BERGHOF DC1000 User Manual

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USER MANUAL 1.10

DC1000 Dialog-Controller

Basic, Prime, Compact, Clean

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Copyright © Berghof Automation GmbH Reproduction and duplication of this document and utilisation and communication of its content is prohibited, unless with our express permission. All rights reserved. Damages will be payable in case of infringement.

Disclaimer

The content of this publication was checked for compliance with the hardware and software described. However, discrepancies may arise, therefore no liability is assumed regarding complete compliance. The information in this document will be checked regularly and all necessary corrections will be included in subsequent editions. Suggestions for improvements are always welcome. Subject to technical changes.

Trademarks

 CANtrol® and CANtrol®- dialog are registered trademarks of Berghof Automation GmbH  Microsoft®, Windows® and the Windows® Logo are registered trademarks of Microsoft Corporation in

the USA and other countries.

 EtherCAT® is a registered trademark and patented technology, licensed from Beckhoff Automation

GmbH, Germany.

 CiA® and CANopen® are registered community trademarks of CAN in Automation e.V.

General Information on this Manual

This equipment manual contains product-specific information valid at the time of publication. This equipment manual is only complete in conjunction with the product-related hardware and software user manuals required for the individual application.

You can reach us at: Berghof Automation GmbH Harretstr. 1 72800 Eningen Germany T +49.7121.894-0 F +49.7121.894-100 e-mail: [email protected] www.berghof.com

Berghof Automation GmbH works in accordance with DIN EN ISO 9001:2000.

 Content  Completeness

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Update

Version

Date

Subject

1.1

22.09.2006

First version

1.2 Inexistent

1.3

31.05.2007

Dimensions updated under “Technical specifications” and in the graphs. Plug/unplug cycles added to the “USB pin assignment” section of the “Tech-

nical specifications”. Description, “Chemical resistance for touch screens

and I/O-Modules” included. Notice to “SD-card reader” included. Update under “Power supply - internal

power pack”, “Profibus master card” and “Profibus slave card”.

1.4

23.09.2009

General revision. New chapter: “Copyright and software licenses”.

1.5

28.10.2009

Supplement of technical data for DC 1005, 1010 and 1012. Update of “Service Menu” chapter.

1.6 Inexistent

1.7

07.04.2011

Updates of “Declaration of conformity”, “Chemical resistance” and “Notes on the copyright and software license”. Description of DC1010 Compact (CP)

and DC1012 Compact (CP) incorporated, XR01 and XR02 extension modules inserted.

“Battery change” diagram corrected. Corrections of the DC1010 (CP) “Panel cut-out”, DC1012 “Technical data”

(dimensions), new warning for XR01 and XR02 I/O cards (power supply) integrated.

1.8

08.11.2012

Update in the “Declaration of conformity” section. Note on terminating resistors, switches S2+S3 with Profibus Master/Slave card inserted. Update of chapter “Annex, Standards / Bibliography”. Update of the trademarks. Update in the “DC1010 Compact (CP) panel cutout” section.

1.9

04.09.2013

Transition into new CD. New corporate name “Berghof Automation GmbH”. Update of chapter “Extension modules”.

1.10

03.05.2016

New EMC directive. Correction standards.

Update of chapter “Chemical resistance”. Update of section “Nameplate”.

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Contents

1. GENERAL ............................................................................................................................................ 9

1.1. About this manual .............................................................................................................................. 9

1.2. Hazard categories and terminology ................................................................................................ 10

1.3. Qualified personnel .......................................................................................................................... 11

1.4. Due diligence .................................................................................................................................... 11

1.5. Basic safety measures ..................................................................................................................... 12

1.6. Use as prescribed ............................................................................................................................ 13

1.7. Conformity declaration .................................................................................................................... 14

1.7.1. Extension modules ............................................................................................................................. 14

1.8. Transport and setup ......................................................................................................................... 15

2. PRODUCT DESCRIPTION ................................................................................................................ 17

2.1. Identification ..................................................................................................................................... 19

2.2. The different versions of the Dialog-Controller ............................................................................. 20

2.2.1. Interfaces ........................................................................................................................................... 20

2.2.2. Front foil sheeting ............................................................................................................................... 20

2.2.3. Overview of types ............................................................................................................................... 21

2.2.4. Variable thanks to extension cards ..................................................................................................... 21

2.3. Dialog-Controller DC1005 / DC1010 / DC1012 construction ........................................................ 22

2.3.1. Block circuit diagram .......................................................................................................................... 22

2.4. Technical data DC1005 .................................................................................................................... 23

2.4.1. DC1005 Front view ............................................................................................................................. 25

2.4.2. DC1005 Rear view ............................................................................................................................. 25

2.4.3. DC1005 Dimensions .......................................................................................................................... 26

2.4.4. DC1005 Panel cutout ......................................................................................................................... 27

2.4.5. Mounting regulation DC1005 .............................................................................................................. 27

2.5. Technical data DC1010 .................................................................................................................... 28

2.5.1. DC1010 Front view ............................................................................................................................. 30

2.5.2. DC1010 Rear view ............................................................................................................................. 30

2.5.3. DC1010 Dimensions .......................................................................................................................... 31

2.5.4. DC1010 Panel cutout ......................................................................................................................... 32

2.5.5. Mounting regulation DC1010 .............................................................................................................. 32

2.6. Technical data DC1010 Compact (CP) ................................ ............................................................ 33

2.6.1. DC1010 Compact (CP) front view ...................................................................................................... 35

2.6.2. DC1010 Compact (CP) rear view ................................ ....................................................................... 35

2.6.3. DC1010 Compact (CP) dimensions ................................................................................................... 36

2.6.4. DC1010 Compact (CP) panel cutout .................................................................................................. 37

2.6.5. Mounting regulation DC1010 Compact (CP) ...................................................................................... 37

2.7. Technical data DC1012 .................................................................................................................... 38

2.7.1. DC1012 Front view ............................................................................................................................. 40

2.7.2. DC1012 Rear view ............................................................................................................................. 40

2.7.3. DC1012 Dimensions .......................................................................................................................... 41

2.7.4. DC1012 Panel cutout ......................................................................................................................... 42

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2.7.5. Mounting regulation DC1012 .............................................................................................................. 42

2.8. Technical data DC1012 Compact (CP) ................................ ............................................................ 43

2.8.1. DC1012 Compact (CP) front view ...................................................................................................... 45

2.8.2. DC1012 Compact (CP) rear view ....................................................................................................... 45

2.8.3. DC1012 Compact (CP) dimensions ................................................................................................... 46

2.8.4. DC1012 Compact (CP) panel cutout .................................................................................................. 47

2.8.5. Mounting regulation DC1012 Compact (CP) ...................................................................................... 47

2.9. Mounting and connection ................................................................................................................ 48

2.9.1. Mounting ............................................................................................................................................ 48

2.9.2. Connections ....................................................................................................................................... 48

2.10. Pin assignment ................................................................................................................................. 49

2.10.1. Pin overview ....................................................................................................................................... 49

2.10.2. Power supply ...................................................................................................................................... 49

2.10.3. 10/100 Base-T Network Connection (Ethernet) .................................................................................. 49

2.10.4. USB .................................................................................................................................................... 50

2.10.5. CAN bus ............................................................................................................................................. 51

2.10.6. Serial ports ......................................................................................................................................... 52

2.10.7. E-bus .................................................................................................................................................. 55

2.10.8. Connections for expansion ports ........................................................................................................ 55

2.11. SD card .............................................................................................................................................. 56

3. DIALOG-CONTROLLER OPERATION ............................................................................................. 57

3.1. Commissioning ................................................................................................................................ 57

3.2. Function selection, indicators, diagnostics ................................................................................... 57

3.2.1. Status indicators ................................................................................................................................. 57

3.3. Service menu .................................................................................................................................... 59

3.3.1. Using the service menu ...................................................................................................................... 60

3.3.2. Parameter window .............................................................................................................................. 60

“Config” service menu ........................................................................................................................ 61

“PLC” service menu ............................................................................................................................ 64

“INFO” service menu .......................................................................................................................... 65

“Display” service menu ....................................................................................................................... 66

3.3.3. PLC window ....................................................................................................................................... 67

3.4. Decommissioning ............................................................................................................................ 70

3.4.1. Disposal ............................................................................................................................................. 70

3.5. Maintenance...................................................................................................................................... 71

3.6. Help in case of problems ................................................................................................................. 71

4. EXTENSION MODULES .................................................................................................................... 73

4.1. I/O card with SC-CAN interface ....................................................................................................... 74

4.1.1. Technical data .................................................................................................................................... 75

4.1.2. Pin assignment ................................................................................................................................... 77

4.1.3. Analog inputs ..................................................................................................................................... 81

4.1.4. Digital inputs/outputs 12/4/8-0.5 ......................................................................................................... 82

4.1.5. Digital inputs, positive switched .......................................................................................................... 83

4.1.6. Digital outputs, positive switched........................................................................................................ 86

4.1.7. Digital input/output pin assignments ................................................................................................... 89

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4.2. PROFIBUS-MASTER card ................................................................................................................ 91

4.2.1. Technical data .................................................................................................................................... 92

4.2.2. Front view and pin assignment ........................................................................................................... 93

4.3. PROFIBUS-SLAVE card ................................................................................................................... 96

4.3.1. Technical data .................................................................................................................................... 97

4.3.2. Front view and pin assignment ........................................................................................................... 98

4.4. PROFIBUS card (Master/Slave functionality) ............................................................................... 101

4.4.1. Technical data .................................................................................................................................. 102

4.4.2. Front view and pin assignment ......................................................................................................... 103

4.5. I/O XR01 and XR02 cards with analog and digital I/O ................................................................. 106

4.5.1. Technical data .................................................................................................................................. 107

4.5.2. Pin assignment ................................................................................................................................. 108

4.5.3. Power supply .................................................................................................................................... 108

4.5.4. Plug-in connectors ............................................................................................................................ 109

4.5.5. Installation ........................................................................................................................................ 110

4.5.6. 8/8-0.5 digital inputs/outputs ............................................................................................................ 110

4.5.7. Terminal assignment of digital inputs/outputs ................................................................................... 116

4.5.8. Analog inputs/outputs ....................................................................................................................... 117

5. MAINTENANCE ............................................................................................................................... 127

5.1. Real-time clock with backup battery ............................................................................................ 128

5.1.1. Battery replacement ......................................................................................................................... 129

6. CHEMICAL RESISTANCE .............................................................................................................. 131

6.1. Resistance of the touch screen .................................................................................................... 131

6.2. Resistance of the AUTOTEX front foil sheeting to chemicals .................................................... 132

6.2.1. General resistance of the foil sheeting material ............................................................................... 132

6.2.2. Resistance to household chemicals ................................................................................................. 133

6.2.3. Environmental values ....................................................................................................................... 133

6.3. Resistance of the AUTOFLEX- front foil sheeting to chemicals................................................. 134

6.3.1. General resistance of the foil sheeting material ............................................................................... 134

6.3.2. Resistance to household chemicals ................................................................................................. 135

6.3.3. Outdoor use ..................................................................................................................................... 135

7. COPYRIGHT AND SOFTWARE LICENSES ................................................................................... 137

8. ANNEX ............................................................................................................................................. 139

8.1. Environmental Protection .............................................................................................................. 139

8.1.1. Emission ........................................................................................................................................... 139

8.1.2. Disposal ........................................................................................................................................... 139

8.2. Maintenance/Upkeep ...................................................................................................................... 139

8.3. Repairs/Service .............................................................................................................................. 139

8.3.1. Warranty ........................................................................................................................................... 139

8.4. Nameplate ....................................................................................................................................... 140

Nameplate descriptions (example) ................................................................................................... 140

8.5. Addresses and Bibliography ......................................................................................................... 141

8.5.1. Addresses ........................................................................................................................................ 141

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8.5.2. Standards/Bibliography .................................................................................................................... 142

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1. General

Documentation

This equipment manual is intended for qualified personnel and contains information regarding the mounting, installation, commissioning and maintenance of the Dialog Controller. The information contained in this manual is subject to change without prior notice.

1.1. About this manual

This equipment manual is an integral part of the product. Make sure the equipment manual is always available near the product’s point-of-employment. The manual contains information about the following topics

 Areas of application  Safety  Mechanical construction  Electrical construction  Connections  Commissioning  Care and maintenance  Decommissioning  Disposal

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1.2. Hazard categories and terminology

DANGER

Immediate danger

Failure to observe the information indicated by this warning will result in death, serious injury or extensive property damage.

WARNING

Potential danger

Failure to observe the information indicated by this warning may result in death, serious injury or extensive property damage.

CAUTION

Danger

Failure to observe the information indicated by this warning may result in injury or property damage.

NOTICE

No hazard

Information indicated in this manner provides additional notes concerning the product.

