6.11 Interface to Flowmeter ...................................................................................................... 20 6.12 Technical data ................................................................................................................... 20

7 Fieldbus interface BI ............................................................................... 21 7.1 Operation ........................................................................................................................... 21

7.1.1 Parameterisation of the fieldbus ..................................................................................... 21 7.1.2 Setting the address of the EHS-CM3 / CCM modules .................................................... 21 7.1.3 Setting the address and operation mode of the RK 16/8 ................................................ 22 7.1.4 Skipping addresses ........................................................................................................ 23 7.1.5 Display functions ............................................................................................................ 23 7.1.6 Start messages and self test .......................................................................................... 24 7.1.7 Power management ....................................................................................................... 24 7.1.8 Set-up of Quick Close Functions .................................................................................... 25 7.1.9 Alarm output .................................................................................................................. 25 7.1.10 Lamp test ....................................................................................................................... 25 7.1.11 Bus Termination ............................................................................................................. 25

7.2 Terminal assignment ........................................................................................................ 25 7.3 Technical data ................................................................................................................... 26

8 BI Modbus interface (slave) .................................................................... 27 8.1 Modbus data model ........................................................................................................... 27

8.1.1 Fieldbus interface BI status, register 1, (read only) ........................................................ 27 8.1.2 CM3 status register (read only) ...................................................................................... 28 8.1.3 CCM status register (read only) ..................................................................................... 29 8.1.4 IO status register (read only) .......................................................................................... 30 8.1.5 Fieldbus interface BI remote control, register 142 (read/write) ....................................... 30 8.1.6 CM3 control register (read/write) .................................................................................... 30 8.1.7 CCM control register (read/write) ................................................................................... 31 8.1.8 IO control register (read/write)........................................................................................ 31 8.1.9 RK status register (read only) ........................................................................................ 32 8.1.10 RK control register (read / write) .................................................................................... 32

8.2 Fieldbus Watchdog ........................................................................................................... 32 8.3 Register summary ............................................................................................................. 33

9 BI Profibus DP interface (slave) ............................................................. 34 9.1 Profibus data model .......................................................................................................... 34

9.1.1 Fieldbus interface to superimposed control system (status words) ................................. 34 9.1.2 34 9.1.3 Data Valid Bit .................................................................................................................... 35

10 Secondary BI Module .............................................................................. 36 10.1 Parameterisation of the secondary BI module ................................................................ 36 10.2 Fieldbus interface BI status, register 1 (read only) ......................................................... 36 10.3 Fieldbus interface BI remote control, register 142 (read/write) ...................................... 37 10.4 Operating redundant BI .................................................................................................... 37 10.5 Alarm output ...................................................................................................................... 37

11 PCM modules, available versions .......................................................... 37 11.1 CM3 .................................................................................................................................... 37 11.2 BI ........................................................................................................................................ 37 11.3 IO 8/8/4 ............................................................................................................................... 38 11.4 RK 16/8 ............................................................................................................................... 38

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11.5 CCM .................................................................................................................................... 38

12 Assembly of the system ......................................................................... 38 12.1 Controlling via mimic diagram ......................................................................................... 38 12.2 Commissioning hints ........................................................................................................ 39 12.3 Safety Advice ..................................................................................................................... 39 12.4 Accessories ....................................................................................................................... 39

12.4.1 Adapting Cable .............................................................................................................. 39 12.4.2 Extension Cable ............................................................................................................. 40 12.4.3 Adapting Cable for RK 16/8 ........................................................................................... 40 12.4.4 Safety Advice Plate ........................................................................................................ 40 12.4.5 End Holder ..................................................................................................................... 40 12.4.6 Noise Suppression Filter ................................................................................................ 40 12.4.7 CM-ExE Capacitor Module ............................................................................................. 40

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1 General information This manual contains instructions and drawings for correct handling and using the equipment. Please observe all instructions of this manual carefully. Please note that not respecting the information, using the equipment not according the regulations be-low, wrong installation or incorrect handling could influence personal or plant safety seriously!

This manual is part of this operation resource. Keep the manual safe for later use. The manufacturer

reserves the right to change performance data, specification data or the design layout without an ad-

vance notice.

1.1 Transportation and storage instructions

The equipment must be inspected upon reception for damages that may have occurred during transportation or handling. If damages are obviously, inform the carrier and the manufacturer immediately. Dropped components must not be applied because invisible damages may influence the reliability.

1.2 Installation and electrical connection

The equipment has to be installed by qualified personnel only, that is familiar with the

safety requirements and potential risk. Please note the special safety requirements be-

longing the point of installation, generally accepted rules of technology, the connection

instruction in this manual and the available imprint on the component.

1.3 Intervention into the component

If malfunctions occur or something is dubious please contact the manufacturer. Intervention into the component could heavily affect the safety of person and plant and will lead to termination of liability and caveat emptor.

1.4 Intended use

To use the equipment is approved only if the instructions of this manual are complied and the use is

appropriate to the type label and to an application it is intended to.

In the field the technical specifications and denoted limit values have to be generally maintained. This

applies particular with regard to voltage, temperature and other noted environmental conditions. The

use beyond the specified and approved edge conditions could put life at risk, damage the component

or cause secondary damages to the plant.

1.5 Not intended use

Every use of the component that is not equal to the use described in chapter „1.4 intended use“ is obtained as not intended use. Damages that result from not intended use and / or result from unauthor-ised intervention on the component, not according to this manual, or not using original spare parts the claim for warranty and liability of the manufacturer expires.

1.6 Use in safety related vital functions

It is the responsibility of the user to perform a risk analysis of the whole installation and to define potential safety related functions. It is the responsibility of the user to take care of appropriate measures to achieve the safeness in safety related vital functions.

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1.7 Certificates and Approvals

PCM-modules meet the requirements of the following Directives:

• Directive 2014/90/EU on marine equipment

• DNV GL Guidelines VI-7-2

The following approvals apply:

• Type approval 26 092 – 05 HH by DNV GL

Certificates and approvals can be downloaded from our website or ordered from the manufacturer.

Technical Support:

+49 2324 398 333 [email protected]

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2 Overview The system consists of the components: ART.NO.

• EHS control module CM3 9341100100, 140, 150, 160, 170, 180

• Input/output module IO 8/8/4 9341100300

• Relay module RK 16/8 9341100400

• Conti Control Module CCM 9341100500

• Fieldbus interface BI 9341100200 or 9341100250

The EHS control module CM3 is for the control and monitoring of electro hydraulic swivel drives. Op-

eration can be carried out manually with the assistance of the control module operation elements, via

digital inputs and outputs of the control module and via a serial data connection to a supervisory con-

trol system. The CM3 control function can be adapted to the different actuator types by means of a

quadruple switch.

The input/output module IO8/8/4 has 8 analog inputs, 8 digital inputs and 4 digital outputs and is for

monitoring and output of control signals. Link-up to a supervisory control system is carried out via a

serial data connection.

The RK16/8 module provides 8 relay outputs (normally open) and 16 digital inputs with opto-couplers.

This module is primarily used to control centralized hydraulic actuators. Up 4 double acting or 8 single

acting actuators can be operated by a single module.

The CCM module is used to control centralized hydraulic actuators with analog position feedback.

Those actuators use flowmeters with digital outputs that can directly be connected to the CCM.

The fieldbus interface BI forms the interface between the bus protocol of the local module bus and the

fieldbus according to the Modbus RTU or Profibus DP standard. Furthermore, the fieldbus interface

acts as a monitor for all modules at the local bus and enables simple parameterisation of these mod-

ules.

2.1 Assembly

The modules BI, CM3 / CCM and IO are installed in a narrow, compact top-hat rail housing

(22.5x105x115, WxHxD). They are interconnected via a connector system in the top-hat rail and can

be removed from the system independently or re-applied without interfering with the function of the

overall system. The RK 16/8 module is installed in a flat top-hat rail housing (102x126x30) connected

to the local bus by means of a prefabricated connetcion cable.

CM3 CCM IO 8/8/4 BI RK 16/8

The local bus connects all modules to a 24V supply voltage, a serial databus and a common digital

control line used for lamp test. Up to 50 CM3 modules, 10 IO and 20 RK modules can be connected to

a fieldbus interface. In doing so the IO modules must be aligned to the left of the fieldbus interface and

the CM3 and RK modules to the right of the fieldbus interface.

15

26

37

48

9 10 11 1213 14 15 16

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3 EHS control module CM3 The EHS CM3 control module monitors and controls electro-hydraulic flap or valve actuators manu-

factured by Pleiger Maschinenbau. One control module is required for each actuator. The actuator can

be connected directly to the control module. The module is equipped with the necessary power relays

and actuator supply voltage fusing.

3.1 Operation

The EHS control module has several operating and display elements that enable manual on-site oper-

ation of the actuator.

switch „local - remote“

In position “local” the drive can be operated by means of the „close-0-

open“ switch. In position „remote” the can be operated using the digital

control inputs or the local serial bus.

button „close - 0 - open“

This button is used to operate the drive while the operating mode is „lo-

cal“. If the operation mode is “remote” pressing this button will indicate

the device and software version on the BI display.

Furthermore, operation of the local-remote switch causes temporary display of the module address on

the fieldbus interface. In addition, these control elements are also used for the parameterisation of the

local bus (see also: 7.1.2).

Three LED (red, yellow, green) signalise the operating status of the actuator and the con-

trol module.

LED red LED green meaning

on off Drive in closed position

on blinking 1/s Drive in closed position, open command received

off blinking 1/s Drive is opening, closed position left

off on Drive in open position

blinking 1/s on Drive in open position, close command received

blinking 1/s off Drive is closing, open position left

blinking 2/s on / off Not closed within supervision time

on / off blinking 2/s Not opened within supervision time

blinking 2/s blinking 2/s No valid position on module start up

blinking 4/s blinking 4/s Illegal feed back

For drive type no. 10 only:

blinking 1/2s off Command close, opened manually, open position not reached

blinking 1/2s on Command close, opened manually completely

The yellow LED serves to display the operating status of the control module.

