Kuhnke KUAX 680I User manual

Kuhnke Electronics
Instruction Manual
E 326 GB
Modules of Controllers
KUAX 680I, KUAX 680C, KDT 680CT
7 May 1997 / 39.785

This manual is primarily intended for use by design, project, and development
engineers. It does not give any information about delivery possibilities. Data
is only given to describe the product and must not be regarded as guaranteed
properties in the legal sense. Any claims for damages against us - on whatever
legal grounds - are excluded except in instances of deliberate intent or gross
negligence on our part.
We reserve the rights for errors, omissions and modifications.
Reproduction even of extracts only with the editor's express and written prior
consent.

Table of contents
Contents - 1
Table of contents
1. Introduction............................................................... 1-1
1.1. Manual breakdown ................................................................. 1-2
1.2. Further modules....................................................................... 1-3
2. Safety and Reliability.................................................. 2-1
2.1. Target group ........................................................................... 2-1
2.2. Reliability ............................................................................... 2-1
2.3. Notes..................................................................................... 2-2
2.3.1. Danger................................................................................ 2-2
2.3.2. Dangers caused by high contact voltage ................................. 2-2
2.3.3 Important information / cross reference.................................... 2-2
2.4. Safety .................................................................................... 2-3
2.4.1. To be observed during project planning and installation............ 2-3
2.4.2. To be observed during maintenance and servicing ................... 2-4
2.5. Electromagnetic compatibility .................................................... 2-5
2.5.1. Definition............................................................................. 2-5
2.5.2. Resistance to interference ...................................................... 2-5
2.5.3. Interference emission............................................................. 2-6
2.5.4. General notes on installation.................................................. 2-6
2.5.5. Protection against external electrical influences ........................ 2-7
2.5.6. Cable routing and wiring....................................................... 2-7
2.5.7. Location of installation........................................................... 2-8
2.5.8. Particular sources of interference ............................................ 2-8
3. Modules and slots ...................................................... 3-1
3.1. Design.................................................................................... 3-2
3.2. Screw-type locking connectors................................................... 3-3
3.2.1. Coding................................................................................ 3-3
3.3. Slots....................................................................................... 3-4
3.3.1. Function slots ....................................................................... 3-4
3.4. Service modules ...................................................................... 3-5
3.4.1. Transfer address ranges ........................................................ 3-5
3.4.2. Interrupt modules .................................................................. 3-5
3.5. Power supply of inputs and outputs............................................ 3-6
3.6. Differences between KUAX 680C/KDT 680CT and KUAX 680I.... 3-7

Table of contents
Contents - 2
4. Digital inputs and outputs............................................ 4-1
4.1. Plugging digital input and output modules .................................. 4-2
4.1.1. Addressing (input/output groups and channels)........................ 4-2
4.1.2. Reserved slots ...................................................................... 4-3
4.2. Digital input modules ............................................................... 4-4
4.2.1. Input module, 24 V DC, 8 inputs ............................................ 4-5
4.2.1.1. Technical specifications ...................................................... 4-6
4.2.2. Input module, 24 V DC, 8 inputs, with real-time clock ............... 4-7
4.2.2.1. Real-time clock .................................................................. 4-7
4.2.2.2. Parameters of KUBES module “CLOCK” ............................... 4-8
4.2.2.3. Programming suggestion for the real-time clock ................... 4-10
4.2.2.4. Technical specifications .................................................... 4-11
4.2.3. Input module, 24 V DC, 16 inputs ........................................ 4-12
4.2.3.1. Technical specifications .................................................... 4-13
4.2.4. Input module, 24 V DC, 8 inputs, 1 ms ................................. 4-14
4.2.4.1. Technical specifications .................................................... 4-15
4.2.5. Input module, 24 V DC, 16 inputs, 1 ms ............................... 4-16
4.2.5.1. Technical specifications .................................................... 4-17
4.2.6. Input module, 24 V DC, 16 inputs, interrupt capability............ 4-18
4.2.6.1. Signal delay ................................................................... 4-18
4.2.6.2. Interrupt inputs ................................................................ 4-20
4.2.6.3. Technical specifications .................................................... 4-23
4.3. Digital output module, 24 V DC, 0.5 A, 8 outputs ..................... 4-24
4.3.1 Technical specifications ........................................................ 4-26
4.4. Digital input/output module, 24 V DC, 8/8.............................. 4-27
4.4.1. Technical specifications ....................................................... 4-28
4.5. Pneumatic output module, 4 outputs 3/2 way ........................... 4-29
4.5.1. Technical specifications ....................................................... 4-30
5. Analogue inputs and outputs ....................................... 5-1
5.1. Plugging analogue input and output modules .............................. 5-2
5.1.1. Addressing (anal. input/output groups and channels) ............... 5-2
5.1.2. Reserved slots ...................................................................... 5-3
5.2. Analogue input modules........................................................... 5-5
5.2.1. Analogue input module, 0...10 V, 10 bit, 4 channels ............... 5-5
5.2.1.1. Slots................................................................................. 5-5
5.2.1.2. Connectors ....................................................................... 5-6
5.2.1.3. Representation of the analogue value................................... 5-6
5.2.1.4. Technical specifications ...................................................... 5-7
5.2.2. Analogue input module, 0(4)...20 mA, 10bit, 4 channels.......... 5-8

