Pepperl+Fuchs ICA-8DIO4M1-G20-IO User manual

ICA-8DIO4M1-G20-IO
Motor Control Module with
Standard Process Data
Manual

With regard to the supply of products, the current issue of the following document is applicable: The
General Terms of Delivery for Products and Services of the Electrical ndustry, published by the Central
Association of the Electrical ndustry (Zentralverband Elektrotechnik und Elektroindustrie (ZVE ) e.V.)
in its most recent version as well as the supplementary clause: "Expanded reservation of proprietor-
ship"
Worldwide
Pepperl+Fuchs Group
Lilienthalstr. 200
68307 Mannheim
Germany
Phone: [phone] - 0
E-mail: [e-mail]
orth American Headquarters
Pepperl+Fuchs nc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: [phone]
E-mail: [e-mail]
Asia Headquarters
Pepperl+Fuchs Pte. Ltd.
P+F Building
18 Ayer Rajah Crescent
Singapore 139942
Phone: [phone]
E-mail: [e-mail]
https://www.pepperl-fuchs.com

3
CA-8D O4M1-G20- O
Contents
2021-02
1 Introduction................................................................................................................ 5
1.1 Content of this Document............................................................................. 5
1.2 Target Group, Personnel ............................................................................... 5
1.3 Symbols Used ................................................................................................ 5
1.4 General Safety Information........................................................................... 6
1.5 Konformitätserklärung .................................................................................. 6
2 Product Description .................................................................................................. 8
2.1 Use and Application ...................................................................................... 8
2.2 Housing.........................................................................................................10
2.3 LED Indicators ............................................................................................. 10
2.4 Interfaces and Connections ....................................................................... 12
2.5 IO-Link Interface Properties .......................................................................13
2.6 Braking Energy Power Feedback ...............................................................13
3 Installation................................................................................................................14
3.1 Storage and Transportation ........................................................................14
3.2 Unpacking ....................................................................................................14
3.3 Mounting.......................................................................................................14
3.4 Connecting the Auxiliary Current Flat Cable ............................................ 14
3.5 Connecting Motors and Sensors ...............................................................17
4 IO-Link Process Data...............................................................................................18
4.1 Input Process Data Structure .....................................................................18
4.2 Output Process Data Structure ..................................................................19
5 IO-Link Parameters..................................................................................................22
5.1 Device-Specific Operating/Configuration Parameters.............................22
5.2 Device Parameters....................................................................................... 27
5.3 Standard Configuration Parameters..........................................................28
5.4 Specific Device Information........................................................................ 29
5.5 Operating Monitor........................................................................................ 29
5.6 Diagnostics .................................................................................................. 30
5.7 Device-Specific Commands........................................................................33
0.1ICA-8DIO4M1-

CA-8D O4M1-G20- O
Contents
4
2021-02
6 Repair and Servicing ...............................................................................................34
7 Appendix...................................................................................................................35
7.1 Event Codes .................................................................................................35
7.2 Error Codes ..................................................................................................36
7.3 ASCII table ....................................................................................................37

CA-8D O4M1-G20- O
ntroduction
2021-02
5
1 Introduction
1.1 Content of this Document
This document contains information required to use the product in the relevant phases of the
product life cycle. This may include information on the following:
•Product identification
•Delivery, transport, and storage
•Mounting and installation
•Commissioning and operation
•Maintenance and repair
•Troubleshooting
•Dismounting
•Disposal
The documentation comprises the following parts:
•This document
•Datasheet
n addition, the documentation may comprise the following parts, if applicable:
•EU-type examination certificate
•EU declaration of conformity
•Attestation of conformity
•Certificates
•Control drawings
•nstruction manual
•Other documents
1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and dismount-
ing lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation, com-
missioning, operation, maintenance, and dismounting of the product. The personnel must have
read and understood the instruction manual and the further documentation.
Prior to using the product make yourself familiar with it. Read the document carefully.
1.3 Symbols Used
This document contains symbols for the identification of warning messages and of informative
messages.
ote
For full information on the product, refer to the further documentation on the nternet at
www.pepperl-fuchs.com.
Table 1.1 CA-8D O4M1-G20- O

2021-02
6
CA-8D O4M1-G20- O
ntroduction
Warning Messages
You will find warning messages, whenever dangers may arise from your actions. t is mandatory
that you observe these warning messages for your personal safety and in order to avoid prop-
erty damage.
Depending on the risk level, the warning messages are displayed in descending order as fol-
lows:
Informative Symbols
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
1.4 General Safety Information
Responsibility for planning, assembly, commissioning, operation, maintenance, and dismount-
ing lies with the plant operator.
nstallation and commissioning of all devices may be performed only by trained and qualified
personnel.
t is dangerous for the user to carry out modifications and/or repairs and doing so will void the
warranty and exclude the manufacturer from any liability. n the event of any serious errors, stop
using the device. Secure the device against unintended operation. To have the device repaired,
return it to your local Pepperl+Fuchs representative or your sales center.
1.5 Declaration of Conformity
This product was developed and manufactured in line with the applicable European standards
and directives.
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure.
ote
This symbol brings important information to your attention.
ote
Disposal
Electronic waste is hazardous. When disposing of the equipment, observe the current statutory
requirements in the respective country of use, as well as local regulations.

