Operating Instructions C25BAY Safety Bus Coupler
c250 SC25BAYCBTranslation.URjÄ.URjäc250 S Safety bus couplerOperating InstructionslEN
Safety bus coupler1Preface . 41.1Version information. 41.2Information about this Operating Instructions . 41.2.1Literature. 41.3Reliability, Safety . 51.3.1Hazard and other Warnings . 61.3.2Other Notices . 72Introduction. 102.1EtherCAT — Ethernet Control Automation Technology. 102.2Lenze Safety System . 103System Description . 113.1General conditions of use. 113.2Dimensions . 113.3Mechanical Design. 113.3.1Earth . 123.3.2Installation. 133.4System Power Supply . 163.4.1General . 163.4.2Safety Bus coupler. 173.5Statusanzeigen. 173.5.1LED "EtherCAT Run" . 173.5.2LED "In L/A", LED "Out L/A" . 173.5.3LED "IO" . 183.5.4LED "Power" . 184Module . 194.1Safety bus coupler . 194.1.1Terminals . 194.1.2Status LEDs . 204.1.3Function . 205Appendix . 215.1Technical data (Overview) . 215.1.1System features. 215.1.2Safety bus coupler . 21EDBC250SBC 1.2†3
1Preface1Preface1.1Version informationDocument HistoryDateComments / modification1.231/01/2017Version 1.002/08/2017Version 1.113/05/2020Version 1.2Information about this Operating InstructionsThis Operating Instructions contains general Information for parameterization, configurationand diagnosis of the Lenze Safety System.Target GroupThis Operating Instructions is directed to Persons, who project and setup the Lenze SafetySystem with the Engineering ToolInformationInformation and Tools about the Lenze Products can be found in the Internethttp://www.lenze.com DownloadCopyrightMicrosoft , Windows and the Windows logo are registered trademarks of Microsoft Corp. inthe USA and other countries.EtherCAT is a registered trademark and patented technology, licenced by BeckhoffAutomation GmbH, Germany.Further information about the PLCopen organisation is available at www.plcopen.org.Title to all companies and company names mentioned heron as well as to products andproduct names is held by the respective enterprises.Structure and goal of this Operating InstructionsThis guide aims to familiarize you with the use of the modules.In examples preferably »PLC Designer« Version 3.14 and the Lenze Controller 32xx C whichcontains an EtherCAT Master is used.Further knowledge of the programming in accordance with IEC 611131-3, please refer to the»PLC Designer« online help or the literature.For beginners in »PLC Designer« it may be appropriate to use the comprehensive training offerfrom Lenze.1.2.1LiteratureTitel / ThemeEtherCAT, Technology, FAQs, DownloadsSPS Programmierung nach IEC 61131-3EDBC250SBC 1.2Number/ AuthorHeinrich Lepers†Sourcehttp://www.ethercat.orgFranzis Verlag GmbH4
1Preface1.3Reliability, SafetyScopeFor reasons of personal safety and to avoid material damages when working with or handlingthis Lenze product, you are advised to take heed of the notes and information contained in thisinstruction manual.Target Group of Operating InstructionsThis instruction manual contains all information necessary for the use of the described product(control device, control terminal, software, etc.) according to instructions. It is written fordesign, project planning, servicing and commissioning experts. For proper understanding anderror-free application of technical descriptions, instructions for use and particularly of notes ofdanger and warning, extensive knowledge of automation technology is compulsory.Intended UseLenze products are designed, developed and manufactured for standard industrial use. Theymust not be used for any other purposes than the ones specified in the catalogue or theassociated technical documentation. Proper and safe operation depends on the products beingtransported, stored, lined up, mounted, installed, put into service, operated, and servicedcorrectly. Ambient conditions must be within the admissible limits. Notes and information inthe associated documentation apply at all times.ReliabilityReliability of Lenze products is brought to the highest possible standards by extensive and costeffective means in their design and manufacture.These include: selecting high-quality components,quality agreements with our suppliers,actions to avoid static charges when handling MOS circuits,worst case planning and design of all circuits,visual inspections at various stages of fabrication,computer-aided tests of all assemblies and their interaction in the circuit,statistical assessment of the quality of fabrication and of all returned goods for theimmediate taking of appropriate corrective actions.EDBC250SBC 1.2†5