LED yellow meaning

on No 230VAC power supply or fuse blown

off Power supply OK, no (valid) data on local bus

blinking Power supply OK, valid data on local bus but module is not addressed

flickering,

dim

Power supply OK, data exchange OK

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3.2 Control functions

The control function that is required for the various types of actuators can be selected with the

assistance of a quadruple switch in the front of the control module housing. For this the trans-

parent module cover flap must be opened. To accept the new type the module has to be reset.

ATTENTION: It is absolutely necessary to adapt the control function to the type of actuator

as otherwise correct function of the actuator is not guaranteed and the actuator or

the control module can be damaged as the case may be.

Typ Type of actuator Operation mode Runtime Switch

1 2 3 4

0 EHS double acting open / close 4s..260s 0 0 0 0

1 EHS double acting step open / close 4s..260s 1 0 0 0

2 EHS double acting open / step close 4s..260s 0 1 0 0

3 MOV open / close 4s..260s 1 1 0 0

4 EHS single acting, spring close open / close 4s..260s 0 0 1 0

5 EHS single acting, spring open open / close 4s..260s 1 0 1 0

6 EHS double acting % 4s..260s 0 1 1 0

7 EHS double acting %Pos 4s..260s 1 1 1 0

8+ EHS single acting, spring close %Pos 4s..260s 0 0 0 1

9 EHS single acting, spring open %Pos 4s..260s 1 0 0 1

10 EHS single acting, spring close with handwheel open / close 4s..260s 0 1 0 1

11 EHS double acting with separated hydraulic unit open / close 4s..260s 1 1 0 1

12# EHS spring close, electro-hydraulic override open / close 4s..260s 0 0 1 1

13~ EHS double acting, Ex-Type open / close 4s..260s 1 0 1 1

14* EHS double acting, Ex-Type %Pos 4s..260s 0 1 1 1

15+ EHS single acting, spring close, hydraulic override open / close 4s..260s 1 1 1 1 # only for firmware version V2.0 or higher Switch position 0= OFF, 1= ON

~ only for firmware version V2.2 or higher

* only for firmware version V2.4 or higher

+ only for firmware version V2.5 or higher

3.2.1 Types of actuators

Double-acting

This actuator actively opens and closes with activated drive motor. In the event of a power failure it

stops in the current position.

Single-acting, spring close

This actuator actively opens with activated drive motor. The closing procedure is carried out by spring

force. The actuator closes in the event of a power failure.

Single-acting, spring open

This actuator actively closes with activated drive motor. The opening procedure is carried out by

spring force. The actuator opens in the event of a power failure.

MOV, motor valve

This actuator behaves likes a double-acting actuator and contrary to this automatically turns the drive

motor off upon reaching the end position. The control module always leaves the current supply

switched on during normal operation.

Spring close, mechanical override with handwheel

This actuator corresponds to a normal spring-close actuator, but can be opened manually with the as-

sistance of a handwheel. This operating status is permitted and the control module will not report this

as an error. In order to re-close the manually opened actuator this must initially be completely opened

electrically. This function is carried out automatically by the control module.

type

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spring close, electro-hydraulic override with hand pump and separate hand valve

The actuator operates like a standard spring close type but can manually be opened by means of a

manual operated valve and a hand pump. This operation mode is signalised at the CM3 module but is

not indicated as a fault. The actuator may be closed again by the CM3 by powering the magnetic

valve of the EHS. This will open the manual operated valve again.

spring close, hydraulic override with hand pump and separate hand valve

The actuator operates like a standard spring close type but can manually be opened by means of a

hand pump. Using the hand pump will open actuator and automatically prevent the oil from flowing

back to the tank. This operation mode is signalised at the CM3 module but is not indicated as a fault.

The actuator may be closed again manually by pressing a button or by the CM3 by starting the pump

for a few s.

double acting, Ex-Type

The Ex-type actuator can only be operated in combination with the capacitor module (9311222810).

The function equals a standard double acting actuator. This kind of actuator is available with

open/close and analog position indicator.

3.2.2 Operation modes of the actuators

Operation mode: open / close

After the drive command has been given, e.g. by pushing the command key in the direction of ”close“,

the actuator will operate until the final position is reached or the maximum permissible operating time

is exceeded. The alarm output is activated if the operating time is exceeded and alarm status signal-

ised via the light-emitting diodes on the module.

Operation mode: open / step closing

To a large extent this operation mode corresponds to the open/close operation mode. Upon closing,

however, the actuator is repeatedly stopped briefly in order to extend the closing time. In this connec-

tion the closing time is extended by the set operating time, i.e. the closing time is approximately dou-

bled. The turn-on times of the actuator amount to at least 1 second. Depending on the operating time

the actuator is halted up to 20 times.

Operation mode: step opening / step closing

To a large extent this operation mode corresponds to the open/close operation mode. Upon closing

and opening, however, the actuator is repeatedly stopped briefly in order to extend the closing or

opening time. In this connection the closing or opening time is extended by the set operating time. The

turn-on times of the actuator amount to at least 1 second. The actuator is halted up to 20 times.

Operation mode: %

In this operation mode the actuator is only operated for as long as the command key is depressed or

the command is pending. The actuator can thus be stopped in any position. Only exception: Insofar as

either of the actuator limit switches is operated, the actuator is moved to the appropriate end position

when the key is released. This ensures that the actuator has actually moved completely to the end po-

sition if this is signalised by the end position switch. For example, this function is used for throttle

valves.

Operation mode: %Pos

This operation mode is only used in connection with the issue of a command via a superimposed con-

trol system. In this case the superimposed control system prescribes the desired position of the valve

as a percentage and the control module automatically moves the valve into the target position. Devia-

tions from the target position not exceeding 2% are ignored by the module. This operation mode is al-

ways replaced by operation mode % during mimic diagram operation or local command input.

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3.3 Adjusting the operating time

The operating time of the actuator can be adjusted by means of a potentiometer on the front side of

the module. The transparent module cover flap must be opened for this. In general a fairly rough ad-

justment (-5% .. +25%) is sufficient whereby, if anything, the time should be assessed somewhat too

generously.

The operating time should only be determined exactly for actuators with a successive opening or clos-

ing function and in particular for actuators with the %Pos operation mode. A help function is integrated

into the control software for this purpose, allowing this to be very simple and reliable.

In case of a %Pos operation mode the runtime setting determines when the actuator is stopped while

it is approaching the nominal position. If the actuator stops too early and does not reach the nominal

position please increase the runtime a bit. On the other hand, if the actuator overshoots the nominal

position please decrease the runtime.

3.3.1 Calibration of the operating time

• Set the operating time to maximum (r.h. limit stop).

• Move the actuator from the closed position to the open position by selecting the “local”

operation mode and pushing the command key in the direction of “open”.

• Once the actuator has opened completely, push the command key again in the direction of “open“

and hold depressed. Now slowly reduce the operating time until the red LED also starts blinking. If

both LED are blinking, the time has been adjusted correctly.

3.4 Extended operation modes

The function of the CM3 module can be changed by setting several extended operation modes. This

feature is implemented from Version V2.0 upwards. Up to four extended operation modes can be set:

1. mimic inputs are active even in local operation mode (V2.3 or higher)

2. mimic close input is inverted, that means it is activated if connected to 0V (V2.5 or higher)

3. mimic open input is inverted, that means it is activated if connected to 0V (V2.7 or higher)

4. the alarm contact indicates the position of the local remote switch,

closed = remote, open = local (V2.7 or higher)

One or more extended operation modes may be set concurrently.

3.4.1 Mimic wire break detection (article numbers 9341100160 / 170 only)

As an alternative to the a.m. extended operation modes 2 and 3 a wire break detection for the mimic

command inputs is available. In this case the software version 3.1 or higher is required. In this version

the following extended operation modes are available.

1. mimic inputs are active even in local operation mode

2. mimic close input with wire break detection

3. mimic open input with wire break detection

4. the alarm contact indicates the position of the local remote switch,

closed = remote, open = local

For wire breakage detection the input must be permanently pulled up to the 24VDC supply voltage of

the PCM modules by a 10 kOhm to 20 kOhm resistor (15kOhm is recommended). This resistor must

be installed parallel to the contact of the command button or relay. If two parallel command buttons

are used a resistor of 30kOhm to 45kOhm must be installed parallel to each contact (36kOhm is rec-

ommended).

runtime

60

120180

2040 4

260

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In case of a wire break the alarm, contact opens and the fault condition is indicated in the CM3 status

byte, Bit3 and Bit4 (see also: 8.1.2).

3.4.2 Extended operation mode set-up

Depending on the requested extended operation mode one or more type selector switches 1..4 must

be changed while the module is running. Now turn operation mode to “remote”.

• To set the extended operation push the command button to „close“ position until the yellow LED

starts flashing several times. The extended operation mode is set now.

• To reset the extended operation push the command button to „open“ position until the yellow LED

starts flashing several times. The extended operation mode is reset now. Please note that the

mimic close input must be connected to 24V if the extended operation mode shall be reset!

• to set the extended op modes the mimic inputs must not be activated!

ATTENTION: Do not forget to turn the type selector switches back to the original position.

3.4.3 Displaying extended operation modes

If at least one of the extended operation modes is set it will be displayed at the BI module if the „close“

button is pressed in operation mode „remote“. If no extended operation mode is selected the version

number of the CM3 is displayed as usual.

display extended op mode

1 2 3 4

display 0 0 0 0

1 0 0 0

0 1 0 0

0 0 1 0

1 1 0 0

1 0 1 0

1 1 1 0

If any extended operation mode is set and the mode switch is turned to local mode the yellow lamps

starts flashing several times.

3.5 Start reports and self-test

Directly after the programme has started up, the module displays the last “reset“ cause by illuminating

one or two LED briefly. The module subsequently carries out a short self-test. In the event that the

self-test is not carried out successfully, the yellow LED will start to flash.

Once the self-test has been carried out successfully, the normal status display will start up.