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1.3. Qualified personnel

Only qualified personnel may install, operate and maintain the Dialog Controller. Within the context of this documentation and the safety information it contains, qualified personnel constitutes trained specialists who have the authority to mount, install, commission, ground and identify equipment, systems and power circuits in accordance with the standards of safety technology, and who are familiar with the safety concepts of automation technology.

1.4. Due diligence

The operator or original equipment manufacturer (OEM) must ensure …

 that the Dialog Controller is only employed for its intended use.  that the Dialog Controller is only employed in a fault-free, operational state.  that the equipment manual is always maintained in a complete and legible condition and is available at

the point-of-employment of the Dialog Controller.

 that only properly qualified and authorized personnel mount, install, commission and maintain the

Dialog Controller.

 that these specialists receive regular and ongoing instruction in all pertinent questions related to work

safety and environmental protection and that they are familiar with the contents of the equipment manual, in particular, with the safety information it contains.

 that the equipment identifiers as well as safety and warning information applied to the Dialog Control-

ler are not removed and that they are maintained in a legible condition.

 that all international, federal, state and local ordinances governing the control of machinery and

equipment applicable at the location at which the Dialog Controller is employed are complied with.

 that the users always have available all relevant information they require with regard to the Dialog

Controller and its employment.

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1.5. Basic safety measures

WARNING

If damage can be seen on the faceplate of the dialog controller, the device must not be operated any more! It must be disconnected from the supply voltage immediately!

Besides the danger of injury owing to the visibly sharp edges, there is also the risk of touching parts under high voltage. Contact with high voltage can still occur even some time after the supply voltage has been shut off.

HAZARDOUS VOLTAGE

Working on the DC

Before beginning work on the Dialog Controller you must always

 first ensure that the equipment is in a safe state,  then first switch the DC off, followed by the equipment, and  only then disconnect the DC from the equipment.

WARNING

Hazards due to unforeseeable functional and processing movements when the Industrial PC is disconnected.

These can result in death, serious injury or extensive property damage. All equipment components must be disconnected from the Dialog Controller

whenever the Dialog Controller is not being used for operational or control purposes, e.g., during maintenance or during functional checks after repairs.

Lock out and tag out all equipment components after they have been switched off!

HAZARDOUS PROCESSES

Opening the DC

First, please note all the tasks steps outlined in the above section “Working on the DC”. The supply voltage

must be switched off before opening the housing or when components are being installed or removed. To do this, switch the power supply to the Dialog Controller off. Then remove the plug from the power supply socket on the Dialog Controller.

WARNING

Do not open the housing cover with the power switched on! Hazard due to contact with live components.

This can result in death, serious injury or extensive property damage. Only open the housing cover once the Dialog Controller has been safely dis-

connected from the power supply.

HAZARDOUS VOLTAGE

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1.6. Use as prescribed

This is a modular automation system based on the CANbus, intended for industrial control applications within the medium to high performance range.

The automation system is designed for use within Overvoltage Category I (IEC 364-4-443) for the controlling and regulating of machinery and industrial processes in low-voltage installations in accordance with the following general parameters:

 maximum rated supply voltage of 1,000 VAC (50/60 Hz) or 1,500 VDC;  for use in maximum category 2 pollution environment (EN 60950);  for use up to a maximum altitude of 2,000 m above msn;  for indoor use only in areas not exposed to direct UV radiation;  max. ambient temperature inside and outside the control cabinet is within the technical specifications

(see section “Technical data”)

Qualified project planning and design, proper transport, storage, installation, use and careful maintenance are essential to the flawless and safe operation of the automation system. The automation system may only be used within the scope of the data and applications specified in the present documentation and associated user manuals.

The automation system is to be used only as follows:

 as prescribed  in technically flawless condition  without arbitrary or unauthorized changes  exclusively by qualified users

The regulations of the German professional and trade associations, the German technical supervisory board (TÜV), the VDE (Association of German electricians) or other corresponding national bodies are to be observed.

Safety-oriented (fail-safe) systems

Particular measures are required in connection with the use of SPC in safety-oriented systems. If an SPC is to be used in a safety-oriented system, the user ought to seek the full advice of the SPC manufacturer in addition to observing any standards or guidelines on safety installations which may be available.

WARNING

As with any electronic control system, the failure of particular components may result in uncontrolled and/or unpredictable operation.

All types of failure and the associated fuse systems are to be taken into account at system level. The advice of the SPC manufacturer should be sought if necessary.

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1.7. Conformity declaration

Both the standard version of the Dialog Controller and with the extension modules mentioned below comply with and make allowance for the following directives and standards:

 EMC Directive 2014/30/EU  EN 61131-2:2007 Programmable logic controllers

Part 2: Equipment requirements and tests Class B, connector cable of the I/O, max 30 m

 EN 61000-6-2:2005/AC:2005 Electromagnetic compatibility (EMC)

Part 6-2: Generic standard – immunity for industrial environments

 EN 61000-6-4:2007/A1:2011 Electromagnetic compatibility (EMC)

Part 6-4: Generic standard – electrostatic discharge for industrial environments

1.7.1. Extension modules

Conformity is declared to the above-stated directives for the extension modules given below, built into the Dialog-Controller:

 PROFIBUS-MASTER card  PROFIBUS-SLAVE card  PROFIBUS card (Master/Slave functionality)  I/O cards XR01 and XR02 with analog and digital I/O

No general conformity can be declared for extensions with contact line system, built into the DialogController:  I/O card with SC-CAN interface

With connected contact line system the compliance of the EMC requirements on the complete system must be checked and ensured („fixed installation“ for the purpose of the EMC directive).

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1.8. Transport and setup

NOTICE

Please note the specified storage conditions in the section “Technical specifications”.

Transport

Protect the Dialog Controller against extreme mechanical stress during transport. Always transport the Dialog Controller in its original packaging. The built-in components are extremely sensitive to jarring and strong vibrations.

CAUTION

Condensation hazard resulting from climatic fluctuations

Risk of damage as a result of moisture forming on or in the Dialog Controller (condensation). This can result in destruction of the device or consequential damages.

After storage or transport in cold weather or under conditions of strongly fluctuating temperatures, the Dialog Controller must be allowed to slowly adjust to the ambient temperature at its point of use before it can be taken into service.

In case of condensation, the unit may not be taken into service for at least 12 hours (temperature compensation).

CONDENSATION

Unpacking

Proceed as follows:  Inspect the packaging for any external damage. If the packaging is severely damaged or if damage to

the contents can be detected, do not open the packaging any further. Immediately contact your shipper and your supplier.

 Remove the packaging. Do not discard the original packaging! The packaging can be used for sub-

sequent transport.

 Inspect the contents for visible shipping damage.  Check the contents against the order for completeness. Save all included documentation. This docu-

mentation contains important information concerning the Dialog Controller and is an integral part of the product.

 If shipping damage is detected or if the received contents do not agree with the order, please contact

your supplier immediately.

Setup

This Dialog Controller is designed for installation in fully enclosed circuit cabinets of industrial machinery and equipment. When installing the Dialog Controller, take particular care to ensure that the included seal profiles are not damaged. Also ensure compliance with the ambient conditions specified under “Technical specifications”.

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2. Product description

The Dialog-Controller is a real-time control module with a display and a broad spectrum of data interfaces. The module can be programmed in 'C' or in accordance with IEC 61131-3 (CODESYS 2.3).

Installation

The Dialog-Controllers are intended for front panel or switch cabinet installation in harsh industrial environments. Maintenance is minimal, thanks to their fan-free design and flash memory.

Processors

The Dialog-Controller is equipped with either a 266 MHz or 400 MHz POWERPCTM processor from Freescale.

Display

The great differences in the appearance of the Dialog-Controller are based on the selection of the employed display technology and a common display diagonal size. 5.7” units with a monochrome (STN), color (CSTN)

or TFT display are available. Above a diagonal screen size of 10.4” only TFT displays are employed. Unit

housing dimensions and protective method (IP65 on the front) do not depend on whether the version in question has a touch screen or matrix keypad.

Ethernet

A 10/100 MBit/s Ethernet interface is included. TCP/IP and UDP/IP protocols offer highly flexible connections to visualization software, higher order control units or an IT infrastructure.

USB ports

The two USB host ports provide interfaces for widely dispersed peripheral devices. For example, one USB stick can be used to quickly and easily perform application updates or data extraction. Please contact our Technical Support if no driver support is available for a specific USB device.

CAN ports

The Dialog-Controller is equipped with two standard CAN interfaces, both of which can be operated at 1 MBit/s.

Serial ports

A total of three serial ports can be used on the Dialog-Controller. The RS232 programming interface is supplemented by an additional RS232 and an RS485 port.

E-bus extension

The Dialog-Controller’s I/O level can be expanded via the E-bus socket to include up to seven E-bus subscribers.

 Short description

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Expansion slots

The device is equipped with three expansion slots for expansion cards (e.g., I/O cards) with the associated

SPI interface. Alternately, one of the slots can be used for an “Anybus®” embedded bus module (e.g., Profibus

DP) manufactured by HMS.

Real-time clock

A software interface can be used to set or reset a real-time clock equipped with a backup battery.

SD card reader

Data can be written to or read from memory cards using the conventional MMC/SD card interfaces.

NOTICE

If the SD card reader is activated, then the second RS232 interface (X5) is not longer available.

Performance feature overview

 Freescale POWERPCTM CPU 266 (400) MHz  Application program and data memory (RAM): 64 (128) MB onboard / 32 (96) MB for the application  Application program memory (Flash): 16 (32) MB onboard / 8 (24) MB for the application  Retain memory 16 KB  1 Ethernet 10/100 port  1 (3) USB host ports  1 (2) CAN ports  1 RS232 serial port for programming tools and applications  1 (2) serial data ports RS232 / RS485  I/O level locally expandable via an internal E-bus for up to seven subscribers (digital / analog)  Up to 3 onboard expansion slots for I/Os and a bus module  Real-time clock  MMC/SD card slot

The scope of supply of the controller module consists of:  Dialog-Controller DC10xx

incl. 2-pin plug-in connector for power supply

 Scope of supply

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2.1. Identification

Product: Dialog-Controller, Type DC10xx Identification code

The features of the Dialog-Controller (see nameplate) can be itemised according to the identification code.

2VF100227DG04.cdr

D C 1 0 05M T M P 66

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ... ...

S C AP B A CIS

Screen size (diagonal)

Activation method

Processor type

Display technology

Resolution

Extension-Modules

05 10 12 15

= 10,4”

= 12,1”

= 5,0”1

5,7”

M =

= Color (CSTN)

= Color TFT

C T

Monochrome (STN)

V = VGA 640 x 480

T K A

= Touchpanel

= Keyboard

= Touch + Keyboard

BASIC CLEAN

= DC1000 with

basic equipment

= Continuous of the

front foil sheeting

= compact modelCP

MP266 MP400

= Power PC 266 MHz = Power PC 400 MHz

SC PS= I/O card

= Profibus Slave

= Profibus Master

= Profibus Master/Slave

= XR I/O card

PM PA IO

Model

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DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx

2.2. The different versions of the Dialog-Controller

2.2.1. Interfaces

Communication is the forte of the DC1000. Its spectrum of interfaces and extension options makes is the reason for this. The DC1000 with a Prime interface is extremely adaptable. The maximum scope of the interfaces can be supplemented with further communication an I/O extension cards. So it is easy to always find the rigth automation solution.

2VF100397DG00.cdr

The DC1000 with the Basic Interface is optimal for standard applications. With high processor power and equipped minimally with interfaces, it is the right solution for a price sensitive market.

2VF100398DG00.cdr

2.2.2. Front foil sheeting

If cleanliness is a priority, the Clean Front is the right choice. Dust and dirt do not stand a chance here; and what's more, it is easy to clean.

2VF100399DG01.cdr

Machine parameters or data records can be exchanged simply and fast by means of a USB stick. It is very convenient to have a USB port available at the front. The Connect front is distinguished by the USB port at the front with IP65 cover.

2VF100400DG01.cdr

Touch screen or membrane key pad: this is not merely a philosophical operational issue. Gloves are often needed on site. If this is the case, keys are simple and safe to use.

2VF100401DG01.cdr

 Prime Interface

 Basic Interface

 Clean Touch

 Connect Touch

 Connect Key

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2.2.3. Overview of types

Prime Interface

Basic Interface

Clean Touch

Connect Touch

Connect Key

Compact Touch

Clean Touch

12,1“

SVGA 800 x 600 65536 colours (16 bit p. P.)

DC1012T T

DC1012T K

DC1012T T

Clean

10,4“

VGA 640 x 480 65536 colours (16 bit p. P.)

