Bosch Rextroth Indramat RECO R-IB IL CNT Instructions for use

Application Manual
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
SYSTEM200
RECO Inline
Counter Terminal R-IB IL CNT

About this Documentation Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
RECO Inline
Counter Terminal R-IB IL CNT
Application Manual
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Document Number, 120-0400-B344-02/EN
This documentation
•describes the commissioning and programming of the module within
a Reco Inline station,
•serves as general information for the module terminals,
•serves to specify technical data,
•serves to specify diagrams and formulas.
Description Release
Date Notes
120-0400-B344-02/EN 01/02 First English issue
2001 Rexroth Indramat GmbH
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Rexroth Indramat GmbH
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.de/
Dept. EP (UK/CH/NH)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by
Note

Counter Terminal Contents I
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Contents
1 Functional Description of the Terminal 1-1
1.1 Functional Description....................................................................................................................1-1
Features of the Terminal..........................................................................................................1-1
Areas of Usage ........................................................................................................................1-2
1.2 Design of the Terminal...................................................................................................................1-3
Housing Dimensions................................................................................................................1-3
Assignment of Terminal Points................................................................................................1-5
Diagnostic and Status Indicators .............................................................................................1-6
Internal Block Diagram.............................................................................................................1-8
2 Important Directions for use 2-1
2.1 Appropriate Use .............................................................................................................................2-1
Introduction ..............................................................................................................................2-1
Areas of Use and Application...................................................................................................2-2
2.2 Inappropriate Use...........................................................................................................................2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 Introduction.....................................................................................................................................3-1
3.2 Explanations...................................................................................................................................3-1
3.3 Hazards by Improper Use..............................................................................................................3-2
3.4 General Information .......................................................................................................................3-3
3.5 Protection Against Contact with Electrical Parts............................................................................3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)...........................................3-6
3.7 Protection Against Dangerous Movements....................................................................................3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting..........3-9
3.9 Protection Against Contact with Hot Parts...................................................................................3-10
3.10 Protection During Handling and Mounting...................................................................................3-10
3.11 Battery Safety...............................................................................................................................3-11
3.12 Protection Against Pressurized Systems.....................................................................................3-11
4 Mounting and Dismounting Counter Terminals / Connecting Lines 4-1
4.1 Mounting Instructions for Replacing the Terminal .........................................................................4-1
4.2 Mounting and Dismounting a Terminal..........................................................................................4-1
4.3 Voltage Supply...............................................................................................................................4-2

II Contents Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
4.4 Connecting Sensors and Actuators ...............................................................................................4-2
Connection Methods for Sensors and Actuators.....................................................................4-2
Connecting a 24 V Sensor.......................................................................................................4-3
Connecting a 5 V Sensor.........................................................................................................4-4
Connecting an Actuator ...........................................................................................................4-5
4.5 Connecting Lines ...........................................................................................................................4-6
Connecting Unshielded Lines..................................................................................................4-6
Connecting Shielded Lines via the Shield Connector..............................................................4-7
5 Process Data Operation 5-1
5.1 Assignment of the Process Data Channel.....................................................................................5-1
5.2 Output Words.................................................................................................................................5-2
5.3 Input Words....................................................................................................................................5-3
6 Commands used when working with the Counter Terminal 6-1
6.1 Order of the Commands.................................................................................................................6-2
6.2 Frequency Measurement Mode.....................................................................................................6-2
Time-Controlled Frequency Measurement..............................................................................6-3
Condition-Controlled Frequency Measurement.......................................................................6-4
6.3 Event Count Mode .........................................................................................................................6-5
6.4 Time Measurement Mode..............................................................................................................6-7
6.5 Pulse Generator Mode.................................................................................................................6-11
6.6 "System Settings" Command.......................................................................................................6-12
6.7 "Read Firmware Version" Command...........................................................................................6-17
6.8 "Default Start Value" and "Default End Value" Commands.........................................................6-18
6.9 "Stop Counter" and "Start counter" Commands...........................................................................6-19
6.10 "Set Counter to Default Condition" Command.............................................................................6-20
6.11 "Read Counter" Command" .........................................................................................................6-21
6.12 Limit Values and Limits to the Commands...................................................................................6-23
6.13 Survey of all Commands..............................................................................................................6-23
7 Examples and Hints 7-1
7.1 Example for Event Counting ..........................................................................................................7-1
7.2 Example for a Time Measurement with Comparative Conditions..................................................7-3
7.3 Example for a Time Measurement using System Settings............................................................7-5
7.4 Tips for Working with the Counter Terminal...................................................................................7-9
8 Programming, Technical Data and Ordering Information 8-1
8.1 Programming Data.........................................................................................................................8-1
8.2 Process Data Words......................................................................................................................8-2
Output Data Words for Configuring the Terminal ....................................................................8-2
Input Data Words.....................................................................................................................8-3
8.3 Technical Data...............................................................................................................................8-4
8.4 Ordering Information....................................................................................................................8-12