Table of contents
Contents - 3
5.2.2.1. Slots................................................................................. 5-8
5.2.2.2. Connections...................................................................... 5-9
5.2.2.3. Representation of the analogue value................................... 5-9
5.2.2.4. Transfer address ranges ................................................... 5-10
5.2.2.5. Technical specifications.................................................... 5-11
5.2.3. Analogue input module, PT100, 0...300 °C, 10 bit,............... 5-12
5.2.3.1. Slots............................................................................... 5-12
5.2.3.2. Connectors ..................................................................... 5-13
5.2.3.3. Transfer address ranges ................................................... 5-14
5.2.3.4. Evaluation in the user program .......................................... 5-15
5.2.3.5. Technical specifications.................................................... 5-16
5.2.4. Analogue input module, thermocouple NiCrNi (type K),.......... 5-17
5.2.4.1. Slots............................................................................... 5-17
5.2.4.2. Connections.................................................................... 5-18
5.2.4.3. Transfer address ranges ................................................... 5-19
5.2.4.4. Evaluation in the user program .......................................... 5-20
5.2.4.5. Technical specifications.................................................... 5-21
5.2.5. Analogue input module, potentiometer, 10bit, 4 channels ....... 5-22
5.2.5.1. Slots............................................................................... 5-22
5.2.5.2. Connectors ..................................................................... 5-23
5.2.5.3. Representation of the analogue value................................. 5-24
5.2.5.4. Technical specifications.................................................... 5-25
5.3. Analogue output modules ....................................................... 5-27
5.3.1. Analogue output module, 0...10 V, 8 bit, 4 channels ............. 5-27
5.3.1.1. Slots............................................................................... 5-27
5.3.1.2. Connectors ..................................................................... 5-28
5.3.1.3. Repesentation of the analogue value.................................. 5-28
5.3.1.4. Technical specifications.................................................... 5-29
5.3.2. Analogue output module, 0(4)...20 mA, 8bit, 4 channels........ 5-31
5.3.2.1. Slots............................................................................... 5-31
5.3.2.2. Connectors ..................................................................... 5-32
5.3.2.3. Repesentation of the analogue value.................................. 5-32
5.3.2.4. Transfer address ranges ................................................... 5-33
5.3.2.5. Technical specifications.................................................... 5-34
5.4. Analogue input/output modules .............................................. 5-35
5.4.1. Analogue I/O module, 2 I 0...10 V, 2 O 0...±10V ................ 5-35
5.4.1.1. Slots............................................................................... 5-36
5.4.1.2. Connectors ..................................................................... 5-37
5.4.1.3. Representation of the analogue value................................. 5-38
5.4.1.4. Technical specifications.................................................... 5-39

