Keba KeControl CP 50 Series Project Engineering Manual Download

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CP 503/A, CP 505/A,D,K, CP 507/
A,C

Introduction

Project engineering manual V1.06

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Maintenance

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Technical data

1.4.2

Not contained in this document

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Programming instruction

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Application diagnosis

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Firmware description

1.5

Documentation for further reading

Name

Target group

Provided system manual

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Project engineer

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Electrician

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Programmer

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Commissioning foreman

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Service technician

Summary of Contents for KeControl CP 50 Series

Page 1: ...KeControl CP 503 A CP 505 A D K CP 507 A C CPU module Project engineering manual V 1 06 Translation of the original instructions...

Page 2: ...rther technical developments Details presented may be subject to correction All rights reserved KEBA Industrial Automation GmbH Reindlstra e 51 4040 Linz Austria 43 732 7090 0 43 732 7309 10 keba keba...

Page 3: ...ious chapters 7 segment display Micro SD card technical data hasl 1 03 10 2021 Various chapters Expansion interface created new structure of adding modules expansion bus updated change to new company...

Page 4: ...CP 503 A CP 505 A D K CP 507 A C Project engineering manual V1 06 4 KEBA 2021...

Page 5: ...structions 13 2 3 Safety instructions for device maintenance 14 2 4 ESD information 14 3 Description of the module 15 3 1 Front view 15 3 2 Side view 16 3 3 Bottom view 18 3 4 Storage media 18 3 4 1 M...

Page 6: ...Removing expansion modules 37 5 8 Air conditioning and ventilation 38 5 8 1 Use of air filters 38 6 Connections and wiring 39 6 1 Power supply 39 6 1 1 Connection example 40 6 2 EMC and wiring guidel...

Page 7: ...rrors 63 8 6 Watchdog 63 8 7 Failure of power supply 63 8 8 Battery monitoring system 63 8 9 Temperature monitoring 64 9 Diagnosis 65 9 1 LEDs 65 9 2 7 segment display 65 9 3 State report 65 9 4 Crash...

Page 8: ...76 12 5 Interfaces 77 12 6 Dimensions weight 78 13 Directives standards and regulations 79 13 1 EU Directives 79 13 2 Standards for checking the conformity 79 13 3 Other standards 79 13 4 Regulations...

Page 9: ...ith the following skills Target group Knowledge and skills pre requirement Project engineer Basic technical training University of Applied Science University level engineering degree or corresponding...

Page 10: ...pproved devices The CP 50x x has been developed manufactured tested and documented observing the relevant instructions and standards Therefore provided that the instructions and safety precautions are...

Page 11: ...Maintenance Technical data 1 4 2 Not contained in this document Programming instruction Application diagnosis Firmware description 1 5 Documentation for further reading Name Target group Provided sys...

Page 12: ...or seri ous bodily injury if the corresponding precautions are not taken CAUTION means that if the corresponding safety measures are not taken a potentially hazardous situation can occur that may resu...

Page 13: ...Use in environments with harmful solutions steams or radiations Use in non stationary applications The CP 50x x is not designed for safety relevant control tasks e g shutdown in case of an emergency...

Page 14: ...t discharges are so low that they are not noticeable However they can nevertheless put unprotected electronic components at risk or even destroy them Therefore any handling with open electronics is on...

Page 15: ...nge performance within the KEBA automation system 3 1 Front view Fig 3 1 Front view 1 Locking hooks expansion module 2 USB interface 3 DVI interface 4 Ethernet interfaces 5 Serial number and DataMatri...

Page 16: ...le Project engineering manual V1 06 16 KEBA 2021 3 2 Side view Fig 3 2 Left side view 1 Locking hooks expansion module 2 Area for type plate printing 3 Area for connection diagram print ing 4 Mounting...

Page 17: ...ing manual V1 06 17 KEBA 2021 Fig 3 3 Right side view 1 Recesses for locking 2 Lock of the input output module 3 Area for type plate printing 4 Area for symbol printing 5 Mounting rail locking 6 KeBus...

Page 18: ...operated with the following storage media Micro SD card 3 4 1 Micro SD card The CP 50x x uses a Micro SD card that contains the operating system It is possible to insert and remove the Micro SD card...

Page 19: ...ed as follows 1 Turn off the power supply 2 Gently push the Micro SD card into the Micro SD slot until it clicks into place audible click Insert in the proper direction Fig 3 5 Inserting the Micro SD...

