Lenord, Bauer GEL 8251 Application guide

Right to technical changes and errors reserved. 2012-03
D-02G-8251 (2.0)
CompactController
GEL 8251
Axis control with PLC functionality in
accordance with IEC 61131–3
... automates motion.
LENORD
+BAUER
Device manual

2GEL 8251
Device manufacturer and publisher:
Lenord, Bauer & Co. GmbH
Dohlenstraße 32
46145 Oberhausen ●Germany
Phone: [phone] ●Fax: [phone]
Internet: www.lenord.de ●E-Mail: in[email protected]
Doc. no. D-02G-8251 (2.0)

Lenord + Bauer Table of contents
GEL 8251 3
Table of contents
1 About this document ....................................................................................... 5
1.1 General .................................................................................................... 5
1.2 Target group ............................................................................................ 5
1.3 Symbols, marks, notes ............................................................................ 6
2 Safety ................................................................................................................ 7
2.1 Safety instructions ................................................................................... 7
2.2 Designated use ........................................................................................ 7
3 Product identification ...................................................................................... 8
3.1 Scope of supply ....................................................................................... 8
3.2 Rating plate .............................................................................................. 8
3.3 Parts named ............................................................................................ 9
3.3.1 Front panel .................................................................................. 9
3.3.2 Display ........................................................................................ 9
3.3.3 Rear side ................................................................................... 10
4 Assembly ........................................................................................................ 11
4.1 Installation .............................................................................................. 11
4.2 Removal ................................................................................................. 11
4.3 Module installation ................................................................................. 12
5 Connections ................................................................................................... 13
5.1 Information on wiring ............................................................................. 13
5.2 Connector coding ................................................................................... 14
5.3 Overview ................................................................................................ 15
5.4 Power supply V ...................................................................................... 16
5.5 Serial interfaces C1 ............................................................................... 17
5.6 CAN bus C2 ........................................................................................... 18
5.7 Encoder inputs Z1–3 .............................................................................. 19
5.8 Digital inputs E1–4 ................................................................................. 20
5.9 Analogue inputs E6 ................................................................................ 21
5.10 PT100 analogue inputs E5 .................................................................... 22
5.11 Digital and analogue outputs A1–3 ........................................................ 23
6 Commissioning .............................................................................................. 24
6.1 CompactController ................................................................................. 24
6.2 Operating system update ....................................................................... 24
7 Technical data ................................................................................................ 28
7.1 Specifications ......................................................................................... 28
7.2 Dimensional drawing ............................................................................. 29

4GEL 8251

Lenord + Bauer 1 About this documentGeneral
GEL 8251 5
1 About this document
1.1 General
The device manual is part of the product and contains the information necessary for
installation and for safe operation.
Information on the operation of the device, the system parameters that can be pro-
grammed for configuration of the CompactController and the axes controlled, on the
PC parameter editor supplied and on the proprietary serial LB2 protocol is contained in
the reference manual that is included on the installation CD in electronic form as a PDF
file.
Descriptions of any pre-installed PLC program and of the library functions for writing
custom programs are not covered here; the comments in the individual function blocks
contain appropriate instructions on how to use them.
Please note the following:
Carefully read the documents provided prior to the installation and usage of the
device.
Keep the documentation for the service life of the product.
Ensure the necessary documentation is available to the personnel at all times.
Pass the documentation on to the subsequent owner or user of the product.
Add all supplements provided by the manufacturer of the device.
Read and follow the information in the documentation to prevent damage to the
product and malfunctions.
Scope
This manual is applicable to the standard version of the product. This includes all types
that are n o t marked with a Yafter the product number in the type code.
A product marked with a Y is a customer-specific version with customised features and/
or modified technical specifications. Depending on the customer-specific modification,
further documents or other documents may be applicable.
1.2 Target group
The device manual is aimed at operating companies, machine manufacturers and
qualified specialist staff.
Personnel must have adequate knowledge on how to handle components that are sus-
ceptible to electrostatic. They must also be familiar with and follow national health and
safety regulations.
The operating company must ensure that the safety instructions in this manual are
followed and that all individuals tasked with working on the CompactController have
read and understood the manual.

