Digitronic CamCon DC16 Bedienungsanleitung

DigitalCamSwitch Unit

CamConDC16

DigitronicAutomationsanlagen GmbH

Steinbeisstraße 3

•

D -72636 Frickenhausen

•

Tel. (+49)7022/40590-0

•

Fax -10

Auf derLangwies 1

•

D -65510 Hünstetten-Wallbach

•

Tel.(+49)6126/9453-0

•

Fax -42

Internet: http://www.digitronic.com

•

E-Mail: mail@digitronic.com

2 rue René Laennec 51500 Taissy France

Fax: 03 26 85 19 08, Tel : 03 26 82 49 29

E-mail:[email protected]

Site web : www.hvssystem.com

Digitronic DigitalCamSwitchUnit

AutomationsanlagenGmbH CamCon DC16

Foryourattention

Thisinstruction manualrelatesto the CamCon DC16 from10/2003. The companyDigitronic

Automationsanlagen GmbH reservesthe right to makechangeswhichpresent an improvement ofthe

qualityorfunctionalityofthe devicewithout priornotice. The instruction manualwascreated with great

care, although itmaynot be error-proof.Wewouldbe gratefulforanycommunication relating to any

errors you mayhave found.

UP-date

You can alsoobtainthisinstruction manualon the Internet at http://www.digitronic.com inthe latest

version asPDFfile.

Qualifiedpersonnel

Thisdevicemayonlybe started and operated byqualified staff.Byqualified wemean personnelwho

areentitled to handle, to earth and to labledevices,systemsand powercircuitsinaccordancewith the

technologysafetystandards.

Liability

(1)The supplierisliablefordamagescaused byhimselforbythe ownerofthe rightsup to the sumof

the salesprice. He isnot liableforloss ofprofits,forfeited savings,intermediate and successive

damages.

(2)The abovementioned limitsto liabilitydo not applyto insuranceofnamed characteristics and

damageswhich were caused deliberatelyorthrough negligence.

Protection

The CamCon DC16 and thisinstruction manualareprotected bycopyright. All rightsarereserved.

Neitherthe CamCon DC16, northisdocument maybe copied asawholeorpartially,photocopied,

reproduced, translated ortransferred to electronicmediaofanykind orinto machine readableformat

without priorwritten permission bythe companyDigitronicAutomationsanlagen GmbH.

Note: Wehaveexamined the devicesofthe CamCon seriesforyear2000 compatibilityand

have not found anyadverse effectson anyfunctions.

Note: CamCon isaregistered trademarkofthe companyFirmaDigitronic

Automationsanlagen GmbH.

Note: The devicesofthe CamCon seriescomplywith the standardsforelectromagnetic

compatibility:EN 55011, EN 55022, EN 55024 Part 2, EN 50082 Part 2, ENV50140,

VDE0843 Part 2, VDE0843 Part 4, VDE0871, VDE0875 Part 3 ("N"),

VDE0875 Part 11, VDE0877 Part 2, IEC 801 Part 3, IEC 801 Part 2, IEC 801 Part 4,

IEC 801 Part 5.

DigitronicAutomationsanlagen GmbH

AufderLangwies1

D-65510 Hünstetten -Wallbach

Tel. (+49)6126/9453-0 Fax. (+49)6126/9453-42

Internet: http://www.digitronic.com

E-Mail: mail@digitronic.com

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Digitronic DigitalCamSwitchUnit

AutomationsanlagenGmbH CamCon DC16

Table of contents

1. Introduction..........................................................................................................................................7

2. Operating Pinciples..............................................................................................................................8

2.1. Speed Compensation .......................................................................................................................9

2.1.1. Measuring delaytime forSpeed Compensation..........................................................................11

2.1.1.1. Measuring delaytime through actualdifferences.....................................................................11

2.1.1.2. Measuring delaytime bymeansofdifferent measuring points.................................................11

2.1.2. Speed Compensation using off-centre pressure, e.g. brake functions........................................12

2.1.3. Separate delaytime forSpeed Compensation ofswitch-ON and switch-OFF points.................13

2.2. Time -Cam.....................................................................................................................................13