Counter Terminal Contents III
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
9 Glossary 9-1
10 List of Figures 10-1
11 Index 11-1
12 Service & Support 12-1
12.1 Helpdesk ......................................................................................................................................12-1
12.2 Service-Hotline.............................................................................................................................12-1
12.3 Internet.........................................................................................................................................12-1
12.4 Vor der Kontaktaufnahme... - Before contacting us.....................................................................12-1
12.5 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................12-2

IV Contents Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P

Counter Terminal Functional Description of the Terminal 1-1
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
1 Functional Description of the Terminal
1.1 Functional Description
The R-IB IL CNT terminal is a counter terminal designed for use within an
inline station. The counter terminal is also simply called a counter.
The counter detects and processes fast pulse sequences of sensors. It
has a counter input (source), a control input (gate) and a freely
configurable switch output that is set independently by the module. Fast
reaction times that are independent of the bus and the control system can
thereby be achieved.
The terminal can be operated in four different modes. These modes are:
frequency measurement, event count, time measurement and pulse
generator.
Sensors with 24 V DC power supply and 5 V DC power supply can be
connected at the terminal.
The connection output delivers a maximal current of 500 mA.
5979A 001
5979a001.eps
Fig. 1-1: The R-IB IL CNT terminal with its appropriate connectors
Features of the Terminal
•Event counting:
The counting conditions and the output switching condition can be
freely selected.
•Frequency measurement:
Time and condition visualisation controlled frequency measurements
with gate times (time of the measurement) between 10 ms and 10 s
can be made.
•Time measurement:
Comparative conditions can be evaluated using the time
measurement. The evaluation result can be outputted by the process
data or at the digital output. This allows a targeted reaction to be made
if limit values are exceeded or fallen short of.

1-2 Functional Description of the Terminal Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
•Pulse generator:
The pulse generator generates square signals with frequencies of
1 kHz to 10 kHz in 500 Hz steps.
•The event count and frequency measurement modes deliver a 24 bit
test value; the time measurement delivers a 16 bit test value.
•A link between the source signal and the gate signal can be selected
as the counting signal.
•During operation, a start or end value can be changed without having
to stop the counter.
•An RC filter can be connected at the source and at the gate. This
allows mechanical switches to be used.
•A counter-start command does not have to be issued to start counting.
Counting begins immediately when the command for the selection of
the operating mode is transmitted.
•The counter terminal works in process data mode.
Areas of Usage
Event counting has been designed for unit counting.
12
1
2
3
4
1
2
3
4
D
S
G
12
1
2
3
4
1
2
3
4
1
E
12
1
2
3
4
1
2
3
4
RD
LC
12
1
2
3
4
1
2
3
4
UL
12
1
2
3
4
1
2
3
4
BA
RC
BK-T
12
1
2
3
4
1
2
3
4
US
UM
IB IL 2 4 B K -T IB IL C N T
12
3
58970002
58970002.eps
Fig. 1-2: Example configuration for counting separately packed articles
Legend:
No. Sensor/Actuator Corresponding input/output
1 Valve (control of the flap) Switch output
2 Sensor (control signal) Control input
3 Sensor (count pulse) Counter input
In the example shown in Fig. 1-2, e.g. 100 screws should be packaged in
a box. The control input (2) releases the counter at the counter input (3)
when there are screws in the funnel. Every screw that falls from the funnel
into the box triggers a pulse at the counter input. When there are 100
screws in the box, the switch output (1) is set ad the valve closes the
funnel. A new box can now be filled.
Event counting
Example for event counting

