Lenord, Bauer MotionLine GEL 8230 User manual

Subject to errors and technical change Operating Instructions
Edition: 2004-05
GEL 8230/8231
GEL 8235/8236
Multifunctional Control with
PLC Functionality in Accordance
with IEC 61131-3

Doc. no. DS12-823xB
Editions to date:
Edition Remarks
2002-05 First edition
valid for firmware version ≥3.02
2002-12 Adaptation to new firmware version 5.03
New: Auto scan and status display of the CAN buses – changes to various
default settings and extensions of the system parameters – implementation of
the LB2 protocol functions – integration of additional Field bus software modules
– analog actual value inputs – inclusion of type GEL 8231
2003-01 Adaptation to new firmware version 5.05
New: Axis positioning with ramps – parameter editor BB 8200
2003-07 Adaptation to new firmware version 5.09
New: Control of stepper motors – changes to various default settings and exten-
sions of the system parameters
2004-05 Adaptation to new firmware version 5.15 – incorporation of GEL 8235/8236
models
New: limit switch function (system parameters) – signal states of encoder inputs
– parameter editor 'Paraminator III' (replaces BB 8200) – Ethernet field bus
module
Issued by:
Lenord, Bauer & Co. GmbH
Dohlenstrasse 32
46145 Oberhausen •Germany
Tel: [phone] •Fax: [phone]
Internet: http://www.lenord.de •E-Mail: [email protected]

Lenord + Bauer Table of Contents
GEL 823x 3
Table of Contents
1 General........................................................................................................ 5
1.1 Safety instructions.........................................................................................5
1.2 Proper use.....................................................................................................5
1.3 Device models...............................................................................................6
1.4 Characteristics ..............................................................................................6
1.5 About this manual .........................................................................................8
2 Assembly .................................................................................................. 10
2.1 Scope of delivery.........................................................................................10
2.2 Mounting .....................................................................................................11
2.2.1 GEL 8230/8231.................................................................................11
2.2.2 GEL 8235/8236.................................................................................11
2.3 Removal......................................................................................................12
2.3.1 GEL 8230/8231.................................................................................12
2.3.2 GEL 8235/8236.................................................................................12
2.4 Fitting a module...........................................................................................12
3 Connections ............................................................................................. 14
3.1 Wiring Instructions.......................................................................................14
3.2 Connector coding ........................................................................................15
3.3 Overall view.................................................................................................16
3.4 Voltage supply (V).......................................................................................17
3.5 Serial interface (C1) ....................................................................................18
3.6 CAN bus (C2)..............................................................................................19
3.7 Encoder inputs (E1/2/3)...............................................................................20
3.8 Digital inputs (I1/2/3) ...................................................................................21
3.9 Analog input (I6)..........................................................................................22
3.10 PT100 analog inputs (I5, GEL 8231/8236 only) ..........................................22
3.11 Digital and analog outputs (Q1/2/3).............................................................23
4 Operation .................................................................................................. 24
4.1 The key pad ................................................................................................24
4.2 The display..................................................................................................25
4.3 The windows and menus.............................................................................26
4.3.1 Menu structure ..................................................................................26
4.3.2 Main window (axes) ..........................................................................27
4.3.3 Main window (I/O) .............................................................................28
4.3.4 Main menu ........................................................................................29
5 Commissioning ........................................................................................ 35
5.1 MotionController..........................................................................................35
5.2 Operating system update ............................................................................37
6 System parameters .................................................................................. 41
6.1 Explanations................................................................................................41
6.2 Factory defaults...........................................................................................42