1 About this document Lenord + BauerSymbols, marks, notes
6GEL 8251
1.3 Symbols, marks, notes
The following symbols, marks and notes are used in this document so that you can
recognise specific information more quickly:
Dangerous situation: There is a risk of injury on failure to follow the in-
structions!
Instructions on preventing damage
Important information for improved understanding, on operation or opti-
misation of the work processes
Work step to be undertaken
→page 6 Page reference to another part of this manual

Lenord + Bauer 2 SafetySafety instructions
GEL 8251 7
2 Safety
2.1 Safety instructions
The operating software for the CompactController permits on-line changes to sys-
tem parameters during operation to make it easier to set up the plant and to make
service visits easier.
It is imperative on the utilisation of this feature that it is ensured no dangerous sit-
uations can arise for individuals in the area of the plant or for the plant itself by
●Consciously and carefully checking prior to transmission every parameter to be
modified for correct application and for the possible effect (above all on changing
pitch rates)
●Ensuring adequate protective measures as well as limit switches and emergen-
cy stop buttons are provided.
Do not disconnect any connectors or any screen connection with the device
switched on to avoid the occurrence of uncontrolled states.
Prior to updating the operating system (→page 24), switch off the power cir-
cuits for the drives controlled by the CompactController.
2.2 Designated use
The CompactController is only intended to be used for controlling and regulating drives
in the industrial sector.
On operation in residential, business and commercial sectors compliance with the re-
quirements on electromagnetic emissions in accordance EN 61000-6-3 is to be ensured
with additional external screening and filtering measures.
The PLC functionality makes it possible to execute customer control programs or control
programs supplied using the function implemented in the operating system for control-
ling drives.
The display and the keyboard make it possible, with appropriate programming, to use
the CompactController as an operator terminal for controlling operating states.
The devices are configured using system parameters. This action is undertaken either
on the device itself, via the PC editor software BB2100K supplied or via a loaded PLC
program.
The data and information given in this manual are to be followed.

3 Product identification Lenord + BauerScope of supply
8GEL 8251
3 Product identification
3.1 Scope of supply
●CompactController GEL 8251
●Fastening set with 6 nuts, spring washers and washers as well as 2 earthing ter-
minals (order no. BG 4623)
●Mating connector set (order no. GEL 89042
●Cable clip set (order no. BG 4622)
●Installation CD with the following content (can vary):
– Operating system file in the latest version (for download to the CompactCon-
troller), electronic documentation (PDF) and configuration files
– Update software LingiMon (→page 24)
– CoDeSys (PLC programming environment)
❍Setup
❍Libraries
❍Documentation (PDF files in various languages)
– Acrobat Reader for reading the PDF files supplied (self-extracting installation
program)
The CD has an autorun program that provides information and various possible
options in a dialog box after the insertion of the CD, provided the autorun function
is activated on the PC. If the CD does not start automatically, you can start the
installation manually by running the program start.exe in the root folder on the CD.
●Optional: Cable terminals for horizontal cable outlet (without separate attachment
frame)
3.2 Rating plate
The rating plate is bonded to the side on the connection frame.
Example: GEL 825xxxxx
S/N 0805000469
V 24 VDC
1
2
3
1 Type (order) code
2 Serial number
3 Nominal operating voltage

Lenord + Bauer 3 Product identificationParts named
GEL 8251 9
3.3 Parts named
3.3.1 Front panel
1
3
4
5
6
7
8
9
10
2
1 Display
2 Function keys (assignment dependent on the current window)
3 Numerical keys (value entry)
4 Enter key: Confirm entry, select/open entry marked (identical to 7)
5 Escape key: Cancel entry/function; return to next menu level up
6 Navigation and selection keys (select property of a system parameter)
7asfor4
8 Scroll keys (move up/down by one line the window in the overall list that can be displayed)
9 Delete key: Delete value entry
10 Menu keys (assignment dependent on the actual window, row orientated)
3.3.2 Display
The function of the display is dependent on the CompactController operating system
and any software expansions loaded. There is a corresponding description in the ref-
erence manual.

