PLEIGER ELEKTRONIK PPC-PLD-7 User manual

Pleiger Elektronik GmbH & Co. KG Fon [phone]
D-58456 Witten ●Im Hammertal 51 Fax [phone]
www.pleiger-elektronik.de [e-mail]
PCL
PCL Modules
Pleiger Control Loop
Manual version 2018-03 - subject to modification -
•System Description
•PCL-Valve Control Interface
•PCL-IO
•PCL-Master
•PLD-7 local operation

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Contents
1.1 Transportation and storage instructions...........................................................................3
1.2 Installation and electrical connection................................................................................3
1.3 Intervention into the component........................................................................................3
1.4 Intended use........................................................................................................................3
1.5 Not intended use.................................................................................................................3
1.6 Use in safety related vital functions...................................................................................3
1.7 Certificates and Approvals................................................................................................4
2PCL system overview ...............................................................................5
3The Data Bus System................................................................................6
3.1 PCL Master Function ..........................................................................................................6
3.2 Multiple Data Busses..........................................................................................................6
3.3 Function PCL Slave.............................................................................................................6
3.3.1 The physical layer............................................................................................................6
3.3.2 Data communication and address selection.....................................................................6
4The power bus system..............................................................................8
4.1 Handling power bus faults, interruption............................................................................8
4.2 Handling power bus faults, short circuit ...........................................................................8
4.3 Power Management.............................................................................................................8
4.4 Power Bus Cable.................................................................................................................9
4.4.1 Cable Length ...................................................................................................................9
4.4.2 Reduced current ..............................................................................................................9
4.4.3 Additional supplies...........................................................................................................9
4.4.4 Installation rules...............................................................................................................9
4.5 Fusing................................................................................................................................10
5Valve Control Interface (PCL-VCI)..........................................................11
5.1 Interface to actuator..........................................................................................................11
5.1.1 Quick Closing Operation................................................................................................11
5.2 Valve Control Function.....................................................................................................12
5.2.1 PCL-VCI versions ..........................................................................................................12
5.3 Connection of actuator for hazardous area (CM-ExE)....................................................13
5.4 Technical data PCL-VCI....................................................................................................13
5.4.1 Connector for bus cable.................................................................................................14
5.4.2 EHS connector...............................................................................................................14
5.5 PCL-VCI with extended inputs and outputs (V3-3 and V3-4 (vertical connectors)) ......14
5.5.1 External local indication box...........................................................................................15
5.5.2 External local control box...............................................................................................15
5.5.3 Extended SCADA-Inputs and SCADA-Outputs..............................................................15
5.5.4 Technical data (extended inputs and outputs)................................................................16
5.5.5 Connector (extended inputs and outputs) ......................................................................16
6Bus IO Unit (PCL-IO)...............................................................................17
6.1 Analog / digital inputs.......................................................................................................17
6.2 Isolated digital inputs .......................................................................................................17
6.3 Digital relay outputs..........................................................................................................17
6.4 Technical data PCL-IO ......................................................................................................17
6.4.1 Connector for bus cable.................................................................................................18
6.4.2 Connector for process IO...............................................................................................18
7PCL-Power Control (PCL-PC).................................................................19
7.1 Bus-Master connection and begin of power loop...........................................................19
7.2 Technical description PCL-PC .........................................................................................19
7.3 Power loop interconnection .............................................................................................20

