zm modular-dn v1 tb0018 en

Technical Description Date: July 2013

LJU Automatisierungstechnik GmbH

PCM Modules ZM modular

Field bus connection: DeviceNet DN Version 1 with ZM-DN modules WNR 60134 or WNR 60138

ZM modular-DN V1_TB0018_en

© LJU Automatisierungstechnik GmbH

Am Schlahn 1

14476 Potsdam

Germany

Tel.: +49 (0) 33201 / 414-0

Fax: +49 (0) 33201 / 414-19

E-mail: [email protected]

Internet: www.ljuonline.de | www.grenzebach.com

The standard names, trade names, product names etc. used in this technical documenta-

tion may also be brand names even when not specially indicated and as such subject to

the statutory stipulations.

July 2013

Technical Description ZM modular DeviceNet DN

Table of Contents

ZM modular-DN V1_TB0018_en 3

Table of Contents

1 General Information ..................................................................................... 6

1.1 Information about the Technical Description ................................................ 6

1.2 Symbols in the Documentation .................................................................. 7

1.3 Limitation of Liability ................................................................................ 8

1.4 Copyright................................................................................................ 8

1.5 Conformity .............................................................................................. 8

1.6 Proper use .............................................................................................. 9

1.7 Spare Parts and Repair ............................................................................. 9

1.8 Disposal Instructions and Environmental Specifications ...............................10

1.9 Warranty ...............................................................................................10

1.10 Customer Service ...................................................................................10

1.11 Modifications and Alterations ....................................................................11

1.12 Personnel and qualification.......................................................................11

2 System - Overview ..................................................................................... 12

2.1 Principle of the modular PCM-System ........................................................12

2.2 Important Note - Power Supply ................................................................13

2.3 Important notice for command rail segmentation ........................................14

3 Central Module ZM-DN ................................................................................ 15

3.1 General Facts .........................................................................................15

3.2 Design of the Central Module ZM-DN .........................................................16

3.3 Monitoring and Protection Function ...........................................................16

3.4 Installation and Commissioning ................................................................16

3.4.1 Installation ....................................................................................16

3.4.2 Synchronization .............................................................................16

3.5 Technical Data and Connections ...............................................................17

3.5.1 Technical Data of the Central Module ZM-DN .....................................17

3.5.2 Connections of the Central Module ZM-DN ........................................18

3.6 DeviceNet Connection .............................................................................19

3.6.1 DeviceNet Connection .....................................................................19

3.6.2 DeviceNet Configuration Switch ........................................................20

3.6.3 LED Status Display .........................................................................20


Table of Contents


4 Pulse Code Module PCM-8-Bus.................................................................... 21

4.1 General .................................................................................................21

4.2 Design of the Pulse Code Module PCM-8-Bus ..............................................21

4.3 Monitoring and Protection Functions ..........................................................22

4.4 Installation ............................................................................................22


4.5.1 Technical Data of the Pulse Code Module PCM-8-Bus ...........................23

4.5.2 Connections of the Pulse Code Module PCM-8-Bus ..............................24

5 Input Module EM-8-Bus .............................................................................. 25

5.1 General .................................................................................................25

5.2 Design of the Input Module EM-8-Bus ........................................................25

5.3 Installation ............................................................................................26


5.4.1 Technical Data of the Input Module EM-8-Bus ....................................26

5.4.2 Connections of the Input Module EM-8-Bus ........................................27

6 Digital Input Module DI-8-Bus .................................................................... 28

6.1 General .................................................................................................28

6.2 Design of the Digital Input Module DI-8-Bus ..............................................28

6.3 Installation ............................................................................................28


6.4.1 Technical Data of the Digital Input Module DI-8-Bus ...........................29

6.4.2 Connections of the Digital Input Module DI-8-Bus ...............................30

7 Digital Output Module DO-8-Bus ................................................................. 31

7.1 General .................................................................................................31

7.2 Design of the Digital Output Module DO-8-Bus ...........................................31

7.3 Installation ............................................................................................31


7.4.1 Technical Data of the Digital Output Module DO-8-Bus ........................32

7.4.2 Connections of the Digital Output Module DO-8-Bus............................33

8 Resistor Module RM-8-Bus (optional) ......................................................... 34

8.1 General .................................................................................................34

8.2 Design of the Resistor Module RM-8-Bus ....................................................34

8.3 Installation ............................................................................................34


Table of Contents



8.4.1 Technical Data of the Resistor Module RM-8-Bus ................................35

8.4.2 Connections of the Resistor Module RM-8-Bus ...................................35

9 Communication and System Configuration ................................................. 36

9.1 DeviceNet Communication .......................................................................36

9.2 Cyclic Data Exchange ..............................................................................37

9.2.1 Cyclic Data: System Controller -> ZM-DN: 28 bytes ..........................37

9.2.2 Cyclic Data: ZM-DN -> System Controller: 11 bytes .........................38

9.2.3 Cyclic Data: Counter Connection ......................................................38

9.3 Acyclic Data Exchange .............................................................................39

9.3.1 Acyclic Data: System Controller -> ZM-DN: 244 byte ..........................39

9.3.2 Acyclic Data: ZM-DN -> System Controller: 244 byte ..........................39

9.3.3 Acyclic data: Message Structure and Handshake ................................40

9.3.4 Acyclic Data: System Access Indexes ................................................42

9.4 ZM-DN Parameterization 38 Byte ..............................................................43

9.5 Default System Structure.........................................................................45


General Information


1 General Information

1.1 Information about the Technical Description

This technical description contains technical information to the PCM-System with De-

viceNet connection and the devices of the ZM modular system:

Central module ZM-DN (WNR 60134 and 60138)

PCM module PCM-8-Bus

Input module EM-8-Bus

Input module DI-8-Bus

Output module DO-8-Bus

Resistor module RM-8-Bus (option)

It gives important information about the system and the devices.