Counter Terminal Functional Description of the Terminal 1-3
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Frequency measurement is suitable for measuring speeds.
You can use the time measurement option for a most varied range of
applications.
•One example would be to determine the size of a part using the time
measurement. This then allows you to determine the differences in
size on a conveyor belt using the time differences.
•You can use the time measurement for measuring speed if you want
to react to situations where the limit values are exceeded or fallen
short of.. You can, e.g. set the output when a stipulated highest speed
has been reached.
Note: Please note that when in time measurement mode, you can
measure lower speeds than when in frequency measurement
mode as the time measurement works with 16-bit test values
but the frequency measurement works with 24-bit values.
You can generate and output pulse sequences at various frequencies
using the pulse generator.
1.2 Design of the Terminal
Housing Dimensions
Nowadays, small I/O stations are often used in standard switch cabinets
with a depth of 80 mm. The design of the Inline terminals allows for use in
this type of switchbox.
The housing dimensions of a terminal are defined by the dimensions of
the electronic socket and of the connector.
The electronics base of the terminal is 24.4 mm wide (see Fig. 1-3) .
Two plugs, each with a width of 12.2 mm are plugged onto this base (see
Fig. 1-4).
With plugged-on connector, the terminal has a depth of 71.5 mm.
The height of the terminal depends on the type of connector used. Either
one standard connector and one shielded connector (connector set for
the counter terminal), or two standard connectors, can be used on the
counter terminal.
Frequency measurement
Time measurement
Pulse generator

1-4 Functional Description of the Terminal Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
24,4 m m
(0.961")
55201022
120 m m (4.724")
7 1 ,5 m m (2 .8 1 5 ")
55201022.eps
Fig. 1-3: Dimensions of the electronics base of the R-IB IL CNT terminal
12
1
2
3
4
1
2
3
4
112,4 m m (4.425")
12,2 m m
(0 .4 8 0 ")
12
1
2
3
4
1
2
3
4
12,2 m m
(0 .4 8 0 ")
132 m m (5.197")
A B
5979A 015
5979a015.eps
Fig. 1-4: Connector dimensions
Legend:
A Shield connector
B Standard connector
The connector depth is irrelevant as it has no effect on the overall module
depth.
Electronic socket
Connector

Counter Terminal Functional Description of the Terminal 1-5
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Assignment of Terminal Points
The R-IB IL AO/CNT-PLSET connector set has been designed for
connecting the lines. It comprises one R-IB IL SCN-6 SHIELD shielded
connector and one R-IB IL SCN-8 standard connector.
You must use the shielded connector when you use shielded lines. A
shielded line must be used when you are connecting sensors at the 5 V
counter input and at the 5 V control input.
If you are not using a shielded line then you can use two R-IB IL SCN-8
standard connectors.
59790006
12
1
2
3
4
1
2
3
4
1.1
1.2
1.3
1.4
2.1
2.2
2.3
2.4
12
1
2
3
4
1
2
3
4
1.1
1.2
1.3
1.4
2.1
2.2
2.3
2.4
12
59790006.eps
Fig. 1-5: Assignment of terminal points

1-6 Functional Description of the Terminal Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Connector Terminal
point Signal Assignment
1.1 S+ Counter input 24 V (source)
2.1 G+ Control input 24 V (gate)
1.2 UINI Sensor voltage +24 V
2.2 UINI Sensor voltage +24 V
1.3 S- Ground for the counter input (source) and
the segment voltage
2.3 G- Ground for the control input (gate) and the
sensor voltage
1.4 Shield Shield connection (high capacitive
resistance at FE)
1
2.4 Shield Shield connection (high capacitive
resistance at FE)
1.1 S+* Counter input 5 V (source)
2.1 G+* Control input 5 V (gate)
1.2
2.2
OUT Output: the terminal points are bridged.
1.3
2.3
GND Ground for the output: the terminal points
are bridged internally.
1.4 FE Functional earth ground (directly to FE)
2
2.4 FE Functional earth ground (directly to FE)
Fig. 1-6: Connector assignment
Note: The sensor voltage UINI (protected by short-circuit) is
generated from the main voltage UM. The main voltage UMis
not used directly at the terminal points of the counter terminal.
Diagnostic and Status Indicators
5979A 007
S
G
D
CNT
1
E
OUT
5979a007.eps
Fig. 1-7: Diagnostic and status indicators

Counter Terminal Functional Description of the Terminal 1-7
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
The display of the counter terminal informs you of the following
conditions:
DLED green Diagnostics
On:
Flashing:
0.5 Hz:
(at a slow rate)
Local bus is active
Logic voltage available, local bus not active
2 Hz:
(at a medium rate) Logic voltage available, LOCAL BUS
active, peripheral fault
4 Hz:
(at a rapid rate) Logic voltage available;
terminal before the flashing terminal failed
Terminals after the flashing terminal are
not included in the configuration frame
Off: Logic voltage not available, LOCAL BUS
not active
ELED red
On:
Short-circuit at the sensor supply voltage
Short-circuit at connector 1 between
terminals 1.2 and 1.3 or between terminals
2.2 and 2.3
Off: No fault
The state of the input or output can be seen from the corresponding
yellow LED:
SLED yellow Status of counter input (source)
On: Input is set
Off: Input is not set
G+ LED yellow Status of the control input (gate)
On: Input is set
Off: Input is not set
1LED yellow Status of the output
On: Output is set
Off: Output is not set
Diagnostics
Status

