DEWESOFT IOLITEiw-3xMEMS-ACC Series User manual

IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
V23-2
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
Table of contents
Table of contents 2
Introduction 3
Tools needed 4
Basic wiring and system requirements 5
Wiring requirements for long chains 6
Single power injector, non-conductive structure (i.e. concrete bridge) 6
Step-by-step instructions for connecting the EtherCAT communication cables to the device 14
Attaching the device to the measured object 22
About this document 23
Legend 23
Warranty information 24
Calibration 24
Support 24
Service/repair 24
Restricted Rights 24
Printing History 25
Copyright 25
Trademarks 25
Safety instructions 25
Safety symbols in the manual 25
General Safety Instructions 25
Environmental Considerations 26
Product End-of-Life Handling 26
System and Components Recycling 26
General safety and hazard warnings for all Dewesoft systems 26
Documentation version history 29
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
Introduction
This manual will present the tools and procedure needed to install the IOLITEiw-3xMEMS-ACC (device)
including the wiring of the cables.
The same procedure should be followed when installing the cables to the other product types of the
same product family, including but not limited to:
IOLITEiw-3xMEMS-ACC-8g
IOLITEiw-3xMEMS-ACC-40g
IOLITEiw-3xMEMS-ACC-8g-T
IOLITEiw-3xMEMS-ACC-40g-T
IOLITEiw-3xMEMS-ACC-S
IOLITEiw-3xMEMS-ACC-INC
The cover of the sensor needs to be removed in order to make the RJ45 ports accessible. The cable
glands and bend relieves need to be tightened onto the sensor and finally the cover is put back in place.
Detailed step by step instructions are presented in the remaining of this document.
Important
Only the cables approved by Dewesoft should be used in order to ensure the IP67 rating of the
cable glands. If different cables are used, the user should perform a test to ensure that the cable
glands will properly grip the cable and achieve the IP67 rating. Clamping range: 6 .. 9 mm
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
Tools needed
1.) 3 mm Allen/imbus key wrench
2.) 4mm Allen/imbus key wrench
3.) 19 mm wrench with an open circular end
4.) Threadlocking compound, example: Loctite 243
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
Basic wiring and system requirements
The devices should be connected to the industrial PC according to the schematic from the device
datasheet using Dewesoft IOLITE POWER-INJECTOR.
The required power supply: Mean Well SDR-75-48
The minimum industrial PC requirements are listed below. The values are minimal and assume no
mathematics or other plugins running on the PC. In case of additional mathematical channels higher
CPU specs might be required.
Required PC specifications (1-10 devices connected):
●CPU: 4 core, 2 GHz per core, Intel i3 minimum
●RAM: 8 GB
Required PC specifications (10-20 devices connected):
●CPU: 4 core, 2.5 GHz per core, Intel i5 minimum
●RAM: 16 GB
Required PC specifications (20-50 devices connected):
●CPU: 8 core, 3 GHz per core, Intel i7 minimum
●RAM: 16 GB
Maximum number of EtherCAT devices that can be connected to the same PC: 50
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INSTALLATION MANUAL
Wiring requirements for long chains
The exact wiring of the chain of devices depends on the local conditions such as the overall length of the
chain, conductivity of the structure, type of power supply, existence of additional power injectors along
the chain, availability of local earth connections etc. The most common configurations are presented in
this section.
Single power injector, non-conductive structure (i.e. concrete bridge)
The power supply and power injector should be installed in an electrical cabinet. A single network cable
connects the devices outside of the cabinet. The cable shield may be connected at each end of the
cables, effectively forming a continuous shield connection along the chain. This is only allowed if the
structure to which the devices are mounted is not conductive (i.e. concrete bridge).
Single power injector, conductive structure (i.e. steel bridge)
In this case, especially in case of long cables, there is a risk of ground loop formed by the cable shield,
device housing and the structure itself. It is therefore necessary to either break the shield at each IN port
by using a non-conductive plastic RJ45 connector (4). Using non-shielded cables is not a viable solution
as the cables themselves always need to be shielded.