Please read this technical description carefully before using the device!

It will ensure smooth operation and prevention of errors, defects and damage to the sys-

tem. Moreover, universal safety and accident prevention specifications must be imple-

mented at sites where the devices are in use.

The technical description includes important instructions regarding the operation and

safety; it is a part of the product and must readily available, close to the device, so that

it is accessible to the personnel at all times.

Every person who is assigned to work on or with the device must have read and under-

stood this technical description before working with the devices. This is mandatory even

if the concerned person has already worked with such a device or the like, or has been

trained by the manufacturer.


General Information


1.2 Symbols in the Documentation

There are warning instructions and symbols in this technical description. It is absolutely

mandatory to comply with these and follow them. These are working aids and they will

warn you of possible damage to property and personnel. Always follow these instructions.

Moreover, always follow the universal safety specifications and accident prevention speci-

fications.

Warning!

This symbol along with the signal word “Warning” refers to a potentially

dangerous situation that can lead to serious injuries or fatality if it is not

avoided.

Caution!

This symbol along with the signal word “Caution” refers to a potentially

dangerous situation that can lead to minor injuries and damage to prop-

erty if it is not avoided.

Note!

This symbol indicates that there are additional and important information

and tips on the relevant topic.

See also!

This symbol indicates that other detailed descriptions on the particular

topic are available or provides references to other sections in this docu-

mentation.


General Information


1.3 Limitation of Liability

All data and instructions in this technical description have been compiled taking into con-

sideration the applicable standards and specifications, the state-of-the-art technology

and our knowledge and experience gained over the years.

LJU Automatisierungstechnik GmbH is not liable for any damage or operational disorders

arising due to:

Non-compliance with the technical description

Improper use

Employment of untrained personnel

Independent remodeling and modification of the device

Moreover, non-compliance with the technical description absolves LJU Automatisierungs-

technik GmbH of the warranty obligation.

1.4 Copyright

The contents of this technical description should be treated as confidential. It is meant

solely for persons working with the device. Handing over this technical document to third

parties without written permission of the manufacturer is not allowed.

Note!

The content details, texts, drawings, images and other illustrations of the

technical description are protected by copyright and are subject to the

industrial property rights. Any improper utilization is punishable by law.

1.5 Conformity

Devices of LJU Automatisierungstechnik GmbH have been designed to conform to the EU

Guidelines.

A copy of the EU certificate of conformity can be requested from LJU Automatisierungs-

technik GmbH at any time.


General Information


1.6 Proper use

Devices of the ZM modular system are devices to control industrial and commercial

transportation systems via PCM commands.

Warning!

Danger due to improper use!

Any improper use and/or different use of the devices can lead to danger-

ous situations.

Therefore:

- Only use the devices in a proper manner.

- Under all circumstances, comply with all technical data and permissi-

ble conditions at the site of operation.

- Do not operate the devices in environments with hazardous oils, ac-

ids, gases, vapors, dust, radiation, etc.

1.7 Spare Parts and Repair

Warning!

Risk of injury due to spurious spare parts and incorrect repair!

Spurious or faulty spare parts and repair can lead to damage, malfunc-

tions or total failure and can impair safety.

Therefore:

- Use only original spare parts of the manufacturer.

- Replace defective devices immediately and send them for repair.

When ordering a spare part, specify the plant number

WNR of the component and send it to the address given on

the inner side of the covering sheet (page 2). The plant

number is given on the type plate of the individual compo-

nents. (see figure)

Send in the defective device for repair with a short descrip-

tion of the error scenario, to the address given on the inner

side of the covering sheet (page 2).

LJU-Automatisierungstechnik GmbH

Module 60xxx 123

Type WNR Ser.-Nr.

24V DC Baujahr

2007

Type plate with WNR


General Information


1.8 Disposal Instructions and Environmental Specifications

Provided no agreement for take-back or disposal has been made, the individual compo-

nents of the device, after appropriate dismantling, have to be segregated and disposed of

or recycled, according to the current stipulations.

Materials marked with the recycling symbol or green dot

have to be disposed of using the relevant recycling method.

1.9 Warranty

The warranty covers only production defects and component defects.

The manufacturer is in no way responsible for damage occurring during transit or un-

packing.

In no case and under no circumstances shall the manufacturer be liable under warranty

for defects or damage caused by improper use, incorrect installation or impermissible

operating conditions, or due to dust or aggressive substances.

Consequential and accidental damage are excluded from the warranty.

The warranty is valid for 12 months from the commencement of operation or 24 months

after delivery, whichever is earlier.

Resellers or distributors may negotiate different warranty periods in accordance with

their terms and conditions of sale and delivery.

If you have further questions relating to the warranty, please contact your supplier.

1.10 Customer Service

Our service is available for technical information.

Information about the responsible contact persons is available via telephone, fax, email

or the Internet, see contacts on the inner side of the covering sheet (page 2).