Page 20: ...e pends on the module Fig 3 7 Example type plate 1 Manufacturer s address 2 Manufacturer 3 Product group 4 Product designation 5 Technical data voltage 6 Ambient temperature 7 Country of manufacture 8...

Page 21: ...8 1 Micro SD card The recommended Micro SD card can be requested and ordered from KEBA Designation Description Order no XC 540 C 0000 Micro SD card 2 GB 112917 XC 540 D 0000 Micro SD card 4 GB 112918...

Page 22: ...nector Type II 1 2201855 1 company TE Connectivity The technical data is provided in the manufacturer s technical data sheet for the plugs that are used 3 8 4 Industrial Mini I O cable The appropriate...

Page 23: ...the operating status after start up The decimal point serves as load display A flashing decimal point sig nals that the CPU load is in the allowed range If the decimal point stops blinking then the C...

Page 24: ...s are displayed by flashing in the 7 segment display Once the initial status has been reached again this will be indicated normally again Long keystrokes are used to execute a command and to change in...

Page 25: ...isplay Meaning Dark No power supply or error free transmission Red Bus Off Faulty transmission with activated CAN channel e g cable disconnected faults on cable faulty slave etc 4 6 EtherCAT status LE...

Page 26: ...e operating and load voltage supplies before carrying out as sembly installation or maintenance work 5 2 Mounting rail A steel rail TS 35x7 5 is to be used as mounting rail for the device For the sake...

Page 27: ...4 Space requirements The module housing has ventilation slots for heat dissipation Caution The ventilation slots must be kept free at all costs The cooling system and housing of the module are designe...

Page 28: ...ace for the air circulation of the module At least 30 mm above and below the module 5 5 Installing the module Caution Permissible installation position The mounting rail must be installed so that the...

Page 29: ...ut it on the mounting rail fixture 2 3 Press the lower half of the module onto the mounting rail 3 4 Lock all of the mounting rail locks one after the other 4 5 Use the end brackets to secure the modu...

Page 30: ...e module to release it from the mounting rail 2 6 Remove the module from the mounting rail 3 The module is dismantled 5 7 Adding modules Input output modules and expansion modules can be added to the...

Page 31: ...x x specified in the technical data see Technical data Information In order to calculate the number of input output modules that can be connected on the right the respective performance values specifi...

Page 32: ...end bracket 3 Release the lock on the right side of the module to which the input out put module is to be added by pushing it up Fig 5 16 Releasing the lock 4 Install the input output module to be ad...

Page 33: ...t output modules 6 Secure the lock on the right side of the already mounted module by pushing it down Fig 5 18 Securing the lock 7 Secure the end bracket on the mounting rail The input output module i...

Page 34: ...f the plug connector on the left side of the already installed module 5 Install the expansion module to be added on the mounting rail and lock it see 5 5 Installing the module 6 Slide the expansion mo...

Page 35: ...ion module 7 Secure the lock on the right side of the new added expansion module by pushing it down Fig 5 21 Securing the lock 8 Secure the end bracket on the mounting rail The expansion module is add...

Page 36: ...oved by pushing up Fig 5 22 Releasing the lock 4 Slide the input output module to the right until the hooks have disen gaged from the recesses of the module to the left Fig 5 23 Removing input output...

Page 37: ...2 Remove the end bracket 3 Release the lock on the right side of the expansion module to be re moved by pushing it up Fig 5 24 Releasing the lock 4 Slide the expansion module to the left until the rec...

Page 38: ...erature of the module If this cannot be guaranteed through natural heat dissipation an air conditioning of the control cabinet must be provided The specified required free space above and below the mo...

Page 39: ...supply of the CP 50x x Power supply of the CP at the terminal X00A The CP 50x x is supplied with voltage via the terminal X00A The terminal is located on the lower right on the front side CAUTION Fire...

Page 40: ...equipment an the female connectors used Max load current and required heat dissipation through the connected wire at maximum ambient temperature Permissible voltage drop for error free operation of t...

Page 41: ...front side The USB port is used to connect removable media for exam ple during maintenance or peripherals e g keyboard mouse It is however not suited for unmonitored continuous operation as the connec...

Page 42: ...odule and are used for communication with non real time networks LAN and or visualization systems 6 6 1 Pin assignment Fig 6 28 Pin assignment RJ45 socket Pin no Signal designation Input output 1 MX0...

