Digital Cam Switch Unit CamCon DC190 Digitronic Automationsanlagen GmbH Steinbeisstraße 3 • D - 72636 Frickenhausen • Tel. +49 7022 40590-0 • Fax -10 Auf der Langwies 1 • D - 65510 Hünstetten-Wallbach • Tel. +49 6126 9453-0 • Fax -42 Internet: http://www.digitronic.com • E-Mail: mail@digitronic.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 For your attention This instruction manual relates to the CamCon DC190 from 11/2011. The company Digitronic Automationsanlagen GmbH reserves the right to make changes which present an improvement of the quality or functionality of the device without prior notice. The instruction manual was created with great care, although it may not be error-proof. We would be grateful for any communication relating to any errors you may have found.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 Table of Contents 1. Introduction .......................................................................................................................................... 6 2. Operating Pinciples .............................................................................................................................. 7 2.1. Speed Compensation .......................................................................................
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 5. Commissioning .................................................................................................................................. 26 5.1. Setting the IP-Address .................................................................................................................... 26 6. Programming ............................................................................................................................
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 7. PLC - Logic - Module programming ................................................................................................... 55 8. Error messages and removal of errors (FAQ) ................................................................................... 56 8.1. Problem: Display shows "No contact to unit: XX". .......................................................................... 56 8.2.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 1. Introduction Electronic Cam Switch Units have been successfully used in industry for a long time. Experiences collected in close liaison with users over the years have been included in the development of the CamCon series. The result is a compact digital cam switch unit which is user friendly and reliable to a high degree.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 2. Operating Pinciples Diagram: Principles of a Cam Switch Unit A principle for better comprehension of the function of a Cam Switch Unit is here presented.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 2.1. Speed Compensation Each mechanical switch component (e.g. shield, magnetic valve) has a delay time, i.e. the time between the start signal and the actual switching of the contacts. In processes where positioning is executed on a moving system, this can cause problems. If such a process is driven with different speeds, different positions are caused.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 A small example in figures was designed to eludicate: Supposing the drive cylinder with the measuring system has a circumference of 360mm, so that one millimeter of the circumference corresponds to exactly one angle degree of the measuring system.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 2.1.1. Measuring delay time for Speed Compensation Several ways of measuring delay time of a relay or valve are available. 2.1.1.1. Measuring delay time through actual differences First the switch-ON point of a valve or relay is programmed. We assume that the programmed switch point lies at 200 degrees in this case. If the machine is driven with a speed of for example 40 rpm, a shift occurs due to delay time.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 2.1.2. Speed Compensation using off-centre pressure, e.g. brake functions The Speed Compensation of the CamCon Cam switch unit works using a linear function. If, for example, the speed doubles, then the shift of the compensated cam changes and also moves forward by twice the amount.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 2.1.3. Not linear Speed Compensation (NLT) The method for the compensation of a not linear Speed Compensation, descriptive in the chapter before can with devices with a software starting from 11/2004 by the non linear Speed Compensation (NLT) simplified be entered. You need only one cam or a shift register output of the SPS - logic becomes module with NLT - speed compensation.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 3. Installation The device is snapped onto an "EN - carrier rail" in the switchboard (see chapter "3.1. Dimension" on page 13). The grounding connections and the cable coverings are to be put on the shortest possible way on the serial grounding clip next to the device. The grounded assembly plate and its electrical connection to the "EN carrier rail" allow an excelent grounding of the disturbances onto the covering.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4. Electrical connections Before you begin with wiring, please consult the following chapters: "4.7. Outputs" on page 24, "4.8. Inputs" on page 24 and "4.6. The measuring system" on page 20. 4.1. Pin allocation of the CamCon . 4.1.1. Pin allocation of the power supply Pin Pin 1: 2: +24V DC power supply (5L+) 0V power supply (L-) 4.1.2. Pin allocation of 1. Measuring System - Input . 