DC1010T T

Clean

DC1010T T

DC1010T K

DC1010T T

Clean

DC1010T T

Basic

5,7“

VGA 640 x 480 65536 colours (16 bit p. P.)

DC1005V T

Clean

DC 1005V T

DC1005V K

DC1005V T

Basic

QVGA 320 x 240 256 colours (8 bit p. P.)

DC1005T T

Clean

DC1005T T

DC1005T K

DC1005T T

Basic

QVGA 320 x 240 monochrome 4 shades of grey

DC1005M T

Clean

DC1005M T

DC1005M K

DC1005M T

Basic

2.2.4. Variable thanks to extension cards

The DC1000 can be fitted with a maximum of three extension cards. The spectrum encompasses pure I/O cards as well as communication cards, which are already installed by Berghof. The range is constantly being extended conforming to the market requirements. Extension cards can only be fitted in Dialog-Controllers with Prime Interface.

2VF100403DG00.cdr

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DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx

2.3. Dialog-Controller DC1005 / DC1010 / DC1012 construction

2.3.1. Block circuit diagram

2VF100233DG01.cdr

NOTICE

No potential isolation of the CAN and RS485 interface on the Basic Interface version.

FRONT

Front

USB

Inverter

Display

Touch /

Keyboard

Display Unit

+24 V

CPU

Grafik CAN

SIO

Flash

RAM

USB

BASIS

Controller

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2.4. Technical data DC1005

Module data

Display

1/4 VGA

VGA

Diagonal measurement

5.7“

Resolution

320 x 240 pixels

640 x 480 pixels

Colors

Monochrome (STN): 4 Color (CSTN): 256 (8 bits / pixel) Color TFT: 256 (8 bits / pixel)

Color TFT: 65536 (16 bits / pixel)

CPU, application memory

CPU

Freescale PowerPC 266 MHz

400 MHz

Program memory (Flash)

16 MB onboard / 8 MB for application

32 MB onboard / 24 MB for application

Program memory and data memory (RAM)

64 MB onboard / 32 MB for application

128 MB onboard / 96 MB for application

Retain memory

16 kB

Development environment

CP1131 (CODESYS 2.3)

Dimensions and weights

Dimensions (WxHxD [mm])

194x172x52 (+6 mm front panel)

Weight

Approx. 1.5 kg

Operating conditions

Ambient temperature range

0 °C to +55 °C (if installation rule is adhered to)

Relative humidity

Max. 85 %, non-condensing (monochrome: max. 75 %)

Transport, storage

Ambient temperature range

-20 °C to +70 °C

Relative humidity

Max. 85 %, non-condensing (monochrome: max. 75 %)

Shock resistance

Vibration

Sinusoidal (EN 60068-2-6) test: Fc 10 … 150 Hz, 1 G (operation mode)

Shock resistance

15 G (approx. 150 m/s2); duration:10 ms; semi-sinusoidal (EN 60068-2-27) test: Ea

EMC, protection type

Interference emission

EN 61000-6-4, industrial environments

Interference resistance

EN 61000-6-2, industrial environments

Protection class

III

Insulating resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP20 (front: IP65)

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Module data

Power supply (24 V power pack)

Supply voltage

+24 VDC (-15 % / +20 %) SELV, max. alternating component: 5 %, max. voltage interruption 1 ms (10 ms only with power supply after 61131-2)

Current consumption

Typically 1.0 A; max. 2.0 A at +24 VDC; Fusing depending on the I/O load, max. 12 A

Polarity reversal protection

Yes

Potential isolation

Yes, between CAN bus and I/Os.

Ethernet port

Number / interface type

1 x 10/100 Base-T

Connection method

RJ45

USB ports

Number / interface types

1 x host USB, Rev. 1.1 (on rear) 1 x host USB, Rev. 1.1 (on front, on Prime Interface version)

Plug/unplug cycles

Max. 1,000

CAN bus ports

Number / interface types

2 x Standard CAN ISO 11898 1 x Standard CAN ISO 11898 on Basic Interface

Potential isolation

CAN0 (X6) potential isolated (Prime Interface only)

Transmission rate

Max. 1 Mbit/s

Terminating resistor

Switchable

Serial ports

Number / interface types

2 x RS232 (1x RS232 on Basic Interface) 1 x RS485

Potential isolation

RS485 (X8) potential isolated (Prime Interface only)

Terminating resistor

Switchable with the RS485

E-bus port

Interface type

I/O expansion bus for up to 7 E-bus subscribers

Expansion slots

Number / interface types

3 slots for 3 I/O modules or 2 I/O modules and one AnyBus® module (Prime Interface only)

Further features

Real-time clock

Yes, battery backed.

SD card

1 SD card slot or RS232 (X5) (Prime Interface only)

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2.4.1. DC1005 Front view

2VF100229DG01.cdr

2.4.2. DC1005 Rear view

2VF100230DG01.cdr

Front-USB

Power Status-LED

LED (red) optional

controlled by application

Cover interface boards

Connections Frontpanel

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DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx

2.4.3. DC1005 Dimensions

Dimensions are identical for units equipped with either a keyboard or a touchpad.

2VF100234DG03.cdr

max. 52

ca. 158

Freie Luftzirkulation

free air circulation

Freiraum / clearance > 20 mm

max. 52

ca. 158

Freie Luftzirkulation

free air circulation

Freiraum / clearance > 20 mm

Alle Maße in [mm] All dimensions in [mm]

194

172

DC1005M K

F2 F3 F4

F5 F6

Enter

”

DC1005C T DC1005T T

Schraubenmontage

Screwing assembly

Bolzenmontage

Bolt assembly

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2.4.4. DC1005 Panel cutout

CAUTION

Installation instruction: Only install the Dialog-Controller on a level surface!

The support points on the Dialog-Controller may not deviate from one another by more than +/-0.5 mm. If the Dialog-Controller is nonetheless mounted on a base which is not level, mechanical tension can result in cracks in the front panel.

The Dialog-Controller is intended for front installation. A square panel cutout is required. The support material thickness may not exceed 6 mm. The panel cutouts are identical for units equipped with either a keyboard or a touchpad.

2VF100235DG00.cdr

2.4.5. Mounting regulation DC1005

The Dialog-Controllers are designed for automatic convection cooling.

The Dialog-Controllers must be mounted vertically onto a metallic mounting plate.

WARNING

Danger of overheating and fire!

The Dialog-Controller may be destroyed even at a permissible ambient temperature if the convection cooling cannot function because it is built-in.

It must therefore be installed vertically and the upper and lower housing apertures must not be covered over!

DANGER OF OVERHEATING AND FIRE!

 Vertical

installation

Frontansicht

Front view

Fronttafel-Ausschnitt

184 x 162

front panel cut out

Frontrahmen / front frame

194 x 172

148 159

162

170

181

184

Bohrungen /

5 mm (4x)

drills

Alle Maße in [mm] All dimensions in [mm]

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DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx

2.5. Technical data DC1010

Module data

Display

Diagonal measurement

10.4“

Resolution

640 x 480 pixels (VGA)

Colors

65536 (16 bit per pixel)

CPU, application memory

CPU

Freescale PowerPC 400 MHz

Program memory (Flash)

32 MB onboard / 24 MB for application

Program memory and data memory (RAM)

128 MB onboard / 96 MB for application

Retain memory

16 kB

Development environment

CP1131 (CODESYS 2.3)

Dimensions and weights

Dimensions (WxHxD [mm])

360x260x77 (+6 mm front panel)

Weight

Approx. 5 kg

Operating conditions

Ambient temperature range

0 °C to +55 °C (if installation rule is adhered to)

Relative humidity

Max. 90 %, non-condensing

Transport, storage

Ambient temperature range

-20 °C to +70 °C

Relative humidity

Max. 90 %, non-condensing

Shock resistance

Vibration

Sinusoidal (EN 60068-2-6) test: Fc 10 … 150 Hz, 1 G (operation mode)

Shock resistance

15 G (approx. 150 m/s2); duration:10 ms; semi-sinusoidal (EN 60068-2-27) test: Ea

EMC, protection type

Interference emission

EN 61000-6-4, industrial environments

Interference resistance

EN 61000-6-2, industrial environments

Protection class

III

Insulating resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP20 (front: IP65)

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Module data

Power supply (24 V power pack)

Supply voltage

+24 VDC (-15 % / +20 %) SELV, max. alternating component: 5 %, max. voltage interruption 1 ms (10 ms only with power supply after 61131-2)

Current consumption

Typically 1.0 A; max. 2.0 A at +24 VDC; Fusing depending on the I/O load, max. 12 A

Polarity reversal protection

Yes

Potential isolation

Yes, between CAN bus and I/Os.

Ethernet port

Number / interface type

1 x 10/100 Base-T

Connection method

RJ45

USB ports

Number / interface types

1 x host USB, Rev. 1.1 (on rear) 1 x host USB, Rev. 1.1 (on front, Prime Interface only)

Plug/unplug cycles

Max. 1,000

CAN bus ports

Number / interface types

2 x Standard CAN ISO 11898 Prime Interface 1 x Standard CAN ISO 11898 Basic Interface

Potential isolation

CAN0 (X6) potential isolated (Prime Interface only)

Transmission rate

Max. 1 Mbit/s

Terminating resistor

Switchable

Serial ports

Number / interface types

2 x RS232 Prime Interface / 1 x RS232 Basic Interface 1 x RS485

Potential isolation

RS485 (X8) potential isolated (Prime Interface only)

Terminating resistor

Switchable with the RS485

E-bus port

Interface type

I/O expansion bus for up to 7 E-bus subscribers

Expansion slots

Number / interface types

3 slots for 3 I/O modules or 2 I/O modules and one AnyBus® module (Prime Interface only)

Further features

Real-time clock

Yes, battery backed.

SD card

1 SD card slot or RS232 (X5) (Prime Interface only)

Page 30

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2.5.1. DC1010 Front view

2VF100241DG01.cdr

2.5.2. DC1010 Rear view

2VF100242DG01.cdr

Front-USB

Cover interface boards

Connections

Frontpanel

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2.5.3. DC1010 Dimensions

Dimensions are identical for units equipped with either a keyboard or a touchpad.

2VF100243DG01.cdr

Alle Maße in [mm] / All dimensions in [mm]

360

260

max. 77

ca. 228

Freie Luftzirkulation

free air circulation

Freiraum / clearance > 20 mm

BkSp

PgUp

Pos1

PgDn

Ctrl

Enter

Shift

F2 F3 F4 F5 F6 F7

F8 F9 F10

DC1010T K

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DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx

2.5.4. DC1010 Panel cutout

CAUTION

Installation instruction: Only install the Dialog-Controller on a level surface!

2VF100244DG00.cdr

2.5.5. Mounting regulation DC1010

The Dialog-Controllers are designed for automatic convection cooling.

The Dialog-Controllers must be mounted vertically onto a metallic mounting plate.

WARNING

Danger of overheating and fire!

The Dialog-Controller may be destroyed even at a permissible ambient temperature if the convection cooling cannot function because it is built-in.

It must therefore be installed vertically and the upper and lower housing apertures must not be covered over!

DANGER OF OVERHEATING AND FIRE!

 Vertical

installation

270

330

340

Bohrungen /

5 mm (6x)

drills

-66

-232

-236

170

310

Mittelachse Frontplatte

centerline of front panel

Mittelachse Ausschnitt

centerline of front panel cut out

Alle Maße in [mm] / All dimensions in [mm]

Frontansicht

Front view

Fronttafel-Ausschnitt

330 x 232

front panel cut out

Frontrahmen / front frame

360 x 260

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2.6. Technical data DC1010 Compact (CP)

Module data

Display

Diagonal measurement

10.4“

Resolution

640 x 480 pixels (VGA)

Colors

65536 (16 bit per pixel)

CPU, application memory

CPU

Freescale PowerPC 400 MHz

Program memory (Flash)

32 MB onboard / 24 MB for application

Program memory and data memory (RAM)

128 MB onboard / 96 MB for application

Retain memory

16 kB

Development environment

CP1131 (CODESYS 2.3)

Dimensions and weights

Dimensions (WxHxD [mm])

313x250x77 (+6 mm front panel)

Weight

Approx. 5 kg

Operating conditions

Ambient temperature range

0 °C to +55 °C (if installation rule is adhered to)

Relative humidity

Max. 90 %, non-condensing

Transport, storage

Ambient temperature range

-20 °C to +70 °C

Relative humidity

Max. 90 %, non-condensing

Shock resistance

Vibration

Sinusoidal (EN 60068-2-6) test: Fc 10 … 150 Hz, 1 G (operation mode)

Shock resistance

15 G (approx. 150 m/s2); duration:10 ms; semi-sinusoidal (EN 60068-2-27) test: Ea

EMC, protection type

Interference emission

EN 61000-6-4, industrial environments

Interference resistance

EN 61000-6-2, industrial environments

Protection class

III

Insulating resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP20 (front: IP65)

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DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx

Module data

Power supply (24 V power pack)

Supply voltage

+24 VDC (-15 % / +20 %) SELV, max. alternating component: 5 %, max. voltage interruption 1 ms (10 ms only with power supply after 61131-2)

Current consumption

Typically 1.0 A; max. 2.0 A at +24 VDC; Fusing depending on the I/O load, max. 12 A

Polarity reversal protection

Yes

Potential isolation

Yes, between CAN bus and I/Os.