Page 43: ...ion The connection SGND Signal Ground and GND optional ground connec tion are connected internally The designation was chosen according to the norm CiA CAN in Automation 6 7 2 Bus termination To activ...

Page 44: ...participants can comminicate by point to point con nection The wire has to be shielded 6 8 1 1 Pin assignment Fig 6 31 Industrial Mini I O socket type 2 RS 232 C Pin No Signal designation Input outpu...

Page 45: ...output 1 A Transmit Data Output 2 B Transmit Data Output 3 A Receive Data Input 4 n c Not connected 5 n c Not connected 6 B Receive Data Input 7 n c Not connected 8 GND Ground Signal ground 6 8 2 2 Bu...

Page 46: ...at the bus due to cable routing To select a particular bus termination the DIP switch S1 on the front of the module is set see Serial interface configuration 6 8 2 3 Connection example Information It...

Page 47: ...For details refer to the system manual 6 8 3 RS 485 A interfaces Several participants can communicate via the RS 485 A bus at which the maximum number of participants is limited to 32 The wires to oth...

Page 48: ...f the bus termination beginning end is done by an external par ticipant the termination must be deactivated for the CP 50x x The bus termination must take place at the bus end i e at the first and las...

Page 49: ...is only allowed once per RS 485 A bus The resistors Rpull up and Rpull down pull the RS 485 A bus to a defined level even if no data is sent by the participants To select a particular bus termination...

Page 50: ...r termination Fig 6 37 Example Resistor termination 1 CP 50x x 2 External participant 3 Other participants 4 Transmitter receiver Bus termination with resistor termination without fail safe wiring Fig...

Page 51: ...ple AC termination 1 CP 50x x 2 External participant with AC termi nation 3 Other participants 4 Transmitter receiver Fig 6 40 Example AC termination 1 CP 50x x 2 External participant with resistor te...

Page 52: ...pin as signment KEBA does not perform any tests for the correct functionality of operating devices from third party manufacturers 6 9 1 Pin assignment Fig 6 41 Pin assignment DVI socket Pin no Design...

Page 53: ...PCIe lanes and sync lines provided by the CP 50x x see Technical data Each extension module requires its own line on the extension bus A line cannot be used jointly by several extension modules This m...

Page 54: ...information on configuration 7 1 CAN configuration The termination of the CAN interface CAN is activated ON or deactivated OFF via DIP switch S1 ON OFF position of the switches The illustration shows...

Page 55: ...he termination of the serial interface SI is activated AC R R without fail safe or deactivated OFF with the DIP switch s1 ON OFF position of the switches The illustration shows the position of the swi...

Page 56: ...operating system is located in the re spective slot of the CPU module 8 1 1 Display during start up The progress in each stage is signaled via the 7 segment display If an error occurs during startup t...

Page 57: ...e controller is in error state Exception Pressing the CTRL key toggles between the operating states 8 3 7 segment display The CP 50x x has a 7 segment display During operation the current status is sh...

Page 58: ...Copy last status report The last status report is copied to the root directory of the plugged USB stick The process may take some time Error while copying the data e g USB stick disconnected during c...

Page 59: ...eport copy The crash report is copied to the root directory of the plugged USB stick The process may take some time Error while copying the data e g USB stick disconnected during copying no space left...

Page 60: ...continue with short key press Action execute with long key press Controller is in RUN state Go to action stop controller Stop controller The controller goes to STOP state Stop controller The controll...

Page 61: ...ck The process may take some time Error while copying data e g USB stick removed during copying no space left on USB stick etc The error must be confirmed by a long keystroke EXCEPTION Displayed state...

Page 62: ...must be confirmed by a long keystroke Copy last SysStatus report The last SysStatusreport is copied to the root directory of the plugged USB stick The process may take some time Error while copying d...

Page 63: ...alog outputs are set to 0 V The CPU continues to run for diagnostics purposes The CPU watchdog monitors the principal function of the CPU and runs independent from the IO watchdog After the CPU watchd...

Page 64: ...System manual 8 9 Temperature monitoring The temperature of CP 50x x is checked via internal sensors If the tempera ture violates an alarm limit a message will be sent and the application has the poss...

Page 65: ...e file is stored in the log directory Please send this to your contact at KEBA or sup port a keba com 9 2 7 segment display The CP 50x x has a 7 segment display for signalling status information and e...