General Information


1.11 Modifications and Alterations

To avoid danger and to ensure optimal performance, no modifications, remodeling or

add-ons are allowed on the device, unless expressly approved by LJU Automatisierungs-

technik GmbH.

Warning!

Risk of injury due to design modification!

Unauthorized technical modifications can lead to considerable damage to

persons and property.

Therefore:

- Replace the defective device!

- Replace it with an LJU device of the same model.

1.12 Personnel and qualification

Warning!

Risk of injury due to inadequate qualification!

Inappropriate handling can lead to considerable personal and property

damage.

Therefore:

- The installation, operation and maintenance of the device must be

carried out by trained and instructed personnel.


System - Overview


2 System - Overview

2.1 Principle of the modular PCM-System

PCM module

PCM-8-Bus

Input

module

EM-8-Bus

Input

module

DI-8-Bus

Output

module

DO-8-Bus

Field businternal

LJU-Bus

L 3 N L+ L-

230 AC 24 V DC

8

Outputs

PCM

8

Inputs

230V 50 Hz

8

Inputs

digital 24 V

8

Outputs

digital 24 V

max 3 modules

per type max 2 modules

L 3 N N L- L- L+

Command bar

Message bar

Central module

ZM-DPZM-DN


System - Overview


2.2 Important Note - Power Supply

Important!

All mentioned devices with L3-reference are designed for use with

230VAC!

In case of main power of more than 230VAC it is mandatory to use

a transformer to generate 230VAC!

Principle:

to the PCM-modules


System - Overview


2.3 Important notice for command rail segmentation

Important notice!

Definitely to be observed!

Consecutive command rail segments where switchover from

PCM commands ≤10 to PCM commands >10 shall be performed,

must be separated by active changeover segments.

Carrier entry into changeover segment with previous segment

command, switchover to following segment command only

when carrier brush gear is located completely within changeo-

ver segment.

Combinations of PCM commands ≤PCM10 will result in recogni-

tion of the smaller command by the control box.


Central Module ZM-DN


3 Central Module ZM-DN

3.1 General Facts

The ZM-DN module is a central module that can be controlled via DeviceNet and serves

to generate mains-synchronized clock signals.

A processor evaluates the mains power and sends mains-synchronized +24 VDC square

wave voltages with various clock combinations over the internal bus to one or more pulse

code modules.

Up to 190 different codes can be generated:

PCM 6 16 PCM codes

PCM 10 190 PCM codes

The codes are generated through relevant parameters of the PLC, which are transmitted

over the DeviceNet bus to the ZM-DN. These codes are transmitted over the internal bus

to the pulse code module PCM-8-Bus.

The pulse code module can convert these signals directly into 230 V quasi sine half-wave

combinations, since these signals run synchronized to the mains voltage, and feed them

to the trolley controllers over the control rails (S1).

Every pulse code command is detected depending to the software by the trolley control-

lers and executed.

The user can freely assign the various commands like various speeds, forward/backward,

for example, in trolleys controlled by frequency inverters. The hoisting function in inte-

grated hoisting gears can be controlled in the same way.

The advantages of this form of differentiated instructions, sent over only one control rail,

(S1) are high jamming resistance and prevention of incorrect instructions caused by

short circuit, wire break or reflections.

Mix-up with the sinus signal of the mains power is avoided.




3.2 Design of the Central Module ZM-DN

The mains supply of 24 VDC and 230 VAC is provided through 2 separate printed-

circuit sub-unit terminals with threaded ends.

The connection to the activating modules is implemented through a 37-pin plug

connection. Besides the transmission of 5 VDC power supply for the downstream

modules, this connection implements the coupling with the internal bus.

The module is connected to the DeviceNet over a certified standard DeviceNet

module AB4004 of HMS (integrated in the ZM-DN).

The reference phase of the trolley controllers and the modules is fixed at L3.

The 24VDC power supply is safeguarded using multi fuses.

The ZM-DN can be optionally fitted with a 16 x 4 LCD display module.

3.3 Monitoring and Protection Function

Monitoring of the mains voltage and supply voltage

Error messages via DeviceNet bus

Synchronization with other central modules in the installation

Display “Ready for operation“ through 3 red LEDs for 24VDC, Main and Online

(top down)

Display “Synchronization” through separate red LED (down)

3.4 Installation and Commissioning

3.4.1 Installation

The ZM-DN is designed for horizontal installation in a stationary housing.

The module is mounted by locking on to a carrier rail.

3.4.2 Synchronization

For synchronization with other central modules, these are connected with each other.

The sync connections of the ZM modules must be connected in parallel.

ZM 1

Sync1 Sync2

ZM 2

Sync1 Sync2

ZM x

Sync1 Sync2




3.5 Technical Data and Connections

3.5.1 Technical Data of the Central Module ZM-DN

General

WNR 60134 for 50Hz

60138 for 60Hz

Housing Polyamide attachable to rails

Transparent lid Polycarbonate, break-proof

Dimensions (W x H x D) 182 x 126 x 80mm

Ambient temperature range +10C to +50C

Storage temperature range -10ºC to +50ºC

Humidity < 80% non-condensing

Inputs DeviceNet over DeviceNet card

Addressing 2 x HEX switch

Outputs System bus

Error reporting via DeviceNet DN

Potential isolation Optocoupler

Isolation voltage Ueff 2.5kV

Fuse protection of the 24 VDC supply voltage Multi-fuses

DeviceNet card AB4004

Supply input24VDC

Current consumption ZM-DN:

with 1 PCM and 1 EM module

with 2 PCM and 2 EM modules


110mA

140mA

170mA

Supply input 230VAC

Reference phase L3 230V /50Hz

Reference potential N

Power max. 50W

Current consumption ZM-DN:

with 1 PCM and 1 EM module



additional

55mA

110mA

165mA

10mA per trolley in control segments

Power dissipation

No-load

Full-load

1W

2W

We reserve the right to make technical changes!