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3.6 Alarm output

Once the self-test has been carried out successfully, the alarm output is closed initially. As soon as an

error occurs the output is opened. The output is not closed until the error is reset, e.g. by entering a

new drive command. Errors that will raise an alarm are:

• power supply failure 24VDC or 230VAC

• invalid or inadmissible position indications

• timeout while closing or opening

see also 2.4

3.7 Lamp test

Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied, the 3 LED

on the module are illuminated and in addition to this both report outputs “LED open” and “LED closed”

to the mimic diagram are activated.

3.8 Placing commands

Commands can be placed in three different ways:

• Using the open/close button while the operation mode is “local”

• Using the control inputs “CMD-close / CMD-open” while the operation mode is “remote”

• Using a command sent via the BI module

Note: As long as the command inputs are set, they will overrule the commands sent via the BI

module.

3.9 Terminal assignment

Lower terminals, to the control system:

X1 (grey) pluggable

1 LED-open o Drive open, to mimic diagram

2 LED-closed o Drive closed, to mimic diagram

3 CMD-open i Command open, from mimic diagram

4 CMD-close i Command close, from mimic diagram

X2 (red) pluggable

5 N i Drive supply voltage 230VAC max. 3,15A

6 L i Drive supply voltage 230VAC max. 3,15A

7 Alarm a o Contact opens in case of error

8 Alarm b o Contact opens in case of error

Upper terminals, to the EHS:

X3 (grey) pluggable

9 FB-closed i Feed back closed, 0V = closed, internal pull up

10 FB-open i Feed back open, 0V = open, internal pull up

11 0V o DC power supply for position sensors

12 24V o DC power supply for position sensors

X4 (black) pluggable

13 FB- analog i Position signal (4..20mA) (optional)

14 N o Common power

15 L-close o Power output: pump close / solenoid valve / pump run

16 L-open o Power output: pump open / pump open / pump direction

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Safety Advice: Always plug in red connector to connect AC supply voltage last and

always pull it off to disconnect AC supply voltage first! (see also 10.4)

Bus connector

1 Data A io Local data bus, rs485

2 Data B io Local data bus, rs485

3 lamp test i Lamp test input, 24V = lamps on

4 0VDC i Local power supply

5 +24VDC i Local power supply

ATTENTION: It is imperative to ensure that the supply voltage is not under any circumstances

applied to the local data bus. This may cause the destruction of all connected

modules.

3.10 Technical data

Supply voltage DC 24V +30% -25%

Current requirement DC max. 40mA, plus external load*

Fuse DC self resetting fuse, 500mA - 1100mA

Supply voltage AC 230V 20%

Fuse AC 2 x 3,15AT miniature fuse

Analog input position 4..20mA = 0..100%, deviation 1%, resistance249Ohm

LED-open / -close semiconductor high side switches, max. load 150mA, short

circuit proof

size WxHxD 22,5mm x 105mm x 115mm

Terminal type max. 2,5mm²

Operating temperature 0°C – 55°C

protection IP20

*The current consumption of the feedback modules in the EHS, for example OC3 and the

currents emitted via the mimic diagram outputs X1, Pin1 and Pin2, must be added to the

current consumption of the module.

The miniature fuses for AC power supply are accessible at the lower side of the casing.

To exchange the fuses the casing has to be removed from the hat-rail. The fuse holder

can be opened by means of a screw driver.

3.11 Connecting Ex-Type actuators

open

close

N

PCM-CM3

16

15

14

4

5

1

2

3

16

15

14

CM-ExE

PL56-03: 1~

auxiliary winding

main winding

6

5

4

3

2

1

To operate an Ex-type actuator a capacitor module CM-ExE (see also: 12.4.7) is required.

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4 Input/output module IO 8/8/4 The IO module is an assembly group for registering analog and digital signals and for the output of

digital signals. All signal transmitters must be isolated, as this module does not provide internal poten-

tial separation. Generally speaking, this is the case for temperature and pressure sensors or limit

switches, floating switches and dry relay contacts. Insofar as this is not applicable, isolation amplifiers

or isolating relays must be used.

This also applies correspondingly to the digital outputs that are designed as short-circuit proof semi-

conductor relays, dispensing 24V supply voltage.

4.1 Displays

The module has a total of 20 LED at its disposal to display the input or output status.

• 8 green LED indicate the status of the individual measured values.

green LED input signal meaning

on >=3.8mA and <=20.2 mA valid measurement

blinking fast > 20.2mA above range or short circuit

blinking slowly >0.2 mA and <3.8mA below range

off <=0.2mA not used or wire broken

• 8 yellow LED indicate the status of the digital inputs.

• 4 red LED indicate the status of the digital outputs.

Furthermore, the LED are used to display any error status. In this connection the 4 lower and 4 upper

green LED flash alternately whilst the yellow LED indicate the error number from 1..8.

LED Error status Comment

1. address changed the address of the module was changed

2-7. reserved

8. module offline There is no data connection to the BI module

Alteration to the module address initially brings about the output of the “address changed“ error mes-

sage. This error message also brings about the display of the module address on the fieldbus inter-

face. The new module address is not accepted until the module has been re-started.

4.1.1 Start messages and self-test

Directly after the start of the programme the module displays the last reset cause by illuminating one

of the yellow LED briefly. The module subsequently carries out a short self-test. In the event that the

self-test is not carried out successfully, the two lowest green LED will start to flash.

Normal status display commences once the self-test has been carried out successfully (see above).

4.1.2 Lamp test

Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied the 8 green

and 8 yellow LED are illuminated. The red LED are not activated during the lamp test.

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4.2 Adjusting the address

The module address is adjusted with the as-

sistance of a quadruple switch. The switch is

to be found behind a transparent cover flap.

The address range of the IO modules starts at

51 and finishes at 60.

The range beginning with setting 0101 is also mapped to

the addresses 51 to 56. In this case the state of the digital

input is hold for at least 0,9s. By this means even very

short events like pressing a push button can be detected

securely (Version B.6 and higher).

0= OFF, 1= ON

* state of digital inputs is hold for at least 0,9s

4.3 Terminal assignment

Lower terminals (factory):

X1 (grey) pluggable

1 digital input 5 i 24V DC to 0V of supply voltage

2 digital input 6 i 24V DC to 0V of supply voltage

3 digital input 7 i 24V DC to 0V of supply voltage

4 digital input 8 i 24V DC to 0V of supply voltage

X2 (black) pluggable

5 digital output 1 o 24V DC to 0V of supply voltage

6 digital output 2 o 24V DC to 0V of supply voltage

7 digital output 3 o 24V DC to 0V of supply voltage

8 digital output 4 o 24V DC to 0V of supply voltage

Upper terminals (dockyard):

X3 (grey) pluggable

9 analog input 4 i 0 .. 20mA, to 0V DC

10 analog input 3 i 0 .. 20mA, to 0V DC

11 analog input 2 i 0 .. 20mA, to 0V DC

12 analog input 1 i 0 .. 20mA, to 0V DC

X4 (black) pluggable

13 analog input 8 i 0 .. 20mA, to 0V DC

14 analog input 7 i 0 .. 20mA, to 0V DC

15 analog input 6 i 0 .. 20mA, to 0V DC

16 analog input 5 i 0 .. 20mA, to 0V DC

X6 (grey) pluggable

17 digital input 4 i 24V DC to 0V of supply voltage

18 digital input 3 i 24V DC to 0V of supply voltage

19 digital input 2 i 24V DC to 0V of supply voltage

20 digital input 1 i 24V DC to 0V of supply voltage

module address

switch

S1 S2 S3 S4

51 0 0 0 0

52 1 0 0 0

53 0 1 0 0

54 1 1 0 0

55 0 0 1 0

56 1 0 1 0

57 0 1 1 0

58 1 1 1 0

59 0 0 0 1

60 1 0 0 1

51* 0 1 0 1

52* 1 1 0 1

53* 0 0 1 1

54* 1 0 1 1

55* 0 1 1 1

56* 1 1 1 1

addre

ss

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Bus connector

1 Data A io Local data bus, rs485

2 Data B io Local data bus, rs485

3 Lamp test i Lamp test input, 24V = lamps on

4 0VDC i Local power supply

5 +24VDC i Local power supply

ATTENTION: It is imperative to ensure that the supply voltage is not under any circumstances

applied to the local data bus. This may cause the destruction of all connected

modules.

4.4 Technical data

supply voltage DC 24V

current requirement DC max. 70mA, plus external load*

fuse DC Self resetting fuse, 500mA - 1100mA

size WxHxD 22,5mm x 105mm x 115mm

terminal type max. 2,5mm²

operating temperature 0°C – 55°C

protection IP20

*Current via digital outputs

Analog inputs

range 0 (4) .. 20mA

resolution 12 Bit, 0 = 0mA, 4000 = 20mA, 4096 = 20,48mA

precision 0,4% of full range, typ. 0,2%

filter Median / low pass app. 200ms

shunt resistance 100 Ohm

overload protection self resetting fuse 30 - 50mA per input (max. 30V)

Digital inputs

threshold app. 9,5V

input current app. 5mA

low pass filter app. 10ms

Digital outputs

output voltage 24VDC

output current, on max. 200mA per output, max. 400mA totally

output current, off <1mA

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5 Relay Module RK 16/8 The relay module provides 16 opto-decoupled digital inputs and 8 relay outputs.

The inputs are arranged in two groups with common 0V. A jumper allows to con-

nect both groups to the same 0V. The relay outputs are designed as normally

open contacts with one common terminal. The common terminal is fused

onboard. Standard fuse is 2AT, max. 10AT is allowed. The fuse is monitored. A

voltage drop of more than 100VAC will be indicated and signalled. The relay

contacts may switch up to 3A / 230V. A short cable with two plugs serves to

connect the RK 16/8 with each other.

5.1 Indication

The module is equipped with 24 LED for indication of the input and output state. An addi-

tional yellow LED is used for status display.

- 16 green LED indicate the state of the digital inputs

- 8 yellow LED indicate the state of the digital outputs

The status LED indicates the data traffic on the local bus, a fuse fail and also assists the user during

set-up of the module.