3. Installation..........................................................................................................................................14

3.1. Dimensions.....................................................................................................................................14

4. Electricalconnections........................................................................................................................15

4.1. Pin allocation...................................................................................................................................15

4.1.1. Pin allocation ofthe voltage supply..............................................................................................15

4.1.2. Pin allocation ofthe SSI measuring system.................................................................................15

4.1.3. Pin allocation ofthe incrementalmeasuring system....................................................................15

4.1.4. Pin allocation ofthe outputs1-8 (0.5Amp.)..................................................................................15

4.1.5. Pin allocation ofthe outputs9-16 (40mA)....................................................................................15

4.1.6. Pin allocation ofthe inputs...........................................................................................................15

4.1.7. Pin allocation ofthe serialRS485 interface.................................................................................16

4.1.7.1. Closedown-resistors ofa serialRS485 interface.....................................................................17

4.1.7.1.1. Closedown resistors with DIP-switch.....................................................................................17

4.1.7.1.2. Closedown resistors with solding bridges..............................................................................18

4.1.8. Clamping allocation ofa serialRS232 interface (optional)..........................................................18

4.2. Externalinterface (option)...............................................................................................................19

4.2.1. Pin allocation ofthe externalinterface.........................................................................................19

4.2.2. Externalinterface with a cable length of0.5 to 300m..................................................................19

4.3. The measuring system....................................................................................................................20

4.3.1. SSI Measuring systeminput........................................................................................................20

4.3.2. Parallelmeasuring systeminput..................................................................................................20

4.3.3. Incrementalmeasuring systeminput...........................................................................................21

4.3.3.1. Incrementalmeasuring systeminput with 5VRS422 level.......................................................21

4.3.3.2. Incrementalmeasuring systeminput with 24VPNPlevel.........................................................21

4.3.3.3. IncrementalHiperface measuring systeminput with SINCOSlevel.........................................22

4.3.4. Analog measuring systeminput...................................................................................................22

4.3.5. PLL measuring systeminput........................................................................................................23

4.3.6. Timerasa measuring system......................................................................................................23

4.3.7. RS232 asa measuring system....................................................................................................23

4.4. The outputs.....................................................................................................................................24

4.5. The inputs.......................................................................................................................................24

4.6. Precautionarymeasuresforwelding work......................................................................................24

4.7. The statusLED...............................................................................................................................24

5. Generalprogramming information.....................................................................................................25

5.1. Outline ofkeyfunctions...................................................................................................................25

5.2. Menu selection................................................................................................................................25

5.3. Selection ofa menu point ...............................................................................................................25

5.4. Text input........................................................................................................................................26

6. Commissioning ..................................................................................................................................27

7. Operation ofthe CamCon..................................................................................................................29

7.1. The main menu...............................................................................................................................29

7.2. The standard display.......................................................................................................................29

7.2.1. Changing the display....................................................................................................................29

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Digitronic DigitalCamSwitchUnit

AutomationsanlagenGmbH CamCon DC16

7.2.2. Programchange ..........................................................................................................................30

7.2.3. Programname.............................................................................................................................30

7.3. Camprogramming..........................................................................................................................31

7.3.1. Output selection forprogramming ...............................................................................................31

7.3.2. Programselection forprogramming............................................................................................32

7.3.3. Programming the delaytime/speed compensation......................................................................32

7.3.4. Programing Time-Cams...............................................................................................................33

7.3.5. Programming the output name....................................................................................................34

7.3.6. CamInput ....................................................................................................................................34

7.3.7. Adding cams................................................................................................................................35

7.3.8. CamTeach -In............................................................................................................................35

7.3.9. CamSearch.................................................................................................................................35

7.3.10. Camdeletion..............................................................................................................................36

7.3.11. Output (camtrack)deletion .......................................................................................................36

7.3.12. Copying programmed outputs(camtracks)...............................................................................37

