Kunbus Sercos Series User manual

User manual
Gateway component Sercos
DO0227R00 • 6/28/2016

Table of Contents KUNBUS GmbH
ii Gateway component Sercos
Table of Contents
1 General Information ........................................................................................................................3
1.1 Disclaimer..................................................................................................................................3
1.2 Notes Regarding this User Manual............................................................................................3
1.3 Validity .......................................................................................................................................4
1.4 Limitation of Liability ..................................................................................................................4
1.5 Customer Service ......................................................................................................................4
2 Safe Use ...........................................................................................................................................5
2.1 User ...........................................................................................................................................5
2.2 Symbols.....................................................................................................................................5
3 Overview ..........................................................................................................................................6
3.1 Functionality ..............................................................................................................................6
3.2 Control Elements .......................................................................................................................7
3.3 Status LEDs.............................................................................................................................10
4 Installation .....................................................................................................................................11
4.1 Preparations for Trouble-free Operation..................................................................................11
4.2 Requirements .........................................................................................................................13
4.3 Connecting Gateway Components..........................................................................................14
4.4 Installing a Gateway in the Control Cabinet ............................................................................15
4.5 Connecting a Power Supply ....................................................................................................16
4.6 Connecting a Gateway to the Fieldbus....................................................................................16
5 Configuration.................................................................................................................................17
5.1 Supported Size of the Process Data ......................................................................................17
5.2 Setting Sercos Address ...........................................................................................................17
5.3 Sercos Configuration ...............................................................................................................19
6 Server .............................................................................................................................................20
6.1 Web Server..............................................................................................................................20
6.2 FTP Server ..............................................................................................................................20
6.3 TFTP Server ............................................................................................................................20
6.4 Logon data and access rights..................................................................................................20
7 Technical Data...............................................................................................................................21
7.1 Technical Data.........................................................................................................................21

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1 General Information
1.1 Disclaimer
© 2016 KUNBUS GmbH, Denkendorf (Germany)
The contents of this user manual have been prepared by KUNBUS
GmbH with the utmost care. Due to technical development, KUNBUS
GmbH reserves the right to change or replace the contents of this
user manual without prior notice. You can always obtain the latest
version of the user manual at our homepage: www.kunbus.de
KUNBUS GmbH shall be liable exclusively to the extent specified in
General Terms and Conditions (www.kunbus.de/agb.html).
The contents published in this user manual are protected by
copyright. Any reproduction or use for the in-house requirements of
the user is permitted. Reproduction or use for other purposes is not
permitted without the express, written consent of KUNBUS GmbH.
Contraventions shall result in compensation for damages.
Trademark protection
– KUNBUS is a registered trademark of KUNBUS GmbH
– Windows® and Microsoft® are registered trademarks of Microsoft Corp.
– Sercos is a registered trademark of Sercos International e. V
KUNBUS GmbH
Heerweg 15 c
73770 Denkendorf
Germany
www.kunbus.de
1.2 Notes Regarding this User Manual
This user manual provides important technical information that can
enable you as a user to integrate the Gateways into your applications
and systems efficiently, safely and conveniently. It is intended for
trained, qualified personnel, whose sound knowledge in the field of
electronic circuits and expertise in SERCOS is assumed.
As an integral part of the module, the information provided here
should be kept and made available to the user.
General Information

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1.3 Validity
This document describes the application of the KUNBUS Gateway
with the product number:
– PR100075, release 00
1.4 Limitation of Liability
Warranty and liability claims will lapse if:
– the product has been used incorrectly,
– damage is due to non-observance of the operating manual,
– damage is caused by inadequately qualified personnel,
– damage is caused by technical modification to the product (e.g.
soldering).
1.5 Customer Service
If you have any questions or suggestions concerning this product,
please do not hesitate to contact us:
KUNBUS GmbH
Heerweg 15 C
73770 Denkendorf
Germany
[phone]
[email protected]
www.kunbus.de
General Information

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2 Safe Use
2.1 User
The Gateway may only be assembled, installed and put into
operation by trained, qualified personnel. Before assembly, it is
absolutely essential that this documentation has been read carefully
and understood. Expertise in the following fields is assumed:
– electronic circuits,
– basic knowledge of SERCOS,
– work in electrostatic protected areas,
– locally applicable rules and regulations for occupational safety.
2.2 Symbols
The symbols used have the following meaning:
DANGER Danger
Always observe this information!
There is a safety hazard that can lead to serious injuries and death.
CAUTION Caution
There is a safety hazard that can result in minor injuries and material
damage.
NOTICE Note
There is a safety hazard that can result in material damage.
Safe Use

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3 Overview
3.1 Functionality
The KUNBUS Gateway is a protocol converter. It allows
communication between networks with different protocols.
Illustration1: Functionality
A Gateway consists of 2 gateway components that master one
specific protocol each. You can combine these gateway components
as you wish. This design offers you a high degree of flexibility, since
you can exchange the individual gateway components at any time.
The following gateway components are currently available as slaves:
– CANopen
– CC-Link
– DeviceNet
– EtherCAT
– EtherNet/IP
– Modbus RTU
– Modbus TCP
– POWERLINK
– PROFIBUS
– PROFINET
– Sercos III
Overview

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3.2 Control Elements
Front view
1
2
3
Illustration2: Front view
1 Status LEDs
for signal display.
2 2 rotary coding switches
for setting the station number.
3 Fieldbus connection
RJ45 socket for the connection to SERCOS and/or general LAN.
Auto-Negotiation and Auto-MDI-X are supported. (2 pcs, s. figure
top view)
Overview

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Top
1
2
3
Illustration3: Top
1 Fieldbus connection
RJ45 socket for connection to the fieldbus (2 pcs, see figure
front view).
2 Interconnect ports
for interconnecting the gateway components.
3 Locking clamps
for securely attaching the gateway component to the DIN rail.
Overview

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Bottom
1
2
Illustration4: Bottom
1 Mains connection
with 24 V power supply
2 Locking clamps
for securely attaching the gateway component to the DIN rail.
Overview

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3.3 Status LEDs
The signals of the status LEDs for SERCOS have the following
meaning:
LED
designation
Signal Meaning
Power off Gateway not running
flashes, green Initialization phase not yet completed
on, green All system components are functioning
perfectly
flashes, red Correctable error (e.g. second gateway
component missing)
Flashes, red and
green
Factory reset is executed
on, red Serious error/defect in the gateway
L/A 1 + L/A 2 on, green Connection to another device. No data
exchange takes place.
flashes, green Connection established. Data ex-
change takes place.
off No connection.
SIII Off No communication with Sercos
orange, on Communication phase 0 active
orange, flashes
1x green*
Communication phase 1 active
orange, flashes
2x green*
Communication phase 2 active
orange, flashes
3x green*
Communication phase 3 active
green, on Communication phase 4 active
green/orange,
flashes
Device is in the Hot Plug phase 0
green, flashes
1x orange*
Device is in the Hot Plug phase 1
green, flashes
2x orange*
Device is in the Hot Plug phase 2
green, flashes RT status changed from Fast-Forward
to Loopback
red/orange,
flashes
Error in the application.
red/green,
flashes
Communication warning in the device
status
red, on Communication error
orange, flashes Device is identified.
red, flashes Watchdog Error
*Interval: 3 sec
Overview

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4 Installation
4.1 Preparations for Trouble-free Operation
In the following section we have compiled some general information
for you that is important for trouble-free operation. If you are already
acquainted with this topic, you can skip to the next section. There,
you will learn about which conditions are necessary for installing the
gateway.
Cable routing
Route your cables separately in cable groups. This will protect your
gateway from any unintended electromagnetic interferences.
The following groups should be routed separately from each other:
Group Line
A Data and power supply lines for:
DC voltage below 60V
AC voltage below 25V
B Data and power supply lines for:
DC voltage between 60V and 400V
AC voltage between 25 and 400V
C Power supply lines above 400V
– You can route cables of the same group together in cable ducts or
bundles.
– Cables of group A and B:
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 10 cm from each other.
– Cables of group C
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 50 cm from the other
groups.
Shielding
Shield your cables. This will reduce any unintended electromagnetic
interferences.
Installation

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Potential equalization
Potential differences occur when devices are connected to different
earths. These potential differences cause malfunctions.
To prevent malfunctions, you have to route an equipotential
equalization conductor.
When doing so, bear in mind the following points:
– Select an equipotential equalization conductor with low impedance.
– Select the following as a reference value for the cross-section of the
potential equalization cable:
– 16 mm2 for potential equalization cables of up to 200 m in length
– 25 mm2 for potential equalization cables of more than 200 m in
length
– Use potential equalization cables made of copper or galvanized steel.
– Connect potential equalization cables extensively with the earth rail.
– The smallest surfaces possible should be sandwiched between
potential equalization cables and signal cables.
If the devices of the control system are connected by shielded signal
cables that are earthed on both sides, the impedance must be 10%
of the shielding impedance.
Installation

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4.2 Requirements
The Gateway was designed for use in a control cabinet.
üThe protection class of the control cabinet must be equivalent to at least
IP54.
üFor installation in the control cabinet you need a DIN rail 35 x 7.5mm
(EN50022).
◦ Install the DIN rail horizontally in the control cabinet according to the
manufacturers' specifications. When doing so, make sure that the
Gateway is at a sufficient distance from other devices.
NOTICE Your gateway could be damaged if temperatures are too high.
èMake sure that the ambient temperature in the control cabinet is less
than 60°C.
èKeep the ventilation slots unobstructed. These must not be covered by
cables etc.
èMaintain sufficient distance from other devices.
Illustration5: Distances for installation
◦ Connect each gateway component individually to functional earth.
When doing so, make sure that the power supplies of both gateway
components have the same ground.
ðYour control cabinet now meets all requirements for installing the
gateway.
Installation

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4.3 Connecting Gateway Components
In order to attain a fully functional gateway, you have to interconnect
both gateway components.
◦ Connect an interconnect port to each gateway component using the
plug-in jumper (product number PR100204).
◦
Illustration6: Connecting gateway components
ðYou can now install the gateway in the control cabinet.
NOTICE Only ever interconnect 2 gateway components.
If you connect additional components, severe defects could result on all
devices.
Installation

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4.4 Installing a Gateway in the Control Cabinet
◦ Hold the raster element of the gateway on the DIN rail.
◦ Press down the locking elements towards the gateway.
◦ Make sure that the gateway is firmly attached to the DIN rail.
Installation

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4.5 Connecting a Power Supply
To connect the gateway component to the power supply, you need a
spring-loaded terminal (e.g. Metz-Connect SP995xxVBNC).
You have to connect each gateway component separately to a power
supply. Never interconnect functional earth and GND, otherwise the
galvanic isolation between gateway GND and fieldbus ground will be
removed. Instead, connect the functional earth with low impedance to
the potential equalization. You can then dispense with this
connection if the shield of the fieldbus cable is connected to the
potential equalization with lower impedance when entering the
control cabinet.
NOTICE Connect each of the two gateway components to the power supply
èEnsure in particular that no potential differences occur between the
GND pins (2).
Pin assignment:
Pin Assignment
1 24V for module supply
3
124
2 GND
3 Do not connect!
4 Functional earth
NOTICE Do not connect GND to PE
This connection could cause unintended malfunctions.
4.6 Connecting a Gateway to the Fieldbus
To connect the gateway component to SERCOS, you need one or
two cat-5 cables with RJ45 connectors.
The pin assignment complies with the specifications of the Sercos
specification.
Installation

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5 Configuration
5.1 Supported Size of the Process Data
The gateway component for SERCOS supports process data up to a
length of 250 bytes per direction.
Of these 250 bytes, 4 bytes of control data (for Connection Control
and I/O-Control/status) are reserved.
NOTICE Bear in mind that the maximum length of the process data is always
determined by the fieldbus with the shorter data length.
Example:
Sercos supports 250 bytes je per direction incl. control data,
PROFIBUS supports 488 bytes
In conjunction with Sercos/ PROFIBUS this means that s 250 bytes
are transmitted and updated cyclically.
5.2 Setting Sercos Address
You can set the Sercos Address for the gateway component using
the two rotary switches.
Value
0 The Sercos Address from the webserver
configuration is used (s. section"Configura-
tion of Sercos [}19]").
In this case, the Sercos Address can also be
set by the Sercos Master (IDN S-0-1040).
Tip!: You can use a Sercos Address from 1
tos 511 via the Webserver/Sercos-Master.
1-254 Sercos Address that can be set by the rotary
switch.
255 When switching on, all configuration settings
are reset to the factory settings. Then restart
the device.
Configuration

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1
2
Illustration7: Coding switch
The station address is set as a hexadecimal.
Example: Setting the station number 18.
Set switch x16 (1) to position "2".
Set switch x1 (2) to position "1".
The settings yield the hexadecimal value 0x12 and the decimal value
18.
Configuration

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5.3 Sercos Configuration
Prerequisite: You are logged in as "Admin" on the webserver (s.
section "Logging into Webserver").
Illustration8: Settings for Sercos
You can make the following settings for Sercos:
Value Default Use
Sercos Address 64 Device address for the gateway component.
You can set an address in a value range
between 1 and 511.
Connection
Length Leaving
Slave
18 Determines the maximum lengths of the data
transferred cyclically between the Sercos
Master and gateway component.
This value containss 4 bytes of control data.
Note!: If the input and output data of the partner
gateway component is shorter than these val-
ues, then they will also be shortened accord-
ingly on the Sercos Bus.
Connection
Length Towards
Slave
18
Configuration

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6 Server
6.1 Web Server
The gateway component contains an integrated web server. You can
use this via Internet Explorer or Firefox.
With the web server you can configure the gateway component for
Sercos.
6.2 FTP Server
The FTP server is necessary for updating HTML files of the web
server and for transmitting firmware updates to the module.
As Admin, you can access the FTP server. For this purpose, the
same logon data as for the web server is valid.
Web Server Files You will find files for the web server in the "Web" subfolder.
6.3 TFTP Server
You can access the the gateway component via TFTP. TFTP
supports the reading and writing of files. You can, for example,
transfer a firmware update file to the gateway component via TFTP.
6.4 Logon data and access rights
You can logon to the webserver and FTP server with the following
data:
Username Password Access rights
Admin 1701 – Changing configuration
– Viewing current values
User 1111 – Viewing current values
Tip!: As Admin, you can change logon data in the web server.
Server