3 Product identification Lenord + BauerParts named
10 GEL 8251
3.3.3 Rear side
1456
8
10
111213
14
15
23
3a
7
9
1 Front panel
2 Connection frame
3 Cover with attachment frame mounted (cable clips for vertical cable outlet) and cut-out for
optional field bus module (3a)
4 Encoder connections (terminal strips Z1–3)
5 DIP switch for CAN bus termination
6 CAN bus connection (terminal strip C2)
7 Connection analogue inputs U/I (terminal strip E6)
8 Connection analogue inputs PT100 (terminal strip E5)
9 Connection digital inputs and LED status indicators (terminal strip E4)
10 Connection power supply (terminal strip V)
11 DIP switch for terminating RS 422/485
12 Connection serial interfaces RS 232/422/485 (connector C1)
13 Connection digital and analogue outputs and LED status indicators (terminal strips A1–3)
14 Connection digital inputs and LED status indicators (terminal strip E1–3)
15 Studs for control panel mounting

Lenord + Bauer 4 AssemblyInstallation
GEL 8251 11
4 Assembly
4.1 Installation
Control panel cut-out
225
112.5
6 x Ø 4.3
5
165
5
215
175
(dimensions stated in mm)
Make the necessary control panel cut-out and fastening bores in the required po-
sition in the switch cabinet.
Insert the device in the control panel.
Fasten the device using 6 nuts M4, spring washers and washers.
Make the electrical connections taking into account the information in section 5.
Fit the cover and fasten the 4 knurled screws.
Fix the cable to the connection frame and to the cover itself with the aid of the
clamps.
4.2 Removal
For brief removal of the CompactController undo the four knurled screws in the
cover (are captive in the cover) and disconnect all connectors.
After refitting the cover first press on the knurled screws and then tighten them.
Remove the 6 nuts on the M4 studs on the CompactController and remove the
device.

4 Assembly Lenord + BauerModule installation
12 GEL 8251
4.3 Module installation
The CompactController can be upgraded at a later date with a function module (field
bus). The installation, the connections and other information on the module are descri-
bed in a separate document (also on the CD supplied in electronic form).
Ensure that all pins on the module edge connectors are sitting correctly in the
related housing connector.
Communication with the extension modules is via a PLC program using CoDeSys
function blocks provided. The basic configuration is undertaken using various system
parameters (→reference manual).

Lenord + Bauer 5 ConnectionsInformation on wiring
GEL 8251 13
5 Connections
5.1 Information on wiring
To improve the electromagnetic environment (EMC) please follow the following instal-
lation instructions:
●Correctly earth device: Short connections via cable lug contacts (6.3 mm) housing/
cover →switch cabinet (wall) as well as between housing/cover (use low induc-
tance earth strap or flat conductor)
●Earth connector cable at the device: Strip insulation from cable screen at a suitable
point and clamp under a cable clip on the cover (see figure)
●Use metal D-Sub mating connector and clamp
the cable screen cleanly between the halves of
the connector
●Tighten fastening screws for the D-Sub mating
connector to ensure a reliable earth contact
(however it is recommended to additionally
earth this cable as show in the figure)
optional
●For good electrical contact and mechanical restraint of the cable in the terminals as
well as for reliable isolation, fit the cable cores used with insulated ferrules in ac-
cordance with DIN 46228 Part 4 that are permanently connected to the cores with
the aid of a special crimping tool. If two or more thinner cables are to be connected
to a terminal, the usage of twin ferrules is advantageous. The maximum connection
cross-section is 1.5 mm² (incl. bush).
To tighten the terminal screws (M2) use a screwdriver with a 0.4×2.5 mm blade.
●Keep all unscreened cables as short as possible
●Attach screens at both ends of cables using a connection with as large a surface
area as possible
●Ensure that external protection measures against surges have been implemented
(EN 61000-4-5).
●In case of inductive loads (relays, contactors) on the digital outputs, provide sup-
pression measures (free-wheeling diode or RC element in parallel and in the im-
mediate vicinity of the coil)
●Lay signal cables and control cables physically separate from power cables
●If there are potential differences between the earth connections for the machine and
electronics, or if such differences occur, ensure by means of appropriate measures