4.1.2.1.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.1.4.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.1.6.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.2.2. PIN - Allocation of the Serial Interface RS485 (Optional) DSUB 9 male: Pin Pin Pin Pin Regard: RS485 interface for the connection with a PC or other DC190 units (max. 1000m cable length). 2 3 5 1, 4 and 6 - 9 B (-) A (+) Ground Not connected (NC). When using the RS485 interface, the first and last units in the chain have to have their data transfer cables closed with a terminal resistor. See also next chapter.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.2.2.1. Terminal Resistors of the RS485 Interface To switch the terminal resistors of the CamCon DC190 on or off, a bipolar DIP – switch (labeled “Term”) on the unit can be actuated using a screw driver. If the switches are closed (ON), the RS485 wiring is shut with a terminal resistor of about 2300/220/3200 Ohm. Therefore, always use both switches simultaneously, otherwhise the unbalanced load can disturb the data transmission.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.4. Connecting the Ethernet Interface Connecting the CamCon to the EtherNet or local area network is done using a RJ45-connectoor (Registered Jack) and a standard EtherNet Cat.5 cable with 10/100 Mbit.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.6. The measuring system The measuring system is designed to record the necessary actual values (positions) for the Cam Switch Unit. Many different measuring system can be linked with the CamCon. See chapter "4. Electrical connections" on page 14 and for adjustment of the measuring system to the software of the CamCons please also consult Chapter "6.6.1. Measuring system" on page 32.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.6.3. Incremental measuring system input Systems with 90° phase shift signals such as turning angle encoders, glass measuring rods or flow measuring devices. At the present time incremental measuring inputs for the CamCon DC16/50/51/115/300 and DC1756 are available as an option.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.6.3.3. Incremental Hiperface measuring system input with SINCOS level The Hiperface measuring system is a feedback system for servo-motors of the company Stegmann. It is a mixed system and consists of an absolute measuring system and an incremental measuring system. The absolute measuring system sends its values via RS485 interface to the counter.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.6.5. PLL measuring system input Systems with Phase - Lock - Loop data recording. In these systems the actual value is found through interpolation of initiator impulses. This measuring system is applied to machines with constant speed and with a cyclic pulse. = Initiator impulse = Found actual value The Initiator can be connected to any free input of the CamCon. Note: For CamCon DC115 a special input is available on the 25pol.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.7. Outputs The CamCon DC190 features 32 on board short circuit proof outputs. They deliver 24 volt high-active HTL signal with 0.5 amps steady current (100%ED). They are, nevertheless, not potentially free to the unit’s or the CPU’s power supply. The 32 outputs are gathered in four blocks of eight outputs each and have a separate power supply (1L+ to 4L+), that can be switched on or off individually. See also chapter "6.6.6.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.10. Status Display The CamCon DC190 features several status displays: 32 output indicators, 16 input indicators, 5 indicators for the power supply (1..5L+), one display for the internal DC190 BUS (BUS-Run), one for output-errors or overload, one DC190 Status LED (Device-Status) and status LEDs for EEtherNet and EtherCAT (Link and active).
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 4.10.1. The DC190 Status LED The status LED of the CamCon shows the different blinking intervalls of the the device state. This way, the operation state of the device can be seen without a PC or a terminal. total time: 3.2 seconds State = = = = = = = = "OK" "Clear..." "Pos.Error: 1" "Pos.Error: 2" "Pos.Error: 3" "Pos.Error: 5" "Output Error" "indicates an error in the EEPROM memory" See also chapter "8.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 If the IP address is 169.254.148.76 (for example when using a cross over cable) and the subnet mask 255.255.0.0, the CamCon DC190 can be configured within an address range of 169.254.0.1 up to 169.254.254.254. It must never equal the computer’s IP (like 169.254.148.75, for example). If you know of a free address in the network or the administrator assigned one for you, you can continue with the setting of the IP.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6. Programming Note: The Web programming requires Java Script and ActiveX (Internet Explorer Only). Any popup-blocker must be deactivated for the CamCon’s IP address! 6.1. Deleting the Cam Control The cam control’s memory should be deleted for commissioning, since remains of testing programs needed in the manufacturing process, still are present within the memory.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.2. The Main Menu Every configuration starts in the main menu. No matter what sub menu you are in, the main menu helps you to access every other menu with just one click. The recently selected menu is highlighted. According to the menu configuration the look of the main menu can vary. Options can be missing or additional options can be available (like e.g. tool protection).