Table of Contents Lenord + Bauer
4 GEL 823x
6.2.1 Reset parameter ...............................................................................42
6.2.2 Create parameter image ...................................................................42
6.3 Basic settings..............................................................................................42
6.3.1 General .............................................................................................43
6.3.2 PLC...................................................................................................43
6.3.3 Serial communication (RS 232 C, RS 422/485) ................................44
6.4 Analog inputs ..............................................................................................45
6.4.1 Analog input 1…7 (I61…I57).............................................................45
6.5 CAN bus......................................................................................................45
6.5.1 CAN 1, CAN 2...................................................................................45
6.6 Actual value inputs ......................................................................................48
6.6.1 Actual value input 1…6 .....................................................................48
6.7 Nominal value outputs.................................................................................53
6.7.1 Nominal value output 1…6................................................................53
6.8 Axis configuration........................................................................................57
6.8.1 Axis 1…6...........................................................................................57
6.9 Extension module........................................................................................69
6.9.1 DeviceNet .........................................................................................69
6.9.2 InterBus-S .........................................................................................69
6.9.3 PROFIBUS-DP..................................................................................69
6.9.4 Ethernet ............................................................................................70
6.10 Numerical index ..........................................................................................70
6.11 Application example ....................................................................................72
7 Technical data .......................................................................................... 75
7.1 Dimensional diagram...................................................................................75
7.1.1 GEL 8230/8231.................................................................................75
7.1.2 GEL 8235/8236.................................................................................76
7.2 Specifications ..............................................................................................76
Appendix 1: LB2 protocol............................................................................. 79
Appendix 2: "Paraminator III" parameter editor ........................................ 91
Index ............................................................................................................... 93

Lenord + Bauer 1.1 Safety instructions 1 General
GEL 823x 5
1 General
1.1 Safety instructions
 In order to make it easier for installation and for any possible
servicing, the operating software of the MotionController permits
online change of system parameters during running
operation, therefore
Be absolutely certain, when making use of this feature, that
no dangerous situations can occur for persons or for the
system itself in the system area, by ensuring that
− every parameter to be changed is conscientiously and
carefully checked for correctness and applicability and
for possible effects (above all for changes of velocities)
before transmission,
− adequate electrical safeguards, such as limit switches
and line breakers, are provided.
Please also observe the warning note on manually scanning
the CAN buses on page 32.
 Before carrying out a firmware update (see section 5.2, page
37), switch off the power circuit of all drives which are controlled
by the MotionController.
 The assembly and commissioning of the MotionController may
only be carried out by trained expert personnel, i.e. persons that
are familiar with the safety concepts of electrical and automatic
control techniques. (On request, product training is offered by
LENORD+BAUER.)
1.2 Proper use
The MotionController is intended exclusively for the control of
drives in the industrial sector. If you should make use of it in
typical trade and residential zones you have to take additional
measures like filters, HF-screened switching cabinets etc.
First and foremost it is a PLC, with which programs written by
yourself or control programs supplied with it can be executed. In
addition it can be used as an operator terminal for the control of
operating states and for support during commissioning.
The data and instructions given in this manual must be
complied with.

1 General 1.3 Device models Lenord + Bauer
6 GEL 823x
1.3 Device models
The MotionController device models described here only differ
in their hardware equipment:
GEL 8230: Enclosure with display unit and keypad
for installation into a control panel.
GEL 8231: Same as above, however, with:
+ 2 analog inputs (terminal block I6),
+ 4 analog inputs for PT100 resistors
(terminal block I5),
+ 8 digital inputs (terminal block I4).
7 8 9 0
4 3 6
E S C
1 2 3
F 2 F 3 F 4 F 5
M 1
M 2
M 3
M 4
E n t e r
F 1
L01 HAUPTFENSTER (ACHSEN) MENÜ
*
1. Position Achse 1: [1 | 9870 |
|
2. Position Achse 2: [2 > 12345 |
|
3. Position Achse 3: [3 < 6789 |
[E/A [AUF
[AB
GEL 8235: Enclosure without control and display
elements for DIN top-hat rail or wall
installation and accommodation within a
switch cabinet.
GEL 8236: Same as above, however; with addi-
tional inputs as provided for GEL 8231.
The operating and observing functions described in the following only
apply to the GEL 8230/8231 MotionControllers. For the basic configura-
tion of the GEL 8235/8236 models the PC parameter editor must be used
(cf. Appendix 2).
1.4 Characteristics
The scope of the display can be subdivided into two categories:
 Two so called main windows provide the following
information:
– Actual positions of up to 6 axes and as well as current data
of one axis in a lower level (→section 4.3.2)
– Signal conditions on the input and output terminals
As part of this feature, designed as an aid for commis-
sioning, is the possibility of operating the drive manually
(→section 4.3.3).
 Access is made to the following functions via a main menu
(→section 4.3.4):
– Device information
– System parameters with which the MotionController is
user-specifically configured and which provide the
necessary data for several function blocks (see below) in a
PLC program

