TRANSLATION OF THE ORIGINAL INSTRUCTIONS
DCS1-PCB CONTROL SYSTEMS
SINGLE AXLE RAIL BUS CONTROL
SYSTEM MANUAL
EN | V 1.05 | DCL046
Page 1: ...TRANSLATION OF THE ORIGINAL INSTRUCTIONS DCS1 PCB CONTROL SYSTEMS SINGLE AXLE RAIL BUS CONTROL SYSTEM MANUAL EN V 1 05 DCL046...
Page 2: ...4 5 1 Qualifications 15 4 6 Personal protective equipment 16 4 7 Safety devices 17 4 8 Conduct in case of danger or accident 18 4 9 Signage 19 5 Technical data 20 6 DCS1 control systems 23 6 1 Applic...
Page 3: ...ation 60 13 2 1 Overview parameter screen 61 13 2 2 Parameter General information 62 13 2 3 Parameter Rail bus control 72 13 3 Positioning 78 14 Malfunctions 79 14 1 Safety information about malfuncti...
Page 4: ...TABLE OF CONTENTS 2 19 Declaration 95 19 1 Declaration of Conformity CE 95 19 2 Declaration of Conformity UKCA 97 20 Repair note 98 Index 99...
Page 5: ...t issue 1 02 08 2018 Parameter display modificated 1 03 11 2019 Flange X21 2 DOUT 2 standard Review 1 04 12 2021 Added to parameter Drive Brake opening time 1 05 01 2023 Added new CE Declaration of Co...
Page 6: ...igh frequency IEN Industrial Ethernet PN PROFINET ETH ETHERNET IP SSI Synchronous serial Interfaces SYSCAN System CAN bus HW Half cycle PCB Power CAN bus Rail bus PowerCAN SMGM Slotted Microwave Guide...
Page 7: ...personnel in the immediate vicinity The basic requirement for safe working is compliance with all specified safety instructions and instructions This documentation does not give instructions for opera...
Page 8: ...ricity that will result in death or serious injury unless avoided The actions to prevent the hazard are identified here WARNING The source of the hazard is described here This combination of a symbol...
Page 9: ...bination of a symbol and a signal word indicates a reference to another place in this text or in a different document The places in the text or references to other documents are identified here TIPS A...
Page 10: ...damages resulting from Failure to observe the technical documentation Uses other than the intended use Use by personnel without the required training Unauthorized modifications or technical changes U...
Page 11: ...ges modifications or accessories Changes or modifications to the delivered product require the permission of the man ufacturer Genuine spare parts and manufacturer approved accessories provide safe ty...
Page 12: ...fety aspects relating to the protection of personnel as well as the safe use and fault free operation Other task specific safety instructions can be found in the sections on the individual phases of t...
Page 13: ...system The connectible power depends on the frequency converter used The following principles are available for the communication Half cycle PCB rail bus SMGM through BCC SMGM The position determinat...
Page 14: ...instructions to reduce the risk of injuries or dam age to property and equipment and to avoid dangerous situations Do not change or modify the system inappropriately WARNING Risk of death from imprope...
Page 15: ...e of voltage must be checked with a voltage tester immediately before and after use Grounding and short circuiting Parts on which work will be performed at the work place must first be grounded and th...
Page 16: ...em Over the entire time the owner has to verify that the instructions drafted by him for the operation of the system conform to the current state of applicable regulations and adapt the instructions a...
Page 17: ...ask Electrically qualified person see VDE 0105 100 Due to their professional training knowledge experience and knowledge of the relevant standards and regu lations professional electricians are able t...
Page 18: ...gainst flying particles and liquid sprays Helmet Helmets protect against falling or flying parts and materials Gloves Gloves protect hands against chafing and abrasion cuts and punctures as well as ag...
Page 19: ...y work verify that all safety devices are functional and in stalled properly Never disable or override safety devices In addition to locally applicable safety regulations the following safety instruct...
Page 20: ...ecautions Have first aid equipment first aid kit blankets etc and fire extinguisher ready Maintain free access for emergency services vehicles Conduct in case of accident Secure site of accident and c...