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.4.2. Offline - Simulation The Digisoft 2000 Program gives you the opportunity to simulate the encoders like the Measuring System, hardware inputs (l) and backplane inputs (V) of an S7 (CamCon DC300 or ControlLogix 1756DICAM) in the "Offline" programming. This option makes it possible to test a PLC logic program on your computer without having to install a CamCon or further machinery. This option is not available "Online".
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.5.2. Entering the Speed Compensation You can select between five different modes of Delay Time compensation according to the configuration in the menu "System setting" -> "System upgrading". Note: You will find information about the function and calculation of the speed compensation in chapter "2.1. Speed Compensation". "Normal" The selected Delay Time affects in- and outputs similarly.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6. System settings Select the system parameter of your cam switch of your CamCon controller here. 6.6.1. Measuring system Parameter the measuring system of the cam switch here. 6.6.1.1. Select measuring system You can choose between different preset measuring systems.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.1.4. Electronic Gear Transmission The option "Transmision - multiplier" and "Transmision - divider" can be used to enter a transformation factor for the measuring range. This makes it possible to transform the physical measuring range of e.g. a rotating angle encoder into a visible measuring range for the user. The standard transmission is set to 1:1.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.1.6. Configuration of the special measuring system If your Measuring System is not available in the default options, you will have to configure a special measuring system for the CamCon. There are nine different special measuring systems available at the moment. - Name: When configuring a special measuring system, you can select a name and description of up to two lines length under "Name:". 6.6.1.6.1.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.1.6.3. Special measuring system - Incremental - Resolution Enter the maximum number of pulses here. This value is used as the maximum resolution for the calculation of the cams. If the unit registers more pulses than this set maximum, it restarts counting again at zero. The option "Measuring offset" can be used to switch the movement "System" to "linear", a counter overflow triggers a "Clear....
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.1.6.4. Special measuring system - Multi This Measuring System is needed to use a multiturn turn-encoder (4096*4096 with 24Bit) with a nonbinary number of revolutions. If e.g. the encoder at the shaft revolves more than one turn, but your machine just operates in a single step or product. - Resolution Total resolution of the Measuring System at the CamCon used to calculate the cams.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.1.6.5. Special Measuring System - PLL The PLL Measuring system (Phase - Lock - Loop) determines the position by interpolation of a single pulse over time (like a photo cell or limit switch). If e.g. a rotating disk is equipped with an initiator and you want to measure the recent position at a certain, constant speed without having to install a second Measuring System the PLL is a good solution.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.1.6.7. Special measuring system - AG615 The AG615 - Single - Multiturn – Measuring System creates a multiturn Measuring System from an AAG615 - 8192 Singleturn - Unit. - Resolution Set the resolution that the CamCon shall display per turn (e.g. 360). - Turns Set the number of uses or revolutions that the CamCon shall create (e.g. 5). The results are several revolutions or uses of the CamCon with each turn of the AAG615.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.1.6.9. Special measuring system - HIPER This Special measuring system is used if the CamCon is equipped with an incremental Measuring System input and an uneven gear transmission is likely to cause an error overflow (roll over function). - Multiplier Enter the multiplier for the gear transmission. - Divisor Enter the divisor for the gear transmission (e.g. 5 / 7). Note: - Resolution Each edge change is counted = quadrupling.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.2. Measuring offset Movement - "System" = Rotatory (standard) Movement - "System" = inear - System: Can be used to select the controlled system: Either rotatory (like packaging machines, trimmers or eccentric presses) or a linear system like a positioning unit or a toggle press. - Offset: The offset is subtracted from the physical actual value, thus giving you the possibility to shift the zero value.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.3. Speed This menu is used to set the CamCon’s speed display according to the turning speed of your machine. You can e.g. alter the displayed speed by several factors or adjust a dampening to prevent a fluttering of the display. - Speed factor: Usually the measured speed is displayed in pulses/second. If you want to use another unit like e.g. revolutions/min, a calculating factor has to be set here.