1-8 Functional Description of the Terminal Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Internal Block Diagram
+24 V (U
M
)
+24 V (U
S
)
INTERBUS
U
L+
U
ANA
U
L-
OPC
I
MUX
≥
1
&
1
µP
59790004
U
IN I
59790004.eps
Fig. 1-8: Internal block diagram of the R-IB IL CNT
Legend:
Local bus Data jumper for the local bus
UL+ Logic voltage
UL- Grounded logic voltage
UANA Peripheral equipment supply voltage for analog terminals
UMMain voltage +24 V
UINI Sensor voltage +24 V; generated from the main voltage
USSegment voltage +24 V
OPC
Bus protocol chip (bus logic including voltage treatment)
µP
Microprocessor
Optocoupler
Digital input

Counter Terminal Functional Description of the Terminal 1-9
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Digital output
Transistor (output driver)
Coupling interface
µP
Component with multiplexer, filter and logic
I
Sensor supply voltage with short-circuit protection
Ground
Functional earth ground
Terminal connection
Voltage or data jumpers with lateral routing contacts

1-10 Functional Description of the Terminal Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P

Counter Terminal Important Directions for use 2-1
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
2 Important Directions for use
2.1 Appropriate Use
Introduction
Rexroth Indramat products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth Indramat, as manufacturer, is not liable for any
damages resulting from inappropriate use. In such cases, the
guarantee and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth Indramat products, make sure that all the pre-
requisites for appropriate use of the products are satisfied:
•Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
•If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
•Do not mount damaged or faulty products or use them in operation.
•Make sure that the products have been installed in the manner
described in the relevant documentation.

2-2 Important Directions for use Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
Areas of Use and Application
The RECO Inline system is a decentralized modular fieldbus-coupled
input and output system.
The RECO Inline system by Rexroth Indramat is intended for the cases of
use listed below.
•Machine tools
•Transfer systems
•General automation
Note: The RECO Inline system may only be used with the
accessories and parts specified in this document. If a
component has not been specifically named, then it may not
be either mounted or connected. The same applies to cables
and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant functional descriptions.
The typical fields of application of RECO Inline modules are as follows:
•Turning machines
•Milling machines
•Machining centers
•General automation
The RECO Inline system may only be operated under the assembly,
installation and ambient conditions as described here (temperature,
system of protection, humidity, EMC requirements, etc.) and in the
position specified.
2.2 Inappropriate Use
Using the RECO Inline system outside of the above-referenced areas of
application or under operating conditions other than described in the
document and the technical data specified is defined as "inappropriate
use".
The RECO Inline system may not be used if
•they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extreme maximum temperatures or if
Rexroth Indramat has not specifically released them for that intended
purpose. Please note the specifications outlined in the general Safety
Instructions!

Counter Terminal Safety Instructions for Electric Drives and Controls 3-1
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
3 Safety Instructions for Electric Drives and Controls
3.1 Introduction
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Rexroth Indramat
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
WARNING
Improper use of this equipment, failure to follow
the safety instructions in this document or
tampering with the product, including disabling
of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
3.2 Explanations
The safety instructions describe the following degrees of hazard
seriousness in compliance with ANSI Z535. The degree of hazard
seriousness informs about the consequences resulting from non-
compliance with the safety instructions.
Warning symbol with signal
word Degree of hazard seriousness according to ANSI
DANGER
Death or severe bodily harm will occur.
WARNING
Death or severe bodily harm may occur.
CAUTION
Bodily harm or material damage may occur.
Fig. 3-1: Hazard classification (according to ANSI Z535)

3-2 Safety Instructions for Electric Drives and Controls Counter Terminal
DOK-CONTRL-R-IL*CNT***-AW02-EN-P
3.3 Hazards by Improper Use
DANGER
High voltage and high discharge current!
Danger to life or severe bodily harm by electric
shock!
DANGER
Dangerous movements! Danger to life, severe
bodily harm or material damage by
unintentional motor movements!
WARNING
High electrical voltage due to wrong
connections! Danger to life or bodily harm by
electric shock!
WARNING
Health hazard for persons with heart
pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
CAUTION
Surface of machine housing could be extremely
hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to improper handling! Bodily
harm caused by crushing, shearing, cutting and
mechanical shock or incorrect handling of
pressurized systems!
CAUTION
Risk of injury due to incorrect handling of
batteries!