Ethernet port

Number / interface type

1 x 10/100 Base-T

Connection method

RJ45

USB ports

Number / interface types

1 x host USB, Rev. 1.1 (on rear) 1 x host USB, Rev. 1.1 (on front, Prime Interface only)

Plug/unplug cycles

Max. 1,000

CAN bus ports

Number / interface types

2 x Standard CAN ISO 11898 Prime Interface 1 x Standard CAN ISO 11898 Basic Interface

Potential isolation

CAN0 (X6) potential isolated (Prime Interface only)

Transmission rate

Max. 1 Mbit/s

Terminating resistor

Switchable

Serial ports

Number / interface types

2 x RS232 Prime Interface / 1 x RS232 Basic Interface 1 x RS485

Potential isolation

RS485 (X8) potential isolated (Prime Interface only)

Terminating resistor

Switchable with the RS485

E-bus port

Interface type

I/O expansion bus for up to 7 E-bus subscribers

Expansion slots

Number / interface types

3 slots for 3 I/O modules or 2 I/O modules and one AnyBus® module (Prime Interface only)

Further features

Real-time clock

Yes, battery backed.

SD card

1 SD card slot or RS232 (X5) (Prime Interface only)

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2.6.1. DC1010 Compact (CP) front view

2VF100459DG00.cdr

2.6.2. DC1010 Compact (CP) rear view

2VF100460DG01.cdr

LED (red) optional

controlled by application

Cover interface boards

Connections Frontpanel

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2.6.3. DC1010 Compact (CP) dimensions

2VF100461DG00.cdr

Alle Maße in [mm] / All dimensions in [mm]

313

250

max. 77

ca. 212

Freie Luftzirkulation

free air circulation

Freiraum / clearance > 20 mm

DC1010T T

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2.6.4. DC1010 Compact (CP) panel cutout

CAUTION

Installation instruction: Only install the Dialog-Controller on a level surface!

The Dialog-Controller is intended for front installation. A square panel cutout is required. The support material thickness may not exceed 6 mm.

2VF100462DG02.cdr

NOTICE

In a customized design this device is also with M5 mounting bolts. These bolts require a bore diameter of 6 mm.

2.6.5. Mounting regulation DC1010 Compact (CP)

The Dialog-Controllers are designed for automatic convection cooling.

The Dialog-Controllers must be mounted vertically onto a metallic mounting plate.

WARNING

Danger of overheating and fire!

The Dialog-Controller may be destroyed even at a permissible ambient temperature if the convection cooling cannot function because it is built-in.

It must therefore be installed vertically and the upper and lower housing apertures must not be covered over!

DANGER OF OVERHEATING AND FIRE!

285,8

Bohrungen /

5 mm (8x)

drills

7,5

107,5

Mittelachse Frontplatte

centerline of front panel

Mittelachse Ausschnitt

centerline of front panel cut out

Alle Maße in [mm] / All dimensions in [mm] Frontansicht

Front view

Fronttafel-Ausschnitt

278 x 215

front panel cut out

Frontrahmen / front frame

313 x 250

215

222,5

 Vertical

installation

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2.7. Technical data DC1012

Module data

Display

Diagonal measurement

12.1“

Resolution

800 x 600 pixels (VGA)

Colors

65536 (16 bit per pixel)

CPU, application memory

CPU

Freescale PowerPC 400 MHz

Program memory (Flash)

32 MB onboard / 24 MB for application

Program memory and data memory (RAM)

128 MB onboard / 96 MB for application

Retain memory

16 kB

Development environment

CP1131 (CODESYS 2.3)

Dimensions and weights

Dimensions (WxHxD [mm])

440x300x77 (+6 mm front panel)

Weight

Approx. 6 kg

Operating conditions

Ambient temperature range

0 °C to +55 °C (if installation rule is adhered to)

Relative humidity

Max. 90 %, non-condensing

Transport, storage

Ambient temperature range

-20 °C to +70 °C

Relative humidity

Max. 90 %, non-condensing

Shock resistance

Vibration

Sinusoidal (EN 60068-2-6) test: Fc 10 … 150 Hz, 1 G (operation mode)

Shock resistance

15 G (approx. 150 m/s2); duration:10 ms; semi-sinusoidal (EN 60068-2-27) test: Ea

EMC, protection type

Interference emission

EN 61000-6-4, industrial environments

Interference resistance

EN 61000-6-2, industrial environments

Protection class

III

Insulating resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP20 (front: IP65)

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Module data

Power supply (24 V power pack)

Supply voltage

+24 VDC (-15 % / +20 %) SELV, max. alternating component: 5 %, max. voltage interruption 1 ms (10 ms only with power supply after 61131-2)

Current consumption

Typically 1.0 A; max. 2.0 A at +24 VDC; Fusing depending on the I/O load, max. 12 A

Polarity reversal protection

Yes

Potential isolation

Yes, between CAN bus and I/Os.

Ethernet port

Number / interface type

1 x 10/100 Base-T

Connection method

RJ45

USB ports

Number / interface types

1 x host USB, Rev. 1.1 (on rear) 2 x host USB, Rev. 1.1 (on front)

Plug/unplug cycles

Max. 1,000

CAN bus ports

Number / interface types

2 x Standard CAN ISO 11898

Potential isolation

CAN0 (X6) potential isolated

Transmission rate

Max. 1 Mbit/s

Terminating resistor

Switchable

Serial ports

Number / interface types

2 x RS232 1 x RS485

Potential isolation

RS485 (X8) potential isolated

Terminating resistor

Switchable with the RS485

E-bus port

Interface type

I/O expansion bus for up to 7 E-bus subscribers

Expansion slots

Number / interface types

3 slots for 3 I/O modules or 2 I/O modules and one AnyBus® module

Further features

Real-time clock

Yes, battery backed.

SD card

1 SD card slot or RS232 (X5)

Page 40

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DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx

2.7.1. DC1012 Front view

2VF100272DG01.cdr

2.7.2. DC1012 Rear view

2VF100242DG01.cdr

Front-USB

Cover interface boards

Connections

Frontpanel

Page 41

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2.7.3. DC1012 Dimensions

Dimensions are identical for units equipped with either a keyboard or a touchpad.

2VF100270DG01.cdr

max. 77

ca. 270

Freie Luftzirkulation

free air circulation

Freiraum / clearance > 20 mm

BkSp

PgUp

Pos1

PgDn

1 2 3

Ctrl

EnterShift

F3 F4 F5 F6 F7 F8 F9 F11

F10 F12

S10

Alle Maße in [mm] / All dimensions in [mm]

440

300

DC1012T K

Page 42

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2.7.4. DC1012 Panel cutout

CAUTION

Installation instruction: Only install the Dialog-Controller on a level surface!

2VF100271DG00.cdr

2.7.5. Mounting regulation DC1012

The Dialog-Controllers are designed for automatic convection cooling.

The Dialog-Controllers must be mounted vertically onto a metallic mounting plate.

WARNING

Danger of overheating and fire!

The Dialog-Controller may be destroyed even at a permissible ambient temperature if the convection cooling cannot function because it is built-in.

It must therefore be installed vertically and the upper and lower housing apertures must not be covered over!

DANGER OF OVERHEATING AND FIRE!

 Vertical

installation

Alle Maße in [mm] / All dimensions in [mm]

Frontansicht

Front view

4 0

-136

-272

-276

-4

206

346

386

412

416

Bohrungen /

5 mm (8x)

drills

Fronttafel-Ausschnitt

412 x 272 [mm]

Front panel cut-out

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2.8. Technical data DC1012 Compact (CP)

Module data

Display

Diagonal measurement

12.1“

Resolution

800 x 600 pixels (VGA)

Colors

65536 (16 bit per pixel)

CPU, application memory

CPU

Freescale PowerPC 400 MHz

Program memory (Flash)

32 MB onboard / 24 MB for application

Program memory and data memory (RAM)

128 MB onboard / 96 MB for application

Retain memory

16 kB

Development environment

CP1131 (CODESYS 2.3)

Dimensions and weights

Dimensions (WxHxD [mm])

360x260x77 (+6 mm front panel)

Weight

Approx. 6 kg

Operating conditions

Ambient temperature range

0 °C to +55 °C (if installation rule is adhered to)

Relative humidity

Max. 90 %, non-condensing

Transport, storage

Ambient temperature range

-20 °C to +70 °C

Relative humidity

Max. 90 %, non-condensing

Shock resistance

Vibration

Sinusoidal (EN 60068-2-6) test: Fc 10 … 150 Hz, 1 G (operation mode)

Shock resistance

15 G (approx. 150 m/s2); duration:10 ms; semi-sinusoidal (EN 60068-2-27) test: Ea

EMC, protection type

Interference emission

EN 61000-6-4, industrial environments

Interference resistance

EN 61000-6-2, industrial environments

Protection class

III

Insulating resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP20 (front: IP65)

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Module data

Power supply (24 V power pack)

Supply voltage

+24 VDC (-15 % / +20 %) SELV, max. alternating component: 5 %, max. voltage interruption 1 ms (10 ms only with power supply after 61131-2)

Current consumption

Typically 1.0 A; max. 2.0 A at +24 VDC; Fusing depending on the I/O load, max. 12 A

Polarity reversal protection

Yes

Potential isolation

Yes, between CAN bus and I/Os.

Ethernet port

Number / interface type

1 x 10/100 Base-T

Connection method

RJ45

USB ports

Number / interface types

1 x host USB, Rev. 1.1 (on rear)

Plug/unplug cycles

Max. 1,000

CAN bus ports

Number / interface types

2 x Standard CAN ISO 11898

Potential isolation

CAN0 (X6) potential isolated

Transmission rate

Max. 1 Mbit/s

Terminating resistor

Switchable

Serial ports

Number / interface types

2 x RS232 1 x RS485

Potential isolation

RS485 (X8) potential isolated

Terminating resistor

Switchable with the RS485

E-bus port

Interface type

I/O expansion bus for up to 7 E-bus subscribers

Expansion slots

Number / interface types

3 slots for 3 I/O modules or 2 I/O modules and one AnyBus® module

Further features

Real-time clock

Yes, battery backed.

SD card

1 SD card slot or RS232 (X5)

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2.8.1. DC1012 Compact (CP) front view

2VF100473DG01.cdr

2.8.2. DC1012 Compact (CP) rear view

2VF100242DG01.cdr

Cover interface boards

Connections

Frontpanel

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2.8.3. DC1012 Compact (CP) dimensions

2VF100474DG00.cdr

Alle Maße in [mm] / All dimensions in [mm]

360

260

max. 77

ca. 226

Freie Luftzirkulation

free air circulation

Freiraum / clearance > 20 mm

DC1012T T CP

R 8

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2.8.4. DC1012 Compact (CP) panel cutout

CAUTION

Installation instruction: Only install the Dialog-Controller on a level surface!

The Dialog-Controller is intended for front installation. A square panel cutout is required. The support material thickness may not exceed 6 mm.

2VF100475DG00.cdr

2.8.5. Mounting regulation DC1012 Compact (CP)

The Dialog-Controllers are designed for automatic convection cooling.

The Dialog-Controllers must be mounted vertically onto a metallic mounting plate.

WARNING

Danger of overheating and fire!

The Dialog-Controller may be destroyed even at a permissible ambient temperature if the convection cooling cannot function because it is built-in.

It must therefore be installed vertically and the upper and lower housing apertures must not be covered over!

DANGER OF OVERHEATING AND FIRE!

332

Bohrungen /

5 mm (6x)

drills

Mittelachse Frontplatte

centerline of front panel

Mittelachse Ausschnitt

centerline of front panel cut out

Alle Maße in [mm] / All dimensions in [mm] Frontansicht / Front view

Fronttafel-Ausschnitt

332 x 232

front panel cut out

Frontrahmen / front frame

360 x 260

-232

-236

336

-116

-66

 Vertical

installation

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2.9. Mounting and connection

2.9.1. Mounting

Required tools

Box wrench, Allan key (7 mm) or open-end wrench SW

Securing

The Dialog-Controller is equipped with approx. 15 mm-long, M 4, welded-on stud bolts. The unit is secured using U washers, spring washers/lock washers and nuts (M 4).