3.5.2 Connections of the Central Module ZM-DN

Pin assignment X2

1 N

2 L3

3 PE

Pin assignment X4

1 Sync 1

2 Sync 2

3 L+

4 L-

1 2 3

ZM-

Programming

10 pole

X2 X4 X3

DeviceNet

5 pole

X5

LJU

Syste

m b

us

37

p

ole

1 2 3 4

ZM-DN




3.6 DeviceNet Connection

The central module is connected to the system controller via DeviceNet.

The central module is equipped with a certified standard DeviceNet card AB4004 of HMS

for the bus connection.

See also!

Detailed technical information of the used DeviceNet card can be obtained

from the descriptions of the manufacturer.

Can be obtained from www.hms.se!

The field bus is connected to this module.

The bus address (MAC-ID) is set via the DIP switch and the desired Baud rate is set.

3.6.1 DeviceNet Connection

The ZM-DN is connected to the DeviceNet with a 5 pole printed-circuit sub-unit terminal

with threaded ends.

These are numbered from 1 to 5 (from left to right).

# Description

1 DeviceNet connection

2 Configuration switch

3 Status-LEDs

Pin Signal Description

1 V- -24 VDC

2 CAN_L CAN_L bus line

3 Shield Cable shield

4 CAN_H CAN_H bus line

5 V+ +24 VDC

AB4004

1

3

2




3.6.2 DeviceNet Configuration Switch

The configuration switch is used to setting the baud rate and MAC-ID.

The switches are numbered from 1 to 8 (from left to right).

Setting of Baud rate: Switches 1-2

Setting of address: Switches 3-8 (MAC ID)

3.6.3 LED Status Display

The actual state of the module is displayed with several LEDs.

LED Status Description

1

Reserved - Reserved

2

Network State

Off Not powered / not online

Green Link OK, online, connected

Green (flashing) Online, not connected

Red Critical link failure

Red (flashing) Connection timeout

3

Reserved - Reserved for later use

4

Module State

Off No power to device

Green Device operational

Green (flashing) Data size bigger than configured

Red Irrecoverable fault

Red (flashing) Minor fault

Baud rate Sw. 1 Sw.2

125k OFF OFF

250k OFF ON

500k ON OFF

(reserved) ON ON

MAC-ID Sw. 3

(MSB

Sw. 4

Sw. 5

Sw. 6

Sw. 7

Sw. 8

(LSB)

0 OFF OFF OFF OFF OFF OFF

1 OFF OFF OFF OFF OFF ON

2 OFF OFF OFF OFF ON OFF

3 OFF OFF OFF OFF ON ON

… … … … … … …

62 ON ON ON ON ON OFF

63 ON ON ON ON ON ON


Pulse Code Module PCM-8-Bus


4 Pulse Code Module PCM-8-Bus

4.1 General

The pulse code module PCM-8-Bus serves to control trolleys over a control rail with up to

190 different commands, such as slow/fast forward, slow/fast reverse, variable speeds in

assembly areas, hoist/lower to various positions with various speeds and various

positioning behaviors.

The commands transmitted over DeviceNet from the PLCs at higher levels are converted

by the central module ZM-DN into mains-synchronized timing signals and then converted

by the pulse code module into a pulse-code, which can be clearly recognized by the

trolley controller.

The advantages:

Safeguard against incorrect instructions that could be caused by short circuit,

grounding or line break

Differentiated control transmission over one control rail

System realization without N-type rail

Control from the PLC directly via DeviceNet

Galvanic isolation through Optocoupler

Unlimited hysteresis by using semiconductor switches

Protection wiring of the output ports and short-circuit protection

Error reporting over DeviceNet

The pulse code module has 8 output ports, which means that up to 8 control rail sections

can be driven by one pulse code module.

4.2 Design of the Pulse Code Module PCM-8-Bus

The pulse code module PCM-8-Bus is connected to the internal bus over a 37-pin plug-

connector.

The timing signals are transmitted from the central module over the internal bus.

By using mains-synchronized pulses, the output signal is always started in the voltage

zero-crossing of phase L3 (disconnect in power zero-crossing). The maximum delay time

between input and output signals caused by this is 10 ms at 50 Hz.

The 8 output ports must be connected with the assigned control rail sections using

printed-circuit sub-unit terminals with threaded terminal ends.

The other modules of the system are connected over the internal bus, using a 37-pin

plug-connector.

The reference phase of the trolley controller and the module is assigned to L 3.




4.3 Monitoring and Protection Functions

Output-side short circuit protection (semiconductor switches)

Error monitoring for:

Interruption of the supply voltage

Activation of the safety circuit (multi-fuse)

Disturbance reports over the bus

Can be used as individual disturbance report or together with several modules as

composite disturbance

Protective wiring of the output ports to prevent overvoltage (varistors)

The signal form of the pulse code module's output signals (e.g. drive commands) is

monitored by the micro-controller integrated in the trolley controller.

If the signal form varies due to disruptive influences, the trolley is stopped immediately.

This also holds good for line breaks, short circuits and grounding.