Table of contents
Contents - 4
5.4.2. Analogue I/O module, 2 I 0...20 mA, 2 O 0...±10V ............. 5-40
5.4.2.1. Slots............................................................................... 5-40
5.4.2.2. Connectors ..................................................................... 5-41
5.4.2.3. Representation of the analogue value................................. 5-42
5.4.2.4. Transfer address ranges of the analogue inputs................... 5-43
5.4.2.5. Technical specifications .................................................... 5-44
5.4.3. Analogue I/O module, 2 I 0...10 V, 2 O 0...20 mA .............. 5-45
5.4.3.1. Slots............................................................................... 5-46
5.4.3.2. Connectors ..................................................................... 5-47
5.4.3.3. Representation of the analogue value................................. 5-48
5.4.3.4. Transfer address ranges of the analogue inputs................... 5-49
5.4.3.5. Technical specifications .................................................... 5-50
5.4.4. Anal. I/O module, 2 I 0...20 mA, 2 O 0...20 mA................. 5-51
5.4.4.1. Slots............................................................................... 5-51
5.4.4.2. Connectors ..................................................................... 5-52
5.4.4.3. Representation of the analogue value................................. 5-53
5.4.4.4. Transfer address ranges ................................................... 5-54
5.4.4.5. Technical specifications .................................................... 5-55
6. Counter modules........................................................ 6-1
6.1. Counter module, 1 or 2 multi-function counters, 24bit .................. 6-2
6.1.1. Functions ............................................................................. 6-2
6.1.2. Slots.................................................................................... 6-2
6.1.3. Counter modules with 24V inputs ........................................... 6-3
6.1.3.1. Connectors ....................................................................... 6-3
6.1.3.2. Technical specifications ...................................................... 6-5
6.1.4. Counter module with RS422 interface ..................................... 6-6
6.1.4.1. Connectors ....................................................................... 6-6
6.1.4.2. Technical specifications ...................................................... 6-7
6.1.5. Programming ....................................................................... 6-8
6.1.5.1. Transfer address ranges and interrupt modules...................... 6-8
6.1.5.2. Control flags ................................................................... 6-10
6.1.5.3. Setting the counter to the preset value / to 0....................... 6-10
6.1.5.4. Setting the reference value................................................ 6-10
6.1.5.5. Counter control ............................................................... 6-11
6.1.5.6. Reference value............................................................... 6-11
6.1.5.7. Interrupt.......................................................................... 6-12
6.2. Counter module, 2 event counters, 16bit .................................. 6-13
6.2.1. Slots.................................................................................. 6-13
6.2.2. Connectors ........................................................................ 6-14

Table of contents
Contents - 5
6.2.3. Technical specifications....................................................... 6-15
6.2.4. Programming ..................................................................... 6-16
6.2.4.1. Transfer address ranges ................................................... 6-16
6.2.4.2. Setting the counter to the preset value / to 0....................... 6-18
6.2.4.3. Switching the counter on / off........................................... 6-18
6.2.4.4. Selecting the counting direction ......................................... 6-18
6.2.4.5. Selecting the counting mode ............................................. 6-18
6.2.4.6. Clearing the count ........................................................... 6-18
6.2.4.7. Evaluating the count......................................................... 6-18
6.3. SSI module, 24 bit, for 2 absolute value devices ....................... 6-19
6.3.1. Slots.................................................................................. 6-19
6.3.2. Connectors ........................................................................ 6-20
6.3.3. Technical specifications....................................................... 6-21
6.3.4. Programming ..................................................................... 6-22
6.3.4.1. Transfer address ranges ................................................... 6-22
6.3.4.2. User program.................................................................. 6-24
7. Communication modules............................................. 7-1
7.1. V.24 (RS 232) module ............................................................. 7-1
7.1.1. Slots.................................................................................... 7-1
7.1.2. Connector............................................................................ 7-2
7.1.3. Technical specifications......................................................... 7-3
7.2. TTY module (20 mA) ................................................................ 7-4
7.2.1. Slots.................................................................................... 7-4
7.2.2. Connector............................................................................ 7-5
7.2.3. Technical specifications......................................................... 7-6
7.3. RS 485 module ....................................................................... 7-7
7.3.1. Slots.................................................................................... 7-7
7.3.2. Connector............................................................................ 7-8
7.3.3. Technical specifications......................................................... 7-9
7.4. Programming the V.24, TTY and RS 485 modules ..................... 7-10
7.4.1. Communication programs SE 680I, KUSI680, RS485 ............. 7-10
7.4.2. KUBES modules V24XE, V24XS, V24XSTRG .......................... 7-11
7.4.2.1. Parameters of the KUBES modules ..................................... 7-12
7.4.2.2. Example program ............................................................ 7-15
7.5. PROFIBUS modules ................................................................ 7-21