Page 21: ...ant components are not live or under voltage and that there is no unauthorized approximation WARNING Danger from illegible signs Over time labels and signs can get dirty or can become unreadable in ot...
Page 22: ...ive measures Against motor overtemperature input PTC or thermal contact overcurrent at the out put EMC Interference emission EN61800 3 Adherence to the limit values for the second environment industri...
Page 23: ...ation position vertical Installation clearances Top The actual installation clearances depend on the plugs used and the bending radii of the cables Bottom At the side Drive frequency converter Informa...
Page 24: ...AL DATA 22 Storage capacity depending on the application Parameterization Interface USB mini USB type B bushing Usage Parameterizing configuration etc Required software EHB tool Information Basis Desc...
Page 25: ...lic data transmission on the en tire driving route A continuous monitoring of the driving parameters such as speed and position is possible due to the cyclic communication between stationary PLC and m...
Page 26: ...mounted at the rear for DCS1 control systems with a 1 5 kW converter The dimensions of this variant are 280X230x140 mm incl heat ex changer TIPS AND RECOMMENDATIONS Information about the standard dime...
Page 27: ...n interface 3 Infrared interface 4 Display 5 On off switch 6 Flange IO 7 Mains connection plug field for AC supply HW and PCB communication connection 8 Heat exchanger only for 1 5 kW control variant...
Page 28: ...DCS1 CONTROL SYSTEMS 26 6 4 Type code TIPS AND RECOMMENDATIONS Type code The type code shows DCS1 standard configurations Fig 6 3 Type code of DCS1 controllers...
Page 29: ...cted speed currently issued frequency and the status of the inputs HEX coded Display Explanation Only for PCB communication type Vehicle ID current position current frequency and status of the inputs...
Page 30: ...e software version and parame ter version Display Explanation Current sent value from the bar code reader and the status byte Display Explanation Status of the speed controller Display Explanation Onl...
Page 31: ...nly PCB communication type SYNC data Display Explanation Only PCB communication type TX signals Display Explanation Only communication type PCB and SMGM The state of the individual inputs is displayed...
Page 32: ...ommunication type Current acceleration and deceleration ramp Display Explanation Only SMGM communication type RX signals Display Explanation Only SMGM communication type TX1 signals Display Explanatio...
Page 33: ...YS 31 A transfer to lower level takes place by pressing the button MODE2 The following can be found there Display Explanation Operating minute counter Number of times that the control system was switc...
Page 34: ...and the real fault number with a relative time stamp referenced to the operating minutes The lower line displays the error in plain text Display Explanation Minimum and maximum value of the intermedia...
Page 35: ...ils Data Connection X1 Fig 8 1 Connection X1 supply voltage half cycle communication internal reference L3 Type Description Connection X1 VAHLE DETO plug field 8 poles Line voltage 3 PE PEN AC 360 528...
Page 36: ...Data Connection X1 Fig 8 2 Connection X1 supply voltage rail bus communication Type Description Connection X1 VAHLE DETO plug field 8 poles Line voltage 3 PE PEN AC 360 528V 0 Mains frequency 45 65Hz...
Page 37: ...PE bushing Plug cycles 100 Power Depending on the frequency con verter used Frequency 0 120Hz Pin Function Description 1 Motor phase U Motor phase 2 Motor phase V Motor phase 3 Motor phase W Motor pha...
Page 38: ...ATIONS Information about flange labeling The labeling of the flange can deviate Please refer to the project related documents 8 3 1 Overview flanges The following comparison of the flanges available f...
Page 39: ...CONNECTIONS 37 8 3 2 SA02 Flange for HW PCB Fig 8 4 Diagrammatic view of the flange SA02...
Page 40: ...Sensor connection digital X20 Type Description Connection X20 M12 A coded 5 pole bushing Plug cycles 100 Contact AU gold Pin Function Description 1 Ub Supply voltage 24VDC 2 DIN 8 Digital input 8 3 G...
Page 41: ...nnection digital X21 Type Description Connection X21 M12 A coded 4 pole bushing Plug cycles 100 Contact AU gold Pin Function Description 1 Ub Supply voltage 24VDC 2 DOUT 2 Digital output 2 3 GND Suppl...
