Keba Kemro CP 263/S Installation and operation manual

Kemro
CP 263/S, CP 263/X
CPU module
Project engineering manual V1.01
Translation of the original instructions

Document : V1.01 / article no.: 1008574
Filename : cp263xpjen.pdf
Pages : 42
.
© KEBA 2014
Specifications are subject to change due to further technical developments. Details presented may be subject to correction.
All rights reserved.
KEBA AG Headquarters: Gewerbepark Urfahr, 4041 Linz, Austria, Phone: [phone], Fax: [phone],
[email protected]
For information about our subsidiaries please look at www.keba.com.

Record of Revision
Version Date Change in chapter Description changed by
1.00 09-2014 - Newly created ekt
1.01 10-2014 - Extended by CP 263/X ekt
CP 263/S, CP 263/X Record of Revision
© KEBA 2014
Project engineering manual V1.01 3

Table of Contents
1 Introduction....................................................................................................................... 9
1.1 Purpose of the document........................................................................................ 9
1.2 Preconditions.......................................................................................................... 9
1.3 Intended use......................................................................................................... 10
1.4 Notes on this document........................................................................................ 10
1.4.1 Contents of the document...................................................................... 10
1.4.2 Not contained in this document.............................................................. 11
1.5 Documentation for further reading........................................................................ 11
1.6 EtherCAT declaration............................................................................................ 11
2 Safety notes.................................................................................................................... 12
2.1 Representation...................................................................................................... 12
2.2 General safety instructions.................................................................................... 13
2.3 Safety instructions for personal safety.................................................................. 13
2.4 Safety instructions for device maintenance........................................................... 14
3 Description of the module............................................................................................. 15
3.1 Front view.............................................................................................................. 15
3.2 Compact Flash slot............................................................................................... 15
3.2.1 Precautions when using the CF card..................................................... 16
3.2.2 Inserting the Compact Flash card.......................................................... 16
3.2.3 Removing the Compact Flash card........................................................ 16
3.3 Accessories........................................................................................................... 17
3.3.1 Compact Flash card............................................................................... 17
3.3.2 Connector strip....................................................................................... 17
4 Displays and operating elements.................................................................................. 18
4.1 Diagnostic display (DIAG)..................................................................................... 18
4.2 Status LEDs.......................................................................................................... 18
4.3 Control key (CTRL)............................................................................................... 18
4.4 CAN Status LEDs.................................................................................................. 18
4.5 Ethernet status LEDs............................................................................................ 19
5 Mounting and installation instructions......................................................................... 20
5.1 Mounting of the module......................................................................................... 20
5.2 Inserting and removing of option modules............................................................ 20
5.3 Adding modules.................................................................................................... 22
5.4 Air conditioning and ventilation............................................................................. 23
5.4.1 Use of air filters...................................................................................... 23
6 Connections and wiring................................................................................................. 24
6.1 Power supply......................................................................................................... 24
6.1.1 Connection example............................................................................... 25
6.2 Grounding............................................................................................................. 25
6.3 Graphic interface (PANEL / SI0)........................................................................... 26
CP 263/S, CP 263/X Table of Contents
© KEBA 2014
Project engineering manual V1.01 5