1Preface1.3.1Hazard and other WarningsDespite the actions described in section 1.3, the occurrence of faults or errors in electroniccontrol units - even if most highly improbable - must be taken into consideration.Please pay particular attention to the additional notices which we have marked by symbolsthroughout this instruction manual. While some of these notices make you aware of possibledangers, others are intended as a means of orientation. They are described further downbelow in descending order of importance.Every alert and hazard warning is made up as follows: Type and source of riskPotential consequences of non-observancePreventive measuresDANGERA DANGER warning makes you aware of an immediately hazardous situationwhich WILL cause a serious or fatal accident if not observed.WARNINGA WARNING makes you aware of a potentially hazardous situation which MAYcause a serious or fatal accident or damage to this or other devices if notobserved.CAUTIONA CAUTION alert makes you aware of a potentially hazardous situation whichMAY cause an accident or damage to this or other devices if not observed.NOTEA NOTE makes you aware of a potentially hazardous situation which MAY causedamage to this or other devices if not observed.EDBC250SBC 1.2†6
1Preface1.3.2Other NoticesInformationsThis symbol draws your attention to additional information concerning the useof the described product. This may include cross references to informationfound elsewhere (e.g. in other manuals).SafetyOur products normally become part of larger systems or installations. The information below isintended to help you integrate the product into its environment without dangers to humans ormaterial/equipment.DANGERNon-observance of the instruction manualMeasures for the prevention of dangerous faults or errors may be renderedineffective or new hazard sources created. Thoroughly read the instruction manual Take particular heed of the hazard warningsInformationTo achieve a high degree of conceptual safety in planning and installing anelectronic controller, it is essential to exactly follow the instructions given in themanual because wrong handling could lead to rendering measures againstdangers ineffective or to creating additional dangers.Project Planning 24 VDC power supply: generate as electrically safely separated low voltage. Suitable devicesinclude split-winding transformers built in compliance with European Standard EN 60742(corresponds to VDE 0551). Power breakdowns or power fades: the program structure is to ensure that a defined stateat restart excludes all dangerous states. Emergency-off installations must comply with EN 60204/IEC 204 (VDE 0113). They must beoperative at any time. Safety and precautions regulations for qualified applications have to be complied with. Please pay particular attention to the notices of warning which, at relevant places, willmake you aware of possible sources of dangerous mistakes or faults. Relevant standards and VDE regulations are to be complied with in every case. Control elements are to be installed in such a way as to exclude unintended operation. Lay control cables such that interference (inductive or capacitive) is excluded if thisinterference could influence controller operation or its functionality. Because the Safety bus coupler use capacities for voltage equalization , it is recomended touse line circuit breakers with characteristic B or C.EDBC250SBC 1.2†7
1PrefaceMaintenance and Servicing Precautions regulation to be observed when measuring or checking a controller afterpower-up. Repairs may only be carried out by qualified Lenze personnel. Otherwiese warranty is lost. Spare parts: Only use parts approved of by Lenze. Only genuine Lenze modules must beused in modular controllers. Modular systems: always plug or unplug modules in a power-down state. You mayotherwise damage the modules or (possibly not immediately recognizably!) inhibit theirfunctionality. Always dispose of (rechargeable) batteries as hazardous waste.Electromagnetic CompatibilityDefinitionElectromagnetic compatibility is the ability of a device to function satisfactorily in itselectromagnetic environment without itself causing any electromagnetic interference thatwould be intolerable to other devices in this environment.Of all known phenomena of electromagnetic noise, only a certain range occurs at the locationof a given device. These kinds of noise are specified in the applicable product