 Remove the shipping nuts and washers.  Push the Dialog-Controller through the panel cutout.  Secure the Dialog-Controller in the panel cutout.  Adjust the Dialog-Controller in the panel cutout and tighten all nuts.

NOTICE

Disassembly:

Follow the reverse sequence to disassemble the Dialog-Controller.

2.9.2. Connections

Power supply

Power for the Dialog-Controller comes from an external 24 VDC power supply. Before continuing with the connection, check that the external power supply meets the required specifications.

External power supply (24 VDC)

Output voltage

+24 VDC SELV (-15 % / +20 %)

Alternating component

Max. 5 %. The direct voltage level may not fall below 20.4 V.

Power output

Max. 2.0 A at +24 VDC at 25 °C.

Installation

All connections and wiring must be laid out to prevent any interference due to inductive or capacitive pick-up from arising in the Dialog-Controller. The infeed lines must provide adequate current and voltage carrying capacity.

Connect the Dialog-Controller’s housing to the ground lead (PE) with a copper cross-section of at least 1.5 mm².

The Dialog-Controller is equipped with a 6.3 x 0.8 mm plug-in tab for this purpose.

2VF100236DG00.cdr

 Ground

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2.10. Pin assignment

2.10.1. Pin overview

2VF100231DG00.cdr

2.10.2. Power supply

Internal power pack

A power pack to provide 24 VDC (-15 % / +20 %) input voltage is built into the Dialog-Controller. The power pack is equipped with internal polarity reversal protection and a current at make limiter. The infeed line and the power pack must be protected by means of an external short circuit and overload protector with a maximum of 12 A (depending on the number of I/Os).

Power buffering

The power supply unit can bridge voltage dips lasting 1 ms maximum.

X9 pin assignment

Phoenix MSTB

2.5/2-G-5.08

external power supply 24 VDC (-15 % / +20 %)

external power supply GND

2.10.3. 10/100 Base-T Network Connection (Ethernet)

The onboard 10/100 Base-T Ethernet adapter with an RJ45 connector is used to connect the unit to a network. The “LNK” and “RCV” status LEDs provide information regarding a successful network link.

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X2 pin assignment

RJ45

TX+

TX- 3 RX+

75 Ω

RX-

75 Ω

“LNK” LED

green

ON – operational

“RCV” LED

green

FLASHING – data receive

2.10.4. USB

Devices equipped with USB interfaces can be connected to the two USB master ports (Rev. 1.1). The USB on the back (X3) and the front USB (under the IP65 cover) are connected via an internal USB hub. The only USB devices classes which can be employed for CODESYS users are USB sticks. A mouse can only be employed at the Linux level. The following points must be taken into consideration when USB sticks are employed:

CAUTION

An USB stick may only be pulled during operation if all file operations have been completed, otherwise the USB stick may become unusable!

If programs still have files open, the directory will no longer be able to be removed once the USB stick has been pulled. In this situation file or directory operations will result in blockages because information is to be read from a device that is no longer available in the system. Therefore, always make sure that no program still has open files in the USB stick before pulling the stick.

 USB memory sticks with FAT/FAT32 formatting are supported.  USB memory sticks can be inserted and pulled during operation. The inserted device is automatically

detected and mounted in the /media/usbX directory. When the USB stick is pulled, the associated

/media/usbX directory automatically “disappears” provided no program is currently accessing it (see

above).

 Either the first partition or, if there are no partitions, the entire memory will be mounted on the

memory stick, in other words, the associated directory appears automatically.

 The first stick is mounted under /media/usb0, the second under /media/usb1, and so on. A maximum

of 8 sticks may be inserted simultaneously (/media/usb[0-7]). If a new (or previously inserted, then pulled) stick is inserted it will be placed on the directory with the lowest number. Connecting a USB hub allows multiple sticks to be operated at a given USB interface. Care must be taken that no USB devices are still inserted in the hub when the hub is itself inserted or pulled.

 Based on the variety and number of available USB chip and USB drive manufactures, there is no guar-

antee that every available USB drive on the market works with the device. Every USB drive has to be

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checked if it works with the desired controller in advance. It is also recommended to use always the newest available firmware to get the best possible results.

NOTICE

The mechanical structure of the USB port is designed for a maximum of 1,000 insertion cycles.

X3 pin assignment

USB

VCC

D-

D+

GND

CAUTION

A maximum current of 0.5 A is available at the USB ports (combined)!

A device requiring more current will therefore not function and may be damaged.

2.10.5. CAN bus

The two CAN ports (CAN0/CAN1) comply with the ISO 11898 standard and can be operated up to a maximum baud rate of 1 MBit/s. The smallest CAN baud rate that can be set is 50 kBit/s. In addition, the X6 interface (CAN0) is equipped with a potential isolation.

X6/7 pin assignment

X6/7

Sub-D9 M

NC (Do not connect)

CAN_L

CAN_GND

NC (Do not connect)

CAN_H

8 NC (Do not connect)

9 NC (Do not connect)

 identical for the

front USB

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NOTICE

A terminating resistor can be switched using the S2 (CAN0) and S3 (CAN1) switches.

This is required if the associated CAN interface is located at the beginning or at the end of its CAN bus topology.

2.10.6. Serial ports

In all, the module is equipped with 3 serial communications interfaces, each of which is connected using a 9-pin Sub-D socket. X8 is a potential isolated RS485 interface, while two RS232 ports are available at X4/X5.

NOTICE

The RS232 port at X4 has an exception setting!

Depending on the configuration it can be used as either a Linux console, or as a PPP interface for remote maintenance or a CODESYS programming interface.

If the Dialog-Controller is started in the configuration mode, the device can be configured in this mode using a serial PPP link. Here too, connection is via X4.

The interfaces in the software are addressed by the following names:

Connector

Software interface

COM1

COM2

COM3

X4/5 pin assignment

X4/5

Sub-D9 F

NC (Do not connect)

RXD

TXD

NC (Do not connect)

GND

NC (Do not connect)

7 NC (Do not connect)

8 NC (Do not connect)

9 NC (Do not connect)

 RS232

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NOTICE

If the SD card reader is activated, then the second RS232 interface (X5) is not longer available.

X8 pin assignment

Sub-D9 F

RTXD-

NC (Do not connect)

RTXD+

GND

NC (Do not connect)

7 NC (Do not connect)

8 NC (Do not connect)

9 NC (Do not connect)

The interface is terminated “softly” in the Dialog-Controller at 500 Ω (older devices 5 kΩ ). A 120 Ω differential terminating resistor can be activated for each S4 switch.

 RS485

potential isolated

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NOTICE

For using the symmetrical terminating resistor (S4) on the inoperative bus:

On an inoperative bus the terminating resistor causes a qualitatively unstable signal state, which can give rise to faulty received data.

Background information: Thanks to the differential signal transmission the RS485 interface achieves a

high signal-to-noise ratio and facilitates high data rates and great ranges. An operative bus with defined states - logical ‘1’ (A-B < -0.2 V) or logical ‘0’ (A-B > +0.2 V) - is prerequisite for a high symmetrical signal-to-noise ratio. In an inoperative bus the signals highly resistive and hence susceptible to interference. Thanks to the terminating resistor, which can be activated, a signal state is produced with a low voltage difference between lines A and B.

There are two measures which can prevent this state:

 An appropriate log ensures that one of the bus subscribers operates the

bus actively at all times.

 If the state of the inoperative bus is to be kept under control, a sufficient

signal-to-noise ratio must be established by means of an asymmetric bus termination (at the same time reducing the symmetrical signal-to-noise ratio). With a suitable resistance network as the line termination, a voltage difference between the signals can be produced in an inoperative state. Generally speaking, it is impossible to specify favorable dimensioning because it is affected by the length of the bus and transmission rates. By way of example, reference is made to the line termination in the case of the Profibus.

NOTICE

How to connect "GND": Despite differential signal transmission, depending on the topology and

length of the connected lines, it may be imperative to connect ground reference (GND) may be imperative!

The longer the line the greater the potential differences between bus subscribers may be. In such cases, despite potential isolation, common-mode interference may exceed voltage limits, causing differential signal interference and hence a functional disorder. It is urgently advised to carry along the “GND” si gnal for potentially isolated interfaces, with a connection to the reference ground in one spot. An attenuating connection, for example via 200 Ω at multi-ple points on the bus.

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2.10.7. E-bus

The E-bus (X1) allows up to 7 E-bus subscribers to be connected to the Dialog-Controller. Please note that, due to their function, some E-bus modules represent 2 E-bus subscribers, e.g., QDIO-E 16/16/Z2.

Cable

Type

Ethernet patch cable; 1:1 assignment (not crossed)

Lead cross-section

At least 0.22 mm2

Category

CAT.5

Length

Max. 7 m

CAUTION

The Dialog-Controller makes a max. current of 0.5 A available for E-bus modules!

As a rule, this is sufficient current to supply 7 E-bus modules. However, should this current consumption level be exceeded, the E-bus and the connected modules may become nonfunctioning!

Therefore, please note the current consumption of all E-bus modules and all connected consumers as a whole. In some instances, connection of consuming devices, e.g., an encoder can result in the current limit being exceeded.

Wherever possible you should only employ consumer devices with as low a current requirement as possible!

2.10.8. Connections for expansion ports

NOTICE

Device connection

Prior to connecting any external devices, please carefully read the documentation included with these devices.

Always hold a lead by the plug when connecting or disconnecting a device. Never pull on the lead itself!

The connection level for all external devices is located on the rear of the Dialog-Controller. All connections are plug-in.

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2.11. SD card

WARNING

The SD card must not be plugged in or unplugged while the DialogController is operating as this would result in functional errors with the Dialog-Controller!

The SD card may only be installed or removed when the Dialog-Controller has been switched off!

The SD card drive is equipped with a push-in/push-out insert and eject mechanism. Gold plated contacts ensure low contact resistance and a service life of up to 10,000 plug-in/unplug cycles.

The write protection switch on the SD card is currently not recognized.

The SD card drive must be activated via the web configuration. In this case the application can no longer access the second serial port (SIO2/X5). The files on the SD drive can be written to, read from as well as copied. Access to the drive is along the following path: /media/sd.

At present data memory cards with a memory capacity of up to 1 GB can be used.

2VF100312DG01.cdr

NOTICE

If the SD card reader is activated, then the second RS232 interface (X5) is not longer available.

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3. Dialog-Controller operation

CAUTION

Never plug in, apply, disconnect or touch connections while the device is operating!

This could result in malfunction or destruction of the device. Before working on the modules, always switch all infeeds to them off; including infeeds from connected peripheral devices such as remote-feed encoders, programming devices, etc.

MALFUNCTION

3.1. Commissioning

Before applying the supply voltage, recheck all connections to ensure they are properly wired and have the correct polarity.

Switching on

The Dialog-Controller is not equipped with its own main power switch. The Dialog-Controller starts when the associated equipment is switched on or when the power supply is connected.

Switching off

The Dialog-Controller switches off when the associated equipment is switched off or the power supply is disconnected.

3.2. Function selection, indicators, diagnostics

3.2.1. Status indicators

The function of the status indicators frequently depends on the software development environment employed on the Dialog-Controller.

 CP1131-P: PLC programming using CODESYS and Berghof Target Support Package  CPC++: C programming directly on the LINUX operating system

2VF100232DG00.cdr

Status-LED Ethernet Status-LED

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Operating mode selection switch (S1)

Used to change the operating mode and for module restart.

Switch position

CP1131-P

CPC++

RUN

CP1131-P program in the RUN mode. Can be changed with the programming device.

Freely programmable

STOP

CP1131-P program in the STOP mode.

Freely programmable

RESET

CP1131-P program is restarted with deleted variables (RETAIN variables are not deleted).

Freely programmable

Status LED

Four operating status LEDs provide information about the current status of the power supply, the module mode as well as fault and error messages.

LED

Logical state

PWR (green)

ON = Correct supply voltage to the module electronics

Status LEDs for CP1131-P programs

Status 3 (green)

Status 4 (red)

Status 5 (red)

Description

off

any

Application program status: RUN

off

any

Application program status: STOP

off

flashing

any

Application program status: ERROR STOP

flashing

any

Application program status: Breakpoint STOP

any

CP1131 mode: FORCE

Basic recovery procedure in case of an ERROR STOP:

 determine the cause of the error (indicated in the service menu on the display or can be read using a

web browser)

 correct the cause of the error  perform a controller reset; or alternatively: Mode selection switch / Service menu / CODESYS/ web

browser

 return the controller to operation

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NOTICE

CP1131-P FORCE mode:

FORCE indicates that the application program is running and CODESYS forces a value to be written to at least one variable at the start of every cycle. This makes it evident to the user that the application program might react differently if no such forced access to the PLC program’s process were to occur.

Status LEDs for CPC++ programs

LEDs 3 to 5 can each be separately controlled by application software.