Mixing different pulse code signals, e.g. when traversing rail sections, is possible only to

a limited extent when using asynchronous drive commands (codes 2-9)

(discussion and approval required).

Mixing asynchronous drive commands (codes 2-9) with code numbers > 9 is to be

avoided at all costs.

4.4 Installation

The pulse code module is designed for horizontal installation in a stationary housing.

The module is secured by fastening it to a mounting rail.

Anti-capacitance shielded signal cable is to be used for connections between the pulse

code modules and the control rail sections, and is to be separated from power cables.

Use load resistors against over-crossings.

Recommendation : e.g. UNITRONIC Li2YCY signal cable





4.5.1 Technical Data of the Pulse Code Module PCM-8-Bus

General

WNR 60336







Inputs System bus

Outputs 8

Error reporting via System bus



Output parameters

Reference phase L3

Output switch elements FET

Protection wiring Varistor

Output power per output max. 1A

Total output power max. 1A

Short circuit protection Semiconductor switches

Trolley stops for:

Short circuit against N, L1, L2

Line break

Interruption of the supply voltage

Power dissipation

No-load

Full-load

2W

10W





4.5.2 Connections of the Pulse Code Module PCM-8-Bus

Pin assignment X1

1 L3

2 PCM 1

3 PCM 2

4 PCM 3

5 PCM 4

6 PCM 5

7 PCM 6

8 PCM 7

9 PCM 8

10 N

LJU

Syste

m b

us

37

p

ole

LJU

Syste

m b

us

37

p

ole

X3 X5

X1

1 2 3 4 5 6 7 8 9 10

PCM-8-Bus


Input Module EM-8-Bus


5 Input Module EM-8-Bus

5.1 General

The input module EM-8-Bus converts the 230V AC composite error messages, relayed

from the trolley over the status rail, to the signal level of the internal bus.

This provides for transmission of the input signals over DevicNet to the PLC.

The module has 8 input ports. This means that signals from up to 8 rail sections can be

converted by one input module.

The signal input ports are designed to distinguish between positive half-waves (presence)

and negative half-waves (error messages).

The signals with positive and negative half-waves are displayed differently by LED in the

module for each input port.

The advantages:

Compact modular design


Input switching threshold 140VAC

Differentiated display of (positive/negative) half-waves for each input

5.2 Design of the Input Module EM-8-Bus

The input module EM-8-Bus is connected with the internal bus using a 37-pin plug

connector.

The input signals are sent via internal bus to the DeviceNet module, which then transmits

them via DeviceNet to the PLC.

The 8 input ports and the reference potential (N) must be connected to the assigned

control-rail sections or the power supply using printed-circuit sub-unit terminals with

threaded terminal ends.

Other modules of the system are connected using a second 37-pin plug connector.

The reference phase of the trolley controllers and of the module is assigned to L3.




5.3 Installation

The input module EM-8-Bus is designed for horizontal installation in a stationary housing.


Anti-capacitance shielded signal cable is to be used for the cable connections between

the input modules and the control rail sections, and is to be separated from power

cables.

Recommendation : e.g. UNITRONIC Li2YCY signal cable


5.4.1 Technical Data of the Input Module EM-8-Bus

General

WNR 60247







Inputs 8

Outputs System bus



Input parameters

Reference phase L3

Reference potential N

Input voltage for signal 0 0V to 110VAC

Input voltage for signal 1 140V to 245VAC

Input power per input max. 10mA

Power dissipation

No-load

Full-load

2W

10W





5.4.2 Connections of the Input Module EM-8-Bus

Pin assignment X1

1

2 Input E 1

3 Input E 2

4 Input E 3

5 Input E 4

6 Input E 5

7 Input E 6

8 Input E 7

9 Input E 8

10 N

LJU

Syste

m b

us

37

p

ole

LJU

Syste

m b

us

37

p

ole

X3 X5

X1 1 2 3 4 5 6 7 8 9 10

EM-8-Bus


Digital Input Module DI-8-Bus


6 Digital Input Module DI-8-Bus

6.1 General

The digital input module DI-8-Bus is used to get 24VDC digital signals from automation

devices in the process.

For example, signals are received from the most varied sensors, such as approach

switches, photoelectric barriers and limit switches, and converted in such a way that they

can be transmitted over the internal data bus to the DeviceNet module, which in turn

sends them to the PLC.

These input signals can also be transmitted over the internal data bus to a digital output

module, to control indicator lamps in the process for example.

The module has 8 digital 24VDC input ports, which means that signals from as many as 8

different devices can be converted and transmitted over the internal bus.

The advantages:



Input switching threshold 10VDC

LED display for each input port

6.2 Design of the Digital Input Module DI-8-Bus

The digital input module DI-8-Bus is connected with the internal bus using a 37-pin plug

connector.

The input signals are sent via the internal bus to the DeviceNet module and/or to a

digital output module.

The 8 input ports must be connected to the required devices, initiator lamps etc., over

printed-circuit sub-unit terminals with threaded terminal ends.

Other modules e.g. an output module, are connected using a second 37-pin plug

connector.

6.3 Installation

The digital input module DI-8-Bus is designed for horizontal installation in a stationary

housing.