Table of contents
Contents - 6
8. Stepper motor modules without processor ..................... 8-1
8.1. Plugging stepper motor modules ................................................ 8-2
8.2. Service modules ...................................................................... 8-3
8.2.1. Transfer address ranges ....................................................... 8-3
8.2.2. Assignment of transfer addresses ............................................ 8-4
8.3. Software................................................................................. 8-5
8.3.1. Representation of a run diagram ............................................ 8-5
8.3.2. Terminology and functions ..................................................... 8-6
8.3.2.1. Start/stop ramp SLx01.08 (RAMP)....................................... 8-6
8.3.2.2. Start/stop frequency SLx01.10 (ST_STO_F) .......................... 8-6
8.3.2.3. Travelling frequency SLx01.12 (MOV_FRQ).......................... 8-7
8.3.2.4. Actual position SLx00.04 (RP_LW)....................................... 8-7
8.3.2.5. Destination position SLx00.00 (DP_LW)................................ 8-7
8.3.2.6. Preset value step counter SLx01.00 (SV_LW)......................... 8-8
8.3.2.7. Mode of positioning operations SLx01.14 (MODE) ............... 8-8
8.3.2.8. Control functions SLx01.07 (CONTROL)............................ 8-10
8.3.2.9. Error messages................................................................ 8-12
8.4. Stepper motor module, 1 channel ............................................ 8-13
8.4.1. Connection of the signal lines .............................................. 8-13
8.4.2. Technical specifications ....................................................... 8-14
8.5. Stepper motor module, 2 channels........................................... 8-15
8.5.1. Connection of the signal lines .............................................. 8-15
8.5.2. Technical specifications ....................................................... 8-16
8.6. Example program .................................................................. 8-17
9. Stepper motor module with processor ........................... 9-1
9.1. Plugging stepper motor modules ................................................ 9-2
9.2. Service modules ...................................................................... 9-2
9.2.1. Transfer address ranges ........................................................ 9-2
9.2.2. Assignment of transfer addresses ............................................ 9-3
9.3. Software................................................................................. 9-4
9.3.1. Representation of a run diagram ............................................ 9-4
9.3.2. Terminology and functions ..................................................... 9-5
9.3.2.1. Start/stop ramp SLx01.08 (RAMP)....................................... 9-5
9.3.2.2. Start/stop frequency SLx01.10 (ST_STO_F) .......................... 9-5
9.3.2.3. Travelling frequency SLx01.12 (MOV_FRQ).......................... 9-6
9.3.2.4. Actual position SLx00.04 (RP_LW)....................................... 9-6
9.3.2.5. Destination position SLx00.00 (DP_LW)................................ 9-6
9.3.2.6. Preset value step counter SLx01.00 (SV_LW)......................... 9-7
9.3.2.7. Mode of positioning operations SLx01.14 (MODE) ............... 9-7

Table of contents
Contents - 7
9.3.2.8. Timing diagrams of run jobs ............................................... 9-9
9.3.2.9. Control functions SLx01.07 (CONTROL)............................ 9-10
9.3.2.10. Error messages.............................................................. 9-12
9.4. Stepper motor module, 2 channels........................................... 9-13
9.4.1. Connection of the signal lines .............................................. 9-13
9.5.2. Technical specifications ....................................................... 9-14
9.5. Example program .................................................................. 9-15
Appendix
A. Power consumption of the modules...............................A-1
A.1. Power supply .......................................................................... A-1
A.1.1. 24 V DC system supply ......................................................... A-1
A.1.2. Supply of digital outputs and inputs ........................................ A-1
A.2. Load on the power supply by the modules.................................. A-2
B. Order specifications ................................................... B-1
C. Literature list..............................................................C-1
Index.......................................................................Index-1
Sales & Service