CA-8D O4M1-G20- O
ntroduction
2021-02
7
The product manufacturer, Pepperl+Fuchs Group, 68307 Mannheim, Germany, has a certified
quality assurance system that conforms to SO 9001.
ote
A declaration of conformity can be requested from the manufacturer.
ISO9001

2021-02
8
CA-8D O4M1-G20- O
Product Description
2 Product Description
2.1 Use and Application
General
The CA-8D O4M1-G20- O* roller motor control module is an O-Link connection module for
controlling up to four 24 V DC roller motors. The module enables process-specific control of
features including the following on the connected roller motors:
•Direction of rotation
•Speed
•Start and stop ramps
The module is ideally suited for implementing complex conveying tasks. The module is opti-
mized for nterroll EC310 roller motors but can also be used for compatible DC motors, e.g.,
Rulmeca BL3.
Digital Inputs and Outputs
To be able to optimally control the roller motor rollers based on conditions in the field environ-
ment (e.g., switching signal of a light barrier), the module has 8 freely configurable digital
inputs/outputs (PNP). The input characteristic of the inputs corresponds to type 3 in accor-
dance with EN 61131-2. The outputs are resistant to short circuits and overloading.
The module and the digital inputs/outputs are supplied via O-Link. Each sensor power supply
can be loaded with 200 mA.
For details regarding connection, see chapter 3.5.
Counters
The module has a counter input for connecting an incremental rotary encoder. You can connect
a single- or dual-input rotary encoder with a counting frequency of up to 10 kHz.
•A single-input rotary encoder is connected to O1.
•A dual-input rotary encoder is connected to O1 and O2, and takes the direction of rota-
tion into account.
Roller Motors
The roller motors are supplied with power via an external auxiliary voltage. The auxiliary volt-
age is supplied to the roller motor control module via a flat cable.
•The permissible auxiliary voltage is 18 V to 30 V.
•The maximum continuous current load for each roller motor is 2.5 A.
•For each roller motor, a maximum current load of 5 A is permitted briefly (< 2 s).
f a roller motor is connected to a motor output, the output must be configured accordingly. The
following statuses are transmitted via the process data:
•Roller motor fault
•Fusing
•Switching on and off
ote
nverting the input channels affects the counter. f the counting direction is to be reversed for a
dual-input rotary encoder, one of the two inputs must be inverted.
The counting function has no effect on how inputs are processed at O1 and O2. The input
filters are not taken into account for the counting function.
Table 2.1 CA-8D O4M1-G20- O

CA-8D O4M1-G20- O
Product Description
2021-02
9
•Direction of rotation
•SpeedDifferent Functions Based on ODD91
•Start/stop ramps1
The output at pin 2 is resistant to overloading and short circuits. The roller motor supply is pro-
tected by a fuse.
The speed is expressed as a percentage. The output voltage for controlling the roller motor
speed is output between the configurable limits. The lower limit corresponds to 0 % of the max-
imum speed, the upper limit corresponds to 100 % of the maximum speed.
For details regarding connection, see chapter 3.5.
Braking Function
You can use the process data to activate a brake for each roller motor. An activated brake
causes the analog velocity output to be lowered to 0 V after reaching the lower limit. For some
roller motors, this is mandatory to activate the brake function. This setting has no effect on
nterroll EC310 roller motors, as these roller motors always brake.
Start/Stop Ramps
The configurable ramp duration defines the time from stationary (0 %) to maximum speed
(100 %), or from maximum speed to stationary. When the terminal velocity is lower, the ramp
duration is shorter.
General IO-Link Information
O-Link is a standardized point-to-point O technology ( EC 61131-9) between an O-Link mas-
ter that controls communication and an O-Link device that acquires or executes process val-
ues at the lowest sensor/actuator level. n addition to transmitting process data, O-Link also
provides access to detailed identification, diagnostic and parameter data of the respective O-
Link device.
O-Link uses unshielded 3- or 5-wire cables with a maximum length of 20 meters between the
O-Link master and O-Link device, and enables transfer rates of 4.8 kbit/s (COM1), 38.4 kbit/s
(COM2), or 230.4 kbit/s (COM3). The O-Link interface is backward compatible with the
24 V /O signals specified in EC 61131-2.
Different Functions Based on IODD
The module has two different process data structures - Standard (STD) and Extended (EXT).
Which structure is used depends on the O-Link device D that is set. While the standard pro-
cess data image assigns 8 bytes of input data and 6 bytes of output data, the extended process
data image uses 8 bytes of input data and 18 bytes of output data. n addition to the functions of
the standard process data image, the extended process data image enables control of the
start/stop ramps and continuous, real-time adjustment of the roller motor speed via the process
data.
1. Depending on the selected process data structure, see "Different Functions Based on ODD" on page 9
Tip
f a motor output is not configured for a roller motor, pin 2 of the corresponding output can be
used as a digital power output, which is supplied from the auxiliary voltage PWR. A separate bit
for controlling the power output is available in the process data.

2021-02
10
CA-8D O4M1-G20- O
Product Description
For detailed information on the structure and assignment of the process data image, see chap-
ter 4.
2.2 Housing
The housing is made entirely of plastic, except for the hinge pins for the hinge cable guide.
The housing consists of the following main components:
•a mounting base with integrated electronics
•a folding guide cage as a cable guide for the AS- nterface flat cable
Figure 2.1 Housing dimensions
2.3 LED Indicators
Figure 2.2 LED indicators
Tip
You can download the corresponding manual for each version from our website www.pepperl-
fuchs.com.
100
120
122
135.5
16.6
15
27.5
54
24V Power
M1 M2 IO1 IO2 IO3 IO4 IO5 IO6 IO7 IO8 M3 M4
MOT1
MOT2
MOT3
MOT4
IO1/2
IO3/4
IO-Link
IO5/6
IO7/8
-
+
PWR-ERR IOL-ERR
ote
The LEDs on the inputs and outputs indicate the physical state of the respective channel. You
can find the invertible logical state of a channel in the process data.