This documentation supplements the system manual for the I/O system 1000 by information on
how to configure and parameterise the I/O system with the »PLC Designer« engineering tool.
First, read the I/O system 1000 system manual before you start working.
The system manual includes safety instructions which must be observed!
Target group
This documentation is directed at all persons who would like to parameterise, configure, and
diagnose the L-force I/O system 1000 using the L-force »PLC Designer« engineering tool.
Information regarding the validity
The information provided in this documentation is valid for the following standard devices:
Product seriesType designationVersion
I/O systemsI/O system 1000From hardware version 1B or software version 10
Screenshots/application examples
All screenshots in this documentation are application examples. Depending on the firmware
version of the device and the software version of the installed »PLC Designer«, the screenshots in
this documentation may differ from the screen display.
Document history
VersionDescription
1.211/2012TD05 General revision of the document structure, extension of the module overview by
1.107/2012TD06 Extended by the "Commissioning of a counter" example
1.011/2011TD11 First edition
I/O compound modules EPM-S406 and EPM-S408.
Tip!
Information and tools all about the Lenze products can be found in the Internet:
http://www.Lenze.com
Download
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD053
Engineering toolsSoftware solutions for easy engineering in all phases
»EASY Navigator« – ensures easy operator guidance
• All practical Lenze engineering tools at a glance
• Tools can be selected quickly
• The clarity makes the engineering process easy right from the start
»EASY Starter« – easy-to-use tool for service technicians
• Especially designed for commissioning and maintaining Lenze devices
• Graphic surface with very few icons
• Easy to run online diagnostics, set parameters and perform
commissioning
• No risk of accidentally changing an application
• Loading off-the-shelf applications onto the device
»Engineer« – multi-device engineering
• For all products in our L-force portfolio
• Practical user interface
• Graphic interfaces make it easy to navigate
• Can be applied in every phase of a project (project planning,
commissioning, production)
• Parameter setting and configuration
»PLC Designer« – for programming processes
• The ability to create your own programs
• The ability to program logic & motion in accordance with IEC 61131-3
(AWL, KOP, FUP, ST, AS and CFC-Editor), based on CoDeSys V3
• Function blocks certified according to PLCopen Part 1 + 2
• Graphic DIN 66025 editor (G code) with DXF import
• Integrated visualisation for simple presentation of processes
• All important information at a glance during commissioning
L-force ControllerThe L-force Controller is the central component of the automation system, controlling
the Logic and Motion functionalities (by means of the runtime software).
The L-force Controller uses the fieldbus to communicate with the field devices.
Engineering PCThe Engineering PC with the installed engineering tools serve to configure and
parameterise the system.
The Engineering PC communicates with the L-force Controller via Ethernet.
EtherCAT®EtherCAT® is a registered trademark and patented technology licenced by the Beckhoff
Automation GmbH, Germany.
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD055
Central control technology is increasingly finding its way into automation technology. Due to their
scaling possibilities and the possibilities to combine visualisation and control in one device,
industrial PCs have clear advantages for many applications.
The L-force Controllers are available with the following software programs:
• L-force Controller as control system
• L-force Controller as visualisation system (depending on the model, an additional panel may be
required)
• L-force Controller as component, on request with operating system, without any further
software
The "Controller-based automation" system enables the central control of Logic and Motion systems.
Further information on parameter setting and configuration of the individual bus
systems can be found in the following communication manuals:
• CANopen control technology - Commissioning & Configuration
• EtherCAT control technology - Commissioning & Configuration
• PROFIBUS control technology - Commissioning & Configuration
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD057
• L-force Controller as control and visualisation system
• The L-force Controller is the central component of controller-based automation, controlling
the Logic and Motion functionalities by means of the runtime software.
• The L-force Controller uses the fieldbus to communicate with the field devices.
• Engineering tools for the Engineering PC
• The Engineering PC communicates with the L-force Controller via Ethernet.
• The different engineering tools are used to configure and parameterise the system.
•Fieldbuses
•Field devices
2.2Features of the I/O system 1000
The I/O system 1000 is suitable for the implementation of complex automation applications
consisting of the following components: bus coupler module, I/O compound modules, and
backplane bus.