6.3.1 Pin assignment....................................................................................... 27
6.3.2 Cable and plug specification.................................................................. 27
6.4 CAN interface (CAN0)........................................................................................... 27
6.4.1 Pin assignment, connection example..................................................... 27
6.4.2 Cable and plug specification.................................................................. 28
6.4.3 CAN bus termination.............................................................................. 28
6.5 Ethernet interfaces (ETHERNET0-2).................................................................... 29
6.5.1 Pin assignment....................................................................................... 29
6.5.2 Cable and plug specification.................................................................. 30
6.6 USB ports (USB0, USB1)...................................................................................... 30
6.6.1 Cable and plug specification.................................................................. 30
6.7 EMC and wiring guidelines.................................................................................... 30
7 Configuration.................................................................................................................. 31
7.1 Setting the K-Net address..................................................................................... 31
8 Operating behavior......................................................................................................... 32
8.1 Failure of supply voltage....................................................................................... 32
8.2 Response to module errors................................................................................... 32
8.3 Watchdog.............................................................................................................. 32
9 Diagnosis......................................................................................................................... 33
10 Maintenance.................................................................................................................... 34
10.1 Battery................................................................................................................... 34
10.1.1 Battery type and service life................................................................... 34
10.1.2 Replacing the battery............................................................................. 34
10.2 Fan........................................................................................................................ 35
10.2.1 Service life.............................................................................................. 35
10.2.2 Replacing fan......................................................................................... 35
11 Disposal........................................................................................................................... 38
11.1 Disposal of the module.......................................................................................... 38
11.2 Disposal of the battery.......................................................................................... 38
12 Technical data................................................................................................................. 39
12.1 In general.............................................................................................................. 39
12.2 Environmental conditions...................................................................................... 39
12.3 Computer kernel.................................................................................................... 39
12.4 Interfaces.............................................................................................................. 39
12.5 Dimensions, weight............................................................................................... 40
13 EC directives and standards......................................................................................... 41
13.1 EC directives......................................................................................................... 41
13.2 Standards.............................................................................................................. 41
13.2.1 General procedures and safety principles.............................................. 41
13.2.2 EMC guideline........................................................................................ 41
13.2.3 Electrical safety and fire protection........................................................ 41
13.2.4 Environmental and surrounding conditions............................................ 41
13.3 Standards for the American market...................................................................... 41
13.3.1 UL test for industrial control equipment.................................................. 41
Table of Contents CP 263/S, CP 263/X
© KEBA 2014
Project engineering manual V1.016

14 Declaration of conformity.............................................................................................. 42
CP 263/S, CP 263/X Table of Contents
© KEBA 2014
Project engineering manual V1.01 7

1 Introduction
1.1 Purpose of the document
This document describes the structure of the CP 263/x (CPU module).
Additionally, the installation and configuration is described enough to obtain
anoperationallyreadymodule."Readyforoperation"meansthattheassembly
is ready for the synchronization of the firmware and the application.
Information
This manual is not addressed to end customers! Necessary safety notes for
theend customer haveto be takeninto the customermanual in therespective
national language by the machine builders and system providers.
1.2 Preconditions
This document contains information for persons with the following skills:
Target group Knowledge and skills pre-requirement
Project engineer
Basic technical training (University of Applied Science/University level,
engineering degree or corresponding professional experience).
Knowledge in:
●working mode of a PLC,
●current valid safety regulations,
●the application.
Electrician
Specialized training in the electro-technical field (in accordance with
industrial training guidelines).
Knowledge in:
●current valid safety regulations,
●wiring guidelines,
●circuit diagrams,
●correct installation of electrical connections according to national
and international regulations.
CP 263/S, CP 263/X Introduction
© KEBA 2014
Project engineering manual V1.01 9

Target group Knowledge and skills pre-requirement
Start-up technician
Basic technical training (Vocational high school, engineering degree or
corresponding professional experience).
Knowledge in:
●current valid safety regulations,
●working mode of machine or plant,
●principal functions of the application,
●system analysis and troubleshooting,
●setting options at the operating installations.
Service technician
Basic technical training (Vocational high school, engineering degree or
corresponding professional experience).
Knowledge in:
●working mode of a PLC,
●current valid safety regulations,
●working mode of machine or plant,
●diagnosis possibilities,
●systematic error analysis and rectification.
1.3 Intended use
The CP 263/x was developed for control applications in industrial machines.
The typical applications areas include injection molding machines, robots,
presses, machine tools and similar.
The CP 263/x may only be used for the types of use described in the technical
descriptions and in compliance with described technical general conditions.
The CP 263/x may only be used in conjunction with recommended/approved
third-party equipment/installations.
The CP 263/x has been developed, manufactured, tested and documented in
accordance with the appropriate guidelines and standards. Therefore, the
products do not pose any danger to the health of persons or a risk of damage
to other property or equipment under normal circumstances, provided that the
instructions and safety precautions are properly observed.
1.4 Notes on this document
This manual is an integral part of the product. It is to be retained over the entire
life cycle of the product and should be forwarded to any subsequent owners
or users of the product.
1.4.1 Contents of the document
●Description of the module
●Mounting and installation instructions
●Description of interfaces including EMC guidelines
Introduction CP 263/S, CP 263/X
© KEBA 2014
Project engineering manual V1.0110