LED yellow meaning

on fuse fail, voltage drop on fuse > 100VAC

off no fuse fail, no data on the local bus

blinking no fuse fail, valid data on local bus but module is not addressed

flickering no fuse fail, communication on local bus is running

5.2 Operation

A push button is used to show and to set-up the module address and operation mode. This function is

only available in conjunction with a BI module with software version 2.1 or higher. To set up the ad-

dress the BI must run in set-up mode (see also: 7.1.3).

If BI is running in normal operation mode the push button is used to indicate the RK address. If the

button is pressed for more than 3s the software version of the RK is indicated instead of the address.

5.3 Jumper B1

If the jumper B1 is plugged on (default) the common 0V of both input groups are connected. In this

case only pin 9 of terminal X1 or X2 must be connected to 0V. If both input groups are connected to

independent supply voltages the jumper must be removed.

5.4 Counter function

To collect rapidly changing input values the RK provides a counter function for the input 1. Both rais-

ing and falling edges of the input signal are counted and stored in an 8 bit counter value. If the counter

reaches 255 it will be reset on the next edge of the input signal.

Each pulse must last at least 15ms. The counter value must be read frequently to detect a counter

overrun reliably. With a pulse duration of 15ms the counter must be read at least every 15ms*255 =

3825ms.

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5.5 Technical Data

supply voltage DC 24V

current requirement DC max. 100mA

fuse DC Self resetting fuse, 500mA - 1100mA

size WxHxD 22,5mm x 105mm x 115mm

terminal type max. 2,5mm²

Input voltage 24VDC

Threshold 6-12V, typ. 9V

Counter pulse length >= 15ms

Output voltage max. 230VAC

Output current max. 2A per output

Fuse default 2AT, max. 10AT

operating temperature 0°C – 55°C

protection IP20

5.6 Terminal assignment

terminal X1:

1 digital input 1 i 24V DC

2 digital input 2 i 24V DC

… … i

8 digital input 8 i 24V DC

9 common 0V for 1-8 i common 0V

terminal X2:

1 digital input 9 i 24V DC

2 digital input 10 i 24V DC

... ... i

8 digital input 16 i 24V DC

9 common 0V for 9-16 i common 0V

terminal X3:

1 relay output 1 o normally open

2 relay output 2 o normally open

… … o

8 relay output 8 o normally open

9 common terminal o

terminal X5 and X6:

1 rs485 A i/o local data bus

2 rs485 B i/o local data bus

3 0VDC i/o power supply

4 24VDC i/o power supply

The RK 16/8 does not provide a lamp test input!

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6 Conti Control Module CCM The CCM is used to control centralized hydraulic actuators with analog position indica-

tion. To measure the actuator’s position a flow meter with two 90° phase shifted binary

signals is used. The flow meter is inserted in the hydraulic pipe that is used to open the

actuator.

The CCM fully controls the actuator including the solenoid valves. Operation can be

done by means of local switches, external devices like mimic push buttons or via a

PCM-BI module. The module provides the required power relays and the fuses to safely

control the solenoid valves. The CCM uses the same address range as the PCM-CM3

modules. The casing equals the one of the CM3. From a BI’s point of view the CCM be-

haves like a CM3 for EHS with analog feedback.

The calibration of the CCM is done by teach-in. The module determines the volume of

the actuator as well as different compression volumes and the runtime of the actuator.

6.1 Operation

The CCM provides several control and monitoring devices for local operation of the ac-

tuator.

switch „local – remote“

In position “local” the actuator can be operated by means of the „close-

0-open“ button. In position remote the actuator can only be operated via

local bus or digital control inputs.

button „close – 0 – open“

In operation mode „local“ this button is used to control the actuator. In

operation mode “remote” the button is used to indicate the version of the

device respectively the software.

set button

Pressing this button in local operation mode will start the calibration

function. A transparent plastic cover protects the button against unin-

tended use.

The address setting of the CCM is done in the same way that is described for the CM3 (see also:

7.1.2).

6.1.1 Status LED

Three LED (red, yellow, green) signalise the operating mode of the actuator and the control

module.

LED red LED green Meaning

on off actuator in closed position

on blinking 1/s actuator in closed position, open command received

off blinking 1/s actuator is opening, left closed position

off on actuator in open position

blinking 1/s on actuator in open position, close command received

blinking 1/s off actuator is closing, left open position

blinking 2/s on / off while closing: final position not reached within supervision time

on / off blinking 2/s while opening: final position not reached within supervision time

15

26

37

48

9 10 11 1213 14 15 16

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The yellow LED indicates the operating mode of the control module.

LED yellow Meaning

on missing coil supply voltage

off supply voltage OK, no valid data on local bus

blinking supply voltage OK, valid data on local bus but CCM not properly addressed

flickering supply voltage OK, local bus interface OK

6.1.2 Position measurement

A flow meter inserted in the hydraulic pipe that opens the actuator is used to determine the actual po-

sition of the drive. Several compression volumes are considered to determine the position as exactly

as possible.

As an incremental measuring is used referencing is required from time to time. Each time the final po-

sitions are reached (actuator stops) and the position is less than 3% or more than 97% the actual po-

sition is set to 0% respectively 100%.

6.1.3 Position indication

Two 7 segments LED displays are used to indicate the current position of the actuator. The final posi-

tions are indicated as for “close” respectively for “open”. All intermediate positions are indicated

in percent ...

The decimal point of the lower digit flashes whenever the position value is referenced. A synchronous

blinking of both decimal points indicates that the position value has not yet been referenced after the

CCM was turned on. In this case the shown position value could be invalid if the position changed

while the CCM was turned off!

6.2 Calibration

After installation the CCM must be calibrated. During calibration the CCM calculates all parameters

concerning the actuator and the piping and stores these parameters in an internal non-volatile

memory.

The calibration run is started by pressing the SET button while the operation mode is set to “local“.

The calibration passes the following steps:

- - close actuator and wait for a standstill

- - open actuator and wait for a standstill

- - close actuator once more and wait for a standstill

- - open actuator one third and wait for a standstill

- - close actuator to app. 10% and wait for a standstill

- - close actuator, wait for a standstill and store parameters

The current step is indicated on the 7 segment display ....

The calibration may be started every time when opening the actuator is allowed. During calibration the

operator has to make sure that the actuator reaches the final positions completely.

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6.3 Extended Operation Modes

Besides the default operation mode, the CCM provides several extended modes. If the “set” button is

pressed for 3s while CCM is in “remote” mode the extended operation mode is shown. The upper digit

always shows . and the lower one a number. By means of the “open/close” switch the desired num-

ber can be selected. Each Bit in this number enables a certain mode. The default value is .

extended operation mode “local override“,

the inputs for the mimic push buttons are always enabled. This mode is required if the mimic

inputs are used for some safety functions that must be independent from the local / remote

switch.

extended operation mode “flow meter in pipe used to close the actuator”.

This mode is required if the flow meter is inserted in the pipe that is used to close the actuator.

Attention: During calibration run the actuator first starts opening and remains in open position

at the end of the test.

extended operation mode “very slow actuators”

this mode is required if very slow actuators are used. In this case the timeout periods are ex-

tended:

- close timeout and open timeout from 4 to 10 minutes

- calibration timeout from 10 to 20 minutes

extended operation mode “counter inhibit on lamp test”

In this operation mode the lamp test input has an additional function. When lamp test is set the

counter is blocked and no command can be entered, neither manually nor via serial interface.

The extended operation modes may also be combined. If for example you want to enable the “local

override” mode for “very slow actuators” you may add both numbers 1 and 4 and select mode .

6.4 Start reports and self test

During start-up the CCM indicates cause of the last “reset“ on the 7 segments display and performs a

short self test. If the self test fails the yellow LED starts blinking.

6.5 Alarm output

After self test is finished successfully the alarm contacts are closed. In case of a fault the contacts

open and are closed again if all faults have been removed. The alarm contacts are opened if:

• supply voltages 24VDC or 230VAC fail

• the runtime limit of the actuator is exceeded

• internal device fault

6.6 Lamp Test

Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied, the 3 LED

and all segments of the 7-segment display of the module are illuminated. The mimic outputs are

turned on.

6.7 Placing commands

Commands can be placed in three different ways:

• Using the open/close button while the operation mode is “local”

• Using the control inputs “CMD-close / CMD-open” while the operation mode is “remote”

• Sending a command via the PCM-BI module while the operation mode is “remote”

Note: As long as the command inputs are set they will overrule the commands sent via the BI module.

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6.8 Analog Position Signal

The CCM provides an analog 4..20mA output. The current signal indicates the position of the actuator.

• 4mA = closed

• 20mA = open

The current output is not isolated to local 24V supply voltage. The max. resistance in the current load

must not exceed 150 Ohms. The deviation between analog output and 7 segment display may be up

to 2%. This output is intended to be connectd to a position indication meter. It is not intended for

connecting a supervisory control system.

6.9 Behaviour in case of black out

If the 24VDC supply of the module fails the current counter value is stored in an internal non-volatile

memory. If the supply voltage is turned on again the old counter value is restored. It is not possible to

capture counter pulses while the voltage is turned off.

6.10 Terminals

untere Klemmen, zur Steuerung:

X1 (grau) steckbar

1 LED-open o drive is open, to mimic diagram

2 LED-closed o drive is closed, to mimic diagram

3 CMD-open i command open, from mimic diagram

4 CMD-close i command close, from mimic diagram

X2 (red) pluggable

5 24VDC / 230VAC L2 i solenoid valve supply voltage

6 0VDC / 230VAC L1 i solenoid valve supply voltage

7 Alarm a o contact opens in case of error

8 Alarm b o contact opens in case of error

Upper terminals, to the EHS:

X3 (grey) pluggable

9 Count A i counter input A, A prior to B means counting up

10 Count B i counter input B, B prior to A means counting down

11 0V o DC power supply for flow meter

12 24V o DC power supply for flow meter

X4 (black) pluggable

13 FB- analog o position signal (4..20mA), 4mA means closed

14 N o common terminal for solenoid valves

15 L-close o power output close

16 L-open o power output open

Safety Advice: Always plug in red connector to connect AC supply voltage

last and

always pull it off to disconnect AC supply voltage first!

