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RP GW SECROS III
Instructions
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Instructions
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KUNBUS RP GW SECROS III Instructions

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User manual
Gateway component Sercos
DO0227R00 • 6/28/2016
Table of Contents KUNBUS GmbH

Table of Contents

1 General Information ........................................................................................................................3
1.1 Disclaimer..................................................................................................................................3
1.2 Notes Regarding this User Manual............................................................................................3
1.3 Validity .......................................................................................................................................4
1.4 Limitation of Liability ..................................................................................................................4
1.5 Customer Service ......................................................................................................................4
2 Safe Use ...........................................................................................................................................5
2.1 User ...........................................................................................................................................5
2.2 Symbols.....................................................................................................................................5
3 Overview ..........................................................................................................................................6
3.1 Functionality ..............................................................................................................................6
3.2 Control Elements .......................................................................................................................7
4 Installation .....................................................................................................................................11
5 Configuration.................................................................................................................................17
6 Server .............................................................................................................................................20
7 Technical Data...............................................................................................................................21
ii Gateway component Sercos

1 General Information

1.1 Disclaimer

© 2016 KUNBUS GmbH, Denkendorf (Germany)
The contents of this user manual have been prepared by KUNBUS GmbH with the utmost care. Due to technical development, KUNBUS GmbH reserves the right to change or replace the contents of this user manual without prior notice. You can always obtain the latest version of the user manual at our homepage: www.kunbus.de
KUNBUS GmbH shall be liable exclusively to the extent specified in General Terms and Conditions (www.kunbus.de/agb.html).
The contents published in this user manual are protected by copyright. Any reproduction or use for the in-house requirements of the user is permitted. Reproduction or use for other purposes is not permitted without the express, written consent of KUNBUS GmbH. Contraventions shall result in compensation for damages.
General Information
Trademark protection
– KUNBUS is a registered trademark of KUNBUS GmbH
– Windows® and Microsoft® are registered trademarks of Microsoft Corp.
– Sercos is a registered trademark of Sercos International e. V
KUNBUS GmbH Heerweg 15 c 73770 Denkendorf Germany
www.kunbus.de

1.2 Notes Regarding this User Manual

This user manual provides important technical information that can enable you as a user to integrate the Gateways into your applications and systems efficiently, safely and conveniently. It is intended for trained, qualified personnel, whose sound knowledge in the field of electronic circuits and expertise in SERCOS is assumed.
As an integral part of the module, the information provided here should be kept and made available to the user.
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1.3 Validity

This document describes the application of the KUNBUS Gateway with the product number:
– PR100075, release 00

1.4 Limitation of Liability

Warranty and liability claims will lapse if:
– the product has been used incorrectly,
– damage is due to non-observance of the operating manual,
– damage is caused by inadequately qualified personnel,
– damage is caused by technical modification to the product (e.g.
soldering).

1.5 Customer Service

If you have any questions or suggestions concerning this product, please do not hesitate to contact us:
General Information
KUNBUS GmbH Heerweg 15 C
73770 Denkendorf
Germany
+49 (0)711 3409 7077
support@kunbus.de www.kunbus.de
Gateway component Sercos
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2 Safe Use

2.1 User

The Gateway may only be assembled, installed and put into operation by trained, qualified personnel. Before assembly, it is absolutely essential that this documentation has been read carefully and understood. Expertise in the following fields is assumed:
– electronic circuits,
– basic knowledge of SERCOS,
– work in electrostatic protected areas,
– locally applicable rules and regulations for occupational safety.

2.2 Symbols

The symbols used have the following meaning:
Safe Use
DANGER
CAUTION
NOTICE
Danger
Always observe this information!
There is a safety hazard that can lead to serious injuries and death.
Caution
There is a safety hazard that can result in minor injuries and material damage.
Note
There is a safety hazard that can result in material damage.
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3 Overview

3.1 Functionality

The KUNBUS Gateway is a protocol converter. It allows communication between networks with different protocols.
Overview
Illustration1: Functionality
A Gateway consists of 2 gateway components that master one specific protocol each. You can combine these gateway components as you wish. This design offers you a high degree of flexibility, since you can exchange the individual gateway components at any time. The following gateway components are currently available as slaves:
– CANopen
– CC-Link
– DeviceNet
– EtherCAT
– EtherNet/IP
– Modbus RTU
– Modbus TCP
– POWERLINK
– PROFIBUS
– PROFINET
– Sercos III
Gateway component Sercos
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3.2 Control Elements

1
2
3
Front view
Overview
Illustration2: Front view
1 Status LEDs
for signal display.
2 2 rotary coding switches
for setting the station number.
3 Fieldbus connection
RJ45 socket for the connection to SERCOS and/or general LAN. Auto-Negotiation and Auto-MDI-X are supported. (2 pcs, s. figure top view)
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Top
1
2
3
Overview
Illustration3: Top
1 Fieldbus connection
RJ45 socket for connection to the fieldbus (2 pcs, see figure front view).
2 Interconnect ports
for interconnecting the gateway components.
3 Locking clamps
for securely attaching the gateway component to the DIN rail.
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Bottom
1
2
Overview
Illustration4: Bottom
1 Mains connection
with 24 V power supply
2 Locking clamps
for securely attaching the gateway component to the DIN rail.
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3.3 Status LEDs