●Configuration
●Operating behavior
●Diagnostics functions
●Maintenance instructions
●Technical data
1.4.2 Not contained in this document
●Programming instruction
●Application diagnosis
●Firmware description
1.5 Documentation for further reading
Thefollowingdocuments are tobeobserved depending onthesystem solution
used:
For version CP 263/S:
Doc.No. Name Target group
DE: 65352
EN: 65353 K2-200 automation system manual
●Project engineer
●Electrician
●Programmer
●Commissioning foreman
●Service technician
For version CP 263/X:
Doc.No. Name Target group
DE: 1000868
EN: 1000869 KeMotionautomationsystemmanual
●Project engineer
●Electrician
●Programmer
●Commissioning foreman
●Service technician
1.6 EtherCAT declaration
EtherCAT® is registered trademark and patented technology, li-
censed by Beckhoff Automation GmbH, Germany .
CP 263/S, CP 263/X Introduction
© KEBA 2014
Project engineering manual V1.01 11

2 Safety notes
2.1 Representation
At various points in this manual you will see notes and precautionary warnings
regarding possible hazards. The symbols used have the following meaning:
DANGER!
●indicates an imminently hazardous situation which will result in death or
serious bodily injury if the corresponding precautions are not taken.
WARNING!
●indicates a potentially hazardous situation which can result in death or se-
rious bodily injury if the corresponding precautions are not taken.
CAUTION!
●meansthat ifthecorrespondingsafetymeasures arenot taken,a potentially
hazardous situation can occur that may result in property injury or slight
bodily injury.
CAUTION
●CAUTION used without the safety alert symbol indicates a potentially haz-
ardous situation which, if not avoided, may result in damage to property.
●This symbol reminds you of the possible consequences of touching elec-
trostatically sensitive components.
Information
Useful practical tips and information on the use of equipment are identified
by the “Information” symbol. They do not contain any information that warns
about potentially dangerous or harmful functions.
Safety notes CP 263/S, CP 263/X
© KEBA 2014
Project engineering manual V1.0112

2.2 General safety instructions
WARNING!
●It is absolutely essential that you also observe the safety instructions in the
system manual for your automation system.
●The following areas of application are expressly excluded for the
CPU module:
●Use in areas where there is a risk of explosion or fire
●Use in the mining sector
●Use in the open air
Other products are to be used for these applications!
●The CPU module is not designed for safety-relevant control tasks (e.g.:
shutdown in case of an emergency). For safety-relevant control tasks and
personnel security, additional external safety measures must be implemen-
ted to ensure the system remains in a safe operating condition even in the
event of a fault.
●At the developement of the CPU module the standard EN ISO 13849-1 was
not considered.
●The module is defined as "open type equipment" (UL 508) or as "open
equipment" (EN 61131-2) and must therefore be installed in a control cabi-
net.
CAUTION
Improper use of the assembly or the control system leads to irreparable dam-
age!
●Turn off the power supply before inserting or removing the module. Other-
wise, the module can be destroyed or undefined signal states can lead to
damage of the control system.
2.3 Safety instructions for personal safety
WARNING!
Danger of personal injury due to electric shock!
●Supply the device exclusively from power sources that have an extra low
voltage (e.g. SELV or PELV according to EN 61131-2)
●When using a SELV power source it can become PELV by reason of the
module construction and the connectors (grounding!).
●Protective low voltage circuits must always be installed safely insulated
separated from circuits with dangerous voltage.
CP 263/S, CP 263/X Safety notes
© KEBA 2014
Project engineering manual V1.01 13

CAUTION!
Fire hazard during module failure!
●Provide suitable fuses for the 24 V DC power supply of the control system
for the final application! (for details, refer to the Power supply section).
2.4 Safety instructions for device maintenance
CAUTION!
●The device may only be opened by qualified personnel and only mainte-
nance activities expressly approved by KEBA may be performed (see chap-
ter “maintenance”). Any other manipulations to the device will result in loss
of warranty.
●If this device is damaged, the device must be taken out of commission and
repaired or replaced by qualified personnel.
Safety notes CP 263/S, CP 263/X
© KEBA 2014
Project engineering manual V1.0114

3 Description of the module
TheCPU moduleis an intelligent master module designed fora medium-range
performance within the Kemro automation system.
3 slots for option modules are available for extensions.
3.1 Front view
Fig.3-1: Front view CP 263/x
1... Power supply 2... USB port (USB1)
3... Graphic interface 4... Diagnosis display
5... 3 slots for option modules 6... USB port (USB0)
7... Ethernet interfaces 8... CAN interface
3.2 Compact Flash slot
To operate a Compact Flash card with the respective firmware and the appli-
cation must be plugged into the Compact Flash slot of the CPU module.
Depending on the application used the Compact Flash card can also be used
for storing machine data (e.g. mold data or part data).
For more information please see the system manual for your automation sys-
tem.
Information
Use only Compact Flash cards which are recommended by KEBA.
Information
The Compact Flash Card cannot be used as removable medium since it also
has system programs stored on it.
CP 263/S, CP 263/X Description of the module
© KEBA 2014
Project engineering manual V1.01 15