Digitronic Automationsanlagen GmbH - Display: Digital Cam Switch Unit CamCon DC190 This is only necessary when using a CamCon DC50/51 or CD/CT10 terminal display. You can choose between three modes: "automatic" If a 5% (of the set 100% turning speed) input threshold is passed, the position display switches to a speed display, with the bar chart representing the speed in percent. "speed" The bar chart only display the speed (not the position) in percent of a set 100% maximum speed.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.5. Special outputs The special outputs are divided into analog and digital signals: 6.6.5.1. Special outputs digital - Safty output/RUN-Control: To have the possibility to control the CamCon even in cases of short circuits in the control channels or errors of the Measuring System, a rotating cam can be programmed for a single cam output.
Digitronic Automationsanlagen GmbH - Move detection output: Digital Cam Switch Unit CamCon DC190 Use to set an output for the indication of movement. The output is switched if the threshold set in "Direction hysteresis" is exceeded in positive or negative direction. - Direction hysteresis: Set the threshold speed for the "Direction output" – and the "Move detection output" here.
Digitronic Automationsanlagen GmbH - Analog Cam: Digital Cam Switch Unit CamCon DC190 The CamCon can display cams not only as digital 24Volt outputs but also create position sensitive „analog cams“. Select Select the number of analog cams that the CamCon shall use (from 0 = none to a maximum of 14). In most cases, this directly corresponds to the number of analog hardware outputs. Note: If the option "Speed analog" is set to "Yes", the first analog output is used to indicate the speed. 6.6.5.2.1.
Digitronic Automationsanlagen GmbH - Disable input: Digital Cam Switch Unit CamCon DC190 The output of the analog cam value can be frozen by setting an input to a specific value. For this purpose enter the number of the input that shall be used to set the corresponding analog value to the "Disable value". - Disable value: Enter the value that shall be displayed if the "Disable input" is active.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.6.6. System upgrading - physical inputs: Display the number of available physical inputs that are configured in the "Configure hardware" Menu. - physical outputs: Display the number of available outputs that are configured in the "Configure hardware" Menu. Note: If the "PLC - Logic - Module" is switched on, this menu is used to set the software in- and outputs (P. and N.) for the cam switch module.
Digitronic Automationsanlagen GmbH - Enable - input: Digital Cam Switch Unit CamCon DC190 A Signal (+24V DC) at the selected input enables the cam outputs. A 0V DC signal locks them, respectively. If this input is set to "0", the enable function is switched of and the cam outputs are always available. Note: With the PLC - Logic - Module switched on, not the outputs („O“) but the cam outs („N“) are locked or enabled.
Digitronic Automationsanlagen GmbH "by actual value" Digital Cam Switch Unit CamCon DC190 This option uses the RAM memory to build up the program cam by cam. The unit then waits until a certain actual value is reached to trigger a program change. Also this option requires the double RAM memory’s space but does not leave any output undefined. The CamCon’s safety or RUN - control output is not switched off for a short time for this option.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.7. Configuration menu You can order the CamCon cam controller with different hardware configuration, interfaces and options. This menu is used to define the hardware configuration and to set the device parameters of the CamCon. 6.7.1. Configure hardware - physical inputs: Enter the number of physical cams of the CamCon and any possible I/O expansion set at the „external interface“.
Digitronic Automationsanlagen GmbH - CP-Typ: Digital Cam Switch Unit CamCon DC190 If a CP16 Profibus Module (Order No.: CP16/P/IO) is attached at the unit’s "external interface", set this parameter to "CP16/P/IO". The menu will change then so that you can set the following parameter: - Slave adress: Set also the desired Profibus DP address here. - CP inputs: In addition to the CamCom’s physical inputs the CP16 can simulate inputs that are controlled by a PLC (e.g. PLC outputs).