standards.IEC 61131-2 which, in Europe, has been the basis for European Standard EN 61131-2.InformationRefer to IEC 61131-4, User's Guideline, for general installation instructions to becomplied with to ensure that hardware interface factors and the ensuing noisevoltages are limited to tolerable levels.Interference EmissionInterfering emission of electromagnetic fields, HF compliant to EN 55011, limiting value class A,Group 1InformationIf the controller is designed for use in residential areas, high-frequencyemissions must comply with limiting value class B as described in EN 55011.Fitting the controller into earthed metal cabinets and installing filters in thesupply lines may produce a shielding compliant to the above standard.General Notes on InstallationAs component parts of machines, facilities and systems, electronic control systems mustcomply with valid rules and regulations, depending on their field of application.General requirements concerning the electrical equipment of machines and aiming at thesafety of these machines are contained in Part 1 of European Standard EN 60204 (correspondsto VDE 0113).EDBC250SBC 1.2†8
1PrefaceElectrical Immission SafeguardTo eliminate electromagnetic interference, connect the control system to the protective earthconductor. Practice best cable routing.Cable Routing and WiringKeep power circuits separate from control circuits: DC voltages AC voltages60 V . 400 V25 V . 400 VJoint laying of control circuits is allowed for: shieldedshieldedunshieldedunshieldedunshieldeddata signalsanalogue signalsdigital I/O linesDC voltages 60 VAC voltages 25 VLocation of InstallationEnsure that temperatures, contaminations, impact, vibration or electromagnetic interferenceare no impediment to the installation.TemperatureConsider heat sources such as general heating of rooms, sunlight, heat accumulation inassembly rooms or control cabinets.ContaminationUse suitable casings to avoid possible negative influences due to humidity, corrosive gas, liquidor conducting dust.Impact and VibrationConsider possible influences caused by motors, compressors, transfer lines, presses, rammingmachines and vehicles.Electromagnetic InterferenceConsider electromagnetic interference from various local sources: motors, switching devices,switching thyristors, radio-controlled devices, welding equipment, arcing, switched-modepower supplies, converters / inverters.Particular Sources of InterferenceInductive ActuatorsSwitching off inductances (such as from relays, contactors, solenoids or switching magnets)produces surge voltages. It is necessary to reduce these extra voltages to a minimum.Throttling elements could be diodes, Z-diodes, varistors or RC elements. Their rating shouldconform to the specifications provided by the manufacturer or supplier of the actuators.EDBC250SBC 1.2†9
2Introduction2Introduction2.1EtherCAT — Ethernet Control Automation TechnologyEtherCAT is the most powerful Ethernet-based fieldbus system currently available on themarket. EtherCAT puts up the top speed mark, and its flexible topology and simpleconfiguration make it the perfect means of controlling extremely fast processes. To give you aclue: 1000 I/Os can be addressed in 30 μs.Because of its high performance, the simple wiring and its open protocol support, EtherCAT isoften used as a fast motion control and I/O bus driven by an industrial PC or in conjunctionwith control technology on a smaller scale. EtherCAT moves beyond the limits of conventionalfieldbus systems. Its interconnections between the controller at one end and both the I/Omodules and drives at the other are as fast as those of a backplane bus. EtherCAT controllersthus nearly act like centralised control systems, overcoming the issue of bus transfer times thatconventional fieldbus systems are burdened with.2.2Lenze Safety SystemThe Lenze Safety System is a system of I/O modules for connecting the process signals to anEtherCAT network.The Lenze Safety System consists of the Safety bus coupler and a range of other modules.The Safety bus coupler converts the physical transfer technology (twisted pair) to LVDS (E-bus)and generates the system voltages required by the LVDS modules. The standard 100 Base Txlines used for office network communications connect to the one side, the Safety I/O-modulesfor the process signals connect to the other. This is how the Ethernet EtherCAT protocol isretained right through to the last I/O module. At the end of the modular device, theconnection between the forward and return lines is automatically closed, the effect being thatanother 100 BaseTx line can be plugged in to connect the next EtherCAT unit to the second buscoupler port.If the bus coupler is the last device of the EtherCAT network, i.e. the RJ45-socket "Out"remains free, the connection of the forward and return line are closed automatically.Figure 1: Safety bus coupler with Safety I/O-ModulesEDBC250SBC 1.2†10