Page 42: ...IPS AND RECOMMENDATIONS Information about the connection X22 for rail bus communication PCB The digital output DOUT 1 can be freely actuated through the rail bus by the stationary PLC Type Description...
Page 43: ...Fig 8 8 Sensor connection serial X23 Type Description Connection X23 M12 A coded 5 pole bushing Plug cycles 100 Contact AU gold Pin Function Description 1 Ub Supply voltage 24VDC 2 RS485_A Data 3 GND...
Page 44: ...s IP 54 against the penetration of water and dust All other connections not used must be closed with the cover flaps In addition the data connector protects the connection against electromagnetic radi...
Page 45: ...lures The cover of the USB interface must be mounted at the control system to guaran tee the protection class IP 54 against the penetration of water and dust In addi tion the cover protects the connec...
Page 46: ...nent regenerative mode Available frequency converters Data basis The 560 V DC supply assumes the SMGM communication system The following lists the technical data of the individual frequency converters...
Page 47: ...rcuit PN kW 0 75 Maximum output power SN 8kHz SN kVA 1 3 Output current Duration IN A 1 8 For 60s Imax A 3 0 Switching frequency Selectable frequencies f kHz 2 4 8 16 Preset frequency f kHz 8 Output f...
Page 48: ...rcuit PN kW 1 1 Maximum output power SN 8kHz SN kVA 1 7 Output current Duration IN A 2 6 For 60s Imax A 4 0 Switching frequency Selectable frequencies f kHz 2 4 8 16 Preset frequency f kHz 8 Output fr...
Page 49: ...Startup current Effective Ieff A 4 Peak Ipeak A 6 Rated power typical EHB application Start up current 70 PN kW 1 5 Typical motor power 4 pole ASM star circuit PN kW 1 5 Maximum output power SN 8kHz...
Page 50: ...ission through contact wire contact wire Slotted waveguide Tapping point mobile side Carbons Carbons Coupling Participant assigned No Yes Yes Participant segment 25 15 BCC DCS system Transmission spee...
Page 51: ...ata retrieval In addition occurring possible faults can be easier identified through specific error codes and therefore they can be resolved quickly Fig 10 1 Schematic diagram PCB communication withou...
Page 52: ...e open 2 Activate speed control 3 Acceleration ramp bit 0 4 Acceleration ramp bit 1 5 Deceleration ramp bit 0 6 Deceleration ramp bit 1 7 Reserve 3 0 7 Target position LOW byte mm 4 0 7 Target positio...
Page 53: ...yte mm 3 0 DIN 1 1 DIN 2 2 DIN 3 3 DIN 4 4 DIN 5 5 DIN 6 6 DIN 7 7 DIN 8 4 0 Auto man 1 Standstill fOUT 0Hz 2 Speed control OK speed reached 3 Position reached 4 Position zero 5 Position sensor commun...
Page 54: ...and actuators 8 Absolute position e g APOS optic for half cycle e g EMD4P absolute position only with external IrDA mod ule 9 Communication module here BCC SMGM module integrated for other communicati...
Page 55: ...n of the device The control system must only be installed if the information on the nameplate of the control system agrees with the information for the mains voltage TIPS AND RECOMMENDATIONS Informati...
Page 56: ...se of wrong handling Destruction and malfunction of the external data storage Hard mechanical stresses shocks hits bending can damage the data storage During transport storage and installation the ext...
Page 57: ...if the lines are too long Cut the sensor cables to length or place directly folded and bound together with cable clips in the cable harness to prevent interspersion and inductions Ground the EHB vehic...
Page 58: ...ice and for moving the control system in a case of a fault WARNING Danger of injuries due to inactive limit switches Accidents severe injuries as well as property damages Depending on the configuratio...
Page 59: ...Destruction or damage of the external data storage or its data The control system must be disconnected from the mains before the external data storage is connected disconnected to from the control sys...
Page 60: ...o the PC laptop 2 Using a USB cable USB mini connector type B type A connector connect the control system to the PC 3 Start the VAHLE EHB tool and select the correct parameter set Fig 13 2 Start scree...
Page 61: ...SMGM It is mandatory that each vehicle has a vehicle number that is unique within the sys tem The vehicle number is used for addressing the control system on the bus system If a vehicle number is use...