• Modular system
•Dimensions
• I/O compound module 109×76.5×12.5mm
• Bus coupler module 109 × 76.5 × 48.5 mm
• Mounting on standard DIN rail (35 mm)
• Shield connection to standard metal rail (10 × 3 mm)
• The two-piece structure (separation of electronics and process integration) enables a quick
exchange of modules in the event of service
• Wiring level via spring terminal (max. 1.5 mm²)
• Operation at DC 24 V (DC 20.4 … DC 28.8 V)
• Supply voltage of electronics and process level are separated
• Number of I/O compound modules
• A bus coupler can contain up to 64 modules
• Individual labelling by insertable labels (item designation)
• Electrical wiring diagrams are directly printed on the module
• Electrical isolation to the fieldbus and the process level
• Creation of electrical isolations by power supply modules
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Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD05
Type designationShort designationDescriptionProcess data
EPM-S502AO2, 12BIT, DC 0/4…20mA2 analog outputs, 0/4 … 20 mA4 bytes
EPM-S503AO4, 12BIT, DC 0/4…20mA4 analog outputs, 0/4 … 20 mA8 bytes
Temperature measurement
EPM-S404AI2, 16bits, resistor4 analog inputs
for resistance measurement
EPM-S405AI2, 16bits, thermo2 analog inputs
for thermocouple measurement
Numerator
EPM-S600Counter 1, DC 24V1 counter 32 bits, 24 V DC
(reading, setting, comparing)
EPM-S601Counter 2, DC 24V2 counters 32 bits, 24 V DC
(reading, setting)
EPM-S602Counter 1, DC 5V1 counter 32 bits, 5 V DC
(reading, setting)
EPM-S603Counter 2, DC 24V2 counters 32 bits, 24 V DC
(reading)
Encoder evaluation
EPM-S604SSI1 SSI absolute value encoder6 bytes, reading
Pulse width modulation
EPM-S620PWM 2, DC 24V2 digital outputs, 0.5 A PWM12 bytes, reading
Communication
EPM-S640RS232RS232 module-
EPM-S650RS422/RS485RS485 module-
4 bytes
4 bytes
12 bytes, reading
10 bytes, writing
12 bytes, reading
12 bytes, writing
8 bytes, reading
10 bytes, writing
12 bytes, reading
4 bytes, writing
4 bytes, writing
Note!
I/O compound modules EPM-S207/EPM-S310
• If, for instance, motor positions are to be evaluated via these modules, additional
modules with ticker function as e.e.g. EPM-S600 (HTL), EPM-S602 (TTL) or EPM-S604
(SSI) are required for detecting the encoder signals.
• Only if the modules EPM-S207 and EPM-S310 are connected to the backplane bus of
the L-force Controller: The following modules are available in the
"L_SM3_DriveUtil.lib" function library for the I/O system 1000:
• L_SMC_AbortTrigger_FastIO
• L_SMC_TouchProbe_FastIO
• More information can be obtained from the online help for the function library.
I/O compound modules EPM-S640/EPM-S650
• For using the modules EPM-S640 and EPM-S650, the "L_COM_EPMS640" function
library is available.
• More information can be obtained from the online help for the function library.
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0511
3Establish communication
3.1Establishing communication with the L-force Controller
4Mapping the real station structure in the »PLC Designer«
4.1Creating a new project in the »PLC Designer«
You can create a new project in the »PLC Designer« without having to establish an online
connection. After having configured the project, go online with the I/O system 1000 to transfer
parameters.
How to create a new project in the »PLC Designer«:
1. Select menu command FileNew project to create a new »PLC Designer« project.
2. Go to the New project dialog window and select the "Standard project" template.
• Go to the Name input field and assign a name for the »PLC Designer« project.
• Select the desired memory location under Location.
3. Confirm the entries by clicking OK.
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Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD05
4Mapping the real station structure in the »PLC Designer«
4. Go to the Standard project dialog window and select the "L-force Controller 3200 C Logic
(Lenze)" in the Device selection list.
In the PLC_PRG in selection list, you can additionally select a programming language:
• Sequential function chart (SFC)
• Instruction list (IL)
• Continuous function chart (CFC)
• Function block diagram (FBD)
• Ladder diagram (LD)
• Structured text (ST)
5. Confirm the selection by clicking OK.
Next steps:
The following chapters describe by means of examples how to add the available I/O system to the
device view of the »PLC Designer« depending on the fieldbus used:
Configuring the I/O modules at the backplane bus of the L-force Controller
Configuring I/O modules on the EtherCAT bus coupler module
Configuring I/O modules on the CANopen bus coupler module
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0515
4Mapping the real station structure in the »PLC Designer«
4.2Configuring the I/O modules at the backplane bus of the L-force Controller
4.2Configuring the I/O modules at the backplane bus of the L-force Controller
The L-force Controller consists of the following components:
• I/O bus coupler module: controller with a PLC control in the form of a soft PLC.
• I/O compound modules: Up to 64 modules which are connected to the controller via the Lenze
backplane bus.