Page 66: ...turn into the previous main operating mode 9 4 Crashreport If a system error e g unhandled exception occurs a crash report file is automatically created and saved to a removable storage device of the...

Page 67: ...f the battery is not replaced when there is a warning message the data in SRAM and the real time clock setting can be lost if the supply power is interrupted To prevent loss of data the power supply o...

Page 68: ...oving the battery tray 2 Remove the old battery from the battery tray Inserting the battery 1 Insert the new battery in the battery tray Pay attention to polarity Fig 10 45 Inserting the battery in th...

Page 69: ...peration 8 6 years for 24 7 operation 8 years for 24 7 op eration 6 9 years for 24 7 operation Information Since the data is a typical lifetime L10 it is recommended that the fan be replaced already w...

Page 70: ...r proceed as follows 1 Disconnect the voltage supply 2 Loosen the screws with the screwdriver 3 Remove the fan cover 4 Disconnect the connection cable To do this carefully pull the plug up wards with...

Page 71: ...ring manual V1 06 71 KEBA 2021 2 Attach the fan cover to the housing Caution Possible damage to property by pinching the fan cables Do not pinch the cables when attaching the fan cover 3 Tighten the f...

Page 72: ...ium including all net work settings are backed up KeStudio U4 offers the possibility to install the created backup as a simula tion on the PC For more information see online help of KeStudio U4 To sav...

Page 73: ...ry is changed to the name of the directory of the desired backup The file is saved and when a backup is restored this directory is now used To restore the backup proceed as follows 1 Connect the servi...

Page 74: ...ribution to protecting our environment by reusing renewing and recycling materials and old appliances 11 2 Disposal of the battery Caution When disposing of batteries the regulations for proper dispos...

Page 75: ...er1 0 C to 50 C CP 505 x 0 C to 55 C CP 505 x with additional output power1 0 C to 45 C CP 507 x 0 C to 60 C Storage temperature 40 C to 70 C Relative humidity of air 10 to 95 non condensing Vibration...

Page 76: ...erface is 20 W or 4 5 W respectively CP 507 x Nominal supply voltage 24 V DC from the front rated voltage toler ance 19 2 V DC to 30 V DC in acc with EN 61131 2 Inrush current Max 10 A Total power con...

Page 77: ...Quantity 1 Type microSD CAN interfaces Quantity 1 Data transmission rate 125 kbit s bis 1 Mbit s configurable via soft ware Terminating resistor Yes configurable via DIP switch on front Galvanic isola...

Page 78: ...PCIe lanes 1 SATA 1 USB 2 0 2 Slave sync lines 2 Master sync lines 4 12 6 Dimensions weight Fig 12 47 Dimensions Height H1 Height with lock 126 5 mm H2 Height without lock 121 mm H3 Height to mounting...

Page 79: ...andards Immunity standard for industrial environments EN IEC 61000 6 4 2019 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments Check of the conf...

Page 80: ...t 13 4 Regulations Regulation EG No 1907 2006 REACH EU chemicals regulation Information Information obligation from REACH regulation To meet the information obligation according to article 33 of REACH...

Page 81: ...P 505 A D K CP 507 A C EU Declaration of conformity Project engineering manual V1 06 81 KEBA 2021 14 EU Declaration of conformity The declaration of conformity of this product is available on request...

Page 82: ...forderlich ist die in Gro britannien England Wales und Schottland auf den Markt gebracht werden Authorised representative is KEBA Ltd Aston Court Frederick Place Kingsmead Business Park High Wycombe H...

Page 83: ...life 67 Type 67 Battery slot Position 18 Bus termination 55 C CAN interface Bus termination 43 CAN status LEDs 25 Connection 43 Pin assignment 43 Position 15 Technical data 77 Codes Data matrix code 2...

Page 84: ...cing 69 Service life 69 Fan cover Inserting 70 Oder number 22 Removal 70 Feldbus interface Technical data 77 G Gigabit Ethernet interface Pin assignment 42 Graphic interface Connection 52 Pin assignme...

Page 85: ...unting rail Position 18 Locking hooks Position 15 16 M Micro SD card 18 Inserting 19 Removing 19 Micro SD card slot Position 15 Mini I O plug Plug Connector Type II 22 Module address 32 Module bus 78...

Page 86: ...Termination 45 RS 485 A 47 AC termination 51 Bus termination 48 Configuration 54 No termination 49 Pin assignment 48 Resistor termination 50 Termination 48 S Serial interface Position 15 Technical da...

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