7.3.13. Shifting camtracks ....................................................................................................................37

7.3.14. Deleting programs......................................................................................................................38

7.3.15. Copying programs......................................................................................................................38

7.3.16. Examplesforcamprogramming................................................................................................39

7.3.16.1. First camprogramming...........................................................................................................39

7.3.16.2. Programming additionalcamson an output...........................................................................40

7.3.16.3. Deletion ofa particularcam....................................................................................................41

7.3.17. Programming analog cams........................................................................................................42

7.3.17.1. Creating the first analog cam..................................................................................................43

7.3.17.2. Adding an analog cam............................................................................................................43

7.3.17.3. Changing the analog cam.......................................................................................................43

7.4. Unit configuration (systemsetting)..................................................................................................44

7.4.1. Measuring system........................................................................................................................44

7.4.1.1. The standard measuring systems.............................................................................................44

7.4.1.2. The actualposition hysteresis...................................................................................................44

7.4.1.3. Controlling the measuring system.............................................................................................45

7.4.1.4. The electronicgear...................................................................................................................46

7.4.1.4.1. Electronicallychanging the rotation direction.........................................................................46

7.4.1.5. The displayformat ofthe actualposition..................................................................................46

7.4.1.6. Configuration ofa specialmeasuring system...........................................................................47

7.4.1.6.1. SSI -measuring system.........................................................................................................47

7.4.1.6.2. Parallel-Graymeasuring system..........................................................................................48

7.4.1.6.3. Incremental-measuring system............................................................................................48

7.4.1.6.4. Multiturn measuring systemwith electronicgear...................................................................49

7.4.1.6.5. PLL measuring system ..........................................................................................................50

7.4.1.6.6. Timerwaysimulation (time emitter).......................................................................................50

7.4.1.6.7. RS232 measuring system......................................................................................................51

7.4.1.6.8. AG615 -Single -Multiturn -Measuring system.....................................................................51

7.4.1.6.9. SIM -measuring systemsimulator ........................................................................................52

7.4.1.6.10. HIPER i.e. incremental-measuring systemwith Roll -Over-funktion..............................52

7.4.1.7. Deleting the specialmeasuring system ....................................................................................53

7.4.2. The measuring offset...................................................................................................................54

7.4.2.1. Zero offset with rotatorymovements.........................................................................................54

7.4.2.2. Measuring offset with a linearmoved system...........................................................................54

7.4.2.3. Zero offset with linearmovements............................................................................................54

7.4.2.4. Actualposition preset................................................................................................................55

7.4.3. The speed adjustment.................................................................................................................56

7.4.3.1. The speed factor.......................................................................................................................56

7.4.3.2. The displayformat ofthe speed display...................................................................................56

7.4.3.3. Range adjustment ofthe speed display....................................................................................56

7.4.3.4. Accuracyofthe speed display..................................................................................................57

7.4.3.5. Display, Type ............................................................................................................................57

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Digitronic DigitalCamSwitchUnit

AutomationsanlagenGmbH CamCon DC16

7.4.4. Cable length / Cycle time.............................................................................................................58

7.4.4.1. The cable length .......................................................................................................................58

7.4.4.2. The cycle time ofthe CamCon..................................................................................................58

7.4.5. The specialoutputs......................................................................................................................58

7.4.5.1. The securityoutput....................................................................................................................58

7.4.5.2. The output ofthe actualposition...............................................................................................59

7.4.5.3. Direction output.........................................................................................................................59

7.4.5.4. The standstill output..................................................................................................................59

7.4.5.5. The hysteresis...........................................................................................................................59

7.4.5.6. The analog speed output..........................................................................................................60

7.4.5.7. Configuration ofthe analog cams.............................................................................................60

7.4.5.8. The analog position output........................................................................................................62

7.4.6. Systemupgrading........................................................................................................................62

7.4.6.1. Setting the inputs......................................................................................................................62

7.4.6.2. Setting the outputs....................................................................................................................62