[4-1]Schematic hardware installation with added I/O compound modules
In order to be able to access the modules by means of a PLC program (reading input signals and
writing output signals), the real station layout, i.e. the physical arrangement of the I/O compound
modules in the device view of the »PLC Designer«:
[4-2]Example: Mapping of the physical topology (module 1 to module 7) in the device view in the »PLC Designer«
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4Mapping the real station structure in the »PLC Designer«
4.2Configuring the I/O modules at the backplane bus of the L-force Controller
The following step-by-step instructions describe by means of an example the manual
the available station layout in the device view of the »PLC Designer».
Tip!
When an online connection has been established to the L-force Controller, you can also
start an automatic search to I/O compound modules available on the backplane bus of the
L-force Controller by executing the Search devices... command in the context menu of the
"I_O_Module_Coupler.
How to map the station layout in the device view of the »PLC Designer»:
1. Go to the context menu of the "I_O_Module_Coupler" and execute the Add device...
command:
mapping of
2. Select the physically fist I/O compound module in the Add device dialog box (for this
example, an "EPM-S200" has been selected):
3. Click Add device to add the selected device to the "I_O_Module_Coupler".
•The Add device dialog box remains open.
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0517
4Mapping the real station structure in the »PLC Designer«
4.2Configuring the I/O modules at the backplane bus of the L-force Controller
4.3Configuring I/O modules on the EtherCAT bus coupler module
Note!
Observe the following conditions before creating an EtherCAT configuration in the »PLC
Designer«:
• The sequence of the EtherCAT slaves in the device view has to correspond to the
physical order of the EtherCAT topology.
• For a proper function, do not use any end terminals when establishing the system
configuration in the device view.
• Select cycle times of 1 ... 10 ms according to the technical data.
The following step-by-step instructions describe by means of an example the manual mapping of
the available station layout in the device view of the »PLC Designer».
Tip!
When an online connection has been established to the L-force Controller, you can also
start an automatic search for available devices via fieldbus scan by executing the Searchdevices... command after adding the EtherCAT master (step 3) in the context menu of the
EtherCAT master.
How to map the station layout in the device view of the »PLC Designer»:
Adding the EtherCAT master
1. Go to the context menu of the L-force Controller and execute the Add device... command:
2. Select the "EtherCAT master" device in the Add device dialog box:
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0519
4Mapping the real station structure in the »PLC Designer«
4.3Configuring I/O modules on the EtherCAT bus coupler module
4.4Configuring I/O modules on the CANopen bus coupler module
Note!
An L-force Controller in the CANopen network is to be configured in the »PLC Designer«
since the complete configuration is written to the connected slaves when the L-force
Controller is started. During this process, previous settings in slaves are overwritten.
The following step-by-step instructions describe by means of an example the manual mapping of
the available station layout in the device view of the »PLC Designer».
Tip!
When an online connection has been established to the L-force Controller, you can also
start an automatic search for available devices via fieldbus scan by executing the Searchdevices... command after adding the CANopen master (step 6) in the context menu of the
CANopen master.
How to map the station layout in the device view of the »PLC Designer»:
Adding the CANbus
1. Go to the context menu of the L-force Controller and execute the Add device... command:
2. Select the "CANbus" device in the Add device dialog box:
22
3. Click Add device to add the selected device to the L-force Controller.
•The Add device dialog box remains open.
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD05
4Mapping the real station structure in the »PLC Designer«
4.4Configuring I/O modules on the CANopen bus coupler module
12. Add all other available I/O compound modules of the device view in the same way.
• Exemplary respresentation:
13. Click Close to close the Add device dialog box again.
Setting the CAN baud rate
14. Click the "CANbus" device in the device view to open its settings.
15. Set the baud rate on the CANbus tab:
Note!
• The baud rate set in the »PLC Designer« overwrites the baud rate set for the field devices
via »WebConfig«/»EASY Starter«/»Engineer«/»Global Drive Control«.
• In a CANopen network, set the same baud rate for all nodes.
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4Mapping the real station structure in the »PLC Designer«
4.4Configuring I/O modules on the CANopen bus coupler module
4.4.1Special features of the CANopen bus coupler module (EPM-S110)
Note!
Before inserting I/O compound modules below a CANopen bus coupler module (EPMS110) in the »PLC Designer«, close the tab to the EPM-S110.
• When inserting I/O compound modules while the tab is open, no
displayed for the modules.
• When all I/O compound module are inserted, the tab to the EPM-S110 can be opened
again.
When the counter modules (EPM-S600 ... S604) at the CANopen bus coupler module (EPM-S110) are
used, the following sequence has to be complied with during configuration.