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.7.1.1.1. Advanced hardware configuration for CamCon and external interface For the advanced - hardware – configuration of an external interface a software module called I/ORouter is used. It is a modular system beginning with a module 1. (first) and a number of n further modules. To activate the I/O router select a Cam Con basic unit for the first module (e.g. a DC190) to be used.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.7.1.1.3. Ethercat hardware configuration This option is only available if you have selected the basic module DC190 in the first module of the I/O router. It is used to select and configure the FAST - Ethernet I/O or Ethercat – interface of the CamCon DC190. The FAST Ethernet I/O interface is, just as the I/O router, a modular system, beginning with the first module, the FAST Ethernet I/O basic module (like e.g.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.7.2. PLC configuration The PLC - logic - module of the CamCon combines the hardware - in - and outputs to the internal Cam controller software. This connection is virtual in - and outputs of the PLC - Logic - Module realized. By this technique it is possible, all activities of the cam controller of PLC logic module to change, and to control. In this menu, the PLC - logic - module is switched "on", "off" or to configure. 6.7.3.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 6.7.4. Unit Configuration In this menu, the device can be completely deleted, and the serial port, and various special parameters can adjusted. 7. PLC - Logic - Module programming The PLC - Logic - Module of the CamCon will programmed in this menu. Version from: 19.04.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 8. Error messages and removal of errors (FAQ) The error messages appear on the standard display or in CamCon DC16, 90, 115, 190, 300 and 1756DICAM without a display of their own through the status LED or status bits. The drawings below shows the error message appearing. Device with LC - Display (e.g.Pos-Err:3) Device via Digisoft 2000 or WEB (e.g.Pos-Err: 2) 9.1 Problem: Display shows "No contact to unit: XX".
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 8.4. Problem: "Pos - Err:3" respectively error number 3. Possible causes: The resolution of the connected measuring system is not in accord with the input resolution. The measuring system is faulty. The actual value is outside the range which was entered in the menu path setting for linear systems. See Chapter "6.6.2. Measuring offset" on page 40.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 8.8. Problem: The EEProm memory is full. Cause: Too little memory space available in the EEPROM for the storage process. Solution: Please contact your customer service representative if you require an EEProm storage extension. Also consult Chapter "9. Technical Data on page 60. 8.9. Problem: Outputs will not activate Possible causes: An error message is active. The outputs are not connected to power supply.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 8.13. Problem: "Clear...." respectively error number 3 Cause: The CamCon is waiting for the arrival of the Clear signal in an incremental measuring system. Solution: Set the Clear signal ON or activate an actual value Preset. The result is the immediate release of the Cam Switch Unit. Note: The incremental measuring system is only available as an option for CamCon DC16, DC50/51, DC115, DC190, DC300 and CamCon 1756-DICAM.
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 9. Technical Data Display ................................................................ a status LED for the in- and outputs (48) each, 5 status LEDs for the power supply, 3 LEDs for the operation mode, 2 Ethernet and 2 EtherCAT Status LEDs Interfaces ............................................................ Ethernet, EtherCAT, Digitronic external Interface, RS232 or RS485 and SSI or 24V HTL Number of outputs ...................
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 10. Index Actual value............................................................................................................................................ 40 Actual Value Display Format.................................................................................................................. 33 Analog cams, configuring.......................................................................................................
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 Inputs, general ....................................................................................................................................... 24 Inputs, Hardware, configure................................................................................................................... 50 Installation ............................................................................................................................
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 Pos - Err 5 .............................................................................................................................................. 57 Preset..................................................................................................................................................... 40 Profibus ................................................................................................................
Digitronic Automationsanlagen GmbH Digital Cam Switch Unit CamCon DC190 User........................................................................................................................................................ 27 V-Max..................................................................................................................................................... 32 Welding operations, Safety precautions .................................................................................