5 Connections Lenord + BauerConnector coding
14 GEL 8251
that no equalising currents can flow via the cable screen; (e.g. lay an equipotential
bonding cable with a large cross-section or use cables with a separate double
screen with each screen connected at only one end.)
Do not disconnect any connectors or any screen connection while the
device is switched on.
5.2 Connector coding
A1
E3
E2
E1
Z1 Z2 Z3
E6
E5
E4
C2
A2 A3
V
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5
1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4

Lenord + Bauer 5 ConnectionsOverview
GEL 8251 15
5.3 Overview
A1
E3
E2
E1
Z1 Z2 Z3
E6
E5
E4
C2
C1
A2 A3
V
GND (E1)
DE1.1
DE1.2
DE1.3
DE1.4
DE1.5
DE1.6
GND (E2)
DE2.1
DE2.2
DE2.3
DE2.4
DE2.5
DE2.6
DE2.7
DE2.8
GND (E4)
DE4.1
DE4.2
DE4.3
DE4.4
DE4.5
DE4.6
DE4.7
DE4.8
GND (Z)
GND
24 VDC
24 VDC (Z)
GND (E3)
DE3.1
DE3.2
DE3.3
DE3.4
DE3.5
DE3.6
DE3.7
DE3.8
/AE1.1
AE1.1
/AE1.2
AE1.2
/AE1.3
AE1.3
/AE1.4
AE1.4
/AE1.5
AE1.5
/AE1.6
AE1.6
/AE1.7
AE1.7
GND (A1)
Analog GND
AA 1
24 VDC Ext.
DA1.1 DA1.2 DA1.3 DA1.4 DA1.5
GND (A2)
Analog GND
AA 2
24 VDC Ext.
DA2.1 DA2.2 DA2.3 DA2.4 DA2.5
GND (A3)
Analog GND
AA 3
24 VDC Ext.
DA3.1 DA3.2 DA3.3 DA3.4 DA3.5
GND (C) TxD TxD RxD RxD
Tx- Rx- Tx+ Rx+
COM 1
COM 2
RS 422/485
RS 422/485
COM 1
GND (C) CAN1_H CAN1_L CAN2_H CAN2_L
GND (Z) +5 VDC Out +24 VDC Out SSI-Clock 1/4 /SSI-Clock 1/4 SSI-Data 1 /SSI-Data 1 SSI-Data 4 /SSI-Data 4 Ref_N 1 /Ref_N 1 GND (Z) +5 VDC Out +24 VDC Out SSI-Clock 2/5 /SSI-Clock 2/5 SSI-Data 2 /SSI-Data 2 SSI-Data 5 /SSI-Data 5 Ref_N 2 /Ref_N 2 GND (Z) +5 VDC Out +24 VDC Out SSI-Clock 3/6 /SSI-Clock 3/6 SSI-Data 3 /SSI-Data 3 SSI-Data 6 /SSI-Data 6 Ref_N 3 /Ref_N 3

5 Connections Lenord + BauerPower supply V
16 GEL 8251
5.4 Power supply V
1 2 3 4 Both the power for the internal circuits in the CompactController (U
B
) and
the power for the supply of encoders connected (U
Z
) is provided at ter-
minal strip V.
2
3
1
4
GND (Z)
Z
24 VDC (Z)
Z1+2+3
V
24 VDC
GND
19 - 30 VDC
19 - 30 VDC
5 V
24 V
Controller
Controller
Voltage supply
internal
1.35 A, 30 V
1.35 A, 30 V
Encoder
<0.6 A
If only a single power source is used to supply the controller and encoders, the
related terminals 3 and 4 as well as 1 and 2 must be connected together as shown
dotted in the figure.