Page 62: ...re incorrectly assigned crash of a vehicle The executing specialist and the operator are responsible for the parametrization adaption to the system in which the control is used NOTICE Information abou...
Page 63: ...3 2 1 Overview parameter screen Overview parameter screen Fig 13 3 EHB Configurator parameter screen 1 Parameter area 2 Adjustment area 3 Parameter will be visible after activation 4 Some settings mus...
Page 64: ...ior analysis of the requirements or the existing system in the portfolio by VAHLE Special hardware configurations are required for the communication types HW PCB and SMGM Please refer to the appropria...
Page 65: ...CONFIGURATION PARAMETERIZATION 63 Parameter Parameter information Parameter Selection Description Parameter version 0 999 Parameter version number...
Page 66: ...SP Display language Spanish currently not available Screen saver display connection Active Screensaver active To protect the display from aging the screen saver is always active to maintain compatibil...
Page 67: ...Activate if a data stick is used RF interface connec tion Inactive Activation of the infrared data transmission additional sta tionery module required Currently not available Active Production data c...
Page 68: ...l system Parameter Selection Description MC8 10M IRremote control Check box Activate if a remote control is used Manual mode activa tion mode Via M A button The control system will be switched into ma...
Page 69: ...re to the keys 1 8 of the remote control Parameter Selection Description Speed 0 9 Speed selection forward backward 0 forward right rotating field 1 backward left rotating field Brake 1 Brake will be...
Page 70: ...RATION PARAMETERIZATION 68 Parameter Timer Parameter Selection Description Timer ON 0 65000ms Setting of the switch on delay for each input Timer OFF 0 65000ms Setting of the switch off delay for each...
Page 71: ...ake resistor set tings 1 brake resistor 1 brake resistor is connected to the converter low brake re sistance 2 brake resistors 2 brake resistors are connected to the converter high brake resistance Br...
Page 72: ...terrupt faster Frequency converter voltage controller is processed in the in terrupt faster Controller call up in the polling Frequency converter voltage controller is processed in the polling slower...
Page 73: ...inimum vacuum in vacuum cleaner system Max permissible vac uum 0 200mbar Maximum vacuum in vacuum cleaner system Error triggering delay 0 65000ms Delay time until a failure is triggered Rated current...
Page 74: ...ettings Parameter Selection Description Speed 0 0 This value is always 0 value cannot be changed Speed 1 9 0 1200Hz 10 Associated accelera tion ramp speed 0 9 0 255 Hz s Associated decelera tion ramp...
Page 75: ...e distance measuring systems with RS485 in terface supported by the control system SICK OLM 9N1 binary protocol type 2 Pepperl u Fuchs PCV 8E1 binary code pro tocol Vahle APOS Magnetic 9N2 steel 2 com...
Page 76: ...tings Parameter Selection Description Rail bus identifier STD Identifier Settings of CAN identifier EXT Identifier Timeout multiplier 0 200 Multiplier to generate the communication timeout The value t...
Page 77: ...1 must be inverted Inv input 2 0 1 Must be set to 1 if input 2 must be inverted Anti valence test 0 1 0 no execution 1 will be executed Forward backward 0 1 Configuration active for 0 Right rotary fie...
Page 78: ...oning Graphic Positioning 4 Correction value the oretical brake point 0 999999999mm Correction value to ensure that the target position will always be reached with the fine positioning speed Distance...
Page 79: ...measured speed is within these limits Max speed differ ence target and actu al 0 999 mm s Speed correction fac tor 0 100 The max value for which the speed can be adjusted Min controller volt age 0 10...
Page 80: ...for target positioning IV Target position 1 Driving speed 2 4 Deceleration ramps 3 Distance in which fine positioning speed is traveled v1 Speed Driving v2 Speed Fine positioning Position monitoring...
Page 81: ...4 2 Procedure in the event of malfunction General principle In the event of malfunctions that pose an immediate hazard to persons or property immediately activate the safety devices Determine the caus...
Page 82: ...ommunication method The communication methods are Half cycle HW Rail bus PCB SMGM TIPS AND RECOMMENDATIONS Information about troubleshooting and fault clearance The occurrence of an error always resul...