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8PCL-Bus connector (PCL-BC)................................................................21
8.1 Technical description PCL-BC.........................................................................................21
9PCL-Master (busmaster).........................................................................22
9.1 General description...........................................................................................................22
9.2 Display elements and interfaces of the mc3 processor board.......................................23
9.3 Busmaster and local operation panel..............................................................................24
9.4 Modbus RTU Interface ......................................................................................................24
9.5 Technical data Busmaster................................................................................................25
10 PPC-PLD for local operation and set-up................................................26
10.1 Startup picture of the PLD................................................................................................27
10.1.1 Possibilities of the operation e.g. command or parameter changes................................28
10.2 Backup operation..............................................................................................................28
10.2.1 PLC-VCI node for an EHS with open close drive ...........................................................29
10.2.2 PLC-IO...........................................................................................................................31
10.2.3 PLC-VCI node for an EHS with continuous drive ...........................................................31
10.2.4 PCL-VCI node with input and output..............................................................................32
10.2.5 Control permission for backup operation........................................................................33
10.2.6 Backup operation for an EHS with open close drive.......................................................34
10.2.7 Backup operation for an EHS with continuous drive.......................................................35
10.2.8 Failure indication............................................................................................................36
10.3 Advanced operation with analyzing function..................................................................38
10.3.1 PLC node.......................................................................................................................40
10.3.2 PLC-VCI node for an EHS .............................................................................................41
10.3.3 PLC-IO...........................................................................................................................41
10.3.4 Control permission for advanced operation with analyzing function ...............................42
10.3.5 Advanced operation for a PCL-VCI................................................................................42
10.3.6 Block a valve..................................................................................................................43
10.3.7 End the blocked state of a valve ....................................................................................43
10.3.8 Modify the parameter Actuator.......................................................................................43
10.3.9 Modify the Auxiliary parameter.......................................................................................44
10.3.10 Modify the parameter runtime.......................................................................................46
10.3.11 Modify the parameter quick close..................................................................................47
10.4 Process picture of the busmaster....................................................................................48
10.4.1 Symbol explanation for the connection to SCADA system .............................................48
10.4.2 Symbol explanation for the connection to PLD...............................................................49
10.4.3 Symbol explanation for the PCL-buses..........................................................................51
10.4.4 General symbols............................................................................................................52
10.5 Selftest function of PCL-System......................................................................................53
10.5.1 Basics............................................................................................................................53
10.5.2 Selftest operation...........................................................................................................54
10.5.3 Selftest failure analysis ..................................................................................................55
10.6 General system failure indication ....................................................................................57
10.7 PLD configuration and service functions........................................................................58
10.8 Technical data PPC-PLD...................................................................................................62
11 Figures.....................................................................................................63
12 Tables ......................................................................................................65

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1 General information
This manual contains instructions and drawings for correct handling and using the equipment. Please
observe all instructions of this manual carefully.
Please note that not respecting the information, using the equipment not according the regulations be-
low, wrong installation or incorrect handling could influence personal or plant safety seriously!
This manual is part of this operation resource. Keep the manual safe for later use. The manufacturer
reserves the right to change performance data, specification data or the design layout without an ad-
vance notice.
1.1 Transportation and storage instructions
The equipment must be inspected upon reception for damages that may have occurred
during transportation or handling. If damages are obviously, inform the carrier and the
manufacturer immediately. Dropped components must not be applied because invisible
damages may influence the reliability.
1.2 Installation and electrical connection
The equipment has to be installed by qualified personnel only, that is familiar with the
safety requirements and potential risk. Please note the special safety requirements be-
longing the point of installation, generally accepted rules of technology, the connection
instruction in this manual and the available imprint on the component.
1.3 Intervention into the component
If malfunctions occur or something is dubious please contact the manufacturer. Intervention into the
component could heavily affect the safety of person and plant and will lead to termination of liability and
caveat emptor.
1.4 Intended use
To use the equipment is approved only if the instructions of this manual are complied and the use is
appropriate to the type label and to an application it is intended to.
In the field the technical specifications and denoted limit values have to be generally maintained. This
applies particular with regard to voltage, temperature and other noted environmental conditions. The
use beyond the specified and approved edge conditions could put life at risk, damage the component
or cause secondary damages to the plant.
1.5 Not intended use
Every use of the component that is not equal to the use described in chapter „1.4 intended use“ is
obtained as not intended use. Damages that result from not intended use and / or result from unauthor-
ised intervention on the component, not according to this manual, or not using original spare parts the
claim for warranty and liability of the manufacturer expires.
1.6 Use in safety related vital functions
It is the responsibilityof the user toperform a riskanalysis of the whole installation and to define potential
safety related functions.
It is the responsibility of the user to take care of appropriate measures to achieve the safeness in safety
related vital functions.