Ethernet status LED

Refer to the section “10/100 Base T Network Connection (Ethernet)”.

3.3. Service menu

Functional scope

The Dialog-Controller’s service menu allows the user to define and examine device and communications parameters as well as device states. It also represents a valuable service and commissioning aid. The service menu thus permits setting definition at the Ethernet interface and diagnostics functions in case of errors to be simplified and accelerated.

The service menu has a two-part structure:

Parameter window

The following four menu items are displayed here. Each menu item can contain additional subject-related submenu items.

 Config  PLC  Info  Display

PLC window

Up to two lines reflecting the current PLC status can be displayed. Line 1 will always be visible, while line 2 will only appear when an error occurs.

2VF100273DG01.cdr

PLC window

Parameter window

 Basic structure

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3.3.1. Using the service menu

Touch screen

In Dialog-Controllers with a built-in touch screen, the service menu can be operated directly via screen input.

Keyboard

If the Dialog-Controller is equipped with a keyboard, the following keys are used to operate the service menu:

The cursor block is used to navigate between the individual menu items on a given menu level.

The [Enter] key is used to confirm an input. If a submenu permits values to be modified, this modification is performed with the [Enter] key. The [+] / [-] keys do not function in the service menu. However, using the cursor block, you can navigate to a “+/-” symbol displayed on the screen, then use the [Enter] key to either increment or decrement the associated value.

The [Esc] key is used to exit a menu without saving any changes which may have been made.

3.3.2. Parameter window

Checking and setting options are accessed through this window section.

The following four menu items are available for selection:

 Config to check and adjust Ethernet parameters, system time and the COM1 serial interface (X4).  PLC to check and operate the PLC.  Info to display the hardware and software version levels as well as diagnostic data; and it also offers

the save function (USB, SD, Flash).

 Display to adjust contrast values.

 Cursor block

 [Enter] key

 [Esc] key

 Parameter

window structure

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“Config” service menu

Check and adjust the parameters.

Check and adjust Ethernet parameters.

Check and adjust the IP address.

IP address:

The “+/-” keys can be used to adjust and set each individual IP address byte. The “Save IP” button is then used to save the settings. New settings will only take effect after a restart! The “EXIT” button allows you to leave the menu without saving any changes which may have been made.

 Config

 NETWORK

 Ethernet

“IP ADDRESS”

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Check and adjust the network mask.

Net mask:

The “+/-” keys can be used to adjust and set each individual network mask byte. The “Save Mask” button is then used to save the settings. New settings will only take effect after a restart! The “EXIT” button allows you to leave the menu without saving any changes which may have been made.

Check and adjust the gateway IP address.

Gateway IP:

The “+/-” keys can be used to adjust and set each individual gateway IP address byte. The “Save G-IP” button is then used to save the settings. New settings will only take effect after a restart! The “EXIT” button allows you to leave the menu without saving any changes which may have been made.

Check and adjust the communications parameters.

Link Mode: Auto: Automatic parameter setting negotiated among the

communications parameters (default setting). The default settings should only be changed under special circumstances (e.g. communications problems). 100base-Tx-FD: 100 MBit/s, full duplex 100base-Tx-HD: 100 MBit/s, half duplex 10base-T-FD: 10 MBit/s, full duplex 10base-T-HD: 10 MBit/s, half duplex The “Save” button is used to save the new setting. New settings will only take effect after a restart! The “EXIT” button allows you to leave the menu without saving any changes which may have been made.

 Ethernet

“Net mask”

 Ethernet

“Gateway IP”

 Ethernet

“LINK PARAM”

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DHCP Mode: Disabled: The IP ADDRESS set on the Dialog-Controller

is valid. Enabled: The IP ADDRESS is automatically retrieved from a DCHP server. Caution: If DHCP is enabled, and there is no DHCP server available, the Controller will not boot! The Controller waits for a DHCP to allocate a valid IP address to it. If no DHCP server is present, the Dialog-Controller can only boot if the DHCP disabled setting has been configured. For this purpose the device must be put into configuration mode and can be converted via COM1 (X4) by means of web configuration (see manual: CP1131-P introduction).

Setting the COM1(X4) serial interface.

User only: COM1 is available for CODESYS application Console: Debug outputs of the operating system PPP: TCP/IP over PPP protocol PG Tool: CODESYS can upload and debug serial pro-

grams

CNW: reserved

RTC: Setting the battery-buffered realtime clock.

 Ethernet

“DHCP Mode”

 SIO MODE

“SIO MODE”

 CLOCK “RTC”

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“PLC” service menu

Change the PLC state.

RESET WARM: After an error occurs the PLC program can be reset. With the exception of the RETAIN variables, all variables can be reset. RESET COLD: After an error occurs the PLC program can be reset. With the exception of the RETAIN variables, all of the variables are reset, including the RETAIN variables.

RUN PLC: Starting the PLC program. NOTE: RETAIN data are remanent data. They are saved

when the Controller is switched off and are available to it when it is rebooted. If these data are deleted, important system data of the application may be deleted!

Info:

Acknowledgement of the RESET WARM command. PLC program and all variables, with the exception of the RETAIN variables, have been reset.

Warning:

Acknowledgement of the RESET COLD command. As soon as the “CONTINUE” button is pressed the PLC program and all variables, including the RETAIN variables, are reset.

 PLC

“RESET WARM”

 PLC

“RESET COLD”

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Info:

If there is a PLC program on the Dialog-Controller and it was possible to start it successfully, the Service Menu is terminated and PLC program executed. If the PLC program is not executed, the following may be the causes:

 There is no PLC program on the Dialog-Controller.  Mode selector switch is set at “STOP”.  An error in the PLC program was not acknowledged

by a “RESET” command (see above).

“INFO” service menu

Diagnostics: INFO: Diagnostic data displayed SAVE DIAG: Diagnostic data is saved on USB stick or SD

card.

Info:

Diagnostic data displayed:

 Parameter display  Hardware and software versions  Event logger

Displays all user activities as well as messages and software module problems. To aid in diagnostics, the entire content of the displayed page can be uploaded to a PC using the integrated “Web Configuration” where it can then be saved and sent to Berghof. The individual event logger messages as well as the web configuration are explained in the “CANtrol PPC System Introduction” manual.

Select a device:

The currently available storage media are displayed here. If neither a USB stick nor an SD card is available, the selection is empty.

sd: Data partition of the SD card sd_system: System partition of an SD card is used, for ex-

ample, for the PLC program usb0: the first USB to be plugged in (a maximum of 8 sticks can be plugged in via a USB hub).

 PLC “RUN PLC”

 “Info”

 Info

 Info “SAVE DIAG”

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“Display” service menu

Status display or contrast and backlighting adjustment.

Dialog-Controllers with TFT displays:

The brilliance of the backlighting can be set by means of the “+/-” keys. Changes are applied immediately and will remain in effect until the next restart, even if you leave the menu with the “EXIT” button. The new value is saved by means of the “Save” button. The “EXIT” button allows you to leave the menu without saving any changes which may have been made (although such changes will remain in effect until the next restart).

Dialog-Controllers with monochrome displays:

The contrast can be adjusted here.

 Display

“Brightness”

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3.3.3. PLC window

The following states of the PLC Controller can be represented in line 1 of the PLC window:

 STOP SWITCH ACTIVE  PLC STOPPED  PLC NO PROGRAM  PLC ERROR STOP

Display

Description

STOP SWITCH ACTIVE

Operating mode selection switch S1 is set to the STOP position. The PLC program can only be started with a programming tool if S1 is set in the RUN position.

PLC STOPPED

Operating mode selection switch S1 is set to the RUN position. However the PLC program has been put into the STOP state or there is another upcoming error, which has not yet been acknowledged with RESET.

PLC NO PROGRAM

Operating mode selection switch S1 is set to the RUN position, but no PLC program is loaded.

PLC ERROR STOP

Operating mode selection switch S1 is set to the RUN position. However, the PLC program could not be started due to an error.

 STOP

in the Service menu

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If an error occurs when the PLC program is started, the following states may be displayed on line 2 in the PLC window:

Display

Description

BOOTPROJECT_REJECTED_RETAIN_ERROR

The Dialog-Controller has detected a difference between the PLC program saved as the boot project and the most recently loaded PLC program. The latter was only loaded to RAM and was not saved as a boot project. If the Dialog-Controller is switched off in this situation; the system notes the ID number of the program previously loaded to RAM. The displayed message now prevents the automatic startup of a possibly outdated PLC program.

Error correction:

Either load, save and then start the new PLC program or use a reset command to start the saved and possibly outdated program.

RETAIN_IDENTITY_MISMATCH

The Dialog-Controller was unable to correctly reestablish the retain variables.

Error correction:

By performing a reset, the saved PLC program can be started using the reset retain variables.

RTSEXCPT_IOUPDATE_ERROR

One or all of the E-bus modules were not detected after the PLC program started. The E-bus modules also include the I/O expansion cards installed in the Dialog-Controller. All E-bus modules entered in the controller configuration must be present and must be supplied with power at the time the program starts.

Error correction:

Check the number and type of E-bus modules entered in the controller configuration. Check the contacts and wiring connections on these E-bus modules. Once the number of actually available E-bus modules agrees with the controller configuration setting, the controller can be restarted using a reset command.

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This display appears if an error has occurred when the PLC program is executed, i.e. during program run. The following error statuses can be displayed:

 ACCESS_VIOLATION  RTSEXCPT_WATCHDOG  RTSEXCPT_DIVIDEBYZERO

Standard procedure in case of an error:

Saving all relevant data is an important factor for error analysis. The diagnostic information generated by the device should be saved for this reason. “Save Diag” is used to store the relevant diagnostic data for example on a plugged-in USB stick. After such an error the Controller must be rebooted. This takes place after data backup, using the “Reboot” button.

Note: The diagnostic data must definitely be saved prior to rebooting because only at this time can all the important

data be saved!

 EXCEPTION

Major exceptional errors

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Display

Description

ACCESS_VIOLATION

Illegal memory access by the PLC program, e.g. by an invalid pointer.

Error correction:

The program error can be identified from the diagnostic data and/or the Breakpoint List file (BPL) generated by CODESYS, and eliminated. Further information on debugging with the aid of BPL files and debug-

ging in general is to be found in the “CODESYS Online Help” in the

“Berghof Target” section.

RTSEXCPT_WATCHDOG

It was not possible for a task within the PLC program, which is monitored by a watchdog to become active during the monitoring time. This important watchdog-monitoring makes it possible to find errors in the execution behaviour and in the tasking of the PLC program. For such errors to be found at all it is important that each task is monitored by a watchdog.

Error correction:

ging in general is to be found in the “CODESYS Online Help” in the

“Berghof Target” section.

RTSEXCPT_DIVIDEBYZERO

Division by zero in the PLC program prompts an error stop.

Error correction:

ging in general is to be found in the “CODESYS Online Help” in the

“Berghof Target” section.

3.4. Decommissioning

3.4.1. Disposal

Disassembly

The Dialog-Controller must be disassembled into its component parts for disposal. All metal components can be disposed of as recyclable metal.

Electronic waste

All electronic components such as PCBs, drives, etc. must be set aside and disposed of separately. Disposal is generally regulated by national and local ordinances which must be complied with.

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Battery

CAUTION

Batteries contain materials which represent health and environmental hazards.

Batteries may only be disposed of at an authorized waste disposal facility. Make sure the battery is fully discharged before disposing of it. If necessary,

place an insulating strip across the contacts to prevent short circuits.

HAZARDOUS MATERIAL EMISSIONS

3.5. Maintenance

Cleaning

In order to prevent accidental activation and possible problems, the Dialog-Controller must be switched off when the front panel is cleaned. Use a clean, moistened, lint-free cloth to clean the front of the Dialog-Controller.

Please note the following to avoid damaging the front panel when cleaning it:

 Never use high-pressure or steam washers.  Never use caustic cleaning agents (even diluted), abrasives or hard objects to clean the panel.  Do not apply excessive pressure to the front panel when cleaning it.

3.6. Help in case of problems

Please read the section “Basic safety measures”. If the measures described there do not solve the problem, please contact your supplier’s Service Department.

Fault

Possible cause

Recommended action

No function after the DialogController is started.

No power supply to the Dialog-Controller.

Make sure the power cord is plugged in. Check the pin assignment for reversed polarity. Check (measure) the connecting voltage.

The Dialog-Controller fails to completely boot.

Memory fault.

Return the device for service.

Corrupted software.

Put the device in the configuration mode and reload the firmware.