Lenord + Bauer 1.4 Characteristics 1 General
GEL 823x 7
Besides the routines for the user interface, the MotionControl-
ler’s operating system also contains routines for the control and
feedback control of up to six drives. These routines can be
accessed by a PLC program that, by the use of the program-
ming interface CoDeSys, can be developed according to the
user’s needs. For this purpose an extensive library with function
blocks is made available, which are described separately (see
section 5.1, page 35 also).
Besides the programming interface CoDeSys and the diverse
libraries contained in the delivery of the MotionController, there
are also example programs which illustrate the functionality of
the MotionController and which can be adapted to the operating
requirements. Besides this they are a source of useful help for
designing your own PLC programs.
Apart from this, LENORD+BAUER will be offering ready-made PLC
programs for various applications (e.g. jog sentence program-
ming) in the foreseeable future. Please enquire
The Motion Controller contains 6 actual value inputs, nominal
value outputs and axis controls which can be configured
independently from each other and freely assigned to each
other. The following block diagram illustrates the principle:
[ 1 0 0 ]
[ 6 0 6 ]
0
1
2
3
4
5
6
[ 1 0 1 ] . . . [ 0 1 4 ]
[ 1 0 2 ] . . . [ 0 1 5 ]
[ 1 0 3 ] . . . [ 0 1 6 ]
[ 1 0 4 ] . . . [ 0 1 7 ]
[ 1 0 5 ] . . . [ 0 1 8 ]
0
1
2
3
4
5
6
7
8
0
1
2
3
[ 6 0 0 ]
0
1
2
3
4
5
6
[ 4 5 1 ] , [ 0 2 1 ]
[ 6 1 2 ]
[ 4 5 0 ]
0
1
2
3
4
[ 0 2 0 ][ 0 2 6 ]
[ 6 0 1 ] , [ 0 2 7 ]
[ 4 5 2 ] , [ 0 2 2 ]
[ 4 5 3 ] , [ 0 2 3 ]
[ 4 5 4 ] , [ 0 2 4 ]
[ 4 5 5 ] , [ 0 2 5 ]
[ 6 0 2 ] , [ 0 2 8 ]
[ 6 0 3 ] , [ 0 2 9 ]
[ 6 0 4 ] , [ 0 3 0 ]
[ 0 0 5 ] , [ 0 3 1 ]
[ 6 0 7 ] [ 0 1 3 ]
[ 6 0 8 ] [ 6 1 4 ]
[ 6 0 9 ] [ 6 1 5 ]
[ 6 1 0 ] [ 0 1 6 ]
[ 6 1 1 ] [ 6 1 7 ]
2
[ 1 0 7 ]
[ 1 8 4 ]
[ 1 9 1 ]
[ 0 1 3 ]
3
4
5
6
2
3
4
5
6
A x i s 1A c t . v a u e i n p u t 1 N o m . v a u e o u t p u t 1
n o n e
I n c r e m .
SSI
C A N b u s
V i r t u a 1
V i r t u a 2
A n a o g
A c t . v a u e i n p u t 2
A c t . v a u e i n p u t 3
A c t . v a u e i n p u t 4
A c t . v a u e i n p u t 5
A c t . v a u e i n p u t 6
n o n e
C o n t r o
S i g n a s
R a m p s
s
n o m .
, v
n o m .
V i r t u a
N o m . v a u e o u t p u t 2
n o n e
A n a o g
C A N b u s
S i g n a s
S t e p . m o t .
A x i s 2
N o m . v a u e o u t p u t 3
N o m . v a u e o u t p u t 4
N o m . v a u e o u t p u t 5
N o m . v a u e o u t p u t 6
A x i s 3
A x i s 4
A x i s 5
A x i s 6
A c t . v a l u e i n p u t s A x i s c o n f i g u r a t i o n N o m . v a l u e o u t p u t s
S t e p p e r m o t o r
Explanations:
• Information in square brackets refers to the main system
parameters for the corresponding blocks (see the relevant
comment on page 9).
• For the actual value inputs/axes/nominal value outputs nos.
2…6 the same contents apply in principle as for no. 1;

