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DCS1 CONTROL SYSTEMS

23

 

6

DCS1 CONTROL SYSTEMS

6.1 Application and use

DCS1 control systems provide the control of the drive motors in automated, rail based systems. The digital in

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puts and outputs (IO) are used to analyze a variety of sensors and actuate the actuators.
The DCS1 control system series can in principle be differentiated by the type of communication. The following
communication methods are available:

•

HW (Half cycle)

•

PCB (rail bus)

•

SMGM (Slotted Microwave Guide Mini)

DCS1 - Half cycle control

The half cycle control is the simplest communication method between stationary and mobile control. Three
different signals (pos. half cycle, neg. half cycle, full cycle), which are used to control the system, are made
available for this purpose. The EHB tool is used for parameterizing/configuration. Three commands for the free
configuration - negative half cycle, positive half cycle and full cycle - are available for feedback. 

DCS1 - Rail bus control

The rail bus control permits the control of complex applications as well the cyclic data transmission on the en

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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 mobile control system. In addition, it is possible
to query additional parameters (e.g. temperatures) through a non cyclical data retrieval. In addition, occurring
possible faults can be easier identified through special error codes and therefore they can be resolved quickly.
By using this communication method, the use of an absolute distance measuring system, e.g. APOS, is as

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sumed.

DCS1 SMGM control system

The communication through SMGM is realized through a slotted waveguide, which was especially designed for
this application. This method is suitable for complex control tasks. The advantage is the higher transmission
speed. Using the especially designed slotted waveguide makes it possible to have a parallel operation to other
industrial radio transmission processes, free of failures and interruptions. The field bus of the stationary side,
e.g. PROFINET, is also available on the mobile side - transparent transmission.
By using this communication method, the use of an absolute distance measuring system, e.g. APOS, is as

-

sumed.

Содержание DCS1-PCB

Страница 1: ...TRANSLATION OF THE ORIGINAL INSTRUCTIONS DCS1 PCB CONTROL SYSTEMS SINGLE AXLE RAIL BUS CONTROL SYSTEM MANUAL EN V 1 05 DCL046...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 39: ...CONNECTIONS 37 8 3 2 SA02 Flange for HW PCB Fig 8 4 Diagrammatic view of the flange SA02...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 65: ...CONFIGURATION PARAMETERIZATION 63 Parameter Parameter information Parameter Selection Description Parameter version 0 999 Parameter version number...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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