6.4.1 Technical Data of the Digital Input Module DI-8-Bus

General

WNR 60003







Inputs 8

Outputs System bus



Input parameters

Reference potential - 24VDC

Digital 24 VDC for signal 0 0V to 3.5VDC

Digital 24 VDC for Signal 1 10V to 30VDC

Input power per input < 10mA

Power dissipation

No-load

Full-load

1W

2W





6.4.2 Connections of the Digital Input Module DI-8-Bus

Pin assignment X1

1

2 Digitaler Input DI 1








10 L-

LJU

Syste

m b

us

37

p

ole

LJU

Syste

m b

us

37

p

ole

X3 X5

X1 1 2 3 4 5 6 7 8 9 10

DI-8-Bus


Digital Output Module DO-8-Bus


7 Digital Output Module DO-8-Bus

7.1 General

The digital output module DO-8-Bus serves to output 24VDC digital signals to automation

devices in the process.

For example, signals based on converted signals from a digital input or from the PLC can

be sent to signal or indicator lamps.

Signals from the PLC are transmitted via DeviceNet and the internal data bus.

The incoming digital signals, which result in a digital output signal, are transmitted via

the internal bus.

The module has 8 digital 24VDC output ports, which means that as many as 8 signals

can be output.

The advantages:



LED display for each output port

7.2 Design of the Digital Output Module DO-8-Bus

The digital output module DO-8-Bus is connected with the internal bus using a 37-pin

plug connector.

The signals from the DeviceNet module and/or from a digital input module are

transmitted over the internal bus.

The 8 output ports and the 24 VDC power supply are connected with the devices,

indicator lamps etc., using printed-circuit sub-unit terminals with threaded terminal ends.

Other modules e.g. an input module, are connected using a second 37-pin plug

connector.

7.3 Installation

The digital output module DO-8-Bus is designed for horizontal installation in a stationary

housing.






7.4.1 Technical Data of the Digital Output Module DO-8-Bus

General

WNR 60004







Inputs System bus

Outputs 8



Output parameters

Reference potential + 24VDC

Outputs Digital 24 VDC

max. power per output 1A

Total output power < 2A

Power dissipation

No-load

Full-load

1W

4W





7.4.2 Connections of the Digital Output Module DO-8-Bus

Pin assignment X1

1 L+

2 Digitaler Output DO 1








10 L-

LJU

Syste

m b

us

37

p

ole

LJU

Syste

m b

us

37

p

ole

X3 X5

X1 1 2 3 4 5 6 7 8 9 10

DO-8-Bus


Resistor Module RM-8-Bus (optional)


8 Resistor Module RM-8-Bus (optional)

8.1 General

The resistor module RM-8-Bus serves the compensation of the capacities of the control

bus and rails, that is used to the transfer of PCM- and half-wave signals for the control of

trolleys.

The use of load-resistors in the control bus is necessary to the guarantee of a certain

signal transfer.

8.2 Design of the Resistor Module RM-8-Bus

The resistor module has 8 outputs, that at most 8 rail sections can be compensated.

The 8 output cables and L3 will be connected by using printed-circuit sub-unit terminals

with threaded terminal ends.

8.3 Installation

The resistor module RM-8-Bus is designed for horizontal installation in a stationary hous-

ing.


Caution!

The module can warm up!

The installation must permit adequate air-circulation to prevent the ac-

cumulation of heat.

L3 L3

rail section


Resistor Module RM-8-Bus (optional)



8.4.1 Technical Data of the Resistor Module RM-8-Bus

General

WNR 60412







Inputs 1 x L3

Outputs 1 x L3

8 x Resistor 22kOhm

Power dissipation

No-load

Full-load

0W

20W


8.4.2 Connections of the Resistor Module RM-8-Bus

Pin assignment X1

1 L3 IN

2 L3 OUT

3 Output R1

4 Output R2

5 Output R3

6 Output R4

7 Output R5

8 Output R6

9 Output R7

10 Output R8

X1 1 2 3 4 5 6 7 8 9 10

RM-8-Bus


Communication and System Configuration


9 Communication and System Configuration

9.1 DeviceNet Communication

The system controller communicates with the ZM-DN central module over the DeviceNet

module.

The DeviceNet module makes available several data areas for data exchange.

Data from system controller -> ZM-DN:

Name: Size:

[Bytes] Reached with: Content:

Offset:

[Bytes]

Output 1 28 Polled IO Cyclic data:

Outputs on the slave 0

Output 2 244 Generic Message Acyclic data:

Handshake + messages 240

Output 3

(Not used) 8 Generic Message

Acyclic data:

Handshake + message header 240

Output 4


Cyclic data:

Even unused areas 0

Data from ZM-DN -> System controller:

Name: Size:

[Bytes] Reached with: Content:

Offset:

[Bytes]

Output 1 11 Polled IO Cyclic data:

Outputs on the slave 0

Output 2 244 Generic Message Acyclic data:

Handshake + messages 11

Output 3


Acyclic data:

Handshake + message header 0

Output 4


Cyclic data:

Even unused areas 11

Following data is exchanged here:

Cyclic

data:

Data from system controller -> ZM-DN: Output 1 28 Bytes

Data from ZM-DN -> System controller: Input 1 11 Bytes

Acyclic

data:

Data from system controller -> ZM-DN: Output 2 244 Bytes

Data from ZM-DN -> System controller: Input 2 244 Bytes

Hint!

The transfer of acyclic data from and to the module is necessary only if the

options of enhanced parameterization are used!




9.2 Cyclic Data Exchange

In cyclic data exchange, the system controller sends the desired output data to the slave

and reads the current input data from the slave.