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
The following configurations include an external power injector which is necessary due to voltage drop
in case of long chains. The configurations are presented in the order from the most recommended to
the least recommended in terms of EMI immunity.
Multiple power injectors, non-conductive structure (i.e. concrete bridge),
AC line to external power supply, local earth available
This schematic shows the most recommended wiring in case external power injectors need to be used.
The industrial PC, Ethercat power supply and power injector are typically inside the main electrical
cabinet (1), together with appropriate surge protection for the power supply system used on installation
site (TN or TT).
If additional external power injector (2) is needed (due to voltage drop in a long chain), it is
recommended that it is powered by a local power supply (3) which means the main AC line needs to be
wired to it. This is the most robust wiring against EMI disturbances.
The external power injector and power supply must both have the EARTH pins connected locally. It is
necessary to perform resistance measurement between the EARTH terminals and local earthing point
according to EN-60364 to ensure functionality (i.e. <0.1 ohm resistance at 10 A test current).
To avoid a ground loop, it is important to break the daisy chained network cable shield by placing an
unshielded RJ45 connector (4) at the IN port of the external power injector.
To protect external power supplies from lightning strike, it is recommended that surge protection (6) is
added to each external power supply.
Note on conductive structures (i.e. steel bridge): if the structure is conductive, the shield needs to be
broken at every device’s IN port as explained in the previous section.
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INSTALLATION MANUAL
Multiple power injectors, non-conductive structure (i.e. concrete bridge),
AC line to external power supply, no local earth
If it is not possible to connect the external power supply and power injector EARTH pins to local earth,
there must be an isolation transformer (7) in the MAINS line to the external power supply to protect
against electric shock.
In this wiring it is recommended that the RJ45 connector (4) at the power injector IN port is shielded as
there is no ground loop created by earthing, therefore it is desirable to continue the shield connection
along the full chain.
Note on conductive structures (i.e. steel bridge): if the structure is conductive, the shield needs to be
broken at every device’s IN port as explained in the previous section.
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INSTALLATION MANUAL
Multiple power injectors, non-conductive structure (i.e. concrete bridge),
DC line to external power supply, local earth available
This schematic shows the wiring in case it is not possible to install an external power supply and
therefore a 48 V DC power cable is wired to the external power injector.
It is important that the DC cable is shielded for immunity against EMI disturbances.
The external power injector must have the EARTH pins connected locally. It is necessary to perform
resistance measurement between the EARTH terminal and local earthing point according to EN-60364
to ensure functionality (i.e. <0.1 ohm resistance at 10 A test current).
To avoid a ground loop, it is important to break the daisy chained network cable shield by placing an
unshielded RJ45 connector (4) at the IN port of the external power injector.
Please note: the maximum wire diameter of the power injector input DC cable is 1 mm2(18 AWG) in
order to fit the input connector including the ferrulle. Therefore the voltage drop might be significant if
the length if the DC cable is more than 100 m.
Note on conductive structures (i.e. steel bridge): if the structure is conductive, the shield needs to be
broken at every device’s IN port as explained in the previous section.
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
Multiple power injectors, non-conductive structure (i.e. concrete bridge),
DC line to external power supply, no local earth
This schematic shows the wiring in case it is not possible to install an external power supply and
therefore a 48 V DC power cable is wired to the external power injector.
It is important that the DC cable is shielded for immunity against EMI disturbances.
If it is not possible to connect the external power injector to local earth, it is recommended that the RJ45
connector (4) at the power injector IN port is shielded as there is no ground loop created by earthing,
therefore it is desirable to continue the shield connection along the full chain.
Please note: the maximum wire diameter of the power injector input DC cable is 1 mm2(18 AWG) in
order to fit the input connector including the ferrulle. Therefore the voltage drop might be significant if
the length if the DC cable is more than 100 m.
Note on conductive structures (i.e. steel bridge): if the structure is conductive, the shield needs to be
broken at every device’s IN port as explained in the previous section.
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INSTALLATION MANUAL
Instructions for connecting the EtherCAT
communication cables to the device - quick method
If the cables already come with the M16 cable glands preinstalled (like seen in the picture below), it is
possible to connect the cables to the device without opening the top cover. In that case the cable gland
is already pre-mounted on the cable, therefore the device does not have the cable gland installed yet.