Lenord + Bauer 5 ConnectionsSerial interfaces C1
GEL 8251 17
5.5 Serial interfaces C1
Two independent serial interfaces are available on connector
C1: COM 1 and COM 2.
COM 2 is designed as pure RS 232 C.
COM 1 can be used either as RS 232 C or as RS 422/485.
The serial interfaces have the same earth potential as the CAN buses (connector C2).
In the case of RS 422/485 the internal termination resistors must
be enabled on the first and last device on the bus using the DIP
switch beside the connector: both switches in the ON position.
The resulting termination resistance is approx. 125 Ω
Peripherals
(PC, ...)
Plug (25-) 9-pin
Peripherals
COM 1 only
2/1
3/4
5
6
8
7
9
5
RS 232 C
RS 422 / RS 485
COM 1 / COM 2
COM 1
C1
Rd
Wr
(C)
(C)
RxD
TxD
GND
Rx+
Rx-
Tx+
Tx-
GND
(C)
(C)
+U(C)
(C)
(C)
(C)
+U(C)
(C)
15k
15k
475
267
(C)
Tx+
Tx-
Rx+
Rx-
GND
RS 232 C
RS 422/485
475
2
1
RxD
TxD
GND
(3) 2
(2) 3
(7) 5
Controller
* RS 485
On the usage of RS 485, the connections 6 and 7 as well as 8 and 9 must be
connected using solder jumpers (shown dotted in the figure).

5 Connections Lenord + BauerCAN bus C2
18 GEL 8251
5.6 CAN bus C2
1 2 3 4 5 Two CAN bus interfaces are available on terminal strip C2: CAN1 and
CAN2.
The internal termination resistor for the specific CAN bus must
be enabled on the first and last device on the bus using the DIP
switch beside the connector: Switch in ON position. The termi-
nating resistance is approx. 120 Ω
Z3 C2
CAN1 CAN2
The CAN buses have the same earth potential as the other serial interfaces (connector
C1).
2/4
3/5
1
CAN1, CAN2
CANx_H
CANx_L
x = 1, 2
GND (C)
x
C2
(C)
(C)
CAN
CAN
GND
120
121
CAN Client
Controller

Lenord + Bauer 5 ConnectionsEncoder inputs Z1–3
GEL 8251 19
5.7 Encoder inputs Z1–3
1 2 3 4 5 6 7 8 9 10 11 2 SSI encoders can be connected to each of the terminal
strips Z1 to Z3 .
5 V and 24 V are output there as the operating voltage for the encoders (provided at
terminal strip V). The maximum currents are
●At 24 V: 300 mA per encoder
●At 5 V: 200 mA per encoder, in total 0.6 A
All encoder inputs have the same earth potential.
SSI en-
coder A
SSI en-
coder B
max. 0.6 A
SSI Data A
/SSI Data A
SSI Data B
/SSI Data B
SSI Clock A/B
/SSI Clock A/B
GND (Z)
(V) (Z)
(Z)
24 V
DC
5 V
DC
267
5V6
2k
(Z)
Ref_N
/Ref_N
+5 VDC out
+24 VDC out
Clock
Clock
Data
Data
Clock
Clock
Data
Data
(Z)
(Z)
(Z)
+5/24 V
0 V
4
5
Z1/2/3
6
7
8
9
10
11
3
2
1
+5/24 V
0 V
Controller
A B
Z1 1 4
Z2 2 5
Z3 3 6

5 Connections Lenord + BauerDigital inputs E1–4
20 GEL 8251
5.8 Digital inputs E1–4
1 2 3 4 5 6 7 8 9
The signal state on the 6 (E1) or 8 (E2 to E4) digital inputs is
indicated by green light emitting diodes underneath the related
terminal (on ≙high).
DEx.1
DEx.2
DEx.3
DEx.4
DEx.5
DEx.6
DEx.7
DEx.8
GND (Ex)
2
3
4
5
6
7
8
9
1
(Ex)
E1/2/3/4 Control
+24 V
GND
2k
5V6
x =
2 ... 4 1 ... 4
Controller