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Blank page

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4. Extension modules

2VF100304DG01.cdr

Extension modules

Slot

Type

Designation

I/O card with SC-CAN

U DC XS 12/8/4-CSC

PROFIBUS master

DC Profibus-DPM

PROFIBUS slave

DC Profibus-DPS

PROFIBUS master/slave

DC Profibus-DPV

I/O card, analog/digital

DCXR01

X X X

I/O card, digital

DCXR02

X X X

Slot marking for extension modules

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4.1. I/O card with SC-CAN interface

The I/O card is an I/O module which is permanently installed in a DialogController.

2VF100305DG00.cdr

Performance features - an overview

 12 digital inputs  8 digital outputs  4 digital inputs/outputs  2 digital inputs can also be used as counters  2 analog inputs, 0 ... 10 V or 0 ... 20 mA  1 CAN interface for contact line systems with monitoring capability  Connection for a 5-place 7-segment display with remote control receiver

The scope of supply of the control module consists of:

 I/O card installed in the Dialog-Controller

 Short description

 Scope of supply

IN 1-8

SC-CA

I/O 13-16

7Seg/IR

SC-Test

IN 9-12

2 3

X10

X13

OUT 1-8

X11

L1+

1 2

1 2 3

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 891 2 3 4 5 6 7 8

L1+

2 345 6 7 891 2 345 6 7 8

2 345 6 7 8

1 2 3 4 5 6 7 8

2 3 4 5 6

GNDGNDS

AIN 1GNDShiel

AIN 2GNDShiel

CANGN

- A2

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4.1.1. Technical data

Module data

Versions / part no.

Only available as a built-in module

Dimensions, WxH[mm]

113.5 x 108

Weight

Approx. 100 g

Operating temperature range

5 °C to 55 °C (condensation free) Convection cooling ensured

EMI, protection class, insulation test, protection type (installed)

Interference emission

EN 61000-6-4, industrial application

Interference resistance

EN 61000-6-2, industrial application

Protection class

III

Insulation resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP 20

Supply voltage, current consumption

Module electronics power supply (connection voltage)

SELV DC +24 V < 0.4 A (EN 61131-2)

Digital I/O power supply

DC +24 V (EN 61131-2) together with module supply

Current consumption

At Ue= DC +24 V in neutral, max. 500 mA, fusing based on I/O load, max. 8 A

Protection against supply voltage pole reversal

Yes

Potential isolation

Digitale inputs/outputs (DIO)

Number of inputs

12 (X1/X2), of which 4 can be used as +24 V encoder inputs; counter frequency at 4x evaluation < 20 kHz

Number of outputs

8 (X9)

Number of inputs/outputs

4 (X2)

Output current

0.5 A

Short circuit protection

Yes

Potential isolation

Yes

Connection technique

Standing front wiring for 3.81 terminal strips (not part of the standard delivery)

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Analog inputs

Number

2 analog inputs, 0 … 20 mA / 0 ... 10 V switchable (X10/X13)

Input characteristics

Up to 20 mA U < 5 V in case of short circuit, max. 40 mA

Resolution

10 bit (accuracy 8 bit)

Connection technique

Standing front wiring for 3.81 terminal strips (not part of the standard delivery)

CAN interfaces

Number and type of interfaces

1 CAN interface for (X20) contact line communications / SC_CAN (X3); 1 SC_CAN monitoring interface with standard signals

Connection technique

Standing front wiring for 3.81 terminal strips (not part of the standard delivery)

Operating and display elements

Display elements

Interface (X11) for 5-place, 7-segment display with IR receiver diode for remote control

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4.1.2. Pin assignment

2VF100305DG00.cdr

I/O supply

The digital and analog I/Os must be supplied from an external source. An input voltage of 24 VDC (-15 % / +20 %) is permissible. The I/Os are equipped with a built-in pole reversal protection.

The power cord and the external power supply must be equipped with an external short circuit and overload protection with an activation current of max. 8 A (depending on the number of I/Os).

External power supply

The CAN communications interface is supplied from the Dialog-Controller’s power supply.

 Pin overview

 Power supply

IN 1-8

SC-CA

I/O 13-16

7Seg/IR

SC-Test

IN 9-12

2 3

X10

X13

OUT 1-8

X11

L1+

1 2

1 2 3

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

L1+

2 345 6 7 8

1 2 345 6 7 8

2 345 6 7 8

1 2 3 4 5 6 7 8

2 3 4 5 6

GND

AIN 1GNDShiel

AIN 2GNDShiel

CANGN

- A2

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The I/O card is factory installed and may only be installed in the Dialog-Controller in the position shown in the figure below.

2VF100306DG00.cdr

 Installation

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WARNING

The transmission circuit voltage level of the SC_CAN signals is 85 V or 110 V at 25 Ohm.

Based on the employed voltage level, all signal carrying lines must exhibit the same level of contact protection as the power supply (230 / 400 V).

CAUTION

Directly connecting ISO11898 devices to the SC_CAN bus will result in there being destroyed and is therefore prohibited.

Such devices include, for example, remote I/Os, drive controllers and CAN bus analyzers.

SC_CAN – X3 pin assignment

Signal

Description

Protective earth

SC_CAN signal

Protective earth

CAUTION

The two protective earth (PE) connectors must be laid to the contact line connection using two separate conductors.

Any other type of circuit construction (e.g., a bridge between the two PE connections) may result in functional errors or functional inefficiency of the SC_CAN.

Termination

The SC_CAN must be terminated at both line ends. The values for these terminating resistors deviate from the ISO 11898 (CAN bus) standard and they can be ordered separately from Berghof (CTR-SC-T2, part no.:

201601200).

CAUTION

If the SC_CAN bus is incorrectly terminated, its operation can result in the destruction of the I/O subassembly!

You must ensure that the correct termination is employed!

Baud rate

The preset baud rate for the SC_CAN is 50 kbit/s. The SJA1000 CAN controller is also in the “self test mode”,

that is, when a CAN telegram is correctly transmitted, it is not necessary for a subscriber to send a CAN ACK signal. Should it become necessary, these factory settings can be altered in the application by using the appropriate CAN library.

 CAN bus for contact

line communications

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SC test - X8 pin assignment

Signal

Description

CAN

CAN signal

GND

Signal ground

A test or so-called “monitoring interface” for the SC_CAN is located on this connector. This “monitoring in- terface” serves to analyze the SC_CAN telegrams and possess the following characteristics:

 It is a point-to-point interface;  It is only for devices with an ISO11898 CAN interface;  CAN telegrams cannot be sent;  No terminating resistors may be employed.

Pin assignment for an adapter cable

2-pin post (2.54)

9-pin Sub D

Signal

CAN

CAN HIGH

2 2 GND

CAN LOW

For special applications an external 7-segment display (with integrated infrared receiver) can be connected to the I/O subassembly. Connection is to connector X11 by means of a cable available from Berghof. The external display can be addressed from the software in the same way as the digital I/Os.

 2-pin post connector

 External 7-segment

display

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4.1.3. Analog inputs

The module is equipped with two unipolar analog inputs protected by diodes. Power supply to the sensors is from an external source. The analog current and voltage values are accessible via the CODESYS controller configuration.

Input channel data

Current measurement

Nominal input current value

0 … 20 mA

Maximum input current value

40 mA (Ue = +24 V)

Voltage measurement

Nominal input voltage value

0 … 10 V

Maximum input voltage value

12 V

General data

Input filter, 1st order

 = 1 ms for current;  = 10 ms for voltage measurement

Conversion method

Successive approximation, no error codes

Resolution

10 bit; 1 LSB = 19.5 µA / 9.77 mV

Accuracy within the 0...50 °C temperature range

±1 %

Pole reversal protection

Yes

Sampling rate

Approx. 1 ms

NOTICE

Due to internal protective circuitry, the load is nonlinear for current operation.

Analog IN – X10/13 pin assignment

Signal

Description

AIN

Analog input

GND

Signal ground

Shield

The maximum value will be indicated if no sensor is connected to an analog input.

NOTICE

Shield support in switchgear cabinet is urgently recommended for reasons of EMC!

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4.1.4. Digital inputs/outputs 12/4/8-0.5

Supply is to terminals L1+ and M1. All inputs and outputs have a common feed and therefore also have a common feed potential.

Feed

The feed must come directly (unswitched) from the feed device. Feed for inputs (sensors) must come directly from the feed device. Do not lay the sensor supply across switched circuits.

WARNING

Feedback can result in the destruction of the module and/or the sensors!

With the group power supply switched off, the connected sensors may produce feedback via the output transistors. Make sure that the sensors are all supplied from the same power source as the module’s associated I/O group.

2VF100307DG00.cdr

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

1 2 3 4

6 7 8 9 1 2 3 4

6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3

X12

X10

X13

IN 1-8

SC-

M1 I/O 13-16IN 9-12

GND

L1+

AIN

1GNDShield

AIN 2GNDShiel

7Seg/IR

SC-Test

1 2

2 3 4 5 6

CANGN

X11

OUT 1-8

- A2

1 2 3 4

6 7 8 9 1 2 3 4

6 7 8 9

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4.1.5. Digital inputs, positive switched

The digital inputs are positive-switching, type 1 inputs for 3-wire sensors. They are designed for nominal 24 V input voltages. The inputs are transmitted to the CPU in cycles. An open input is interpreted as being static 0 (LOW).

Impulse detection and interference suppression

Inputs are read in cycles. Impulses of < 100 µs are suppressed by the hardware. The shortest possible sampling rate is 250 µs. In order for impulses to be properly detected they must be longer than the sampling rate defined by the software.

Multiple sampling can be programmed to suppress interference impulses. The sampling rate and multiple sampling (filtering) can be activated in individual groups of 32 inputs.

NOTICE

This function is only available for C applications. The sampling rate is predefined under IEC 61131-3.

2VF100009DG01.cdr

 Basic input circuit

diagram

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Digital input data

Module data

Number of inputs

12 (max. 16 if the I/O is used as an input)

Line length

in the circuit cabinet

Take the voltage drop into account when selecting a conductor. Other than this, there are no relevant restrictions.

field wiring

Comply with all locally applicable requirements as well as those in accordance with EN 61131-3. Where the risk of lightning exists, please consult the manufacturer.

Nominal load voltage, L+ Pole reversal protection

DC 24 V (SELV) Yes

Potential isolation

Yes (optocoupler) in groups

Status indicator

None

Alarms

Definable depending on the software

Input delay

Definable via the software

Input capacitance

< 10 nF

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2VF100010DG01.cdr

Input voltage (DC) of extern power supply

24 V

Rated voltage

Ue max.

30 V

Upper limit

Ue min.

19.2 V

Lower limit

Limits for “1” signal for the “ON” condition

max.

30.0 V

Upper voltage limit

max.

10.0 mA

Upper current limit

min.

13.5 V

Lower voltage limit

min.

3.5 mA

Lower current limit

Limits for “0” signal for the “OFF” condition

max.

5.5 V

Upper voltage limit

max.

1.5 mA

Upper current limit

min.

0 V

Lower voltage limit

min.

0 mA

Lower current limit

U max.

UH max.

IH max. IH min.

U = 24 V DC

U min.

5,0

10,0

15,0

20,0

25,0

30,0

U [V]

0,0

0,00 1,00 2,00 3,00 4,00 5,00 6,00 7,00 8,00 9,00 10,00 11,00

[mA] I

UH min.

UL min.

UL max.

IL max.

IL min.

'ON' / HIGH - area

cross-over area

noise margin < 1 V

'OFF' / LOW - area

 Operating ranges

of the digital inputs

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4.1.6. Digital outputs, positive switched

WARNING

Voltages of > 32 V and / or feed back can destroy the module.

This represents a fire hazard!

Each digital output can also be used as an input. When used as an input, the information provided under “Digital inputs” applies.

Outputs

The outputs are positively switching 24 V outputs (2-wire). Output current max. 500 mA per output. The outputs have a common reference potential (GND). Power supply is separate from the module electronics

supply (refer to “Pin assignment”). If there is no data connection to the CPU or if the internal module supply is inadequate the outputs independently switch to “0” (LOW).

Protected output

All outputs are protected by an internal current limiter and thermal overload protection. In case of an overload, the current limiter switches the overloaded output off. Once the overload has been corrected and the unit has cooled down the output can be reactivated via the program. A quick deactivation using a terminal voltage of 50 V referenced to L+ protects all outputs against induced voltage peaks from inductive loads. If feedback or the quick deactivation produces thermal loads, the overload protection may also be prematurely tripped by uninvolved outputs.

Operating status

The status of each output is indicated by a yellow status LED on the front of the module. The LEDs are spatially assigned to the connection terminals. The LED is on when the associated output is activated, that is, when it is logical “1” (HIGH).