The signals of the status LEDs for SERCOS have the following meaning:
Overview
LED designation
Power off Gateway not running
L/A 1 + L/A 2 on, green Connection to another device. No data
SIII Off No communication with Sercos
*Interval: 3 sec
Signal Meaning
flashes, green Initialization phase not yet completed on, green All system components are functioning
perfectly
flashes, red Correctable error (e.g. second gateway
component missing)
Flashes, red and green
on, red Serious error/defect in the gateway
flashes, green Connection established. Data ex-
off No connection.
orange, on Communication phase 0 active orange, flashes
1x green* orange, flashes
2x green* orange, flashes
3x green* green, on Communication phase 4 active green/orange,
flashes green, flashes
1x orange* green, flashes
2x orange* green, flashes RT status changed from Fast-Forward
red/orange, flashes
red/green, flashes
red, on Communication error orange, flashes Device is identified. red, flashes Watchdog Error
Factory reset is executed
exchange takes place.
change takes place.
Communication phase 1 active
Communication phase 2 active
Communication phase 3 active
Device is in the Hot Plug phase 0
Device is in the Hot Plug phase 1
Device is in the Hot Plug phase 2
to Loopback Error in the application.
Communication warning in the device status
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4 Installation

4.1 Preparations for Trouble-free Operation

In the following section we have compiled some general information for you that is important for trouble-free operation. If you are already acquainted with this topic, you can skip to the next section. There, you will learn about which conditions are necessary for installing the gateway.
Cable routing
Route your cables separately in cable groups. This will protect your gateway from any unintended electromagnetic interferences.
The following groups should be routed separately from each other:
Group Line
A Data and power supply lines for:
DC voltage below 60V
AC voltage below 25V
B Data and power supply lines for:
DC voltage between 60V and 400V
AC voltage between 25 and 400V
C Power supply lines above 400V
Installation
– You can route cables of the same group together in cable ducts or
bundles.
– Cables of group A and B:
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 10 cm from each other.
– Cables of group C
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 50 cm from the other
groups.
Shielding
Shield your cables. This will reduce any unintended electromagnetic interferences.
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Potential equalization
Potential differences occur when devices are connected to different earths. These potential differences cause malfunctions.
To prevent malfunctions, you have to route an equipotential equalization conductor.
When doing so, bear in mind the following points:
– Select an equipotential equalization conductor with low impedance.
– Select the following as a reference value for the cross-section of the
potential equalization cable:
– 16 mm2 for potential equalization cables of up to 200 m in length
– 25 mm2 for potential equalization cables of more than 200 m in
length
– Use potential equalization cables made of copper or galvanized steel.
– Connect potential equalization cables extensively with the earth rail.
– The smallest surfaces possible should be sandwiched between
potential equalization cables and signal cables.
If the devices of the control system are connected by shielded signal cables that are earthed on both sides, the impedance must be 10% of the shielding impedance.
Installation
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4.2 Requirements

The Gateway was designed for use in a control cabinet.
NOTICE
ü The protection class of the control cabinet must be equivalent to at least
IP54.
ü For installation in the control cabinet you need a DIN rail 35 x 7.5mm
(EN50022).
◦ Install the DIN rail horizontally in the control cabinet according to the
manufacturers' specifications. When doing so, make sure that the Gateway is at a sufficient distance from other devices.
Your gateway could be damaged if temperatures are too high.
èMake sure that the ambient temperature in the control cabinet is less
than 60°C.
èKeep the ventilation slots unobstructed. These must not be covered by
cables etc.
èMaintain sufficient distance from other devices.
Installation
Illustration5: Distances for installation
◦ Connect each gateway component individually to functional earth.
When doing so, make sure that the power supplies of both gateway components have the same ground.
ð Your control cabinet now meets all requirements for installing the
gateway.
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4.3 Connecting Gateway Components

In order to attain a fully functional gateway, you have to interconnect both gateway components.
◦ Connect an interconnect port to each gateway component using the
plug-in jumper (product number PR100204).
◦
Installation
NOTICE
Gateway component Sercos
Illustration6: Connecting gateway components
ð You can now install the gateway in the control cabinet.
Only ever interconnect 2 gateway components.
If you connect additional components, severe defects could result on all devices.
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4.4 Installing a Gateway in the Control Cabinet

◦ Hold the raster element of the gateway on the DIN rail.
◦ Press down the locking elements towards the gateway.
◦ Make sure that the gateway is firmly attached to the DIN rail.
Installation
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4.5 Connecting a Power Supply

3
1
2
4
To connect the gateway component to the power supply, you need a spring-loaded terminal (e.g. Metz-Connect SP995xxVBNC).
You have to connect each gateway component separately to a power supply. Never interconnect functional earth and GND, otherwise the galvanic isolation between gateway GND and fieldbus ground will be removed. Instead, connect the functional earth with low impedance to the potential equalization. You can then dispense with this connection if the shield of the fieldbus cable is connected to the potential equalization with lower impedance when entering the control cabinet.
Installation
NOTICE
NOTICE
Connect each of the two gateway components to the power supply
èEnsure in particular that no potential differences occur between the
GND pins (2).
Pin assignment:
Pin Assignment
1 24V for module supply 2 GND 3 Do not connect! 4 Functional earth
Do not connect GND to PE
This connection could cause unintended malfunctions.
Gateway component Sercos