Table of contents
Contents - 8

1 - 1
Introduction
1. Introduction
KUAX 680I,KUAX 680C and KDT 680 CT are efficient,
modularly constructed minicontrollers. They are equipped with
modules which communicate with the user program in the con-
troller either directly or via transfer addresses (SLx...). KUAX
680C and KDT 680CT also have built-in inputs and outputs
which are not, however, described in this instruction manual.
There are connectors for three-conductor connections so that
proximity switches or other similar devices can be supplied via
the same cable as the signal line. Additional terminal strips are
thus made redundant. Simply plug the modules into the appro-
priate slots from above:
Fig.: KUAX 680I
1

1 - 2
Introduction
1.1. Manual breakdown
- Table of contents
- Chapter 1
Introduction
- Chapter 2
Some comments on the reliability of the described products
and their safe use
- Chapter 3
Basic information about application and design of the mod-
ules as well as about slots and plug connectors
- Chapter 4
Digital input and output modules
- Chapter 5
Analogue input and output modules
- Chapter 6
Counter modules and SSI module
- Chapter 7
Communication modules V.24 (RS 232), TTY (20 mA) and
RS 485, without processor
- Chapter 8
Stepper motor modules without processor
- Chapter 9
Stepper motor modules with processor
- Appendix A
Power supply and load characteristics of the controllers
- Appendix B
Module ordering information (summary)
- Appendix C
References to general literature and to Kuhnke instruction
manuals
- Index

1 - 3
Introduction
This manual only describes the modules. Please refer to the rel-
evant instruction manuals to find out more about the actual
controllers:
Controller Instruction manual
KUAX 680I E 380 GB
KUAX 680C E 399 GB
KDT 680CT E 414 GB
1.2. Further modules
Some modules are not described in this manual but, for subject
matter reasons, have their own instruction manuals:
- PROFIBUS module 680.440.05
Instruction manual: E 509 GB
- Positioning module 680.454.06
Instruction manual: E 416 GB
- Servo counter module 680.454.05
Instruction manual: E 416 GB

1 - 4
Introduction

2 - 1
Safety and Reliability
2. Safety and Reliability
2.1. Target group
This instruction manual contains all information necessary for
the use of the described product (control device, software, etc.)
according to instructions. It is written for the personnel of the
construction, project planning, service and commissioning
departments. For proper understanding and error-free applica-
tion of technical descriptions, instructions for use and particu-
larly of notes of danger and warning, extensive knowledge of
automation technology is compulsory.
2.2. Reliability
Reliability of Kuhnke controllers is brought to the highest pos-
sible standards by extensive and cost-effective means in their
design and manufacture.
These include:
selecting high-quality components,
quality arrangements with our sub-suppliers,
measures for the prevention of static charge during the hand-
ling of MOS circuits,
worst case dimensioning of all circuits,
inspections during various stages of fabrication,
computer aided tests of all assembly groups and their
coefficiency in the circuit,
statistic assessment of the quality of fabrication and of all re-
turned goods for immediate taking of corrective action.
Despite these measures, the occurrence of errors in electronic
control units - even if most highly improbable - must be taken
into consideration.

2 - 2
Safety and Reliability
2.3. Notes
Please pay particular attention to the additional notes which we
have marked by symbols in this instruction manual:
2.3.1. Danger
This symbol warns you of dangers which may cause death,
(grievous) bodily harm or material damage if the described
precautions are not taken.
2.3.2. Dangers caused by high contact voltage
This symbol warns you of dangers of death or (grievous) bodily
harm which may be caused by high contact voltage if the de-
scribed precautions are not taken.
2.3.3 Important information / cross reference
This symbol draws your attention to important additional infor-
mation concerning the use of the described product. It may also
indicate a cross reference to information to be found else-
where.