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Bus connector

1 Data A io local data bus, rs485

2 Data B io local data bus, rs485

3 lamp test i lamp test input, 24V = lamps on

4 0VDC i local power supply

5 +24VDC i local power supply

ATTENTION: It is imperative to ensure that the supply voltage is not under any circumstances

applied to the local data bus. This may cause the destruction of all connected

modules.

6.11 Interface to Flowmeter

Any flow meter connected to the CCM must comply with the following technical data:

Supply voltage 24V

Current consumption max. 100mA

Output signals 2 x rectangular signals 24VDC , 90° 20° phase shifted,

Pulse:Pause 1:1 10%

min. edge distance 80us, up to 3kHz pulse frequency

6.12 Technical data

supply voltage DC 24VDC

current requirement DC max. 65mA, incl. counter and analog output, plus external load

fuse DC self resetting fuse, 500mA - 1100mA

supply voltage solenoid

valves

230VAC or 24VDC

fuse AC 2 x 1,25AT miniature fuse

analog position output 4..20mA = 0..100%, deviation 2%, max. burden resistance 180Ω

mimic open / close output solid state high side switches, max. load 150mA, short circuit proof

size WxHxD 22,5mm x 105mm x 115mm

terminal type max. 2,5mm²

operating temperature 0°C – 55°C

protection IP20

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7 Fieldbus interface BI The fieldbus interface serves to connect the control and IO modules to a superim-

posed control system via a fieldbus. Furthermore, the module provides two control in-

puts and a collective alarm output. The module and the local bus are supplied with

24VDC.

Two 7-segment displays and two push-buttons serve to parameterise the module and

display system status.

Two fieldbus protocol variations are available:

• Modbus RTU, slave

• Profibus DP V0, slave

The choice of the fieldbus protocol is carried out via the parameterisation functions on the module.

The fieldbus lines are connected via terminal screws. Bus termination in accordance with the Profibus

standard can be activated via a miniature switch if required.

Note: The Profibus Interface is not available on BI modules with Art.No. 9341100250. Those BI only

provide Modbus RTU. If Profibus is selected anyhow an error message is indicated

7.1 Operation

Parameterisation of the module is carried out with the assistance of the “set“ and “prgm“ push-buttons.

The push-buttons are only accessible if the transparent lid on the module is opened. Display of the

chosen parameters is by means of two 7-segment displays.

7.1.1 Parameterisation of the fieldbus

Parameterisation of the fieldbus settings is only possible if the “prgm“ push-button is depressed for at

least 3s when switching on the module. After this all parameters must be entered in succession. The

“set“ key is always used to set the value and the “prgm“ key to accept the value. All parameters are

saved in a non-volatile memory.

Parameter sequence

Step Meaning Range of values Display (example)

1 Address, least significant digit x 0h … x Fh, x = any ……2 Address, most significant digit 0 xh … F xh, x = any

3 Selection baud rate / protocol 4k8 / 9k6/ 19k2 / 38k4 / 56k / 57k6 /

76k8 / Profibus DP

Modbus only

4 Selection of parity none / odd / even ......

If the Profibus is chosen during step 3, step 4 is not applicable.

Automatic baud rate setting is generally used for the Profibus protocol. When the last parameter is en-

tered the module changes to normal operation.

7.1.2 Setting the address of the EHS-CM3 / CCM modules

The address of the CM3 / CCM control modules is adjusted with the assistance of the CM3 / CCM

control elements. Those modules do not provide separate address switches. Operation mode change-

over on the CM3 / CCM module brings about the indication of the current module address on the

fieldbus interface for the duration of approx. 2 seconds.

As the address setting needs to be protected against unintentional alteration, it is necessary to

put the system in addressing mode. Addressing mode is set by pressing the “prgm” and “set”

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keys on the BI simultaneously. This operation mode is shown as on the BI display. To leave this

mode just press both push buttons once more.

The CM3 / CCM module to be programmed is now switched to “remote“ operation mode. The

lowest available address on the local bus is now displayed by operating the command key in

any direction. An available address is an address to which no CM3 / CCM module will currently

respond. The two programming functions “delete“ and “accept“ are now available.

New modules are programmed in turn from left to right. Once programming has been completed the

fieldbus interface must be set to normal operation mode. For this both buttons are again pressed sim-

ultaneously.

PLEASE NOTE: The module address determines which register / data word is used by this actuator in

the data model of the fieldbus connection. If the address is not allocated as arranged, the wrong

valve will be activated. If possible, addressing should be carried out in such a way that the address

complies with the slot, i.e. that the 7th module, for example, is given address no. 7.

7.1.2.1 Deleting the module address

If the command key is pushed in the direction of “open“ and the operation mode is then switched to

local while the command key is depressed, the module address is erased. The module is then no

longer visible for the fieldbus interface.

7.1.2.2 Accepting the lowest available address

If the command key is pushed in the direction of “close“ and the operation mode is then switched to

local while the command key is depressed, the module address is set to the lowest available address.

This new address can be displayed again by changing the operation mode.

7.1.3 Setting the address and operation mode of the RK 16/8

The address of the RK16/8 control modules is adjusted with by means of the push button near the sta-

tus LED of the RK. If the button is pressed the module’s address is displayed at the BI. If the button is

pressed for more than 3s the module’s software version is displayed instead of the address.

As the address setting needs to be protected against unintentional alteration, it is necessary to

put the system in addressing mode. Addressing mode is set by pressing the “prgm” and “set”

keys on the BI simultaneously. This operation mode is shown as on the BI display. To leave

this mode just press both push buttons once more.

Now the push button of the appropriate RK must be pressed for some seconds. The status LED

first lights brightly and the turns off. The BI module now shows the lowest unused address for

an RK module in the range 61..80. As soon as the LED turns on again the button may be re-

leased. The RK is now programmed.

New modules are programmed in turn from left to right. Once programming has been completed the

fieldbus interface must be set to normal operation mode. For this both buttons are again pressed sim-

ultaneously.

PLEASE NOTE: The module address determines which register or data word in the data model of the

fieldbus connection to the BI is assigned to this RK. If the address is not allocated as arranged, the

wrong outputs are activated respectively the wrong inputs are read

Stetting the operation mode:

If the button is kept pressed after the LED turns on again for at least 2,5s the LED starts blinking. This

indicates the activation of the extended operation mode. In this case the state of each digital input is

hold for at least 0,9s. By this means even very short events can be detected securely. The version

changes from .x to .x if this operation mode is turned on (Version D.4 and higher).

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7.1.3.1 Deleting the module address

To erase the module address the button must be pressed again. As soon as the LED turns off the but-

ton must be released. The module address is erased now and the module becomes invisible for the

BI.

7.1.4 Skipping addresses

If necessary an address gap may be inserted at an arbitrary position. If the BI module is in “set-up

mode” and the CM3 is set to “remote” operation, the lowest unused address is show when the close

button of the CM3 is pressed. Now the address may be increased by pressing the BI´s “Set” button or

decreased again by pressing the “Prgm” button. Only unused addresses are selected by the BI. This

set-up, that means the number of address gaps, is also used for further addressing of the CM3 mod-

ules until the BI´s “set-up mode” is left. (Remark: This function is only available for BI firmware version

V1.6 or higher).

Also addresses of the RK16/8 modules can be skipped. As soon as the lowest used address is shown

on the BI the “set” and “prgm” button can be used to modify the RK address.

7.1.5 Display functions

Various system data can be displayed for diagnosis purposes in connection with the “Set” and “Prgm”

keys of the fieldbus interface or the operation mode switches of the CM.

Display of the address of a CM3 module

Upon changing the operation mode (local – remote) of a CM3 its address is displayed for 2 sec-

onds via the 7 digit display of the BI (. = address 12).

Display of the lowest available address

The lowest available local address is displayed by pressing the set key of the fieldbus interface

(. = address 17). The address of the module in position 17 should be programmed as the

next CM3 module.

Display of modules that have failed

If a module does not respond to queries from the fieldbus interface for a certain period of time,

it moves to “offline“ status. The address of this module is then displayed for 3 seconds (.. =

address 13). The display of the address of the module that have last moved to offline status can

be repeated at any time by pressing the “prgm” key. Displaying .. indicates that none of the modules

have gone offline.

PLEASE NOTE: Only the change to offline status is registered. If a module never answers after

power up, it will not be displayed.

Display of control inputs 1 and 2

If control input 1 or 2 is set, or output will appear on the display.

Position indication of actuators with analog position feedback

If an actuator with analog position feedback is operated in „local“ mode the current position is dis-

played at the 7-segments display of the BI module. This indication is turned off a few seconds after

the actuator comes to a standstill. (Remark: This function is only available for BI firmware version V1.6

or higher).

Normal operation

If status display is not necessary, the display will switch to . (program execution).

.

.

.

.

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Display LEDs

LED Modbus RTU Profibus DP

TxD red Transmit Data Error

RxD green Receive Data Data exchange

24V yellow supply voltage DC

7.1.6 Start messages and self test

Directly after the programme has started up, the module displays the last “reset“ cause in the form of

two digits. The module subsequently carries out a short self test. In the event that the self test is not

carried out successfully, the red LED will start to flash. If Profibus DP is selected as fieldbus the red

LED always indicates an error while the error code is shown in the display.

Once the self test has been carried out successfully the version number of the software (x.y) is dis-

played briefly. The normal status display begins subsequently (see above).

7.1.7 Power management

The BI module provides a power management function to limit the 230VAC supply current. To avoid

that the high starting current of the drives blows the fuses the actuators are started successively al-

ways one drive every 100ms. Additionally the number of running drives that are connected to the

same fuse is limited (default 8). The current that is required to keep the magnetic valve of a single act-

ing drive closed is neglected. A motor valve is treated like an EHS even though the current is much

less.