3System Description3System Description3.1General conditions of useThis section describes the general characteristics of Safety modules which are important forthe installation, wiring and troubleshooting.You can find an overview of the system properties in section 5.1.1 System features on page 21.3.2Dimensions3.3Mechanical DesignThe Safety bus coupler and the Safety I/O-modules differ in their connectors and indicators,however.Figure 2 Module layoutThe housing mount consists of an aluminum profile with an integral snap-on device used tosnap the module to a 35mm DIN rail. The housing trough including the optical fibers for thestatus indicators, the side face and the front is made of plastic and contains the module. Theoptical fibers for the signal state indicators (LEDs) are located next to the spring-assisted combiplug. They slightly protrude from the housing and allow a clear diagnosis at a glance.EDBC250SBC 1.2†11
3System Description3.3.1EarthConnect the Safety modules to earth by attaching the metal housing to operative earth.Since the operative earth connector dissipates HF currents, it is of utmost importance for themodule's noise immunity.HF interference is dissipated from the electronics board to the metal housing. The metalhousing therefore needs to be suitably connected to an operative earth connector.You will normally have to ensure that the connection between module housing and DIN rail conducts well, the connection between DIN rail and switching cabinet conducts well, the switching cabinet is safely connected to earth.In special cases you may attach the earth wire straight to the module. Earth wires should be short and have a large surface (copper mesh).Attach cable shield hereM3 x 5 bolt connectionConnect DIN rail withoperative earthFigure 3: Aluminium profileEDBC250SBC 1.2†12
3System Description3.3.2InstallationThe modules of the Lenze Safety System are intended for mounting rail installation (DIN EN50022, 35 x 7.5 mm).Installation positionThe mounting rail is placed horizontally and the female connector strip of the modules faceforward. For a sufficient ventilation of the convection slits the minimum distance must not fallbelow 20mm upward and 35mm to adjacent equipment and control cabinets The lateraldistance to external devices and cabinet controls must not fall below 20mm.Figure 3: Installation positionInstallation order in the Lenze Safety SystemNOTETo ensure smooth function of the entire Lenze Safety System, the Safetymodules must be arranged based on their e-bus load. The modules with thebiggest e-bus load are to be arranged directly next to the head modules (buscoupler or controller). Make sure that you note the maximum bus load of thehead module.Safety I/O-modules shall be arranged directly next to the head module.EDBC250SBC 1.2†13
3System DescriptionTo snap on a single module1. Push up the module against the mounting rail from below, allowing the metal spring tosnap in between mounting rail and mounting area as illustrated.2. Push the module against the mounting wall until is snaps in.Figure 4: Rail mounting of moduleTo interconnect two module
SPS Programmierung nach IEC 61131-3 Heinrich Lepers Franzis Verlag GmbH . 1 Preface EDBC250SBC 1.2 .
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1. Read instructions. Read the safety and operating instructions before operating the appliance. 2. Retain instructions. Retain the safety and operating instructions for future reference. 3. Heed warnings. Observe all warnings on the appliance and in the operating instructions. 4. Follow instructions. Follow all operating and use instructions. 5.
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IEEE 118-bus case is provided. A. 4-bus Test Case with Exact Solution . Fig. 1 depicts the full 4-bus case with line loadings on the left and PTDF values for a transaction from bus 2 to bus 3 on the right. Lines have a limit in MVA and a reactance in p.u. Bus 1 is the external area to be equivalenced making a reduced 3-bus case in Fig. 2. k. 1 .
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