2 - 3
Safety and Reliability
2.4. Safety
Our product normally becomes part of larger systems or install-
ations. The following notes are intended to help integrating the
product into its environment without dangers for man or mate-
rial/equipment.
2.4.1. To be observed during project planning and installation
- 24V DC power supply:
Generate as electrically safely separated low voltage. Suitable
devices are, for example, split transformers constructed to
correspond to European standard EN 60742 (corresponds to
VDE 0551)
- In case of power breakdowns or power fades: the program has
to be structured in such a way as to create a defined state at
restart that excludes dangerous states.
- Emergency switch-off installations or other emergency instal-
lations have to be realized in accordance with EN 60204/
IEC 204 (VDE 0113). They must be effective at any time.
- Safety and precautions regulations for qualified applications
have to be observed.
- Please pay particular attention to the notes of warning which,
at relevant places, will make you aware of possible sources of
dangerous mistakes or failures.
- The relevent standards and VDE regulations are to be ob-
served in every case.
- Control elements have to be installed in such a way as to ex-
clude unintended operation.
- Control cables have to be layed in such a way as to exclude
interference (inductive or capacitive) which could influence
the operation of the controller.
To achieve a high degree of conceptual safety in the planning
and installation of electronic controllers it is essential to fol-
low the instructions given in the manual exactly because wrong
handling could lead to rendering measures against dangerous
failures ineffective or to creating additional dangers.

2 - 4
Safety and Reliability
2.4.2. To be observed during maintenance and servicing
- Precaution regulation VBG 4.0 must be observed, and section
8 (Admissible deviations during working on parts) in particu-
lar, when measuring or checking a controller in a power-up
condition.
- Repairs must only be made by specially trained Kuhnke staff
(usually in the main factory in Malente). Warranty expires in
every other case.
- Spare parts:
Only use parts approved of by Kuhnke. Only genuine Kuhnke
modules must be used in modular controllers.
- Modules must only be connected to or disconnected from the
controller with no voltage supplied. Otherwise they may be
destroyed or (possibly not immediately recognisably!) de-
tracted from their proper functioning.
- Always deposit batteries and accumulators as hazardous
waste.

2 - 5
Safety and Reliability
2.5. Electromagnetic compatibility
2.5.1. Definition
Electromagnetic compatibility is the ability of a device to func-
tion satisfactorily in its electromagnetic environment without
itself causing any electromagnetic interference that would be
intolerable to other devices in this environment.
Of all known phenomena of electromagnetic noise, only a cer-
tain range occurs at the location of a given device. This noise
depends on the exact location. It is determined in the relevant
product standards.
The international standard regulating construction and degree
of noise resistance of programmable logic controllers is IEC
1131-2 which, in Europe, has been the basis for European
standard EN 61131-2.
2.5.2. Resistance to interference
Electrostatic discharge, ESD
in accordance with IEC 801-2, 3rd degree of sharpness
Fast transient interference, Burst
in accordance with IEC 801-4, 3rd degree of sharpness
Irradiation resistance of the device, HF
in accordance with IEC 801-3, 3rd degree of sharpness
Immunity to damped oscillations
in accordance with IEC 255-4 (1 MHz, 1 kV)

2 - 6
Safety and Reliability
2.5.3. Interference emission
Interfering emission of electromagnetic fields, HF
in accordance with EN 55011, limiting value class A, group 1
If the controller is designed for use in residential districts, then
high-frequency emissions must comply with limiting value class
B as described in EN 55011.
Fitting the controller into an earthed metal cabinet and equip-
ping the supply cables with filters are appropriate means for
keeping the corresponding limiting values.
2.5.4. General notes on installation
As component parts of machines, facilities and systems, elec-
tronic control systems must comply with valid rules and regula-
tions, depending on the relevant field of application.
General requirements concerning the electrical equipment of
machines and aiming at the safety of these machines are con-
tained in Part 1 of European standard EN 60204 (corresponds
to VDE 0113).
For safe installation of our control system please observe the
following notes: