Technical Documentation · 2012. 6. 20. · Berger Lahr GmbH & Co. KG Breslauer Str. 7 D-77933 Lahr...

Berger Lahr GmbH & Co. KGBreslauer Str. 7D-77933 Lahr

Technical Documentation

Berger Lahr Controls

BLC3Document: 0098441113337 / EN

Version: 1.0, 02.2007

PB-DP ENC COM

CAN 2 CAN 1

CAN CAN 2 PB-DP TX ERR RX LAN

SERCOS

USB

CF-CARD

-2 Berger Lahr Controls

BLC3

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BLC3

Berger Lahr Controls -1

Table of Content

Important information

Writing conventions and symbols

1 Introduction

1.1 Scope of supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Components and interfaces . . . . . . . . . . . . . . . . . . . . 1-3

1.4 Documentation and literature references . . . . . . . . . . 1-6

1.5 Directives and standards. . . . . . . . . . . . . . . . . . . . . . . 1-6

1.6 Declaration of conformity. . . . . . . . . . . . . . . . . . . . . . . 1-7

2 Safety

2.1 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3 Hazard categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.4 General safety instructions . . . . . . . . . . . . . . . . . . . . . 2-3

3 Technical Data

3.1 Testing agencies and certificates . . . . . . . . . . . . . . . . 3-1

3.2 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Mechanical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.4.1 Inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.4.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.4.3 Processor, memory and Compact Flash Card . . . . 3-6

4 Installation

4.1 Electromagnetic compatibility, EMC . . . . . . . . . . . . . . 4-1

4.2 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54.3.1 Connecting the 24 V supply voltage . . . . . . . . . . . . 4-64.3.2 Connection of inputs and outputs . . . . . . . . . . . . . . 4-74.3.3 Connection to the Ethernet interface . . . . . . . . . . . 4-84.3.4 Connection to the CAN interface . . . . . . . . . . . . . . 4-94.3.5 Connection to the RS232 interface. . . . . . . . . . . . 4-114.3.6 Connection of the RS422 encoder input. . . . . . . . 4-124.3.7 Connecting the Sercos interface. . . . . . . . . . . . . . 4-134.3.8 Connection to the Profibus interface. . . . . . . . . . . 4-144.3.9 Connection to the CAN Sync interface . . . . . . . . . 4-15


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5 Commissioning

5.1 Overview of menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Starting up device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Establish connection to the device . . . . . . . . . . . . . . . . 5-45.3.1 Establishing network connection . . . . . . . . . . . . . . . 5-45.3.2 Establish FTP-connection . . . . . . . . . . . . . . . . . . . . 5-4

5.4 Configure device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.5 Send and load application . . . . . . . . . . . . . . . . . . . . . . 5-8

6 Operation

6.1 Clone device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Executing a software update . . . . . . . . . . . . . . . . . . . . 6-1

6.3 Using a new Compact Flash Card . . . . . . . . . . . . . . . . 6-2

6.4 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

7 Diagnostics and troubleshooting

8 Accessories and spare parts

9 Service, maintenance and disposal

9.1 Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.3 Shipping, storage, disposal. . . . . . . . . . . . . . . . . . . . . . 9-1

10 Glossary

10.1 Units and conversion tables . . . . . . . . . . . . . . . . . . . . 10-110.1.1 Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.1.2 Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.1.3 Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.1.4 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.1.5 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210.1.6 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210.1.7 Moment of inertia . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210.1.8 Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210.1.9 Conductor cross section . . . . . . . . . . . . . . . . . . . . 10-2

10.2 Terms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . 10-3

10.3 Product name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Index

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Important information

The drive systems described here are products for general use that con-form to the state of the art in technology and are designed to prevent any dangers. However, drives and drive controllers that are not specifically designed for safety functions are not approved for applications where the functioning of the drive could endanger persons. The possibility of unexpected or unbraked movements can never be totally excluded wit-hout additional safety equipment. For this reason personnel must never be in the danger zone of the drives unless additional suitable safety equipment prevents any personal danger. This applies to operation of the machine during production and also to all service and maintenance work on drives and the machine. The machine design must ensure per-sonal safety. Suitable measures for prevention of property damage are also required.

See safety section for additional critical instructions.

Not all product variants are available in all countries.Please consult the current catalogue for information on the availability of product variants.

We reserve the right to make changes during the course of technical de-velopments.

All details provided are technical data and not promised characteristics.

In general, product names must be considered to be trademarks of the respective owners, even if not specifically identified as such.


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BLC3


Writing conventions and symbols

Work steps If work steps must be carried out in sequence, they are shown as fol-lows:

� Special prerequisites for the following work steps

� Step 1

� Important response to this work step

� Step 2

If a response to a work step is specified, this will inform you that the step has been carried out correctly.

Unless otherwise stated, the individual instruction steps must be carried in the given sequence.

Lists Lists can be sorted alphanumerically or by priority. Lists are structured as follows:

• Point 1

• Point 2

– Subpoint to 2

– Subpoint to 2

• Point 3

Making work easier Information on making work easier can be found at this symbol:

This offers supplementary information on making work easier.See the chapter on safety for an explanation of the safety instructions.


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BLC3 Introduction

Berger Lahr Controls 1-1

1 Introduction

1.1 Scope of supply

Figure 1.1 Scope of supply of BLC3

Scope of supply of MotionController

The scope of supply of the BLC3 Motion Controller includes:

� After receiving the package make sure that all parts listed in the scope of supply are included in the package.

� Keep the original packaging in case it is necessary to return the device to the manufacturer for expansion or repair.

PB-DP ENC COM

CAN 2 CAN 1


SERCOS

USB

CF-CARD

Quantity Designation Order number

1 BLC3 Motion Controller BLC382TCPUS1S with Compact Flash memory card 128MB with Profibus interface

BLC3 Motion Controller BLC382TCNUS1S with Compact Flash memory card 128MB without Profibus interface

simplified manual

0086 504 000 202

0086 504 000 200

0000 003 900 033

8 Plug for I/O connection

1-2 Berger Lahr Controls

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1.2 Unit overview

Figure 1.2 BLC3 Motion Controller

The Berger Lahr BLC3 Controller is a Motion Controller with integrated powerful soft PLC. The BLC3 has web visualisation by 3S. A Modbus server is implemented, which simplifies the connection of Magelis ter-minals (XBT series) from Schneider Electric via RS232 or Ethernet. Not only can movements be coordinated but also highly synchronous move-ments can be implemented.

The BLC3 can control at least 24 drives synchronously through the Ser-cos interface. In combination with other Berger Lahr products the most demanding motion profiles can be implemented.

With the addition of a CANsync interface it is possibleto run synchronous movements.

An incremental or SSI encoder interface is available for input of refer-ence values.

Areas of application • Autonomous production cells that require movement and PLC func-tions. The BLC3 can partially replace a conventional PLC in produc-tion cells of this type.

• Applications that require coordinated or stand-alone movement, such as pick & place, handling, assembly and testing.

• Applications that require a connection to the company network.

• Applications that require travelling over paths, such as application of adhesive, cutting shapes and figures, axis portals or XY tables.

• Applications that require technology functions such as cam profiles, cam switching or synchronous angular movement.

• The BLC3 can replace demanding axis movements in master-slave synchronisation or NC axes by spline, parabolic, circular or linear interpolation.

• Intelligent Gateway

PB-DP ENC COM

CAN 2 CAN 1


SERCOS

USB

CF-CARD

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BLC3 Introduction


Movement functions Industry-independent movement functions such as:

• Reference movements

• Manual mode

• Profile position

• 2.5 D interpolation

• Cam profiles

• Can switching

• Synchronous angular movement

• Highly synchronous movements, such as electronic gear

Programming system All Berger Lahr controllers can be programmed with one single program-ming tool. Berger Lahr supplies these tools on a CD-ROM. For program-ming all languages of IEC 61131-3 (IL, KOP, FUP, AS, CFC) can be used. PLCopen blocks are available for all languages. Function blocks that comply with the PLCopen guidelines are available for all functions of Berger Lahr drives. User programs are transferred from the program-ming PC to the BLC3 over Ethernet.

1.3 Components and interfaces

Figure 1.3 Overview of BLC3

(1) 2 CANopen master interfaces(2) RS232 interface(3) Encoder interface(4) Profibus interface (optional)(5) Sercos interface(6) 2 USB connections(7) Ethernet connection(8) Display(9) Control panel(10) Inputs and outputs

The CANsync connection is optional.

SERCOS

CF-CARD

CAN 1 CAN 2 COM ENC PB-DP

CAN CAN 2 PB-DP TX ERR RX LANUSB

� � � � �

� � �

� � � �


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CANopen master 2 CANopen interfaces for monitoring drive axes, CANopen slave de-vices and Berger Lahr drives with CANopen implementation.

RS232 The RS232 connection is the communications interface of the device for connection of an operating terminal.

Encoder For detection of the angular position of a rotating component.

Profibus slave (optional) The BLC3 is also optionally available with a Profibus DP slave. This ex-tension allows information to be received from a Profibus master and the programming to be extended correspondingly. The BLC3 sends status information such as device status and processing status back to the master device as acknowledgment. The data traffic is implemented by a communication protocol, which controls data exchange between master and slave cyclically. Every device is identified by a unique specified de-vice address. The Profibus slave address is set with the controller con-figuration in the Berger Lahr programme tool. The baud rate is determined by the transmission speed of the master device.

Sercos Sercos master supports at least 24 axes. The cycle time of the setpoint value calculation depends on the functions to be calculated and the ac-tual number of connected drives. Sercos is an optical bus system with ring topology. The communication protocol is in accordance with Servos V2. All internal device data, parameters and diagnostic results can be displayed and input with a Sercos interface.

USB 1.0 Interface for transmission of programs and configurations to a USB memory stick for copy to devices or to update software. The USB mem-ory is available as an accessory for the copy function. The format must not be modified. The USB memory is not intended as an accessory for the update function. You can use any standard USB stick.

Ethernet The following functions can be run over Ethernet:

• Operating system update

• Debug applications

• Transfer files via FTP

• Transfer boot projects

• Exchange process data with higher level host systems with OPC mechanisms

Display and control panel Display of device status, operation.

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BLC3 Introduction


LED For display of status or functions of interfaces. The red and green signal can be superimposed; then the red signal is dominant.

The CANsync interface does not have status LEDs, and therefore does not have a status display.

Compact Flash Card Contains the operating system, and is used to store user programs and configurations.

Inputs and outputs The BLC3 has the following inputs and outputs:

• 1 analogue input

• 24 digital inputs

• 10 capture inputs for high accuracy position capture

• 1 analogue output

• 16 digital outputs

All inputs and outputs are freely programmable.

24V power supply The device is supplied with power through the input/output blocks.

Interface Status Colour of LED

Sercos Receive active = RX yellow

Transmit active = TX green

Error = ERR red

CAN 1 or CAN 2 ACTIVE green

Error red

Initialising / booting green flashing

Master stopped green single flash

Warning level red single flash

Heartbeat, guarding error

red double flash

not ready green / red off

Profibus (optional) ACTIVE green

Error red

LAN / Ethernet Physical connection exists, transmission activity

green


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1.4 Documentation and literature references

Manuals • Berger Lahr CD-ROM (ACC 4PACDS0001XX) contains the pro-gramming system with all libraries for all Berger drives, including online help.

• CoDeSys; manual for PLC programme development with CoDeSys in German and English. After installation of the CoDeSys software in the table of contents the software is available.

BERGER LAHR manuals on fieldbuses:

• CAN

• CANopen

• Profibus DP

• RS232

EMC • Installation instructions and assistance for EMC-compliant design of BERGER LAHR motor drives, order no.: 9844 1113 075

1.5 Directives and standards

CE mark With the declaration of conformity and the CE mark on the product the manufacturer certifies that the product complies with the requirements of all relevant EC directives.

EC Machine Directive The drive systems described here are not machines as defined by the EC Machine Directive (98/37/EEC) but components for installation in machines. They do not have moving parts designed for specific pur-poses. However, they can be components of a machine or system.

The manufacturer must certify that the complete system conforms to the machine directive with the CE mark.

EC EMC Directive The EC Electromagnetic Compatibility Directives (93/97/EEC) applies to products that cause electromagnetic interference or whose operation may be adversely affected by electromagnetic interference.

Conformity with the EMC Directive can only be expected for the drive systems after correct installation in the machine. The information on en-suring electromagnetic compatibility given in the chapter on "Installa-tion" must be followed to ensure that the drive system in the machine or system is EMC-compatible and that the product can legally be operated.

EC Low-Voltage Directive The EC Low-Voltage Directive (93/68/EEC) lays down safety require-ments for 'electrical equipment' as protection against the risks that can originate in such devices and can be created in response to external in-fluences.

The drive systems described here comply with the EN 50178 Standard as per the Low Voltage Directive.

Declaration of conformity The declaration of conformity certifies that the drive system complies with the specific EC directive.

Standards for compliance with EMClimit values

EN55011 Limits and methods of measurement for EMC

EN 61131-2: Programmable Logic Controllers

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BLC3 Introduction


1.6 Declaration of conformity

Figure 1.4 Declaration of Conformity in accordance with the EC Low VoltageDirective

EC Declaration of Conformity Year 2003

Designation: BLC382TCPUS1S, BLC382TCNUS1S

Type: Motion Controller

Product number: 86 504 000 20X

Company stamp:

Date/Signature: 12.07.2006

Name/Department: R. Berner / Location management

Applied harmonized standards, especially:

Applied national standards and technical specifications, especially:

according to EC Low-voltage directive 73/23/EECchanged by CE Marking Directive 93/68/EECaccording to EC Directive on Machinery 98/37/ECaccording to EC Directive EMC 2004/108/EC

BERGER LAHR GmbH & Co. KGMaybachstr. 13D-88094 Oberteuringen

EN 61131-2:2003-08

UL 508C

We declare that the products listed below meet the requrement of the mentioned EC Directives with respect to design, construction and version distributed by us. This declaration becomes invalid with anymodification on the products not authorized by us.


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BLC3 Safety


2 Safety

2.1 Qualification of personnel

Only technicians who are familiar with and understand the contents of this manual and the other relevant manuals are authorised to work on and with this drive system. The technicians must be able to detect po-tential dangers that may be caused by setting parameters, changing pa-rameter values and generally by the mechanical, electrical and electronic equipment.

The technicians must have sufficient technical training, knowledge and experience to recognise and avoid dangers.

The technicians must be familiar with the relevant standards, regulations and safety regulations that must be observed when working on the drive system.

2.2 Intended use

The drive systems described here are products for general use that con-form to the state of the art in technology and are designed to prevent any dangers. However, drives and drive controllers that are not specifically designed for safety functions are not approved for applications where the functioning of the drive could endanger persons. The possibility of unexpected or unbraked movements can never be totally excluded with-out additional safety equipment. For this reason personnel must never be in the danger zone of the drives unless additional suitable safety equipment prevents any personal danger. This applies to operation of the machine during production and also to all service and maintenance work on drives and the machine. The machine design must ensure per-sonal safety. Suitable measures for prevention of property damage are also required.

In the system configuration described the drive systems must be used in industrial applications only and must have a fixed connection only.

In all cases the applicable safety regulations and the specified operating conditions, such as environmental conditions and specified technical data, must be observed.

The drive system must not be commissioned and operated until com-pletion of installation in accordance with the EMC regulations and the specifications in this manual.

To prevent personal injury and damage to property damaged drive sys-tems must not be installed or operated.

Changes and modifications of the drive systems are not permitted and if made all no warranty and liability will be accepted.

The drive system must be operated only with the specified wiring and approved accessories. In general, use only original accessories and spare parts.


Safety BLC3

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2.3 Hazard categories

Safety notes and general information are indicated by hazard messages in the manual. In addition there are symbols and instructions affixed to the product that warn of possible hazards and help to operate the prod-uct safely.

Depending on the seriousness of the hazard, the messages are divided into three hazard categories.

@DANGERDANGER indicates an imminently hazardous situation, which, if not avoided, will result in death, serious injury, or equipment damage.

@ WARNINGWARNING indicates a potentially hazardous situation, which, if not avoided, can result in death, serious injury, or equipment damage.

@ CAUTIONCAUTION indicates a potentially hazardous situation, which, if not avoided, can result in injury or equipment damage.

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BLC3 Safety


2.4 General safety instructions

@DANGERRisk of injury with complex systems

Serious injuries may be caused in the action zone of the moving sys-tem components.

Make sure that there are no persons in the range of action of the mov-ing system components when starting the systems.

Failure to follow these instructions will result in death or serious injury.

@DANGERMotor out of view

When the system is started the drives are generally out of the opera-tor's view and cannot be visually monitored.

• Only start the system if there are no persons in the operating zone of the moving components and the system can be operated safely.


@ WARNINGLoss of control

• Observe the accident prevention regulations. (For USA see also NEMA ICS1.1 and NEMA ICS7.1)

• The system manufacturer must take the potential error possibili-ties of the signals and the critical functions into account to ensure a safe status during and after errors. Some examples are: emer-gency stop, final position limitation, power failure and restart.

• The assessment of error possibilities must also include unex-pected delays and the failure of signals or functions.

• Suitable redundant control paths must be in place for dangerous functions.

• Check that measures taken are effective.

Failure to follow these instructions can result in death or serious injury.


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BLC3 Technical Data


3 Technical Data

3.1 Testing agencies and certificates

This product or functions of this product have been certified by the fol-lowing independent testing agencies:

3.2 Environmental conditions

Testing agency Assigned number

UL E171323

IGS applied for

Ambient temperature [°C] +5 ... +50

Average temperature over 24h [°C] max.+35

Transport and storage temperature [°C] -40° to +70

Relative humidity [%] 10 to 95(no condensation permissible)

Protection class(as per EN 50178:1997-07 and EN 61140:2003-08)

3

Pollution degree(as per EN 50178:1997-07)

2

Installation height above mean sea level

[m] < 2000

Oscillation and vibration as per EN 61131-2:2003

Shock as per EN 61131-2:2003

EMC Class C2


Technical Data BLC3

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3.3 Mechanical data

3.4 Electrical Data

3.4.1 Inputs and outputs

I/O terminal clamps Each of the 4 I/O blocks has its own power supply

Weight [kg] 2

Degree of protection IP20

Dimensions:widthheightdepth

[mm]203265102

Interfaces 2 x CAN in / out (electrically isolated)CANsync (optional)Sercos IIserial interfaceEncoder input (electrically isolated)USB 1.0Ethernet 10/100 MBitProfibus (optional) (electrically isolated)

inputs/outputs(electrically isolated)

24 digital inputs16 digital outputs10 capture inputs1 analogue input 1 analogue output

Supply voltage [V] 24 (-15 %, +25 %)

maximum inrush current [A] 5 (for 20ms)

maximum power consumption [W] 50

Current consumption (without load) [A] 2

Ripple voltage [%] 5

I/O power supply per block [A] 2

Supply voltage [V] 24 (-15 %, +25 %)

maximum inrush current [A] 2.5


Class of insulation IIIa

Impulse voltage withstand level (III/3) [kV] 1.5


Impulse voltage withstand level (II/2) [kV] 2.5

Rated voltage (III/2) [V] 160

Rated voltage (II/2) [V] 160

Nominal current [A] 4

Nominal voltage [V] 32

Load current max. [A] 4

Insulation material PA

Flammability class as per UL94 V0

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BLC3 Technical Data


I/O mating connector

Digital inputs

Digital capture inputs

Supply voltage [V] 24 (-15 % +25%)

maximum inrush current [A] 25


Class of insulation I



Rated voltage (III/2) [V] 160

Rated voltage (II/2) [V] 320

Nominal current [A] 4

Nominal voltage [V] 80

Load current max. [A] 4 (at 0.5 mm² conductor cross section)

Insulation material PA

Flammability class as per UL94 V0

Stripped length [mm] 8

Conductor cross section rigid [mm²] min. 0.14

max.0.5

Conductor cross section flexible [mm²] min. 0.14

Imax. 0.5

Conductor cross section flexible with wire end ferrule without plastic ferrule

[mm²] min. 0.25

max.0.5

Conductor cross section AWG min. 26

max.20

Max. input voltage [V] 30

max. switching threshold Low -> High [V] +10

max. switching threshold High -> Low [V] +5

input resistance (pull-down versus 0V I/O)

[kΩ] 3.3 ±0.5

debounce [µs] 500

max. cable length (at 0.25 mm²) [m] 100

Max. input voltage [V] 30

max. switching threshold Low -> High [V] +10

max. switching threshold High -> Low [V] +5

input resistance (pull-down versus 0V I/O)

[kΩ] 3.3 ±0.5

debounce [µs] 50

max. cable length (at 0.25 mm²) [m] 100


Technical Data BLC3

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Digital outputs The digital outputs are short-circuit protected.

Analogue inputs and outputs The analogue inputs and outputs are short-circuit protected.

Profibus (optional)

Max. length of bus segment(max. 32 devices)

min. switching voltage (UEA) [V] 2

max. residual voltage [mV] 200

Max. output current [mA] 500

voltage drop at 500 mA load [V] < 2

Resolution [Bit] 12

Voltage range [V] ± 10

Max. output current [mA] 10

Conversion time [ms] 1

Error [LSB] 2

Specifications EN50170

max. baud rate [Mbaud] 12

min. baud rate [kbaud] 9.6

Cable Approve Profibus cable, preferably Type A

baud rate [kbit/s] max. cable length [m]

9.6 1200

19,2 1200

93,75 1200

187,5 1000

500 400

1500 200

3000 100

6000 100

12000 100

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BLC3 Technical Data


3.4.2 Interfaces

Sercos

Encoder

RS232 This is the RS232 interface, which is controlled depending on the soft-ware settings.

CAN

The baud rates must be adjusted depending on the cable length. With optimum cable installation and suitable cable material longer lengths than those specified are possible.

Specifications IEC/EN 61491

max. baud rate [Mbaud] 16

max. number of nodes 254

max. fibre-optic cable length (plastic POF)

[m] 45

min. bending radius [mm] 30

Specifications RS422

max. frequency [MHz] 1

max. cable length [m] 30

Specifications RS232

max. baud rate [kbaud] 115

max. cable length [m] 15

Specifications ISO-DIS 11898

max. baud rate [Mbaud] 1(default 500 kbaud)

max. number of nodes 100

line length [m] maximum baud rate

specific resistance [mΩ/m]

line cross section [mm²]

0 - 5 1 Mbaud 70 0.26 - 0.34

5 - 40 800 kbaud 70 0.26 - 0.34

40 -100 500 kbaud 70 0.26 - 0.34

100 - 200 200 kbaud < 60 0.34 - 0.50

200 - 600 100 kbaud < 40 0.50 - 0.60

600 - 1000 50 kbaud < 26 0.60 - 0.80


Technical Data BLC3

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3.4.3 Processor, memory and Compact Flash Card

Processor Pentium-3(Low Power Celeron)

Frequency [MHz] 400

RAM [MB] 128

NVRAM [kB] 32

free memory in RAM forapplication

[MB] 20

Power [µs] 20 for 1000 lines of code

Compact Flash Card [MB] 128

Free memory on CF card for applica-tions

[MB] 50

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4 Installation

4.1 Electromagnetic compatibility, EMC

This drive system meets the EMC requirements for the second environ-ment under the IEC 61800-3 standard if the measures described for the installation are taken into account. When operating outside this applica-tion area note the following:

An EMC-compliant design is required to maintain the specified limit val-ues.

@ WARNINGUnexpected behaviour due to external objects

External objects, deposits or humidity can cause unexpected behav-iour.

• Do not use damaged products.

• Prevent external objects such as chips, screws or wire clippings from entering the product.

• Do not use products that contain external objects.

Failure to follow these instructions can result in death, serious injury or equipment damage.

@ WARNINGInterference with signals and devices

Distorted signals can cause unpredictable device responses.

• Install the wiring in accordance with the EMC requirements.

• Check compliance with the EMC requirements, particularly in an environment subject to strong interference.


@ WARNINGHigh-frequency interference

In a domestic environment this product may cause high-frequency in-terference that may require action to suppress interference.


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Switching cabinet setup

Cabling

EMC measures Effect

Use EMC plate or galvanised or chrome-plated mounting plates, make large contact surface con-nections for metal parts, remove paint from contact surfaces

Good conductivity due to two-dimensional con-tacts

Earth the control cabinet, door and EMC plate with metal tapes or cables with a cross section area greater than 10 mm2.

Reduction of emissions.

Fit switching devices such as contactors, relays or solenoids with interference suppressors or spark suppressors (e.g.diodes, varistors, RC elements)

Reduction of mutual interference

Install power and control components separately. Reduction of mutual interference

EMC measures Effect

Keep wiring as short as possible. Do not install "safety loops", short cables from the star point in the switch cabinet to outlying earth connection.

Avoidance of capacitive and inductive interfer-ence injection

Use cable clamps to connect a large surface area of the shield of all shielded cables to the mounting plate at the control cabinet entry.


Fieldbus lines and signal lines must not be laid in the same conduit with lines for DC and AC voltage over 60 V. (Fieldbus lines can be laid in the same conduit with signal and analogue lines)

Recommendation: lay in separate conduits at least 20 cm apart.

Prevention of mutual interference

Connect large surface areas of cable shields, use cable clamps and tapes


Earth shields on digital signal lines over a wide area at both ends or via conductive plug housing.

Preventing interference on control cables, reduc-tion of emissions

Use bonding conductors in system with– wide-area installation– different voltage infeed– networking between different buildings

Protection of wiring, reduction of emissions.

Use fine-core bonding conductors Deflect even high-fre-quency interference cur-rents

Earth shield on analogue signal lines directly at the device (signal input), and insulate the shield at the other end of the cable or earth via a capacitor if interference occurs, e.g. 10 NF.

Preventing ripple loops due to low-frequency interference

Lay connections of the 24VDC supply voltage as “twisted pair”.

Preventing interference on control cables, reduc-tion of emissions

Use shielded cables for the signal lines with IP54 products.

Reduction of EMC emis-sions

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Power supply

Equipotential bonding conductors The shields are connected at both ends for fault protection. Potential dif-ferences can result in excessive currents on the shield and must be pre-vented by equipotential bonding conductor cables.

If lines over 100 m are approved, the following applies: up to 200 m length a cable cross section of 16 mm2 is sufficient, for greater lengths a cable cross section of 20 mm2 is required.

EMC measures Effect

Operate drive system on mains with earthed neutral point (not IT mains).

Mains filter is only effec-tive on systems with an earthed star point.

Connect the negative output of the PELV power supply unit to PE.

Reduction of EMC emis-sions, safety

Circuit breaker if there is danger of overvoltage or lightning strike

Protection against dam-age by overvoltage


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4.2 Mechanical installation

Before installation... Check the device for externally visible damage such as damage to the housing or faulty terminal clamps. Do not install damaged devices.

Control cabinet The control cabinet must be dimensioned so all devices and accesso-ries can be fixed in place and wired to meet EMC standards. The com-ponents include a holding brake controller or braking resistors.

The control cabinet ventilation must be capable of extracting the heat generated by all devices and components installed in the control cabi-net.

Position the device in the control cabinet so the heat airflow of other de-vices, such as an external ballast resistor, does not overheat the cooling air for the device.

Installation clearances Because the BLC3 Motion Controller is only cooled by a passive airflow, the air openings on the top and bottom of the device must be installed at a distance of at least 50 mm from adjacent devices or walls.The device must be operated in a clean, non-salt-containing environment.

The device must be installed upright in the control cabinet to ensure ad-equate air circulation. The device must be permanently installed on a clean and flat metal surface to dissipate the heat generated in operation. At an ambient temperature of 40°C at the back of the device tempera-tures > 60°C may be encountered.

Copper wires suitable for temperatures of 60 °C must be used for con-nections.

Figure 4.1 Installation clearances, dimensions in mm

150203

265

50

50

5,5

4 x M5

SERCOS

CF-CARD



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4.3 Electrical installation

@ WARNINGMalfunction and risk of injury

The EMC of the cables must be guaranteed for operational safety and fault-free operation of the device.

• Use only suitable EMC-safe cables.

Failure to follow these instructions can result in injury or equip-ment damage.

@ WARNINGInterference with signals and devices

Distorted signals can cause unpredictable device responses.

• Install the wiring in accordance with the EMC requirements.

• Check compliance with the EMC requirements, particularly in an environment subject to strong interference.


@DANGERElectric shock from incorrect power supply unit

The +24VDC supply voltage is connected with many accessible sig-nals in the drive system.

• Use a power supply unit that meets the requirements for PELV (Protective Extra Low Voltage)

• Connect the negative output of the power supply unit to PE.


CAUTIONDestruction of contacts

The connection for the controller supply voltage at the drive system does not have a make current limit. If the voltage is switched on by switching contacts, the contacts may be destroyed or welded shut.

• Use a power supply unit that limits the peak value of the output current to a value permissible for the contact.

• Switch the line input of the power supply unit instead of the output voltage.

Failure to follow these instructions can result in equipment damage.


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4.3.1 Connecting the 24 V supply voltage

� Run the 24 V power supply wiring from a power supply (PELV) to the device

� Earth the negative output at the power supply

Figure 4.2 24 V connection on BLC3

Lay the 24V supply line at a distance of at least 20 cm from other lines to ensure EMC protection. For wiring longer than 2m make a twisted pair of the 0V and 24V supply wires.

Connection Signal Description

7 24VDC 24 VDC supply voltage

8 24VGND GND for 24 VDC voltage

L1L2L3N

PE

+24V

0V

230V~

24V=

SERCOS


CF-CARD

ENT

ESC


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BLC3 Installation


4.3.2 Connection of inputs and outputs

The motion controller has a total of 34 digital inputs, 16 digital outputs and one analogue input and output each. Every I/O block must have a separate supply voltage at pin 9 (+24 VDC) and 10 (0 V GND). Of the 34 inputs 10 inputs have a debounce time of 50 µs and 24 inputs have a debounce time of 500 µs.

Eight connection terminals for the inputs and outputs are supplied with the device. The maximum wire diameter is 0.5 mm² (20 AWG).

Figure 4.3 Inputs and outputs

The capture inputs with 50 µs debounce time are used for applications that require a response to input events in a very short time.

All outputs have an output voltage of 24 VDC and a maximum output current of 500 mA.

The inputs and outputs can be queried or addressed from a user pro-gram with the above-listed designations. For example, to address digital output X1.5, in CoDeSys the order %QX0.0:=TRUE; can be used.

X112345678910

123456789

10

123456789

10

12345678910

12345678910

12345678910

12345678910

12345678910

X2 X3 X4 X5 X6 X7 X8

X1 X2 X3 X4 X5 X6 X7 X8

1 %IX0.0 %IX0.4 %IX0.8 %IX0.12 %IX1.0 %IX1.4 Capture 2 / %IX1.10

Capture 6 / %IX1.14


Capture 7 / %IX1.15


Capture 8 / %IX1.14


Capture 9 / %IX1.15

5 %QX0.0 %QX0.2 %QX0.4 %QX0.6 %QX0.8 %QX0.10 %QX0.12 %QX0.14

6 %QX0.1 %QX0.3 %QX0.5 %QX0.7 %QX0.9 %QX0.11 %QX0.13 %QX0.15

7 24V_LOGIC BATTERY+ – – %IB4 Analogue 0V – Analogue 0V

8 0V_LOGIC 0V_LOGIC Capture 0 / %IX1.8

Capture 1 / %IX1.9

– PE %QB2 PE

9 24V_IO1 24V_IO1 24V_IO2 24V_IO2 24V_OPT1 24V_OPT1 24V_OPT2 24V_OPT2

10 0V_IO1 0V_IO1 0V_IO2 0V_IO2 0V_OPT1 0V_OPT1 0V_OPT2 0V_OPT2


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4.3.3 Connection to the Ethernet interface

Interface The Ethernet interface with RJ45 female connector is wired to the PC with a cross-over cable or a data cable from a network.

Figure 4.4 Interface connection of the Ethernet module (female connector)

Cable specifications • Shielded cable

• Twisted pair lines

• Maximum length for 10 BaseT Ethernet: segment: max. 100 mcomplete network: max. 2500 m

• Maximum length for 100 BaseT Ethernet: 30m

In the simplest case one network segment is a cable. In a complex network all ports of a stroke together form one network segment.

Function A user program is uploaded from the PC to the motion controller via the Ethernet interface. Connect a PC with the CoDeSys programming envi-ronment. Data can be exchanged between the controllers over a net-work. In addition, an OPC server is included in the motion controller software package and can also be used for data exchange.

Every device in the Ethernet network is identified by a unique, adjustable IP address.

1 TD+TD-RD+

RD-

8

PIN Signal Pair Description I/O

1 TD+ 1 Transmit Data O

2 TD– 1 Transmit Data O

3 RD+ 2 Receive Data I

4 – – not assigned –


6 RD– 2 Receive Data I



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BLC3 Installation


4.3.4 Connection to the CAN interface

Interface The CAN connection is fitted with two SUB-D plugs and two SUB-D sockets, all 9-pin with UNC thread. Pin assignment is identical for all interface connections.

Figure 4.5 Fieldbus module interface connections with plug and socket


• Minimum cross section of the signal wires 0.14 mm²


• Earthing of the shield at both ends

• Maximum length depends on the number of devices, the baud rate and signal transmission times. The higher the baud rates the shorter the bus cable must be.

• Recommended values: 40 m with 1 MBit/s, 500 m with 100 kBit/s

In digital cables, the shields are connected at both ends to protect against interference. Potential differences can result in excessive currents on the shield and must be prevented by equipotential bonding conductor cables. Wire diameter up to 200 m length: 16 mm2, over 200 m length: 20 mm2.

Function The device can be connected to the following networks via the CAN con-nections:

• CAN bus

• CANopen

GND

CAN_HIGH

-

-

CAN_LOW

GND

-

1

5 9

6 3627

-

CAN_HIGH

GND

-

GND

CAN_LOW

-1

5 9

6

Pin Signal Pair Description I/O

1 – 1 not assigned –

2 CAN_LOW 2 data wire, inverted I/O

3 GND 3 Mass –


5

6 GND 1 Mass –

7 CAN_HIGH 2 data wire I/O



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As a CANOpen master the device sends data and commands to lower-level bus devices, the slaves. Data exchange is with a special commu-nications protocol.

Every device in the network is identified by a unique node address which can be set as desired.

Terminating resistors A terminating resistor of 120 Ohm must be connected at both ends of the bus.

Fieldbus manual The integration of a device into the fieldbus is described in the relevant fieldbus manual in the chapter on installation and commissioning.

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4.3.5 Connection to the RS232 interface

Connection The RS232 interface with Sub-D socket, 9-pin with M3 screw connection is wired 1:1 with the PC. A twisted-pair cable must be used.

Figure 4.6 Interface connection of RS232 interface


• Minimum cross section of signal wires: 0.25 mm², for supply voltage and earth wire 0.5 mm²



• Maximum cable length 15 m

Function Multiple devices cannot be networked via the RS232 interface.

1

5

1

5

6

TxD RxD

GND TxD RxD

9

6

9 2938

5

TxD RxD - -

GND -

RxD TxD

-


1 - 4 not assigned -

2 RxD 1 Transmitted data to input device O

3 TxD 2 Received data to input device I

4 - – not assigned –

5 GND – Mass –

6 – 2 not assigned -


8 RxD (RS485) 2 Transmitted data to input device -

9 TxD (RS485) 1 Data received from input device -


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4.3.6 Connection of the RS422 encoder input

The BLC3 has a RS422 encoder input, which can be operated as an in-cremental and an SSI encoder input. Use encoders with a 24V supply voltage.

Figure 4.7 Interface connections of RS422 encoder input


• Minimum cross section of signal wires: 0.25 mm², 5VDC, 24VDC and GND: 0.5 mm²



• Maximum cable length 30 m

5VDC

BB

5VGNDII

AA

1 6

1623

5489

Pin Signal incremental encoder Signal SSI encoder Pair Description I/O

1 GND GND 1 Encoder supply, ground O

2 I /Clock 2 Index plus channel I

3 I Clock 2 Index plus channel inverted I

4 A Daten 3 Encoder signal A inverted I

5 A Daten 3 Encoder signal A I

6 5VDC 5VDC 1 Encoder supply, 5V, max. 300 mA O

7 24VDC 24VDC – Encoder supply, 24 V O

8 B – 4 Encoder signal B inverted I

9 B – 4 Encoder signal B I

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4.3.7 Connecting the Sercos interface

The BLC3 has a Sercos interface in accordance with the specifications of IEC/EN 61491. The maximum baud rate is 16 Mbaud.

Figure 4.8 Sercos interface connection

The plug connector must meet the F-SMA standard, it must meet a min-imum of quality level 5 and must have a metallic sleeve nut.

Cable specifications • Maximum fibre-optic line length (POF): 45m

• Minimum bending radius: 30 mm

• Maximum node number: 254

Sercos Tx Sercos Rx

LED Colour Description

ERR red Bus Error (no receiver signal)

Tx green Transmitter active

Rx yellow Receiver active


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4.3.8 Connection to the Profibus interface

The Profibus interface is optional.

The sub-D plug for Profibus is always installed. Check the serial number of the device to find out whether you have a Profibus device.

Interface The Profibus DP interface is fitted with a sub-D socket, 9-pin with UNC cable gland.

Figure 4.9 Interface connection of the fieldbus module

A bus terminal forms the docking station to the Profibus. Data lines between module and bus terminal are wired up 1:1.

Terminals A_LT and B_LT must be connected to wires A and B in the net-work in accordance with the minimum wiring requirement.

Cable specifications for connectionto a bus terminal

• Shielded cable

• Minimum cross section of the signal wires 0.14 mm2



• Maximum length 1200 m at 9.6 kBit/s

In digital cables, the shields are connected at both ends to protect against interference. Potential differences can result in excessive currents on the shield and must be prevented by equipotential bonding conductor cables: cable cross section up to 200 m long: 16 mm2, over 200 m length: 20 mm2.

-

A_LT

-

5VDC

GND

RTS

B_LT

-

-

9

61

5 -6384-5

Pin Signal Colour Pair Description I/O

1 - - 1 not assigned -

2 - - - not assigned -

3 B_LT - 2 data wire, inverted I/O

4 RTS - 3 transmission request O

5 GND - - Mass -

6 5VDC - 1 Supply voltage, max. 10 mA for terminator O

7 - - - not assigned -

8 O_LT - 2 data wire I/O

9 - - 3 not assigned -

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Function The motion controller can be connected as a slave to a Profibus DP net-work with the Profibus DP field bus module.

The motion controller receives data and commands from a higher-level bus device, a master. The controller sends status information such as device status and processing status back to the master device as ac-knowledgment. Data exchange is with a special communications proto-col.

Data are exchanged cyclically between master and slave devices. Every device in the network is identified by a unique address which can be set as desired.

Baud rate The baud rate depends on the transmission rate of the master.

4.3.9 Connection to the CAN Sync interface

Interface The CAN Sync DP interface is fitted with a sub-D female connector, 9-pin with UNC cable gland. A 120 ohm terminating resistor is installed in-ternally between CAN_low and CAN_high.Pin assignment is identical for all interface connections.


• Minimum cross section of the signal wires 0.14 mm²



• Maximum length depends on the number of devices, the baud rate and signal transmission times. The higher the baud rates the shorter the bus cable must be.

• Recommended values: 40 m with 1 MBit/s, 500 m with 100 kBit/s

In digital cables, the shields are connected at both ends to protect against interference. Potential differences can result in excessive currents on the shield and must be prevented by equipotential bonding conductor cables. Wire diameter up to 200 m length: 16 mm², over 200 m length: 20 mm².



2 CAN_LOW 2 data wire, inverted I/O

3 GND 3 Mass –


5

6 GND 1 Mass –

7 CAN_HIGH 2 data wire I/O



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Function The device can be connected to the following networks via the CAN con-nections:

• CAN bus

• CANsync

The CAN must be used with Softmotion only.

Terminating resistors A terminating resistor of 120 Ohm must be connected at both ends of the bus.

Fieldbus manual The integration of a device into the fieldbus is described in the relevant fieldbus manual in the chapter on installation and commissioning.

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BLC3 Commissioning


5 Commissioning

5.1 Overview of menu

@ WARNINGUnexpected behaviour

The behaviour of the drive system is governed by numerous stored data or settings. Unsuitable settings or data may trigger unexpected movements or reactions to signals and disable monitoring functions.

• Do not operate a drive system with unknown settings or data.

• Check the stored data or settings.

• When commissioning carefully run tests for all operating statuses and fault cases.

• Check the functions after replacing the product and also after making changes to the settings or data.

• Only start the system if there are no persons or materials in the danger zone and the system can be operated safely.



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Figure 5.1 BLC3 menu

ENT When ENT is pressed for the first time a text with a short explanation of the menu appears.

Accept the selection and jump to the next screen or return ti the starting point. Settings are accepted.

ESC Cancel; jump to the higher menu level. Settings are not accepted.

← Jump to the higher menu level; with inputs the input cursor jumps to the left.

→ Selection of menu item; with inputs the input cursor jumps to the right.

↑ Jump to the previous menu item at the selected menu level; with inputs the numerical value is reduced.

↓ Jump to the next menu item at the selected menu level; with inputs the numerical value is increased.

Software Version SW1001FPGA0008

Language EnglishGerman

Show IP 192.168.0.10

Network DHCP Enable Disable

IP Address

Subnet Mask

Default Gateway

Broadcast Address

NVRam Save NVRam

Restore NVRam

Clear NVRam

Delete Project

Sysinfo

Update

ENT

ESC

ENT

ENT

ENT

ENT

ENT

ENT

ENT

ENT

ENT

ENT

ENT

ENT

ESC

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BLC3 Commissioning


5.2 Starting up device

� Apply the 24 V supply voltage.The device boots.

After the boot procedure the device starts the controller program, if one has been installed.

� If a faulty controller program has been installed, the program must be deleted by opening the menu and selecting "Del.Project".

After running the start phase the device is ready. The device status and the name of the loaded project are shown on the display.

There is no program on the device as delivered. After starting a new de-vice "NO APPL" is displayed.

BergerLahrbooting ******

Start PLC *ENT for Menue

Status Description

RUN The device runs a controller program.

STOP The device runs a controller program. The execu-tion has been stopped.

NO APPL There is no executable controller program on the device, or the execution of the program was sup-pressed during the start phase.

RUNHello World


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5.3 Establish connection to the device

5.3.1 Establishing network connection

� Connect the device to the Ethernet interface to the network.

� Press "Ent" during boot to open the menu for configuration of the device. The device status is shown in the display. Then a short text explaining the menu operation is shown.

� Press "Ent" again to open the menu.

� Select "Network" in the menu. Press "Ent".

Set network address � Activate "DHCP" if the device is to receive network settings from a DCHP server.

If you do not have a DHCP server in the network, you can input the IP address, subnet mask, gateway etc. for the device. The device guides you through the input. After input is complete the device returns to the "Network" menu.

The device must be restarted manually after any changes to the network settings.

5.3.2 Establish FTP-connection

The BLC3 can be addressed with an FTP client and the file transfer pro-tocol (FTP) – if it is integrated into a network. If an FTP connection is es-tablished, files can be exchanged with the device.

� If you have a DHCP server in the network, open the menu and dis-play the IP address that was assigned to the device.

� Open your FTP program and establish the connection to BLC3.

� Input the user name "ftp".

� Input the password "mcm".

Start PLC *ENT for Menue

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BLC3 Commissioning


5.4 Configure device

� Press "Ent" during the device start phase to open the menu.

� Select the desired menu item with the arrow keys and "Ent".

@DANGERUnpredictable system behaviour

Deletion of variables is final and cannot be reversed. The effects on the system behaviour are unpredictable and depend on the loaded program.

• Only delete variables if there are no persons in the operating zone of the moving system components and the system can be operated safely.

Non-observance of these precautions may result in death, se-rious injury or material damage.


Restoration of the RETAIN variables is final and cannot be re-versed.

• Make sure that the RETAIN variables definitely belong to the loaded program.

• Only restore variables if there are no persons in the operating zone of the moving system components and the system can be operated safely.


@DANGER• Execute the function "Configure device" only if required by

Support.



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Software version Display of installed software version..

Language The menu can be displayed in German or English.

Display IP address Shows the IP address of the device. If the display shows "N", the device has not yet had an IP address assigned by the DHCP server. This may occur if you query the address immediately after starting the device. Open the menu entry again after a few minutes.

Network settings The device can receive network data from a DHCP server. Alternatively the network settings can be configured for the device.

<Version info>Show IP

SW 1234FPGA1234

<Language> Version

<English> German

IP Adress10.209.194.136

<Network>Delete Project

DHCP <Disable> Enable

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NVRAM The NVRAM contains all RETAIN variables that were generated in the CoDeSys. The variables can be backed up, restored and deleted with the menu functions.

Create Sysinfo file A file with system information is created and written to the Compact Flash Card. For example, this file can be used to send system informa-tion to Support.

Delete boot project Delete controller program that is started when the device is started. The following files are deleted:

• *.jar

• *.txt

• *.htm

• *.xml

• DEFAULT.*

• persist.dat

<NVRam>Delete Project

<Save NVRam>Restore NVRam

<Restore NVRam>Clear NVRam

<Clear NVRam>Save NVRam

sysinfo -> entUp or Down

<Delete Project>Sysinfo


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5.5 Send and load application

An application is created with the CoDeSys development environment and sent to the device. For more information see the CoDeSys docu-mentation and the online help.

The software package supplied with the device contains all libraries for programming the BLC3. The functions are described in the online help for the target system BLC3.


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BLC3 Operation


6 Operation

6.1 Clone device

Multiple identically configured devices can be created. To do this the complete configuration of a BLC3 can be saved on a USB memory stick. The saved configuration can be transferred to other devices from the USB stick.

Use only USB memory sticks that have been approved for the device by Berger Lahr.USB sticks that do not comply with the specifications may cause problems in operation. For more information see the online help if the TSP for the BLC3 has been installed.

Create backup � Connect the USB memory stick to the USB interface of the config-ured device.

� Restart the device.

� Select "Save" in the menu. The data are saved to the USB stick.

Transfer configuration � Switch off the BLC3.

� Connect the USB memory stick with the saved configuration to the USB interface of the new device.

� Switch on the BLC3 again.

� Select "Restore" in the menu. The data are transferred from the USB stick to the device. The operating system and all information are installed on the new device.

� Remove the USB stick and restart the device.

6.2 Executing a software update

You need two files to update the software: archname and BLC3_1001.tgz.

You can update the software via FTP connection or with a USB memory stick.

Use a standard USB memory stick for the update process. It is not necessary to use the Berger Lahr bootable memory stick.

� Save the two files to the USB stick, or have the files available on the computer that is to be connected to the BLC3 via FTP.

Update via FTP connection � Establish an FTP connection with the BLC3.

� Copy the two files to the root directory of the BLC3.

� Switch off the BLC3.


� Select "Update" in the controller menu. The update is run.


Operation BLC3

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Update with USB stick � Switch off the BLC3.


� Press "Ent" during the start phase to open the controller.

� Select "Update" in the menu.

� Connect the USB stick with the stored update files to the BLC3.

� The update is automatically started.

When the update process is complete, the BLC3 restarts itself.

6.3 Using a new Compact Flash Card

Before using a new Compact Flash Card, the current flash card must be copied. Use only the USB memory stick supplied by Berger Lahr.


� Connect the bootable USB memory stick.


� Select the "Save" command.

� A backup of the configured device is created.


� Remove the old Compact Flash Card and insert a new card.

� If the USB memory stick has been removed, connect it again.


� Select the "Restore" command.

� The backup is restored to the new Compact Flash Card.

� When the process is complete, switch off the BLC3 and remove the USB memory stick.

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BLC3 Operation


6.4 Programming

An application is created with the CoDeSys development environment and sent to the device. For more information see the CoDeSys docu-mentation and the online help.

The software package supplied with the device contains all libraries for programming the BLC3. The functions are described in the online help for the target system BLC3.


PLC Browser The PLC browser can be used to access the motion controller in the CoDeSys programming environment.

? Shows a list of all known commands

ps Show running processes.

ifconfig Shows the network connections.

sysinfo Creates the file sysinfo.tgz. The file sysinfo.tgz can be transferred via FTP, and must always be sent with support questions.

diskspace Shows the free memory on the Compact Flash Card.

e.g. diskspace df -h:filesystem Size Used Available Use% Mounted on/dev/hda1 59.3M 22.7M 36.6M 38% //dev/hda2 61.2M 30.2M 31.0M 49% /home/plc/applications

The partition /dev/hda2 is used to store the CoDeSys programs. The memory used in percent can be displayed with "Use".

reboot Restart the device.

targetid Shows the device identification.

getsystime Shows the system time of the device.


If the file sysinfo.tgz is created, the runtime of the system will be in-fluenced.

• Create the file only when the system is at a standstill.

• Create the file only if there are no persons in the operating zone of the moving system components and the system can be operated safely.



Operation BLC3

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Network settings

The settings are initially only saved in a file and not accepted with the fol-lowing commands. The settings are not activated until after a restart or if "ifupdate" has been called.

ipaddr ipaddr x.x.x.x - specifies the IP address for the device.

Network network x.x.x.x - specifies the network address for the device.

netmask netmask x.x.x.x - specifies the subnet mask for the device.

hostname hostname <foo> - specifies the host names for the device.

broadcast broadcast x.x.x.x - specifies the broadcast address for the device.

gateway gateway x.x.x.x - specifies the default gateway for the device.

ifupdate Restarts the network connection. This command must be called after the network settings have been modified. The settings are activated with the restart.

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BLC3 Diagnostics and troubleshooting


7 Diagnostics and troubleshooting

Error Description Remedy

E10000 File not found

E10001 File archname was not found during an update

Transfer the file again.

E10002 File root.tgz was not found dur-ing an update

Transfer the file again.

E10003 The files archname and root.tgz do not match

Remove USB stick from device. Copy update files to USB stick again.

Disconnect device from mains voltage, restart and run update again.

E10004 File system restored on 2nd partition. All data lost.

The Compact Flash Card was reformatted

Disconnect device from mains voltage, restart and run soft-ware update again.


Diagnostics and troubleshooting BLC3

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BLC3 Accessories and spare parts


8 Accessories and spare parts

Designation Order number

CoDeSys programming system(CoDeSys with Target Support Package for BLC3 and Modbus server library)

6250 1102 600

Fieldbus cable for modules CAN, SERCOS(light guide pre-assembled, connector F-SMA)

6250 1446 yyy 1)

8630 0901 zzz 2)

1) Cable length yyy: 005, 015, 030, 050: 0.5 m, 1.5 m, 3 m, 5 m;2) Cable length zzz: 051, 053, 055, 058: 0.3 m, 1.5 m, 5m, 15m;

CAN terminal plug, 9-pin female connectorCAN terminal plug, 9-pin connector

6250 1518 002 6250 1518 003

Encoder adapter(cable 0.3 m with SUB-D female connector 15-pin and SUB-D connector 9-pin)

8630 0901 000

bootable USB memory stick for backup and cloning 8640 1910 060

Serial cable (RS232 only) for connection with the Magelis terminal:BLC3 to Magelis XBT - R400, R411BLC3 to Magelis XBT - N200ffBLC3 to Magelis XBT - GT1100

8630 0901 0048630 0901 0058630 0901 006

Compact Flash memory card128 MB 8640 1910 039

BLC3 documentationGermanEnglish

0098 441 113 3360098 441 113 337


Accessories and spare parts BLC3

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BLC3 Service, maintenance and disposal


9 Service, maintenance and disposal

9.1 Service address

You cannot carry out repairs yourself. The repair should only be carried out by a certified customer service organisation. No warranty or liability is accepted for repairs made by the customer.

If you cannot resolve the fault yourself please contact your appointed sales partner. Have the following details available:

• Type plate (Type, identification number, serial number, DOM, ...)

• Type of fault (possibly with flash code or fault number)

• Previous and concurrent conditions

• Your own ideas regarding the cause of the fault

Include this information if you return the product for inspection or repair.

If you have any questions please contact your local dealer. Your dealer will be happy to give you the name of a customer service outlet in your area.

http://www.berger-lahr.com

9.2 Maintenance

The device is maintenance free

9.3 Shipping, storage, disposal

Shipping The product must be protected against shocks during transport. Use the original packaging for this purpose.

Storage Store the product only under the specified, approved environmental conditions for room temperature and humidity.Protect the product against dust and dirt.

Disposal The product consists of various materials that can be recycled and must be disposed of separately. Do not dispose of the device with normal do-mestic waste but take it to a recycling collection centre or return it to Berger Lahr.


Service, maintenance and disposal BLC3

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BLC3 Glossary


10 Glossary

10.1 Units and conversion tables

The value in the specified unit (left column) is calculated for the desired unit (top row) with the formula (in the field).

Example: conversion of 5 metres [m] to yards [yd]5 m / 0.9144 = 5.468 yd

10.1.1 Length

10.1.2 Mass

10.1.3 Force

10.1.4 Power

in ft yd m cm mm

in - / 12 / 36 * 0.0254 * 2.54 * 25.4

ft * 12 - / 3 * 0.30479 * 30.479 * 304.79

yd * 36 * 3 - * 0.9144 * 91.44 * 914.4

m / 0.0254 / 0.30479 / 0.9144 - * 100 * 1000

cm / 2.54 / 30.479 / 91.44 / 100 - * 10

mm / 25.4 / 304.79 / 914.4 / 1000 / 10 -

lb oz slug kg g

lb - * 16 * 0.03108095 * 0.4535924 * 453.5924

oz / 16 - * 1.942559*10-3 * 0.02834952 * 28.34952

slug / 0.03108095 / 1.942559*10-3 - * 14.5939 * 14593.9

kg / 0.453592370 / 0.02834952 / 14.5939 - * 1000

g / 453.592370 / 28.34952 / 14593.9 / 1000 -

lb oz p dyne N

lb - * 16 * 453.55358 * 444822.2 * 4.448222

oz / 16 - * 28.349524 * 27801 * 0.27801

p / 453.55358 / 28.349524 - * 980.7 * 9.807*10-3

dyne / 444822.2 / 27801 / 980.7 - / 100*103

N / 4.448222 / 0.27801 / 9.807*10-3 * 100*103 -

HP W

HP - * 745.72218

W / 745.72218 -


Glossary BLC3

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10.1.5 Rotation

10.1.6 Torque

10.1.7 Moment of inertia

10.1.8 Temperature

10.1.9 Conductor cross section

1/min (RPM) rad/s deg./s

1/min (RPM) - * π / 30 * 6

rad/s * 30 / π - * 57.295

deg./s / 6 / 57.295 -

lb·in lb·ft oz·in Nm kp·m kp·cm dyne·cm

lb·in - / 12 * 16 * 0.112985 * 0.011521 * 1.1521 * 1.129*106

lb·ft * 12 - * 192 * 1.355822 * 0.138255 * 13.8255 * 13.558*106

oz·in / 16 / 192 - * 7.0616*10-3 * 720.07*10-6 * 72.007*10-3 * 70615.5

Nm / 0.112985 / 1.355822 / 7.0616*10-3 - * 0.101972 * 10.1972 * 10*106

kp·m / 0.011521 / 0.138255 / 720.07*10-6 / 0.101972 - * 100 * 98.066*106

kp·cm / 1.1521 / 13.8255 / 72.007*10-3 / 10.1972 / 100 - * 0.9806*106

dyne·cm / 1.129*106 / 13.558*106 / 70615.5 / 10*106 / 98.066*106 / 0.9806*106 -

lb·in2 lb·ft2 kg·m2 kg·cm2 kp·cm·s2 oz·in2

lb·in2 - / 144 / 3417.16 / 0.341716 / 335.109 * 16

lb·ft2 * 144 - * 0.04214 * 421.4 * 0.429711 * 2304

kg·m2 * 3417.16 / 0.04214 - * 10*103 * 10.1972 * 54674

kg·cm2 * 0.341716 / 421.4 / 10*103 - / 980.665 * 5.46

kp·cm·s2 * 335.109 / 0.429711 / 10.1972 * 980.665 - * 5361.74

oz·in2 / 16 / 2304 / 54674 / 5.46 / 5361.74 -

°F °C K

°F - (°F - 32) * 5/9 (°F - 32) * 5/9 + 273.15

°C °C * 9/5 + 32 - °C + 273,15

K (K - 273.15) * 9/5 + 32 K - 273.15 -

AWG 1 2 3 4 5 6 7 8 9 10 11 12 13

mm2 42.4 33.6 26.7 21.2 16.8 13.3 10.5 8.4 6.6 5.3 4.2 3.3 2.6

AWG 14 15 16 17 18 19 20 21 22 23 24 25 26

mm2 2.1 1.7 1.3 1.0 0.82 0.65 0.52 0.41 0.33 0.26 0.20 0.16 0.13

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BLC3 Glossary


10.2 Terms and Abbreviations

AC alternating current

Drive solution The drive solution consists of the drive system and the mechanical sys-tem components permanently installed in the motion chain.

Drive system System consisting of controller, power amplifier and motor.

User-defined unit Unit whose reference to motor revolution can be determined by the user via parameters.

CAN (Controller Area Network), standardised open fieldbus in accordance with ISO 11898, allows drives and other devices from different manuf-acturers to communicate.

CoDeSys Programming tool for developing and testing application programs. CoDeSys is compliant with the IEC 61131-3 Standard.

DC direct current

Default value Factory settings.

I/O inputs/outputs

EMC Electromagnetic compatibility.

Encoder sensor for detection of the angular position of a rotating component. When installed in the motor the encoder sows the angular position of the rotor.

EU European Union

Forcing To change signal states regardless of the hardware switching status in the unit; with the commissioning software, for example. The hardware si-gnals remain unchanged.

Error class Classification of operational faults into groups corresponding to the error responses

FI fault current

High/open Signal status of an input or output signal; in the idle state the signal voltage is high, high level.

Incremental signals Angular steps of an encoder in the form of square-wave pulse se-quences. Relative changes in position are signalled by the number of pulses contained in the pulse sequence.

Internal units Resolution of the power amplifier with which the motor is directed to the new setpoint. Internal units are given in increments.

actual position Current absolute or relative position of moving components in the drive system.

IT mains Mains in which all active components are isolated from earth or are earthed by a high impedance. IT: isolé terre (French), isolated earth. Opposite: earthed networks, see TT/TN network

Low/open Signal status of an input or output signal; in the idle state signal voltage is low (low level).

Node guarding ( node monitoring), connection monitoring with the slave at an interface with cyclic data traffic.

Optically isolated Electrical transmission of signals with electrical isolation


Glossary BLC3

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Parameter device data and values that can be set by the user.

PC Personal Computer

PELV Protective Extra Low Voltage, functional low voltage with safe isolation.

Profibus standardised open fieldbus in accordance with EN 50254-2, allows drives and other devices from different manufacturers to communicate.

rms rms value of a voltage (Vrms ) or a current (Arms); abbreviation of “Root Mean Square”.

RS232 interface The RS232 connection is the communications interface, e.g. for con-nection of an operating terminal.

RS485 fieldbus interface in accordance with EIA-485, which enables serial data transmission with multiple devices.

Protection class The protection class is a standardised specification for electrical equip-ment that describes the protection against the ingress of foreign bodies and water (for example, IP20).

PLC Programmable Logic Controller

10.3 Product name

BLC3 Berger Lahr Motion Controller

CoDeSys Programming tool for developing and testing application programs. CoDeSys is compliant with the IEC 61131-3 Standard.

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BLC3


Index

AAbbreviations 10-3Accessories and spare parts 8-1

BBackup 6-1BLC 3 start-up 5-3

CCAN connection 4-9CE mark 1-6Clone BLC 3 6-1clone device 6-1Commissioning 5-1Compact FlashCard new 6-2Components and interfaces 1-3Configuration 5-5configure BLC 3 5-5configure device 5-5connect 5-4Connecting the Sercos interface 4-13connection 4-7, 4-14, 5-4

CAN 4-9Ethernet 4-8inputs and outputs 4-7RS232 4-11RS485 4-11

Control cabinet 4-4

DDanger classes 2-2Declaration of conformity 1-7devices

create identical 6-1Diagnostics 7-1Directives and standards 1-6Disposal 9-1Documentation and literature references 1-6

EElectrical installation 4-5EMC 4-1Encoder input 4-12Environmental conditions 3-1Equipotential bonding conductors 4-3establish connection 5-4Establish device connection 5-4Ethernet connection 4-8


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Fformat CF card 6-2FTP connection 5-4

GGlossary 10-1

IInputs

encoder 4-12RS422 encoder 4-12

Inputs connection 4-7Installation

electrical 4-5mechanical 4-4

Intended use 2-1Introduction 1-1

LLoad application 5-8load controller program 5-8load program 5-8

Mmains connection

Connecting 24V power supply 4-6Maintenance 9-1Mechanical installation 4-4Menu overview 5-1

Nnetwork 5-4Network connection 5-4

OOperation 6-1outputs 4-7

PPLC Browser 6-3Product name 10-4Profibus interface 4-14Programming 6-3

QQualifications, personnel 2-1

RRS232 connection 4-11RS232 interface 10-4RS422 encoder input

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BLC3


encoder input 4-12RS485 connection 4-11

SScope of supply 1-1Second environment 4-1send application 5-8send controller program 5-8send program 5-8Service 9-1Service address 9-1Shipping 9-1Software update 6-1Starting up device 5-3Start-up 5-3Storage 9-1Switching cabinet setup 4-2

TTechnical data 3-1Terms 10-3Testing agencies and certificates 3-1Troubleshooting 7-1Twin Line device

wiring 24 V connection 4-6

UUnit overview 1-2Units and conversion tables 10-1


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Technical Documentation · 2012. 6. 20. · Berger Lahr GmbH & Co. KG Breslauer Str. 7 D-77933 Lahr...

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