If more than 8 actuators of a group connected to the same fuse get a command, the execution of this

command is delayed in such a way that not more than 8 actuators are running simultaneously. Up to 4

of such groups can be configured for each BI. The first group begins with the drive using the address

1 and ends with address A1, the second groups begins with A1+1 and ends with A2 and so on.

The default set up uses 2 groups:

• group 1: drive 1..25

• group 2: drive 26..50

• number of drives: 8

7.1.7.1 Configuring the power management

To configure the power management the „Set“ button must be pressed for at least 3s while the BI

starts up. The display will now show . By pressing the “Set” button the group number can be in-

creased. Pressing the “Prgm” button will select this group and the last address of this group is shown

in the display. The “Set” button may now be used to increment the last address. The highest value is

50, the lowest value is the last address of the preceding group plus one. Pressing the “Prgm” button

once more will store the address and return to the group number display. If the last group (no 3) is

programmed or any group is programmed to address 50 the set-up is finished.

From BI V2.2 the number of drives running at the same time can also be adjusted. Instead of leaving

the set-up mode the number of drives is displayed in the lower digit while the upper digit shows a “.”.

The number can be changed using the “Set” button. Pressing the “Prgm” button will store the selected

number and leave the set-up mode.

PLEASE NOTE: The BI firmware secures that the last address of a succeeding group is always

higher than the last address of the preceding one. If this condition is not fulfilled the

firmware will adjust the addresses automatically.

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7.1.8 Set-up of Quick Close Functions

The control input E2 of the BI module is used to activate differ-ent quick close functions. As soon as the input is set a close or open command is sent to all CM3 modules that are appropri-ately parameterised. This parameterisation is done in the set-up mode of the BI module. At first the appropriate CM3 is se-lected by changing its operation mode. Afterwards the “Prgm” push-button is pressed. The present mode is now displayed.

By pressing the „Set“ push-button the required mode is se-

lected and confirmed by pressing the “Prgm” push-button once more. The mode that is valid at pre-

sent is displayed with the decimal points turned on otherwise the decimal points are turned off.

This function must be repeated for all required CM3. Press both push-buttons simultaneously to leave

the set-up mode.

7.1.9 Alarm output

To begin with the alarm output is closed after the self test has been carried out successfully. Cyclical

testing is carried out subsequently as to whether the modules connected to the local bus are working

accurately. If a module is not available (offline) or if a CM3 / CCM module reports a fault (e.g. timeout)

or is set to local operation mode, the alarm output will be opened and not closed until the fault has

been removed and the alarm acknowledged on the CM3 module.

7.1.10 Lamp test

Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied, the 3 LED

and all segments of the 7-segment display of the module are illuminated.

7.1.11 Bus Termination

If the BI module is placed at a physical end of the bus the bus cable has to be termi-

nated. This can be done by means of a miniature switch at the front of the module. If

both sliders are set to ON position the termination is turned on, if they are set to the op-

posite position the termination is turned off. All other settings are not allowed.

The bus termination is an active one and meets the Profibus standard.

7.2 Terminal assignment

Lower terminals

X2 (black) pluggable

1 PE Protective earth of the hat-rail

2 0V 0V of field bus interface

3 Field bus A io rs485 data

4 Field bus B io rs485 data

Upper terminals

X3 (grey) pluggable

5 E2 0V i Control input 2

6 E2 24V i Control input 2, opto

7 E1 0V i Control input 1

8 E1 24V i Control input 1, opto

X4 (black) pluggable

9 0V i DC power supply, max. 6A

.. none, no quick close function

.. close, if the operation mode is

„remote“

.. open, if the operation mode is

„remote“

.. emergency close in any case

.. emergency open in any case

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10 24VDC i DC power supply, max. 6A

11 Alarm o Alarm output, opens in case of error

12 Alarm o Alarm output, opens in case of error

Bus connector

1 Data A io Local data bus, rs485

2 Data B io Local data bus, rs485

3 Lamp test i Lamp test input, 24V = lamps on

4 0VDC i Local power supply

5 +24VDC i Local power supply

ATTENTION: It is imperative to ensure that the supply voltage is not under any circumstances

applied to the local data bus. This leads to the destruction of all connected

modules.

7.3 Technical data

supply voltage DC 24V

current requirement DC max. 50mA, plus external load*

control inputs 24V DC

alarm output Relay, 24V, 0,5A

size WxHxD 22,5mm x 105mm x 115mm

terminal type max. 2,5mm²

operating temperature 0°C – 55°C

Protection IP20

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8 BI Modbus interface (slave) The Modbus interface of the fieldbus interface serves to exchange data with a superimposed control

and visualisation system, hereinafter referred to as Modbus master. A register in both report direction

and control direction is used for every valve. Transmission is carried out via an RS485 connection.

The baud rate (4800-76800 baud), the parity (none, even, odd) and the Modbus address (1h..6Fh) can

be parameterised. The number off data bit is fixed to 8. One stop bit is used.

The fieldbus interface has a Modbus RTU interface (slave) and serves the following functions:

• 03 Read holding registers

• 06 Preset single register

• 16 Set multiple registers

This chapter describes the applied data model, i.e. the use and meaning of the individual registers of

the Modbus. This information is required for the preparation of the data model of the superimposed

control system and for the commissioning of the Modbus interface as the case may be. More detailed

information about the Modbus protocol may be obtained from www.modbus.org.

8.1 Modbus data model

The data model described here complies with the program version 1.5 or higher.

The first register is always used to monitor the fieldbus interface itself. The following registers are

used for the CM3 and the IO modules.

In detail, the binary digits of the registers have the following meaning:

8.1.1 Fieldbus interface BI status, register 1, (read only)

Bit Meaning

Bit0 CM3 fault, collective message

Bit1 IO fault, collective message

Bit2 reserved

Bit3 control input E1 set

Bit4 control input E2 set

Bit5 control input „lamp test“ set

Bit6 running in passive mode (see also: 10 !used only if secondary BI is connected)

Bit7 RK16/8 fault, collective message

Bit8..14 not used

Bit15 live bit, changes state every 2s *

*implemented in BI version V1.6 or higher

CM3 fault collective message

This binary digit is set if at least one EHS-CM3 reports a fault.

IO fault collective message

This binary digit is set if at least one IO module reports a fault.

Fault on the local data bus

This binary digit is set if at least one module on the local bus replies to broadcast address 0 or if fur-

ther faults arise that cannot be allocated to a specific bus participant.

Control input E1 / E2 set

This binary digit is set if control input E1 / E2 has been set (24V).

Control input lamp test set

This binary digit is set if lamp test input has been set.

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8.1.2 CM3 status register (read only)

The CM3 status register includes the valve position and the valve error messages. The register num-

ber depends on the module address (1-50).

Register number = module address + 1

(50 registers, from no 2 to no 51)

The lower-order byte of the register contains the position information:

Value Meaning

0..100 actual position of valves with analog position feedback

(128..228) most significant bit is set while drive is running (add128)

101 drive closed and in a standstill

102 drive neither open nor closed

103 drive open and in a standstill

105 drive in open position, close command received

106 drive in closed position, open command received

107 drive neither open nor closed while closing

108 drive neither open nor closed while opening

109 drive indicating closed position but is still running

110 drive indicating open position but is still running

111 unknown position

The higher-order byte of the register indicates the error messages:

Bit Meaning

Bit 0: error no 0 = no error

Bit 1: (Bit 0-2) 1 = timeout while opening

Bit 2: 2 = timeout while closing

3 = invalid feedback

4 = invalid command

5 = reserved

6..7 = not used

Bit 3: command close received via mimic input*

Bit 4: command open received via mimic input*

Bit 5: local / remote switch in local position

Bit 6: no AC supply (230VAC)

Bit 7: offline, no response on local bus

The error flags 1..3 stay set until the cause of the error is removed or a new command is sent.

Runtime errors generally require resending a command.

*These status bit are implemented in CM3 firmware V1.9 or higher. The bit is set as soon as the corre-

sponding input is set and reset when the input is released. In any case the bit is set for at least 5s. If

the close input is activated the open input is assumed as deactivated regardless of the physical input

voltage.

In case of an activated wire break detection for the mimic close and mimic open inputs the wire break

case is indicated by setting both bits 3 and 4 concurrently.

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8.1.2.1 Combining error messages

The above mentioned error indications are very detailed. It is not necessary or even recommended to

display all error indications on a SCADA system. A useful combination of different error messages in

several groups is recommended.

Example:

Group 1: runtime error = (error no equals 1) OR (error no equals 2)

Group 2: device error = (error no equals 3) OR (error no equals 4) OR (Bit6 is set)

Group 3: offline error = (Bit7 is set)

Group 2 and 3 may also be combined. Further fault analysis can be done by means of the LED of the

CM3 module.

Furthermore it is recommended that the SCADA control elements of an actuator are hidden or greyed

if the Bit5 is set.

8.1.3 CCM status register (read only)

The CCM status register includes the valve position and the valve error messages. The register num-

ber depends on the module address (1-50).

Register number = module address + 1

(50 registers, from no 2 to no 51)

The lower-order byte of the register indicates the position information:

Value Meaning

0..100 actual position of actuator / valve, 0 = closed, 100 = open

128..228 actual position while valve is moving

While actuator is moving and also during calibration the most significant Bit in the position byte is set.

The higher-order byte of the register indicates the error messages:

Bit Meaning

Bit 0: error message 0 = no error

Bit 1: (Bit 0-2 binary) 1 = timeout while opening

Bit 2: 2 = timeout while closing

3 = reference run required

4 = invalid position counter value

5 = self test error

6..7 = not used

Bit 3: command close received via mimic input*

Bit 4: command open received via mimic input*

Bit 5: local / remote switch in local position

Bit 6: no supply for solenoid valves (both 24VDC or 230VAC)

Bit 7: offline, no response on local bus

The error flags 1..4 stay set until the cause of the error is removed respectively a new command is

sent. Runtime errors generally require resending a command. Flag 3 is set on power up and is deleted

when the counter is referenced the first time.