4.6 Connecting a Gateway to the Fieldbus

To connect the gateway component to SERCOS, you need one or two cat-5 cables with RJ45 connectors.
The pin assignment complies with the specifications of the Sercos specification.
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5 Configuration

5.1 Supported Size of the Process Data

NOTICE
The gateway component for SERCOS supports process data up to a length of 250 bytes per direction.
Of these 250 bytes, 4 bytes of control data (for Connection Control and I/O-Control/status) are reserved.
Bear in mind that the maximum length of the process data is always determined by the fieldbus with the shorter data length.
Example:
Sercos supports 250 bytes je per direction incl. control data,
PROFIBUS supports 488 bytes
In conjunction with Sercos/ PROFIBUS this means that s 250 bytes are transmitted and updated cyclically.

5.2 Setting Sercos Address

You can set the Sercos Address for the gateway component using the two rotary switches.
Configuration
Value
0 The Sercos Address from the webserver
configuration is used (s. section"Configura­tion of Sercos [}19]"). In this case, the Sercos Address can also be set by the Sercos Master (IDN S-0-1040).
Tip!: You can use a Sercos Address from 1 tos 511 via the Webserver/Sercos-Master.
1-254 Sercos Address that can be set by the rotary
switch.
255 When switching on, all configuration settings
are reset to the factory settings. Then restart the device.
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1
2
Configuration
Illustration7: Coding switch
The station address is set as a hexadecimal.
Example: Setting the station number 18.
Set switch x16 (1) to position "2".
Set switch x1 (2) to position "1".
The settings yield the hexadecimal value 0x12 and the decimal value
18.
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5.3 Sercos Configuration

Prerequisite: You are logged in as "Admin" on the webserver (s. section "Logging into Webserver").
Configuration
Illustration8: Settings for Sercos
You can make the following settings for Sercos:
Value Default Use
Sercos Address 64 Device address for the gateway component.
You can set an address in a value range between 1 and 511.
Connection Length Leaving Slave
Connection Length Towards Slave
18 Determines the maximum lengths of the data
transferred cyclically between the Sercos Master and gateway component.
18
This value containss 4 bytes of control data. Note!: If the input and output data of the partner gateway component is shorter than these val­ues, then they will also be shortened accord­ingly on the Sercos Bus.
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6 Server

6.1 Web Server

The gateway component contains an integrated web server. You can use this via Internet Explorer or Firefox.
With the web server you can configure the gateway component for Sercos.

6.2 FTP Server

The FTP server is necessary for updating HTML files of the web server and for transmitting firmware updates to the module.
As Admin, you can access the FTP server. For this purpose, the same logon data as for the web server is valid.
Server
Web Server Files
You will find files for the web server in the "Web" subfolder.

6.3 TFTP Server

You can access the the gateway component via TFTP. TFTP supports the reading and writing of files. You can, for example, transfer a firmware update file to the gateway component via TFTP.

6.4 Logon data and access rights

You can logon to the webserver and FTP server with the following data:
Username Password Access rights
Admin 1701
User 1111
– Changing configuration
– Viewing current values
– Viewing current values
Gateway component Sercos
Tip!: As Admin, you can change logon data in the web server.
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7 Technical Data

7.1 Technical Data

Dimensions
Width 22.5 mm Height 96 mm Depth 110.4 mm Weight 90 g
Electrical data
Power supply 24 V DC Power consumption during operation
(cyclical data exchange) Status display LED
Environmental conditions
Ambient temperature 0 – 60 °C Storage temperature - 25 – 60 °C Humidity 93% (at 40 °C) Condensing Not allowed Protection class
Control cabinet
Housing
Terminal area
Technical Data
100mA
IP54
IP20
IP20
Assembly data
DIN rail 35 x 7.5 mm Height 96 mm Depth 110.4 mm
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Device data
You can find details on the following basic data in the device description file [SDDML].
Device Name KUNBUS Gateway Sercos3 Manufacturer Number 2000 Vendor Name KUNBUS GmbH Vendor Device ID PR100075 Device type Sercos III Slave Device Sercos Protocol V1.3.1 Sercos Communication Profiles Classes SCP_FixCFG, SCP_TFTP,
SCP_NRTPC, and SCP_SWC
Connection length for input and out­put can be set individually (up to a max. of 250 bytes incl. Connection
Control and I/O Control/Status). Generic Device Profile Class GDP_Basic Function specific Profile IO IO Bus coupler, Digital Input, Digital
Output Features supported 2 Connections (Input or Output) Function Specific Profile FSP IO Sercos Cycle Time 250 µs – 65 ms
Technical Data
Gateway component Sercos
Illustration9: Side dimensions
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Illustration10: Front dimensions
Technical Data
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