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1.7 Certificates and Approvals
PCL-system components meet the requirements of the following Directives:
•DNV GL Class Guideline DNVGL-CG-0339 (Nov/2016)
The following approvals apply:
•Type approval TAA00001FM by DNV GL
•Type approval TAA00000S3 by DNV GL (for PPC-PLD-7)
Certificates and approvals can be downloaded from our website or ordered from the manufacturer.
Technical Support:
[phone]
[e-mail]

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2 PCL system overview
The PCL (Pleiger Control Loop) is a fault tolerant data and power
bus system. It is primarily intended for use with Pleiger EHS valves
and similar devices. Major benefit of the system is the robustness
against disturbances and damages to the bus cable and other
parts of the system. Even in most cases of severe damage not
more than two drives of the system will fail.
The main components of the PCL System are:
•Redundant, hot standby busmaster, PCL-Master
•The local operation unit, PLD-7
•The PCL node for valve control PCL-VCI
•The PCL node for input and output application PCL-IO
•The power bus connection module PCL-PC
This manual describes some basics of the system, the operation of the busmaster as well as the tech-
nical data of the busmaster and the valve control interface.
Figure 2-1: Sample configuration with supply from single bus master cabinet

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3 The Data Bus System
The PCL data bus is a master slave system using a communication protocol similar to the Modbus
protocol but providing special function types and a very tight timing for increased performance. Hereby
a fast data transfer is achieved even at low baud rates. The communication nodes connected to the
data loop are called nodes.
3.1 PCL Master Function
In most applications two independent master controllers (A and B) handle the communication with the
nodes at both ends of the data bus. The polling sequence is the major difference between both bus-
masters. While A is starting with the first node of a data loop counting upwards, B starts with the last
one and then counts downwards.
Note:The sequence used for polling the nodes is parameterised by the user. This sequence must be
identical to the physical sequence of the slave units (EHS) on the bus. Otherwise a proper fault
localisation is not guaranteed.
Both masters are connected via CAN bus. This connection is used to copy any information that one of
the masters receives to the other the other master immediately. Therefore both masters’ data are al-
ways identical.
3.2 Multiple Data Busses
To increase the communication speed and to improve the availability in case of multiple errors each
busmaster can serve up to 8 data loops simultaneously. All data loops have identical functions. The
number of data loop and the nodes connected to each data loop can be selected by several parame-
ters. Each data loop can serve up to 100 nodes and up to 250 nodes may be connected to a busmas-
ter resp. a pair of busmasters. If more than 60 nodes shall be connected to a busmaster at least two
data loops are recommended. Four to eight data loops are recommended for 250 nodes.
3.3 Function PCL Slave
The PCL slave interface is the most important link in the PCL safety chain. It is not only acting as a
communication slave but also takes over the following tasks:
•Separating the data bus loop sections electrically
•Acting as a repeater
•Selecting the valid busmaster
•Control of the actuator resp. operating
3.3.1 The physical layer
Electrically the slaves perform a point-to-point communication on two RS485 ports A and B. Both
ports are optically isolated, overload protected and connected by a simple logic. Special 485 drivers
guarantee a differential output signal with extraordinary high amplitude and an improved signal-to-
noise ratio. Each node acts as a signal repeater.
Because of the additional protection devices even a short circuit between the 230V AC supply and the
data bus will not cause a permanent damage of the slave but of course an interruption of the data link.
For data transmission a shielded twisted pair cable with at least 0,75 mm² cross-section is required.
This twisted pair is part of the PCL bus cable. Other cable types (5x2,5) are going to be tested.
3.3.2 Data communication and address selection
The protocol is quite similar to the Modbus protocol. Only the function types are different and the tim-
ing is faster to achieve optimal performance. The most frequently used message exchange is based
on the master’s status request (4 bytes) and the slave’s status response (6 bytes). Using a baud rate

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of 19200 bits/s such a message exchange is handled completely within 9,7ms. A 16 bit CRC in combi-
nation with a parity check is used for error checking.
The node address in the range 1 to 250 is simply set by means of an 8 bit DIP switch. This is a very
simple technique and does not require special skills or equipment during installation or when defective
parts are to be exchanged.
The position ON corresponds to a 1 whereas OFF corresponds to a 0. The
first switch 1 sets the least significant bit and the switch 8 sets the most sig-
nificant bit of the address.
1 2 345 6 78
O
N
O
F
F
Figure 3-1: Address
DIP switch