7.4.6.3. Setting the outputswith speed compensation..........................................................................62

7.4.6.4. Setting the keyboard lock..........................................................................................................62

7.4.6.5. Error-aknowledging Input (EQ)...............................................................................................62

7.4.6.6. Input forenableling Outputs......................................................................................................62

7.4.6.7. Setting the externalprogramselection.....................................................................................63

7.4.6.8. Setting the programselection mode.........................................................................................63

7.4.7. Masterprogram.............................................................................................................................64

7.5. Unit configuration............................................................................................................................65

7.5.1. Userkeyallocation.......................................................................................................................65

7.5.1.1. Creating a newuserkey...........................................................................................................65

7.5.1.2. Deletion ofa userkey...............................................................................................................66

7.5.1.3. Checking the keyconfiguration.................................................................................................66

7.5.2. Complete deletion........................................................................................................................67

7.5.3. Unit configuration.........................................................................................................................68

7.5.3.1. Setting the serialinterface ........................................................................................................68

7.5.3.1.1. The "Cam-BUS" communication mode..................................................................................68

7.5.3.1.2. The "Standard"communication mode...................................................................................68

7.5.3.1.3. The "Multiuser"communication mode...................................................................................68

7.5.3.1.4. The "S5 -L1"communication mode......................................................................................68

7.5.3.1.5. The "3964(R)"communication mode.....................................................................................68

7.5.3.1.6. Input ofthe unit number.........................................................................................................69

7.5.3.1.7. Programming via remote .......................................................................................................69

7.5.3.2. Additionaldevice options..........................................................................................................69

7.5.3.2.1. PLC LogicModule..................................................................................................................69

7.5.3.2.1.1. Examplesforusing the PLC logicmodule..........................................................................69

7.5.3.2.2. PLC LogicModule with text display.......................................................................................70

7.5.3.3. Analog outputs..........................................................................................................................71

7.5.3.3.1. Clearing the integrated analog outputs..................................................................................71

7.5.3.3.2. Adjusting the integrated analog outputs.................................................................................71

7.5.3.3.3. Externalanalog outputs.........................................................................................................71

7.5.3.4. Locking EEPrommemory.........................................................................................................72

7.5.4. Language.....................................................................................................................................73

7.5.5. Configure user .............................................................................................................................73

7.5.5.1. Usertext....................................................................................................................................73

7.5.5.2. User-Menu/OP-functions..........................................................................................................74

7.5.6. Configure Hardware.....................................................................................................................74

7.5.6.1. CP16 Module............................................................................................................................74

8. Device info.........................................................................................................................................75

8.1. StackInfo........................................................................................................................................77

9. Errormessagesand removaloferrors (FAQ)...................................................................................78

9.1. Problem: Displayshows"No contact to unit: XX"...........................................................................78

9.2. Problem: "Pos-Err:1".....................................................................................................................78

9.3. Problem: "Pos-Err:2".....................................................................................................................78

9.4. Problem: "Pos-Err:3".....................................................................................................................79

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AutomationsanlagenGmbH CamCon DC16

9.5. Problem: "Pos-Err:5".....................................................................................................................79

9.6. Problem: An "Pos-Error:"occurs during operation..........................................................................79

9.7. Problem: "RAM-Full" =RAM memoryisfull.....................................................................................79

9.8. Problem: The EEPrommemoryisfull.............................................................................................80

9.9. Problem: Outputswill not activate...................................................................................................80

9.10. Problem: "Out -Error"...................................................................................................................80

9.11. Problem: Errorin the EEPROM....................................................................................................80

9.12. Problem: "Error???".....................................................................................................................80

9.13. Problem: "Clear...."........................................................................................................................81

10. Menu outline.....................................................................................................................................82

11. Calculation EEPROM camstorage..................................................................................................83

12. Calculation the RAM storage-requirement forCamCon..................................................................84

13. Technicaldata ofthe CamCon........................................................................................................85

14. Keywords .........................................................................................................................................86

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Digitronic DigitalCamSwitchUnit

AutomationsanlagenGmbH CamCon DC16

1. Introduction

ElectronicCamSwitchUnitshavebeen successfullyused inindustryforalong time. Experiences

collected incloseliaison with users overthe years havebeen included inthe development ofthe

CamCon series.The resultisacompactdigitalcamswitchunitwhichisuserfriendlyand reliableto a

high degree. The following characteristics testifythe excellence ofthe CamCon:

*Tested and reliable hardware

*Short-circuit-proofoutputs

*Graphicliquid crystaldisplaywith 128x64 pixelsin the CamCon DC50,51.