1. Slide the RJ45 connector into the threaded hole of the device. Make sure that the RJ45 clip is
facing downwards as seen in the pictures below.
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
2. Insert the RJ45 into the connector inside the device. It cannot be seen, but with little practice the
insertion should be easily achievable. Make sure to hear a click of the RJ45 clip.
3. Screw the mounting thread of the cable gland into the device and tighten it with a 19 mm
wrench. Since in this method we cannot install the counter nut on the inside of the housing, it is
advisable to apply some threadlocker on the mounting thread of the cable gland.
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
4. Before tightening of the squeeze nut make sure to push the cable firmly inside the device. Then
tighten the squeezing nut of the cable gland to ensure the cable is tightly gripped and the
connection is waterproof.
5. Repeat the same for the second cable.
The above procedure is especially useful and fast for planned long-term installations. In case the cable
needs to be disconnected, the top cover of the device needs to be opened. The next section describes
the longer procedure of connecting the cables by opening the top cover of the device.
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INSTALLATION MANUAL
Step-by-step instructions for connecting the EtherCAT
communication cables to the device
1. The first step is to unscrew the 6 cylindrical head screws (tool needed: Allen/imbus key 3 mm),
denoted with orange arrows. The screws are only lightly attached with the rubber washers not
yet squeezed. Untightening the screws will detach the cover plate.
2. There are retaining rings on the screws (see the figure below), so that the screws don’t fall out of
the holes. However, care still needs to be taken in order not to detach the retaining rings as well.
Silica gel capsule is glued to the cover.
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INSTALLATION MANUAL
3. After removing the cover plate, care needs to be taken for the o-ring seal not to fall out of the
groove. If it does fall out, it needs to be put back in place before placing the cover plate back
again at the end of the procedure.
4. Cable glands might be already placed on the device or might be supplied separately. If cable
glands are mounted on the device, they need to be removed to follow the procedure below.
5. Carefully place the RJ45 connector through the threaded hole and through the counter nut as
shown below.
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IOLITEiw-3xMEMS-ACC
INSTALLATION MANUAL
6. The cable gland should be already placed on the cable behind the RJ45 connector. It consists of
two parts: the seal part and the tightening part which could also be a bend relief. For easier
installation you can separate them by unscrewing the tightening part / bend relief from the seal
part.
Screw the gland into the thread hole of the sensor as shown below.
7. Tighten the gland by gripping the nut with a 19 mm wrench. For easier manipulation a specially
cut 19 mm wrench should be used.
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INSTALLATION MANUAL
8. Tighten the counter nut on the inside of the device, again using the special 19 mm wrench.
9. Plug the RJ45 connector into the RJ45 port of the sensor.
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INSTALLATION MANUAL
10. Screw the bend relief on the cable gland and make sure to fully insert the cable into the sensor as
shown with the red arrow on the figure below. Before tightening the gland, the connector must
be fully pushed inside the port! Tighten the bend relief with the special 19 mm wrench.
11. A tightened cable gland is shown below.
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INSTALLATION MANUAL
12. If the sensor needs to have both cables connected, repeat the same procedure to mount the
other cable as well.
Note: An alternative procedure is possible in which the cable gland is only untightened (to the
maximum clamping range) but not removed. In that case the cable can be inserted through the cable
gland and the connector is crimped after the cable is already passing through the device housing.
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INSTALLATION MANUAL
13. Attach the cover plate back onto the sensor by applying the threadlocking compound to the
screws and tightening them with a 3 mm Allen/imbus key.
Important: Tightening torque for the M4 screws: 1.5 Nm (higher torque might damage the
thread in the sensor housing while lower torque might not press the main O-ring seal enough)
Note: there are also individual seals mounted around the M4 screws which get squeezed into a
washer-shape when the 1.5 Nm is applied. Those seals are used for galvanically isolating the
stainless steel screws from the aluminum housing.
Alternatively the seals can be applied directly to the screw head (green coating).
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