How to configure the EPM-S600 ... S604 counter modules:
1. Add CANopen bus coupler module (EPM-S110) to the device view.
I/O image is
2. Add I/O discs and counter discs.
3. Click the "EPM_S110" device in the device view S110to open its settings.
4. On the CANopen Remote Device tab:
• Activate the Expert settings option.
• Deactivate the Autoconfig. PDO Mapping option.
5. Execute the menu command WindowClose All Editors.
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4Mapping the real station structure in the »PLC Designer«
4.4Configuring I/O modules on the CANopen bus coupler module
The following example uses a send PDO and a mapping element to describe the basic
configuration process.
• Proceed accordingly when configuring the transmit PDOs (Send PDO Mapping tab).
6. Click the "EPM_S110" device in the device view S110to open its settings.
7. Click Add PDO... on the Receive PDO Mapping to add receive PDOs.
• Depending on the counter discs used, one or several PDOs must be added in send and
receive direction.
• Please refer to the module documentation to see which additional elements of the
process image of the counter modules are required for operation.
8. Select added PDOs and click Add Mapping....
• Select the corresponding settings in the dialog box that appears.
Note!
If Autoconfig. PDO Mapping (see step 3) is reactivated after adding the manual
configuration, the entire configuration that has been added manually will be deleted.
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0527
4Mapping the real station structure in the »PLC Designer«
4.4Configuring I/O modules on the CANopen bus coupler module
When the program starts, the control initialises the I/O system. It changes to the "Operational"
status. While the control initialises the I/O system, the »PLC Designer« must not be online on the
same SDO channel.
There are different methods for restarting the I/O system: automatically with the »PLC Designer«,
or automatically with the factory adjustment (see below).
For the corresponding settings, first tick the "Expert settings" on the CANopen Remote Device tab.
Automatically
You want the control to automatically initialise the I/O system after the device has been replaced.
• Enter all required parameter values on the Service Data Objects tab.
•On the CANopen Remote Device tab ...
• do not
• tick "Create all SDOs" in order that the control initialises all parameters.
tick the "Factory Settings" in order that the control does not execute a factory
adjustment;
• After the I/O system has been changed: Set the node address and the baud rate at the coding
switch and then start the control.
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4Mapping the real station structure in the »PLC Designer«
4.4Configuring I/O modules on the CANopen bus coupler module
14. Select the "Counter Control Word" with the subindex 1(":16#01") in the Select item from object directory dialog box (this starts the counter later):
15. Click OK to accept the selection and close the dialog box again.
Configuring Send PDO Mapping
16. Execute the "Send PDO Mapping" the same way as the "Receive PDO Mapping" before.
Observe the following:
• Select "cyclic - synchronous (type 1-240)" as transmission type.
• Select the "Counter Value" with the subindex 1 (":16#01") in the Select element from object directory dialog box:
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4Mapping the real station structure in the »PLC Designer«
4.4Configuring I/O modules on the CANopen bus coupler module
4.5Setting the cycle time for access to the I/O modules
In the L-force Controller a central bus cycle task is selected, which is valid for the processing of all
fieldbuses and for the I/O modules connected via the backplane bus.
• This selection is a default setting and can be overwritten in the respective bus master nodes
• If you require a shorter cycle time for the backplane bus that the one selected in the L-force
Controller, you can select a faster task for the I_O_Modul_Koppler on the Module I/O Mapping
tab:
The following applies to the I/O modules on the I_O_Modul_Koppler:
• At first, the »PLC Designer« defines a processing task for the PLC for generating the I/O image.
An individual bus cycle task can be defined for each individual module, within which the process
image for the module is then created.
• Altogether three different tasks for the I/O modules can be defined. The limitation to three
tasks is determined by the system on the basis of the backplane bus specification.
• The backplane bus controller uses two internal bus cycle groups for each task; one for input
signals and one for the outputs. A total of six groups is provided.
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5Parameterising I/O modules in the »PLC Designer«
5.1Parameterising I/O modules at the backplane bus of the L-force Controller
By means of examples, this chapter describes how to parameterise I/O compound modules in the
»PLC Designer«.
5.1Parameterising I/O modules at the backplane bus of the L-force Controller
If you double-click an I/O compound module in the Device view of the PLC Designer, the settings and
properties of the I/O compound module are displayed in the Editor view.