* Large and clearlyvisible7-Segment displayforprogram,position and speed on

CamCon DC30,33 and 40.

*Anynumberofcamsperoutput can be programmed.

* Up to 32000 Programsforproduct administration

* Master, forexample: machine cams

*Optimising switch pointswhen machine isin operation

* Compensation ofmechanicaldelaytimeofswitchcomponentsforswitch-ONand switch-OFF

pointscan be set in stepsof100µsseparately(DTC =delaytime orSpeed Compensation).

*Position -Triggert -Time -Cams

*Powersupply24VDC +/-20%

* Mounting ofsuspension railsto EN 50022 on CamCon DC16 and 90

*Switchboard panelstandard casing 144 x144 x63mm to DIN 43700 on CamCon DC33,40 and 51

*S5 Componentsgroup forS5 115U, 135U and 155U on CamCon DC115

*S7 Componentsgroup forS7 300 on CamCon DC300

*AB Componentsgroup forControlLogix



1756 on CamCon 1756-DICAM

* S5 Switch-ON via PGinterface with L1 -Buson CamCon DC16,40,50,51 and 90

*PLC LogicModule (optional)

* Shift register(optional)

*OP-Functions

*Analog outputs(optional)

Cam switchunitsareused whereverswitching operationsareperiodicallyrepeated. Digitalcamswitch

unitsarean optimumreplacement ofmechanicalunitsand offerinaddition manyotheradvantages,

such as:

*Simplification ofmounting and adjustment operations

* Repeatable adjustment facility

*Standardised foralmost all areasofapplication

* Reliability

* High switch speed

*Speed Compensation

*Product administration forquickformat change

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Digitronic DigitalCamSwitchUnit

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2. Operating Pinciples

Diagram: Principlesofa CamSwitch Unit

Aprincipleforbettercomprehension ofthe function ofaCamSwitchUnitisherepresented. It has3

outputswith the following cams:

Output 1: Cam1: Switch-ON position60° Switch-OFF position 85°

Cam2: Switch-ON position95° Switch-OFF position 145°

Cam3: Switch-ON position325° Switch-OFF position 355°

Output 2: Cam1: Switch-ON position5° Switch-OFF position 20°

Cam2: Switch-ON position95° Switch-OFF position 145°

Output 3: Cam1: Switch-ON position30° Switch-OFF position 85°

The positionsofthe output signals,herepresented asthree tracks,occurwhen the three camdisks

turn anti-clockwise past a sensor, which scansthe camson the 0°-axis.

In amechanicalcamswitchunit, the switchinterval,i.e. the range between switch-ONand switch-OFF

position aredetermined bythe length ofthe cam.The length and the position ofthe camcan onlybe

varied marginallyand thisismechanicallyhighlydemanding and timeconsuming. With CamCon such

adjustmentscan be realised inafraction oftime; inaddition, therecan be anynumberoftracks.A

measuring systemwhichisfitted to the devicereportsthe position to the CamCon. The CamCon

comparesitwith the programmed switch-ONand Switch-OFF positionsofall outputs.Ifthe position

liesinthe range ofaprogrammed switch-ON/switch-OFF position (cam),then the respectiveoutputs

are active.