Page 83: ...mber of break processes reduce the load on the carrier F011 Status fault 11 Freely definable fault message the condition can be freely parameterized Depending on the paramerization F012 Status fault 1...
Page 84: ...39 NoDist Altern Code band position did not change al though there was frequency output on the VFD Check for mechanical obstructions check if the clutch is engaged check speed settings in the PLC F040...
Page 85: ...MALFUNCTIONS 83 F066 max PosTries Position fault maximum permissible numbers of position attempts exceed ed Acknowledged fault check drive pa rameters Fault Cause Resolution...
Page 86: ...customer service see section 3 5 Customer service The following information is mandatorily required to guarantee a fast repair Customer name address Designation of the system in which the control syst...
Page 87: ...ere injuries as well as property damages No limit switches are active in the IR manual mode except if it was parameterized Designation Description Ident No MC8 10M Infrared remote control for mobile D...
Page 88: ...e with right or left rotating field and appropriate frequency independent of the pa rameterizing of the control system Error reset The button must be pressed longer than app 1 5 sec foran error reset...
Page 89: ...ACCESSORIES 87 15 2 Data connector DS VD Fig 15 2 DS VD Designation Description Ident No DS VD Data connector for the storage of the control param eters required for operation 10010330...
Page 90: ...re EHB tool Fig 15 3 EHB tool As download from the VAHLE home page Designation Description Ident No EHB tool Software tool for the parameterizing of the DCS con trol systems tool is required forthe pa...
Page 91: ...ions must be observed DANGER Danger of death due to electrical current Contact with live parts can result in life threating injuries Make sure that the relevant components are not live or under voltag...
Page 92: ...due to insufficiently qualified persons Insufficiently qualified persons cannot assess the risks involved in operating the sys tem and expose themselves and others to the risk of serious or fatal inju...
Page 93: ...he symbols on the packaging while unloading the pieces at delivery or during transport on the facilities 17 2 Transport inspection Check the delivery for completeness and transport damage upon receipt...
Page 94: ...that the relevant components are not live or under voltage and that there is no unauthorized approximation 18 1 1 Disassembly During disassembly always observe the information in section 4 3 1 WARNING...
Page 95: ...electrical appliances contain valuable raw materials These must not be de posited in residual waste Disposal instructions Individual product parts to be disposed of must be separated according to the...
Page 96: ...or stored in the assembly must be re moved by the operator or safely and permanently deleted the operator is personally responsible Data on the module Stickers labels etc Data stored in the module dev...
Page 97: ...x 02307 704 444 eMail info vahle de 2014 Die Sicherheitshinweise der mitgelieferten Produktdokumentationen sind zu beachten vDRIVE Industrielle Steuerungstechnik EU Konformit tserkl rung Paul Vahle Gm...
Page 98: ...4 0 Fax 02307 704 444 eMail info vahle de EU Declaration of conformity Paul Vahle GmbH Co KG Westicker Str 52 D 59174 Kamen Germany We herewith declare that the products specified hereafter conform to...
Page 99: ...e UKCA Declaration of conformity Paul Vahle GmbH Co KG Westicker Str 52 D 59174 Kamen Germany We herewith declare that the products specified hereafter conform to the relevant UK regulations This decl...
Page 100: ...ry code Area code Telephone number Extension Guarantee Yes No System Location name Product Type S No Configuration product FW Version Parameter Fault description Error pattern Under what circumstances...
Page 101: ...Error messages 80 External interfaces 52 F First commissioning 57 Frequency converter overview 44 G Graphic positioning 78 Grounding 54 Grounding and short circuiting 13 I Information on the instruct...
Page 102: ...EPAIR NOTE 100 S safety aspects 10 Safety information 7 Software EHB tool 88 Switch on again 13 Switch on sequence 57 Symbols 6 T Technical condition 14 Transport 91 U Unloading 91 V Vehicle number 59...
Page 103: ...Technical Documentation Paul Vahle GmbH Co KG Westicker Str 52 D 59174 Kamen Tel 49 0 2307 704 0 E Mail info vahle de www vahle com...