The bits 3 and 4 are set as long as the corresponding inputs are set. In any case the bit is set for at

least 5s.

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8.1.4 IO status register (read only)

The IO status registers contain the status of the analog and digital inputs of an IO module. An IO mod-

ule occupies a total of 9 registers. The register number depends on the module address.

The module addresses are in the range of 51 – 60.

Register number of the first register = 9*(module addresses -51) + 52

(90 registers, from no 52 to no 141)

The first register contains the status of the 8 digital inputs in the lower-order byte and error messages

in the higher-order byte.

Bit Meaning

Bit 0..7: digital input 1..8 set

Bit 8: address was changed after last start up

Bit 9: error analog input 1..8

Bit 10: used internally

Bit 15: offline, no response on local bus

The following 8 registers contain one each of the 8 measured values as 12 binary digit value (0..20mA

= 0..4000 Incr.). A valid value must be even.

Attention: An odd value indicates that the last measurement has not been updated because of an

invalid measurement.

8.1.5 Fieldbus interface BI remote control, register 142 (read/write)

This register can be used by the Modbus master to control various functions of the fieldbus interface.

Bit Meaning

Bit0 reserved

Bit1 force BI to passive mode (see also: 10)

Bit2..14 not used

Bit15 *Profibus data are valid (see also: 0)

*implemented in BI version V1.6 or higher

8.1.6 CM3 control register (read/write)

A CM3 control register is used to send a command to a valve. The register number depends on the

module address (1-50).

Register number = module address + 142

(50 registers, from no 143 to no 192)

Only the lower-order byte of the valve control register is used.

Command Meaning

0..100 position set point for %Pos drives

101 close drive

102 stop drive

103 open drive

104 acknowledge error, erase last command

111 commands by mimic diagram inputs only

If command 111 is sent the BI completely passes control to the CM3 modules. The CM3 acts as if

there is no BI. Only old CM3 versions V1.6 or lower require this command to enable the mimic inputs

permanently. V1.7 and newer always react properly on mimic inputs in remote mode and do not re-

quire this command any longer.

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Any command change will reset the errors 1..4. To force a command change the following way is sug-

gested:

Set the most significant bit of the command byte to indicate a new command. The CM3 / CCM

will react on this command immediately. The bit should be kept high for at least 1s and should

be reset afterwards.

Beside resetting error conditions restarting a command may be useful in certain applications like actu-

ators that may be operated manually by hand wheel (override). If such a drive is closed by command

and opened manually afterwards a repeated close command will close it again.

example:

• send close command 128+101=229, actuator starts running, wait 1s, send close command

101

• actuator is closed

► actuator is opened manually

• send close command 128+101=229 once more , actuator starts running, wait 1s, send close

command 101

• actuator is closed again

8.1.7 CCM control register (read/write)

The CCM control register is used to send a command to the actuator. The register number depends

on the module address (1-50).

Register number = module address + 142

(50 registers, from no 143 to no 192)

Only the lower-order byte of the valve control register is used.

Command Meaning

0..100 position set point

101 close drive completely (same as 0)

102 stop drive

103 open drive completely (same as 100)

104 acknowledge error, erase last command

105 start calibration

111 commands by mimic diagram inputs only

Commands 104 and 111 are used for compatibility to older CM3 versions only.

Attention: During calibration the actuator will be completely opened and closed again. The operator

has to make sure that the actuator completely reaches both final positions.

8.1.8 IO control register (read/write)

The IO control register is used to set the 4 digital outputs of the IO 8/8/4 module. The register number

depends on the module address. The module addresses are in the range of 51 – 60.

Register number = (module address – 51) + 193

(10 registers, from no 193 to no 202)

Bit Meaning

Bit 0..3: digital output 1..4 set, outputs are reset if IO 8/8/4 goes offline

Bit 4..7: digital output 1..4 set, outputs stay on if IO 8/8/4 goes offline

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8.1.9 RK status register (read only)

The RK status registers contain the status of the digital inputs and error flags of an RK module. An RK

module occupies a total of 2 registers. The register number depends on the module address.

The module addresses are in the range of 61 – 80.

Register number = 2*(module address – 61) + 203

(40 registers, from no 203 to no 241)

The first register shows the error flags in the lower byte and a 8 bit counter value in the upper byte.

Value Meaning

Bit 0: fuse is damaged

Bit 1: address button pressed

Bit 2: used internally

Bit 7: offline, no response at the local bus

Bit 8-15 8 Bit counter, all changes of input 1 are counted.

The second register shows the status of the 16 digital inputs.

Value Meaning

Bit 0: digital input 1 (24V = Bit set)

Bit 15: digital input 16 (24V = Bit set)

8.1.10 RK control register (read / write)

The RK control register are used to control the relay outputs. Each module uses one register.

The register number depends on the module address.

The module addresses are in the range of 61 – 80.

Register number = (module address – 61) + 243

(20 registers, from no 243 to no 262)

Value Meaning

Bit 0..7: set relay output 1..8;

all outputs are reset if the data connection between PLC and PCM system fails

Bit 8..15: set relay output 1..8;

all outputs keep the current state if the data connection between PLC and PCM system

fails

8.2 Fieldbus Watchdog

The BI Module permanently supervises the proper function of the Modbus (Profibus). The BI must re-

ceive at least one valid Modbus request every 5s otherwise the following functions will be carried out:

• A command 111 „enable mimic diagram inputs“ is sent to all CM3 modules.

• All control bits 0..3 of all IO8/8/4 are set to 0, that means that all outputs are reset

• All control bits 0..7 of all RK16/8 are set to 0, that means that all outputs are reset

We recommend to start a request at least every second. This function is implemented for the Profibus

protocol is the same way.

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8.3 Register summary

Reg.

No Status-Register

Bit

higher -order byte lower-order byte

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

1 BI status p Inputs Faults

2 CM3/CCM status, module 1 messages Errors Position information

up to

51 CM3/CCM status, module 50 messages Errors Position information

52 IO status, module 51 Error messages 8 <---digital inputs---> 1

53 analog input 1

54 analog input 2

55-

59

up to

60 analog input 8

up to

133 IO status, module 60 Error messages 8 <---digital inputs---> 1

134 analog input 1

135 analog input 2

136-

140

up to

141 analog input 8

Reg.

No

Control-Register

Bit

higher -order byte lower-order byte

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

142 BI control V P R

143 CM3/CCM control, module 1 control commands

up to

192 CM3/CCM control, mod. 50 control commands

193 IO control, module 51 4<dig.outp.>1 4<dig.outp.>1

up to

202 IO control, module 60 4<dig.outp.>1 4<dig.outp.>1

Reg.

Nr.

Status-Register

Bit

higher -order byte lower-order byte

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

203 relay module 61 counter Error messages

204 16 <---digital inputs---> 9 8 <---digital inputs---> 1

up to

241 relay module 80 counter Error messages

242 16 <---digital inputs---> 9 8 <---digital inputs---> 1

Reg.

Nr.

Control-Register

Bit

higher-order byte lower-order byte

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

243 relay module 61 8 <-- digital outputs --> 1 8 <-- digital outputs --> 1

up to

262 relay module 80 8 <-- digital outputs --> 1 8 <-- digital outputs --> 1

not used =

p = running in passive mode if set (see also: 10.2)

P = force to passive mode (see also: 10.3)

V = Data Valid Bit for Profibus ( see also:0)

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9 BI Profibus DP interface (slave) The Profibus DPV0 interface is available as an alternative to the Modbus and can be chosen via the

set-up menu of the fieldbus interface (BI). Automatic baud rate identification is used. Baud rates be-

tween 9600 baud and 1.5 Mbaud are permissible. If required a bus terminator (in accordance with the

Profibus standard) can be connected via a miniature two-pole switch in the front of the housing.

The advanced V1 and V2 services are not available. Differing from the Profibus standard an inexpen-

sive screw-type terminal is used for the electrical connection instead of a sub-D connector. More de-

tailed information about the Profibus protocol may be obtained from the standard EN 50170 or from

the „Profibus Nutzer Organisation“ (PNO, www.profibus.com).

Note: The Profibus Interface is not available on BI modules with Art.No. 9341100250. Those BI only

provide Modbus RTU. If Profibus is selected anyhow an error message is indicated

9.1 Profibus data model

For compatibility reasons the same data model is used as for the Modbus. 16 binary digit-wide data

words are used instead of the Modbus registers. On account of the maximum telegram length of 244

bytes a maximum of 7 IO modules can be used for the Profibus protocol. The data model is described

in the “PE_PCMV2.gsd“ GSD file (or newer versions). The meaning of the individual data words corre-

sponds to those in the registers for the Modbus protocol.

To avoid unnecessary data transfer the BI module is set-up as a modular station. The following mod-

ules are available.

Module 1 BI, status & control, 1 word read, 1 word write

Module 2 5x CM3/CCM, status & control, 5 words read, 5 words write

Module 3 10x CM3/CCM, status & control, 10 words read, 10 words write

Module 4 1x IO8/8/4, status & control, 9 words read, 1 word write

Module 5 1x RK16/8, status & control, 2 words read, 1 word write

Module 6 5x RK16/8, status & control, 10 words read, 5 words write

The module type 1 must always be inserted in first place. Next up to 50 CM3, 7 IO8/8/4 and 20

RK16/8 may be added. Please keep in mind that the number of data bytes both read and write must

not exceed 244.

9.1.1 Fieldbus interface to superimposed control system (status words)

Data word Meaning

1 Status field bus interface

1 each Status CM3, address 1..50

9 each Status IO 8/8/4, address 51..57

2 each Status RK 16/8, address 61..80

Superimposed control system to fieldbus interface (control words)

9.1.2

Data word Meaning

1 Command field bus interface

1 each Command CM3, address 1..50

1 each Command IO 8/8/4, address 51..57

1 each Command RK 16/8, address 61..80

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9.1.3 Data Valid Bit

Some Profibus DP masters keep on sending data even if the supervisory controller is stopped. In this

case all commands are set to 0. This is not suitable for PCM system. Therefore the highest Bit15 of

the control word of the BI is used as a „Data Valid Bit“. If this bit is not set the Profibus connection is

treated as invalid.