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Digitronic DigitalCamSwitchUnit

AutomationsanlagenGmbH CamCon DC16

2.1. SpeedCompensation

Eachmechanicalswitchcomponent (e.g. shield, magneticvalve)hasadelaytime, i.e. the time

between the startsignaland the actualswitching ofthe contacts.In processeswherepositioning is

executed on amoving system,thiscan causeproblems.Ifsuchaprocess isdriven with different

speeds,different positionsarecaused. Toavoidthishappening, newtimingsforthe switchsignalsof

each speed would have to be calculated.

In orderto ilustrate the complicated issuessurrounding delaytimeorspeed compensation, thiswill be

shownon the exampleofapackaging machine. In the process showninthe diagram,aglue point has

to be placed in an exactlydefined spot on a moving papertrack.

magneticvalve

gluenozzle

drop

paper

Pointswheretheglue

hitsthepaper at the

different speeds .

paper track

encoder

CamCon The systemhasthe following parameters:

vp-Speed ofthe papertrack

vT-Falling speed ofthe drop ofglue

d - Distance between the glue nozzle and

the papertrack

TMV - Delaytime ofthe magneticvalve

Without speed compensation the following would happen:

Assoon asthe measuring systemhasreached acertainposition, the CamCon sendsasignalto the

magneticvalve. The glue nozzle opensfora short time during whichadrop of glue ejects.Between the

startofthe impulseand the exitofthe drop timepasses,whichismainlycaused bythe delaytimeof

the magneticvalveTMV..Afurtherdelayiscaused bythe timewhichthe droplet needsto pass the

distance between the glue nozzle and the surface ofthe paper.

Thisflight time iscalculated asfollows:

tFlight = d

In totaltherethe delaytimeistFlight+TMV. During thistimethe papertrackmoveson byaspecific

distance x.

It wouldnowbe possibleto movethe position, wherethe magneticvalveisswitched on, forwardbya

specificamount, sothat the glue droplet hitsthe samespot againasduring standstill.In thiswaya

speed compensation iscreated whichworksonlyat aspecificspeed ofthe paper.Assoon asthe

speed ofthe deviceand consequentlythat ofthe papertrackis,forexample, doubled, the hitpoint of

the glue droplet isshifted bythe distancex,sothat, without anyspeed compensation, itwouldmove

backward bydouble the distance (2 ⋅x) in total.

The automaticspeed compensation ofthe CamCon makesitnowpossibleto driveprocesseswith

variablespeed; CamCon registers the speed ofthe devicecontinuouslyand adjuststhe camswhich

determine the switchtimepoints"OnLine"depending on the speed. Thishasthe effectthat the

outputsforthe switchcomponentsareswitched ONorOFF earlier.The direction ofthe movement is

ofno significance in thisinstance.

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Digitronic DigitalCamSwitchUnit

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Asmall example in figureswasdesigned to eludicate:

Supposing the drivecylinderwith the measuring systemhasacircumferenceof360mm,sothat one

millimeterofthe circumference correspondsto exactlyone angle degree ofthe measuring system.

The device hasthe following parameters:

vdroplet = 20m/s

d = 20cm

TMV = 20ms

Thisresultsin the following flight time ofthe droplet:

tFlight= d

vT=0,2m

20m/s = 10ms

The totaldelaytime isthen Tdead, altogether =TMV +tFlight =20ms+10ms=30ms

During thistimethe papertrackmoveson bythe distancex=vpaper ⋅Ttotaldelay. =1m/s ⋅30ms=

30mm.In orderto compensate the delaytime, the switchpoint forthe magneticvalvemustbe moved

forward by30°.

Ifthe speed ofthe deviceand consequentlythat ofthe paperisdoubled vpaper,then the distancexis

also doubled bythe speed ofthe papertrack. In thiscase the switch point must be moved by60°.

Note: Pleasetakeinto account intheseexplanationsthat delaytimeisofafixed size, whichis

determined bythe mechanicalconstantsofthe set and switchcomponentsand bythe

dimensionsofthe construction and therefore doesnot change!

Ifthe totaldelaytimeof30mswasprogrammed into the respectiveoutput ofCamCon, then the glue

droplet would alwayshit the right spot, regardless ofthe speed.

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