The communication takes place over the access points Output 1 and Input 1.

The data flow is parameterized in the DeviceNet parameterization as “polled” connection.

(see ZMDN_52_Zyklisch_Azyklisch_11inp_28outp.pdf: section 2.1)

In case of ZM-DN, the slave is a modular parameterizable slave!

In the default configurations described here, 28 / 11 Bytes are transferred cyclically be-

tween the system controller and the slave!

As described later in this documentation, the slave (if necessary) can also be operated

with parameterizations other than this default configuration!

Then the number of inputs/outputs as well as the significance and position of the bytes

within the messages can differ from the following details.

9.2.1 Cyclic Data: System Controller -> ZM-DN: 28 bytes

Byte Meaning Note

0 Command Byte 00H = Normal mode

88H = Without Online->Offline Automatic reset

1 Cyclic Counter see 9.2.3

2 PCM – Output 1.0 1. Output card

8 x PCM outputs - -

9 PCM – Output 1.7


8 x PCM outputs - -



8 x PCM outputs - -


26 DIG – Output Byte 1 1. Output card

8 x Digital 24 VDC outputs

27 DIG – Output Byte 2 2. Output card

8 x Digital 24 VDC outputs




9.2.2 Cyclic Data: ZM-DN -> System Controller: 11 bytes

Byte Meaning Note

0 Error status Byte

(Automatically resetting)

00H = No error

01H = Error Configuration

02H = Error Mains frequency

04H = Error PCM output card

08H = Error Digital output card

10H = Error EEPROM

20H = Reserved

40H = Error Communication DeviceNet

80H = Error Parameterization

1 Cyclic Counter see 9.2.3

2 EM – Input 1 Pos. 1. Input card

8 x PCM inputs: Positive half wave

8 x PCM inputs: Negative half wave 3 EM – Input 1 Neg.







8 DIG – Input Byte 1 1. Input card

8 x Digital 24 VDC inputs

9 DIG – Output Byte 2 2. Input card


10 DIG – Output Byte 3 3. Input card


9.2.3 Cyclic Data: Counter Connection

The ZM-DN module sends back the counter received in Byte 1 in its response message to

Byte 1. If the module is in ONLINE state and the counter reading does not change within

2000 ms, then it switches to OFFLINE state, deletes all connected outputs and triggers a

(local) hardware reset, if this is not disabled due to an entry of 88H in the command

byte.

The system control must cyclically activate this counter to maintain the data flow.

Moreover, the system controller (regardless on the bus cycle running asynchronous to

the program cycle) can thus easily detect whether a new response message exists.

Recommended procedure:

Comparison: Counter of output data equal to counter of input data?

yes => Receive new data from slave! => Evaluate + Trigger monitoring

Program processing

Equalize output data counter to (counter of input data + 1)




9.3 Acyclic Data Exchange

In acyclic data exchange, the system controller can send data messages to the slave or

read data messages from it using CIP Generic Messages.

The communication takes place over the access points Output 2 and Input 2.

The messages are always 244 Bytes long and consist of a message header that always

needs to be filled up as well as the useful data.

9.3.1 Acyclic Data: System Controller -> ZM-DN: 244 byte

Configuration of message for Output 2:

Message type: CIP Generic

Service Code: 10 Hex DeviceNet-Code: SetData

Object Type: 04 Hex

Object ID: 151 Decimal

Object Attribute: 03 Hex

Source: 244 Byte memory in Scanner Scope with sending message

Num. of elements: 244 Decimal

Destination: 244 Byte Dummy memory in Scanner Scope

9.3.2 Acyclic Data: ZM-DN -> System Controller: 244 byte

Configuration of message for Input 2:

Message Type: CIP Generic

Service Code: 0E Hex DeviceNet-Code: GetData

Object Type: 04 Hex

Object ID: 101 Decimal

Object Attribute: 03 Hex

Source: -

Num. of elements: 0 Decimal

Destination: 244 Byte Memory in Scanner Scope with receipt message




9.3.3 Acyclic data: Message Structure and Handshake

The acyclic messages from and to the slave have the following structure:

Byte Meaning Note

0 Acyclic counter Job number

1 Service Code

Response Code

10 Hex DeviceNet-Code: SetData

0E Hex DeviceNet-Code: GetData

2 Access index see 9.3.4.

3 Length of following data 0 … 240

4 Data

Max. 240 Byte

-

243

ata flow between System controller -> Slave -> System controller:

If data is to be sent to the slave, the following schema is to be applied!

Acyclic counter, job number:

A new job number is to be entered in this counter for every new message.

The slave evaluates this number and processes the message only if the job num-

ber has changed!

(After a reset, the slave initializes itself with the job number 80 Hex.)

Service Code:

Enter 10 Hex => Data master -> Slave

Enter 0E Hex => Data slave -> Master

Access index / Enter length of following data

See 9.3.4.

Send the job to the memory area Output 2 via message

See 9.3.1.

As soon as the slave has received the message, it processes the message and generates

a response message in its memory area Input 2.

The system controller must wait for this (timer and/or wait counter in cyclical data ex-

change) or must read the response several times if need be, via read message!

Read the response from the memory area Input 2 via message

See 9.3.2.

Acyclic counter, job number:

The slave enters the job number of the received message in its response mes-

sage. If the job number does not match (yet), the slave has not yet processed the

slave. The response must be read again.




Access index:

The slave copies the access index of the received message into its response mes-

sage.