This Bit is used only if the Bit0 of the first Parameter Byte is set to 1, otherwise the data is always

treated as valid data. This function is only implemented in BI firmware version V1.6 or higher.

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10 Secondary BI Module To achieve an improved availability of the field

bus connection (either Profibus DP or Modbus

RTU) an additional, secondary BI module may

be used. This secondary module is usually

running in passive mode permanently reading

the traffic on the local bus. Therefore it will al-

ways show the latest data of all modules con-

nected but it can not and must not send any

command to the modules.

Whether a BI runs in passive or active mode

depends on its priority on the local bus. Al-

ways the BI with the highest priority becomes

active. The priority depends on the following

conditions:

Priority Condition

3 primary module, field bus connection to supervisory control is working properly

3 primary module, running in set-up mode

2 secondary module, always

1 primary module, no field bus connection and no set-up mode

If the field bus connection of the primary module fails the priority of this module is reduced to 1 and

therefore the primary module becomes passive whereas the secondary module becomes active. Be-

cause a BI running in set-up mode needs full access to the local bus the priority of the primary BI is

set to 3 if set-up mode is turned on. To use the secondary BI in set-up mode the fieldbus connection

of the primary BI must be interrupted during set-up.

The secondary BI should preferably be mounted on the right side of the CM3 modules. The control

inputs E1 and E2 are connected in parallel to the primary BI if used at all.

10.1 Parameterisation of the secondary BI module

The address setting is the only difference between primary and secondary BI. If both BI are connected

to separate field busses they both may (and preferably should) use the same real fieldbus address.

The secondary BI module is set to a fieldbus address “real address + 80h”. That means that the sec-

ondary BI with the fieldbus address 1 is set to address 1+80h = 81h.

ATTENTION: All functions described here are available only in software version 2.0 or higher!

10.2 Fieldbus interface BI status, register 1 (read only)

One entry is added to this register. As long as the BI is running in passive mode all data are valid but

no command will be sent to the modules.

Bit Meaning

Bit6 running in passive mode

IO

prim.BI CM3 CM3

1 21

sec.BICM3 CM3

3 ...

+24V

0V

primary bus

secondary bus

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10.3 Fieldbus interface BI remote control, register 142 (read/write)

One entry is added to this register. For test purpose the BI can be forced into passive mode. The

other BI will than change to active mode.

Bit Meaning

Bit1 force BI to passive mode

10.4 Operating redundant BI

Both master interfaces should be (but don’t have to be) identical. If two separate bus cables are used

even the slave addresses may and should be the same. The master software should treat both BIs ás

well as the connected modules identically. There is no need to send commands to the passive BI as

this BI can’t send commands to the connected modules. Anyhow you may do so if it is more conven-

ient. The passive flag in the BI status register should be indicated to the user. Of course both masters

must poll the primary and the secondary BIs permanently. Otherwise a failure of the secondary bus

may not be noticed.

For test purpose the master should be able to stop polling the primary bus. In this case the secondary

BI must indicate that it turned to active state a few seconds later. If turning off the primary master is

not possible the primary BI can be forced to passive mode by setting the corresponding bit in the con-

trol register.

10.5 Alarm output

The alarm output of the passive BI is always closed that means an alarm is never signalised. The ac-

tive BI behaves like a standard BI.

11 PCM modules, available versions To reduce the need of an extensive set-up and to implement outrageous control functions the CM3

module is available in different versions.

11.1 CM3

Article number Function

9341100100 Standard device as described in this manual if not otherwise mentioned

9341100110 CM3 with control functions for hydraulic actuators with 24V solenoid valves (see

separate manual)

9341100120 CM3 for spring close actuators with separated hydraulic unit (separate manual)

9341100140 Like standard device but extended operation mode 1+2 is already set

9341100150 Like standard device but extended operation mode 1+3 is already set

9341100160 Device with wire break detection and extended operation mode 1+2 is already set

9341100170 Device with wire break detection and extended operation mode 1+4 is already set

9341100180 Like standard device but extended operation mode 1 is already set

11.2 BI

Article number Function

9341100200 Standard device as described in this manual, provides Modbus + Profibus inter-

face

9341100250 Simplified version, provides Modbus interface only

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11.3 IO 8/8/4

Article number Function

9341100300 Standard device as described in this manual

11.4 RK 16/8

Article number Function

9341100400 Standard device as described in this manual

11.5 CCM

Article number Function

9341100500 Standard device as described in this manual

12 Assembly of the system Certain boundary conditions must be adhered to during the assembly of the complete control systems

in order to ensure reliable and trouble free operation.

• Only a maximum of 50 CM3 / CCM, 10 IO8/8/4 (7 for Profibus DP) and 20 RK modules are to be

connected to a fieldbus interface.

• The IO modules must be aligned to the left and all other modules must be aligned to the right of

the fieldbus interface. RK modules must be mounted on the very right side of all other modules.

• All 230VAC supplies must be fused with max. 16A B characteristic.

• The 24VDC supply may be connected several times to separate the supply for different systems

(etc. bilge, ballast). Each 24V supply is separately fused up to 4AT. All 0V supplies must be

connected directly to the same terminal. 0V supply is fused with a common 6AT fuse. For

the connection of the DC supply the BI (9, 10) or the plugs of the prefabricated cable sets must be

used.

• The local data bus and the lamp test control may be extended by means of prefabricated cable

sets. Up to 4 adapting cables and one extension cable may be used per BI module. The screen of

these cables must be connected to a PE terminal right beside the plug connector. The PE terminal

is also used to fix the modules on the rail mount.

• All control signals from and to the CM3 / CCM and IO 8/8/4 modules are supplied via the 24VDC

of the CM3 respectively the IO 8/8/4 modules.

• All cables leaving the control cabinet and being connected to the modules must be screened. The

screen must be connected extensively to the mounting plate. So-called “pigtails“, i.e. cables be-

tween the screen and a PE terminal, are not permissible.

12.1 Controlling via mimic diagram

The CM3 modules can be used without a fieldbus interface for applications in which the actuators are

controlled exclusively by a mimic diagram. The feeding-in of the 24VDC supply voltage is then via the

local bus connector pins 4 and 5. The voltage must have external fuse protection amounting to a max-

imum of 6A. Insofar as necessary, a 24VDC lamp test signal is also connected via the local bus con-

nector. The current consumption of this control input amounts to approx. 1mA per module.

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12.2 Commissioning hints

Incorrectly connected drives or defective cables may cause damage of the CM3 modules or

the OC3 feedback modules. To avoid this some tests must be performed before 24VDC or

230VAC supply is turned on.

1. 24VDC and 230VAC are completely separated from each other and from protective earth (PE),

e.g. the rail-hat. Therefore a high insulation resistance must be measured between those circuits.

The insulation resistance measurement should be

performed with an insulation resistance meter with 50

to 500VDC test voltage. The following minimum re-

sistance values must be achieved:

Using a standard multi-meter as a substitute may re-

sult in uncertain results. This measuring must be per-

formed during commissioning and should be re-

peated after any repair works on the cabling of the

actuators.

2. Please also check that pin 13 of the CM3 module, this is the position feedback input 4..20mA, is

connected only for those actuators that really use an analog position feedback signal.

3. Turn on 230VAC for a few devices only and check proper operation carefully before connecting

the next devices to 230VAC.

12.3 Safety Advice

The plate beside shows an important safety advice and

must be fixed at the top-hat rail right beside the installed

CM3 modules.

If CM3 modules are mounted on different top-hat rails

one plate has to be fixed at each rail.

Pay attention to this safety advice during any kind of work on the pluggable screw terminals!

12.4 Accessories

For the proper installation of PCM systems the following accessories are required.

12.4.1 Adapting Cable

This cable is used if the 24VDC supply shall be feed several times. The length of the cable is app.

20cm must not be extended or replaced by a different cable. The modules are fixed on both sides of

the cable by means of an end holder that is fastened on the hat-rail. The right plug (4+5) must be con-

nected to 24VDC power

supply. Connect pin 4 to

the common 0V directly,

connect pin 5 to 24V fused

up to 4A.

Article-No: 9319710190

CM3 Safety Advice Always plug in

red connector last and pull it off first!

(AC supply voltage)

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1. 0VDC to PE 1 MOhm

2. 0VDC to L, N 1 MOhm

3. 24VDC to PE 1 MOhm

4. 24VDC to L, N 1 MOhm

5. N to PE 1 MOhm

6. L to PE 1 MOhm

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12.4.2 Extension Cable

This cable is used to connect additional modules on a second hat-rail to the same BI module. Only

one cable can be used per BI module. The shield of the extension cable must be connected to the

hat-rail via PE terminals. These termi-

nals are also used to fix the modules

mechanically. The cable is app. 150 cm

long and must not be extended! If such

a cable is used the 24VDC power sup-

ply must be connected to the modules

separately.

Article-No: 9319710180

12.4.3 Adapting Cable for RK 16/8

This cable is required to connect one or more relay

modules to the local bus of BI, CM3 or IO 8/8/4.

Artikel-Nr.: 9319710330

12.4.4 Safety Advice Plate

This safety advice must be fixed at the hat-rail close by the installed

CM3 modules (at each hat-rail with CM3).

Article-No: 9319932210

12.4.5 End Holder

The end holder are fixed to the hat-rail on the right side of the mod-

ules. If the adapter cable is used one holder is also fixed on the left

side of the modules.

Article-No: 4639020830

12.4.6 Noise Suppression Filter

If a BI module is used on the bridge one filter must be inserted in the common

24VDC supply of all modules (according GL-Rule EMC1: Using on the bridge

or on the open deck).

The current must not exceed 16A. The filter is screwed on the mounting plate

directly. A sufficient electrical and thermal contact to the mounting plate must

be ensured.

Article-No: 4470200050

12.4.7 CM-ExE Capacitor Module

To connect double acting actuators for explosion proof areas to a CM3

module a capacitor module is required.

Article-No: 9311222810

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