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4 The power bus system
Besides the data communication the bus cable also provides power supply with 230V AC. Similar to
the data bus the power bus is also configured as a loop. Both ends of the loop are protected by the
same 16A fuse. Several power loops may be installed within a single data bus loop.
DANGER
Electrical shock
Mains supply with 230 V AC
•All installations must only be carried out by an electrically qualified person.
•Disconnect the system from the mains and secure it against being switched on un-
intentionally.
•Obey the accident prevention regulations when testing the live system.
4.1 Handling power bus faults, interruption
If one or both conductors of the power bus break the current is still conducted by the both parts of the
power loop. Therefore any kind of interruption is not even noticed by the system. To detect such faults
the system is equipped with a self-test function. Such a self-test has to be performed in regular inter-
vals (see chapter 10.5 Selftest function of PCL-System).
4.2 Handling power bus faults, short circuit
Naturally the effect of a short circuit is much more severe. Because the current is the same within the
whole loop the fuse of this loop will blow and all slaves connected to this loop will fail. Because the
PCL masters supervise the power loop voltage this event is going to be indicated via Modbus connec-
tion immediately.
The fuse may now be reset manually. Of course without any additional measures the fuse would just
blow again. Therefore the master cabinet as well as each slave is equipped with a power relay and a
short circuit snooping device. If a short circuit is detected the power relay stays open. This prevents
that the fuse is blown once again.
Note:If a short circuit is detected on either side of the slave the slave is not connected to the power
bus and therefore stays turned off.
4.3 Power Management
As each valve requires up to 1,8A and the cable is fuse protected with 16A, approximately 8 valves
can run simultaneously. If more than 8 valves shall be connected to a single bus section a power
management is required. This power management assures that not more than 8 valves connected to
the same fuse will run simultaneously. To avoid unacceptable delays it is recommended to limit the
number or valves within one power section to 25…30.
For power management the master adds up all required current in each of up to 10 power loops. A
command is sent to the valve only if the required current for running this drive is still available within
the power loop. Because the start-up current of the valves is significantly higher than the nominal cur-
rent the time between valve starts are at least 100ms.
The maximum required current of each valve as well as the maximum current within each power loop
can be individually parameterised by the user.

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4.4 Power Bus Cable
Of course the length of the power bus cable is limited because of the voltage drop on the bus. There-
fore it is necessary to make a rough estimate of the allowed cable length. Please note that this max
length does not concern the data bus but only a single power bus loop.
The max allowed voltage drop on the power bus cable is 20% = 46V. By this and the max current of
8x1,8A = 14,4A the maximum cable length can be determined. Of course the worst case must be
taken into consideration. Therefore it is assumed that the power loop is supplied at one side only. Un-
der normal conditions the bus loop is supplied at both sides and therefore the maximum voltage drop
is reduced to less than 10%. The max allowed conductor resistance is:
Rmax = 46V/14,4A = 3,2Ohm
First it is assumed (worst case) that all 8 drives are mounted directly beneath each other at the end of
the cable.
4.4.1 Cable Length
The max cable length depends on the type of cable used. The EHS bus interface provides 4 terminals
to connect up to 4x2.5mm² power cable. If such a cable is used the max length between the power
supply and the last drive within the power loop is 441m.
Type
Conductors, power loop
Resistance
Length
1
3x1.5 mm²
9.08 mOhm/m
176 m
2
2x2.5mm²
7.26 mOhm/m
220 m
3
4x1,5mm²
6.05 mOhm/m
264 m
4
3x2,5mm²
5.45 mOhm/m
294 m
5
2x4mm²
4.54 mOhm/m
352
6
4x2.5mm²
3.63 mOhm/m
441 m
Table 4-1: PCL bus cable length
Additional power bus loops should be connected via a 2x4mm² or a 2x6mm².
Note:If conductors of a power loop cable are connected in parallel an external connection to Protec-
tive earth with sufficient cross section is required.
4.4.2 Reduced current
If longer cables shall be used the maximum current must be reduced by limiting the number of drives
running concurrently. This can easily be parameterised for each single power loop. The maximum
length may be enlarged by the following factor.:
No of drives
8
7
6
5
4
3
Length multiplier
1
1.14
1.33
1.6
2
2.6
Table 4-2: Cable length multiplier and maximum loop current
4.4.3 Additional supplies
If the max length of the power bus loop is exceeded or the number of drives is more than app. 25-30 a
new power bus loop must be inserted. Therefore an additional cable (4x4mm²) connects the end of
the first power bus loop with its supply within the switch cabinet and the supply of the next power bus
loop with the bus cable vice versa.
4.4.4 Installation rules
The bus cable may be laid parallel to other cables conduction a voltage of 230/400V with a maximum
current of 63A. If current or voltage is above this limit or if the cable is used to connect a drive to a fre-
quency inverter, a minimum distance of 1 m must be kept.