2VF100011DG01.cdr

 Basic output

circuit diagram

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Digital output data

Module data

Number of outputs

8 (max. 12 if the I/O is used as an output)

Type of output

Semiconductor, non-saving

Protected circuit for inductive loads

Quick deactivation, 50 V terminal voltage (typical) against +24 V

Power dissipation resulting from deactivation

Max. 0.5 W / output; max. 4 W / module

Status indicator

None

Diagnostic function

None

Load connection

Total load (100%)

6 A (12 x 0.5 A)

Overload protection

Yes, for thermal overloads. Activation of the thermal overload protection may influence adjacent outputs.

Short circuit protection1) Activation threshold

Yes, electronic current limiter min. 0.5 A; typically 0.9 A.

Current is electronically limited. Activation of the short circuit protection results in a thermal overload

which activates the thermal overload protection.

Output delay

from “0” to “1” from “1” to “0”

Max. 0.5 ms Max. 0.5 ms

Output capacitance

< 20 nF

Reference voltage Voltage drop (at reference current)

DC +24 V < 0.5 V

Reference current for “1” signal Leakage current for “0” signal

0.5 A Max. 0.1 mA

Total current, all outputs (horizontal installation on vertical panel)

Max. 6 A (12 x 0.5)

Lamp load (DC +24 V)

Max. 6 W

Parallel switching of two outputs for logical linkage to increase performance

Permissible Prohibited

Insulation resistance

Reference voltage

0 V < Ue < 50 V

Test voltage up to an altitude of 2000 m

DC 500 V

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2VF100021DG01.cdr

NOTICE

No assurance as to whether a shutdown or a return to the working range will occur can be made within the current limiter scatter band. Therefore, this state should be avoided!

The output will again be operational once the overload has been corrected and the unit has cooled down.

[Ohm]

20 30 40 50 100 2001

0,1

100

1000

10000

100000

[ms]

UB18 V

max

2 A

Tu0 °C

= =

UB24 V

max

1 A

Tu25 °C

= =

UB30 V

max

0,7 A

Tu50 °C

= =

Overload behavior of the digital outputs

full-load

unload

Output ON

Output OFF Switching Off by

thermal overload

Safety clearance

Current limit scatter band

Current limiting range

Within the current-limit scatter band the reaction of current limiting is undefined.

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4.1.7. Digital input/output pin assignments

Connection

Signal name

Configured as

Note Digital I/O

TPU-I/O

X12 9 L1+

Feed

X12 X9 X7 X6 X1 X2

1 … 8 9

1 … 9 1 … 9

9 9

GND for module and I/O feed

X4 X5

1 … 9 1 ... 9

+24 V =

I/O feed

Across L1+

IN1

Digital IN +24 V

Counter input, +24 V

Form encoder 1

IN2

Digital IN +24 V

Counter input, +24 V

IN3

Digital IN +24 V

Counter input, +24 V

Form encoder 2

IN4

Digital IN +24 V

Counter input, +24 V

IN5

Digital IN +24 V

IN6

Digital IN +24 V

IN7

Digital IN +24 V

IN8

Digital IN +24 V

IN9

Digital IN +24 V

IN10

Digital IN +24 V

IN11

Digital IN +24 V

IN12

Digital IN +24 V

I/O13

Digital I/O +24 V

I/O14

Digital I/O +24 V

I/O15

Digital I/O +24 V

I/O16

Digital I/O +24 V

OUT1

Digital OUT +24 V

OUT2

Digital OUT +24 V

OUT3

Digital OUT +24 V

OUT4

Digital OUT +24 V

OUT5

Digital OUT +24 V

OUT6

Digital OUT +24 V

OUT7

Digital OUT +24 V

OUT8

Digital OUT +24 V

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Groups of 2 inputs can be combined to form a quadrature encoder for evaluation.

Function

Input 1

Input 2

Encoder 1

IN 1 (X1)

IN 2 (X1)

Encoder 2

IN 3 (X1)

IN 4 (X1)

The encoder values are only reset (0) when the unit is switched on or rebooted after a reset.

 Encoder interface

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4.2. PROFIBUS-MASTER card

The PROFIBUS-MASTER card is a PROFIBUS-MASTER module, permanently installed in a Dialog-Controller.

2VF100308DG00.cdr

Performance features – an overview

 PROFIBUS-DP Master bus module  Max. of 125 slave nodes can be connected  Max. 3 kbyte process data (1536 byte input and 1536 byte output data)  Baud rates 9600 bit/s - 12 Mbit/s  Potential isolated PROFIBUS-MASTER RS485 interface with integrated DC/DC converter and opto-

couplers

 Cyclic DP-Master services

The scope of supply consists of:

 PROFIBUS-MASTER card installed in the Dialog-Controller

 Short description

 Scope of supply

Indicators

Diag.

Profibus

DC Profibus-DP M

Database

Comm.

Master Token

2 134

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4.2.1. Technical data

Module data

Versions / part no.

Only available as a built-in module

Dimensions, WxHxD [mm]

56.5x108x8

Weight

Approx. 100 g

Operating temperature range

5 °C to 55 °C (condensation free) Convection cooling ensured

EMI, protection class, insulation test, protection type (installed)

Certification

CE, UL, cUL

Interference emission

EN 61000-6-4, industrial application

Interference resistance

EN 61000-6-2, industrial application

Protection class

III

Insulation resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP 20

Supply voltage, current consumption

Module electronics power supply (connection voltage)

5 V / max. 350 mA from the Dialog-Controller’s mains power supply

PROFIBUS-MASTER interfaces

Number and type of interfaces

1 PROFIBUS-MASTER DP interface for connecting a max. of 125 slave nodes

Potential isolation

Yes

Connection technique

9-pin, Sub-D

Operating and display elements

Display elements

4 diagnostic LEDs

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4.2.2. Front view and pin assignment

2VF100308DG00.cdr

External power supply

The PROFIBUS-MASTER communications interface is supplied from the Dialog-Controller's power supply.

Installation

The PROFIBUS-MASTER card is factory installed and may only be installed in the Dialog-Controller in the position shown in the figure below.

2VF100309DG00.cdr

 Pin overview

Indicators

Diag.

Profibus

DC Profibus-DP M

Database

Comm.

Master Token

134

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The embedded PROFIBUS-MASTER bus module is a PROFIBUS DP Master. The module has been tested for conformity with the PROFIBUS standard and for inter-operability with many leading PROFIBUS slave devices. The onboard microprocessor automatically performs all PROFIBUS bus traffic thus completely reliving the automation device’s main processor of any PROFIBUS protocol processing.

The PROFIBUS-MASTER module supports a max. of 125 slaves with up to 3 kbyte of I/O data. All baud rates from 9.6 kbit/s to 12 Mbit/s can be set. All cyclic PROFIBUS services are available.

PROFIBUS-X2 (jack) pin assignment

Signal

Description

N.C.

Do not connect

N.C.

Do not connect

RS485 signal

RTS

Ready to send

GND

Bus ground

+5 V

Bus (output)

N.C.

Do not connect

RS485 signal

N.C.

Do not connect

Diag.–X1 (pins) pin assignment

Signal

Description

N.C.

Do not connect

RxD

RS232 signal

TxD

RS232 signal

N.C.

Do not connect

GND

Bus ground

N.C.

Do not connect

N.C.

Do not connect

N.C.

Do not connect

N.C.

Do not connect

 PROFIBUS-MASTER

interface

 galvanically isolated

field bus interface

 serial diagnostics

interface

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NOTICE

All application and diagnostic data are set up via the CODESYS controller configuration or are provided by the application. Therefore, the diagnostic interface cannot be used in an application-specific manner.

Termination

The PROFIBUS-MASTER has a linear topology. It must be terminated at both ends. The PROFIBUSMASTER module is not equipped with any internal terminating resistors and we therefore recommend the use of a plug with switchable termination.

Baud rate

The baud rate is set in the CODESYS controller configuration.

GSD file

The PROFIBUS-MASTER module is integrated in the CODESYS controller configuration with a GSD file. As of Version 1.10.0, this GSD file will be part of the Berghof Target installation package.

Indicator LEDs

Indicator

Signal

Description

Master

Green:

Operating mode

Green, flashing:

Delete mode

Red:

Stop mode

Off:

Offline

Database

Green:

Databank OK

Green, flashing:

Database load procedure running

Red:

Database invalid

Off:

No database available

Comm.

Green:

Data exchange with all configured slaves

Green, flashing:

Data exchange with at least 1 configured slave

Red:

Bus error, e.g., due to a short circuit or configuration error

Off:

No data exchange

Token Green:

Module has the token

Off:

Token not at the module

All Red:

Fatal error

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4.3. PROFIBUS-SLAVE card

The PROFIBUS-SLAVE card is a PROFIBUS-SLAVE module, permanently installed in a Dialog-Controller.

2VF100310DG00.cdr

Performance features – an overview

 PROFIBUS-DP SLAVE bus module  Max. 244 byte input and 244 byte output data (all together 416 byte)  Automatic baud rate recognition, 9600 bit/s - 12 Mbit/s  Potential isolated PROFIBUS-SLAVE RS485 interface with integrated DC/DC converter and

optocouplers

 All required DP services as well as user parameter data and device-specific diagnostics

The scope of supply consists of:

 PROFIBUS-SLAVE card installed in the Dialog-Controller

 Short description

 Scope of supply

Indicators

Address x1

Termination

ON OFF

Address x10

Profibus

DC Profibus-DPS

Online Offline

n.c. Error1

2 3

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4.3.1. Technical data

Module data

Versions / part no.

Only available as a built-in module

Dimensions, WxHxD [mm]

56.5x108x8

Weight

Approx. 100 g

Operating temperature range

5 °C to 55 °C (condensation free) Convection cooling ensured

EMI, protection class, insulation test, protection type (installed)

Certification

CE, UL, cUL

Interference emission

EN 61000-6-4, industrial application

Interference resistance

EN 61000-6-2, industrial application

Protection class

III

Insulation resistance

EN 61131-2; DC 500 V test voltage

Protection type

IP 20

Supply voltage, current consumption

Module electronics power supply (connection voltage)

5 V / max. 350 mA from the Dialog-Controller’s mains power supply

PROFIBUS-SLAVE interfaces

Number and type of interfaces

1 PROFIBUS-SLAVE interface DP

Potential isolation

Yes

Connection technique

9-pin, Sub-D

Operating and display elements

Display elements

4 diagnostic LEDs

Address switch

Switches not used for applications

Termination

Switchable terminating resistor

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4.3.2. Front view and pin assignment

2VF100310DG00.cdr

External power supply

The PROFIBUS-SLAVE communications interface is supplied from the Dialog-Controller's power supply.

Installation

The PROFIBUS-SLAVE card is factory installed and may only be installed in the Dialog-Controller in the position shown in the figure below.

2VF100311DG00.cdr

 Pin overview

Indicators

Address x1

Termination

ON OFF

Address x10

Profibus

DC Profibus-DPS

Online Offline

n.c. Error1

2 3

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The embedded PROFIBUS-SLAVE module is a complete PROFIBUS-DP SLAVE. It contains all analog and digital components for a high performance PROFIBUS extension circuit. The module is certified and has been tested for inter-operability with many leading PROFIBUS master subassemblies. The onboard micro-

processor automatically performs all PROFIBUS bus traffic thus completely reliving the automation device’s

main processor of any PROFIBUS protocol processing.

The PROFIBUS module supports a maximum PROFIBUS data width of 244 input bytes and 244 output bytes as well as all rates from 9.6 kbit/s to 12 Mbit/s.

NOTICE

The PROFIBUS station address is set with the CODESYS controller configuration. Rotary switches S1 and S2 have no effect and can therefore not be used in an application-specific manner.

PROFIBUS-X1 (jack) pin assignment

Signal

Description

N.C.

Do not connect

N.C.

Do not connect

RS485 signal

RTS

Ready to send

GND

Bus ground

+5 V

Bus (output)

N.C.

Do not connect

RS485 signal

N.C.

Do not connect

Termination, S3

The PROFIBUS has a linear topology. It must be terminated at both ends. The PROFIBUS-SLAVE module has an integrated bus termination which can be activated by a DIP switch (ON position).

Baud rate

The baud rate is automatically detected.

GSD file

The PROFIBUS-SLAVE module is integrated in the CODESYS controller configuration with a GSD file. As of Version 1.10.0, this GSD file will be part of the Berghof Target installation package.

Indicator LEDs

Four diagnostic LEDs indicate the current operating state and any error messages.

 PROFIBUS-SLAVE

interface

 galvanically isolated

field bus interface

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Indicator

Signal

Description

N.C.

Not used

Online Green:

Online / data exchange permitted

Off:

Not online

Offline Red:

Offline, no data exchange possible

Off:

Not offline

Error

Red, flashing at 1 Hz:

Configuration error; initialized data length does not match configuration

Red, flashing at 2 Hz:

Missing user parameter; initialized data length does not match configuration

Red, flashing at 4 Hz:

Initialization error in the ASIC

Off:

No diagnostic data available