Response Code:

The slave codes its response in this byte:

80 Hex = 1000 0000: ERROR

40 Hex = 0100 0000: OK

10 Hex = 0001 0000: Response to DN code: SetData => Data Master -> Slave

0E Hex = 0000 1110: Response to DN code: GetData => Data Slave -> Master

Response Code ERROR with enhanced error message:

If the slave responds with an error (Bit 7 = 1) (at least during the software devel-

opment!), the enhanced error code, if generated, should be evaluated.

If 2 is entered in Byte 3 “Length of following data“ (i.e. 2 bytes of data follow), the

error reason is entered in Byte 4 and 5.

Following error codes are currently generated by the standard LJU firmware:

0xFF: False data length

0xB0: Access to an invalid index OR Access locking error during access

0xC3: Resource not available

0xC9: Resource not in this segment

0xC8: Resource not reachable (no communication)

0xC2: Resource is busy

Response Code OK:

If the slave responds with an OK (Bit 6 = 1), the message sent to it could be pro-

cessed correctly and any received data can be copied.




9.3.4 Acyclic Data: System Access Indexes

The following system access points are implemented in the slave:

Access

Index Meaning

Length

READ

[Byte]

Length

WRITE

[Byte]

01 Hex (R/W) Cyclic input/output data 11 28

7F Hex (R/W) Parameter (setting, mapping of I/O ranges) 38 38

Index 01H: Cyclic input/output data

Through this access point, the same variables as in cyclic data exchange can be

addressed. (see 9.2.1.)

Index 7FH: Parameter (setting, mapping of I/O areas)

Through this access point, the IO mapping of the slave can be set.

Parameters!

A table with the meaning of the parameters is given under “ZM-DN Para-

metrization”.

Warning!

The number and position of I/O data for the cyclic data exchange is calcu-

lated from this parameter data!

The parameters are stored on the slave in an EEPROM, so that the slave

can automatically start with the specified parameters.

An incorrectly parameterized slave cannot be addressed correctly through

the cyclic service!

These parameters CANNOT be set through the DeviceNet parame-

terization!

Only the memory areas of the DeviceNet communication modules can be

set (conditionally) there.

Therefore we recommend that the slave be operated in its default configu-

ration!

If a different system-specific parameterization is selected, the system con-

troller can (must) supply the slave with a parameterization through this

access point




9.4 ZM-DN Parameterization 38 Byte

In case of ZM-DN, the slave is a modular parameterizable slave!

In the default configurations described here, 28/11 Bytes are transferred cyclically be-

tween the system controller and the slave!

The number and position of I/O data for the cyclic data exchange is calculated from this

parameter data!

The parameters are stored on the slave in an EEPROM, so that the slave can automatical-

ly start with the specified parameters.

Attention!

A slave with incorrect parameter settings cannot be correctly addressed

through the cyclic service!

Permanently defined parameterizations:

Some parameterizations are permanently defined in the firmware of the ZM-DN

module.

For selecting these, the mode configuration switch present on the module (2 x

16 time rotary switch in the middle of the assembly) is used.

This is requested when the system software is started, the desired parameter rec-

ord is determined depending on the setting, and saved in the EEPROM of the as-

sembly.

Coding

Switches Function

00 Hex Normal” start with the parameters saved currently in the EEPROM

FF Hex Saves the DEFAULT parameters (described here) in the

EEPROM and then starts the module with these values!

FE Hex

Determines the assemblies connected to the central module using

Autodetect, generates the parameters using this data, saves these in

the EEPROM and then starts the module with these values.

FD Hex Deletes the parameters saved in EEPROM.

Byte Meaning

Def.

Value

Param.

Defaultpos.

Output Input

Byte Byte

0 PCM Module 1: Fixed code Enable Mask 0

1 PCM Module 1: Channel 1: PCM-Code: 0 - 190 1 2






Byte Meaning

Def.

Value

Param.

Defaultpos.

Output Input

Byte Byte
























27 EM Module 1: Positive half-wave 1 2

28 EM Module 1: Negative half-wave 2 3





33 DA Module 1: Dig 24V outputs 25 26

34 DA Module 2: Dig 24V outputs 26 27

35 DE Module 1: Dig 24V inputs 7 8



The activation as well as the position of variables is parameterized in the data for the

cyclic data flow.

In case of default parameterization, the central module is a ZM-DN central module with

maximum expansion of input/output modules.

We recommend the use of this configuration for all the central modules present in the

system and then to mark all the input-/output modules that are not connected in the sys-

tem controller as “reserved” or “optional”.




9.5 Default System Structure

Default (maximum) configuration:

Device list Slave configuration

(modules used)

PCM-8-Bus 8 bytes

EM-8-Bus 2 bytes

DI-8-Bus 1 byte DO-8-Bus 1 byte

Protocol 2 byte

PCM-8-Bus 8 byte

PCM-8-Bus 8 byte

PCM-8-Bus 8 byte

DO-8-Bus 1 byte

DO-8-Bus 1 byte

Outputs: 28 byte

Protocol 2 byte

EM-8-Bus 2 byte

EM-8-Bus 2 byte

EM-8-Bus 2 byte

DI-8-Bus 1 byte

DI-8-Bus 1 byte

DI-8-Bus 1 byte

Inputs: 11 byte

zm modular-dn v1 tb0018 en

Documents

zmdn modules wnr

central module zmdn

devicenet dn version

modular pcmsystem

technical description

product names

standard names

trade names