1 General 1.5 About this manual Lenord + Bauer
8 GEL 823x
differences occur with several factory settings and adjustable
characteristics.
• Function elements with grey background are, by default (from
the factory), de-activated.
1.5 About this manual
This document as well as any additional documentation are
only available in electronic form as PDF files on the setup CD
(*.pdf, see also section 2.1) under "manuals" in the respective
device folder. Hard copies are available for some fee.
Amendments or extensions which could not yet be included in
the manual are described in the "readme.txt" file" in the
documentation folder.
The manual provides information on the installation and
operation of the MotionControllers GEL 823x. It also deals, in
brief, with the system parameters, by means of which you can
configure the device and the controlled axes, and with the PC
parameter editor provided on CD and the local serial LB2
protocol (→appendices).
Descriptions of a PLC program that has possibly been pre-
installed and of the library functions for the development of user
programs are not handled here (separate manual under con-
struction; the commentary texts in the declaration part of the
individual function blocks provide some information).
Symbols and designations used:
Paragraphs marked in this way provide important additional
information to the subject.
Paragraphs marked in this way contain statements that are
important for operation according to instructions.
This symbol points out critical situations or possible damage to
the installation or property.
User
measuring
unit
Position or velocity values for an axis are given in 'user meas-
uring units' or 'user measuring units per second'. The user-
specific actual position is derived from the measuring value
provided by the actual value input according to the following
formula:
A = XHN
m
m
cR
d
n−+⋅⋅⋅
A: Actual value in user measuring units (displayed value)
R: Reading from the actual value input (incremental count or
absolute value of an encoder)

Lenord + Bauer 1.5 About this manual 1 General
GEL 823x 9
c: Factor of the edge evaluation (4 or 2 with incremental
encoders [adjustable], else 1)
m
n,d: Multiplier (numerator, denominator) [adjustable] ⇒resolution
N: Negation (1/-1) [adjustable]
H: Home offset [adjustable]
X: Internal offset (will be adjusted when the actual value changes
event-controlled, e.g. when calibrating the axis: calibration
value →actual value)
In addition, the display and input format for the position and
velocity values my be adjusted by a programmable decimal
point.
Example: incremental encoder with 2 counting tracks and
10,000 pulses per revolution (four-edge evaluation ⇒40,000
counting pulses per revolution); required is a counting range of
360.00° per revolution. This yields the result:
Multiplier = 36000/40000 = 0.900;
Decimal point = "X.XX" for the required display resolution of
1/100.
All position inputs are then to be made in the user measuring
unit '°', if necessary with two decimal digits (velocity in '° /s').
[123] A three digits number in square brackets designates a program-
mable system parameter, described in chapter 6, numerical
index on page 70.

2 Assembly 2.1 Scope of delivery Lenord + Bauer
10 GEL 823x
2 Assembly
2.1 Scope of delivery
• MotionController GEL 823x
• Mounting kit with 6 nuts, spring washers and plain washers
as well as 2 earth clamps (order no. BG 4623)
• Set of mating connectors (order no. GEL 89042 for the
MotionController GEL 8230/8235, or GEL 89043 for the
MotionController GEL 8231/8236)
• Set of cable clips (order no. BG 4622)
• Installation CD containing the following (may vary):
♦ CoDeSys (PLC programming environment)
− Set up
− Libraries
− Documentation (electronic manuals in various
language versions as PDF files)
♦ Updating software LingiMon (tool; see page 37)
♦ MC8230 operating system, latest version (for download-
ing into the MotionController) and this manual in electro-
nic form as a PDF file as well as configuration files and
manuals for the extension modules
♦ Acrobat Reader (tool)
Self-extracting installation program; the PDF files
supplied can be read with the Acrobat Reader
(Freeware from ADOBE SYSTEMS INCORPORATED)
The CD has an auto start program that offers information and
various selection alternatives in a dialog window after
inserting the CD, providing the auto start function is activated
in the PC. If the CD does not start up automatically – but this
is required so – an appropriate setting must be made in the
system control; Windows Help provides the necessary infor-
mation for this. The same effect as auto start is obtained by
manually calling the program 'start.exe' in the CD root direc-
tory.