3.2.1 Precautions when using the CF card
CAUTION
Improper insertion can cause damage to the contact pins.
Do not use force when inserting the Compact Flash card into the slot. It is con-
structed so that it can only be inserted in one direction and it should slide into
the slot easily with little force.
The card:
●should be kept away from moisture, heat and direct sunlight,
●should be protected against static electricity,
●should not be dropped or bent.
●should not be removed or the device switched off while the card is being
written to.
3.2.2 Inserting the Compact Flash card
1) Turn off the power supply.
2) Insert the Compact Flash card (see drawing).
Fig.3-2: Inserting the CF card
3.2.3 Removing the Compact Flash card
1) Turn off the power supply.
2) Press the eject button ( 1, see drawing).
3) Pull out the Compact Flash card ( 2).
Fig.3-3: Removing the CF card
Description of the module CP 263/S, CP 263/X
© KEBA 2014
Project engineering manual V1.0116

3.3 Accessories
3.3.1 Compact Flash card
The recommended Compact Flash cards may be requested and ordered from
KEBA.
3.3.2 Connector strip
Socket board Color Number Weidmüller order number
2-pole sw 1 BLZF 5.08/2 SN SW - 1707690000
The appropriate female connectors are not included in the delivery of KEBA,
but can be purchased via KEBA.
The technical data for the terminals are contained in the technical data sheet
of the manufacturer of the female connectors.
CP 263/S, CP 263/X Description of the module
© KEBA 2014
Project engineering manual V1.01 17

4 Displays and operating elements
4.1 Diagnostic display (DIAG)
A single-digit 7-segment display on the front side indicates the start-up modes
and error codes.
Fig.4-1: Diagnosis display and CTRL key
Further information: See system manual.
4.2 Status LEDs
The multi-colored status LED on the CPU module is located above the control
key (CTRL).
Display Significance
Dark No supply voltage
Flashing green Initialization phase
Green Operation
Flashing red Error on module (e.g. overload, line interruption, etc.)
Red Fatal module error – the module is out of operation.
4.3 Control key (CTRL)
The control key (CTRL) is located next to the 7-segment-display on the right.
Differentfunctionscanbeexecutedwiththekey,e.g.switchingoverthecontrol
to a different operating state. For further information see: System manual
4.4 CAN Status LEDs
The module has two CAN Status LEDs (RX- and TX-LEDs) per CAN interface,
which are activated from the Microcontroller.
Displays and operating elements CP 263/S, CP 263/X
© KEBA 2014
Project engineering manual V1.0118

Display Significance
RX-LED (green) briefly lights up on receipt of a CAN-message.
TX-LED (yellow) briefly lights up on transmission of a CAN-message.
4.5 Ethernet status LEDs
The Ethernet-socket (RJ-45) offers a Link-Status-LED and an Activity-LED.
Display Significance
Link-Status-LED
(green) Lights up as soon as an Ethernet connection is available.
Activity-LED Lights up when sending and receiving data.
CP 263/S, CP 263/X Displays and operating elements
© KEBA 2014
Project engineering manual V1.01 19

5 Mounting and installation instructions
5.1 Mounting of the module
Further information: See system manual.
5.2 Inserting and removing of option modules
Thefront side of the CP263/x provides3 slots for the optionmodules. Modules
from the Kemro series can be inserted into these slots.
Assignment of the slots
●Left slot
1SX 210/A for RS 232
SX 220/A for Current-Loop
SX 230/A for RS-485-A, RS-422-A
●Middle slot
2FX 200/A for CAN
●Right slot
3NX 252/A for Ethernet
BX 250/A for K-Net
BX 252/A for K-Net, Ethernet
FX 271/C for Sercos, Ethernet
Fig.5-1: Assignment of the slots
●Slots not used must be closed with reserve modules to secure contact pro-
tection of the ESD-sensitive parts.
Mounting and installation instructions CP 263/S, CP 263/X
© KEBA 2014
Project engineering manual V1.0120