•The Parameter tab serves to make the settings desired for the selected I/O compound module
(for this example, an "EPM-S400" has been selected):
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0535
5Parameterising I/O modules in the »PLC Designer«
5.2Parameterising I/O modules on the EtherCAT bus coupler module
5.2Parameterising I/O modules on the EtherCAT bus coupler module
If you double-click the EtherCAT bus coupler module (EPM-S130) in the Device view of the PLC
Designer, the settings and properties of the bus coupler module are displayed in the Editor view.
•The All parameters tab displays the parameters of the bus coupler module and all attached I/O
compound modules in a hierarchical structure.
• The following example displays the setting parameters of an "EPM-S400":
Optionally, you can display the settings and properties of an individual I/O compound module by
double-clicking the corresponding one in the Device view.
•The Modules tab serves to make the settings desired for the selected I/O compound module (for
this example, an "EPM-S400" has been selected):
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5Parameterising I/O modules in the »PLC Designer«
5.3Parameterising I/O modules on the CANopen bus coupler module
5.3Parameterising I/O modules on the CANopen bus coupler module
If you double-click the CANopen bus coupler module (EPM-S110) in the Device view of the PLC
Designer, the settings and properties of the bus coupler module are displayed in the Editor view.
•The All parameters tab displays the parameters of the bus coupler module and all attached I/O
compound modules in a hierarchical structure.
• The following example displays the setting parameters of an "EPM-S400":
Optionally, you can display the settings and properties of an individual I/O compound module by
double-clicking the corresponding one in the Device view.
•The Modules tab serves to make the settings desired for the selected I/O compound module (for
this example, an "EPM-S400" has been selected):
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0537
5Parameterising I/O modules in the »PLC Designer«
5.3Parameterising I/O modules on the CANopen bus coupler module
The diagnostics tab of the "I_O_Modul_Koppler" displays the total error status of the I/O system
and the current error status of the available I/O compound modules.
• In the following example, the represented station structure in the device view is faulty and thus
the I/O compound module EPM-S503 at the backplane bus is not available:
Short overview of the possible error messages
Error numberError textRemedy
11Too many I/O modules for the task cycle time selectedIncrease cycle time
12FIFO response fullContact Lenze
32Timeout resetContact Lenze
33Timeout reset errorContact Lenze
96Too many I/O modules for the task cycle time selectedIncrease cycle time
97Too many I/O modules for the task cycle time selectedIncrease cycle time
98Too many I/O modules for the task cycle time selectedIncrease cycle time
99Too many I/O modules for the task cycle time selectedIncrease cycle time
100Too many I/O modules for the task cycle time selectedIncrease cycle time
101Timeout for master queue operationContact Lenze
102Bus initialisation error with one I/O moduleContact Lenze
103Master queue operation error
Not all I/O modules can be reached
104Read semaphore timeout for group 1
105Read semaphore timeout for group 2
106Read semaphore timeout for group 3
107Write semaphore timeout for group 1
108Write semaphore timeout for group 2
109Write semaphore timeout for group 3
110Internal backplane bus hardware errorContact Lenze
116Read semaphore timeout for group 1
117Read semaphore timeout for group 2
118Read semaphore timeout for group 3
119Write semaphore timeout for group 1
120Write semaphore timeout for group 2
121Write semaphore timeout for group 3
136Configuration error in the topology of the I/O modulesCheck sequence of the I/O
Contact Lenze
modules in the device view.
Lenze · I/O system 1000 · commissioning guidelines for the PLC Designer · DMS 1.2 EN · 11/2012 · TD0539
Configuring, station structure 14
Conventions used 4
D
Device architecture, I/O system 1000 9
Document history 3
E
E-mail to Lenze 42
Establishing communication with the L-force Controller 12
F
Feedback to Lenze 42
M
Mapping the station structure in the PLC Designer 14
N
New project, creating 14
P
Parameter settings, I/O system 1000 35
Project, creating 14
Properties, I/O system 1000 8
S
Safety instructions 6
Structure of safety instructions 6
Structure of the safety instructions 6
T
Target group 3
Terminology used 5
V
Validity, information regarding 3
Lenze · I/O-System 1000 · Inbetriebnahme-Leitfaden für den PLC Designer · DMS 1.2 EN · 11/2012 · TD0541
Your opinion is important to us
)(('%$&.
We have created these instructions to the best of our knowledge
with the objective of providing you with the best possible support
when handling our product.
Perhaps we did not succeed in every aspect. If you have suggestions
for improvement, please e-mail us to:
feedback-docu@Lenze.de
Thank you very much for your support.
Your Lenze documentation team
42
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I/O system 1000 · commissioning guidelines for the PLC Designer · EDSPMIO1000 · 13395451 · DMS 1.2 EN · 11/2012 · TD05