SIGMA TEK CCP 621 User manual

CCP 621
C-DIAS Processor Module
Date of creation: 26.11.2013
Version date: 27.03.2020
Article number: 13-104-621-E

Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: [phone]
Fax: [phone]
Email: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2013
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced, edited using an electronic system, duplicated or dis-
tributed in any form (print, photocopy, microfilm or in any other process) without the express permission.
We reserve the right to make changes in the content without notice. The SIGMATEK GmbH & Co KG is not responsi-
ble for technical or printing errors in the handbook and assumes no responsibility for damages that occur through
use of this handbook.

C-DIAS PROCESSOR MODULE CCP 621
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C-DIAS Processor Module CCP 621
The CCP 621 processor module runs the control program and
thereby represents an essential component of an automation
system. The internal DC/DC converter powers all modules on
a C-DIAS module carrier.
The CAN bus, an Ethernet interface or the USB device (Mini
USB) can be used as the online interface.
A 7-segment display and two status LEDs provide information
on the actual status of the CPU.
For program updates, the integrated USB host interface can
be used (USB stick, keyboard). With help from the exchange-
able microSD card, the entire control program can be easily
exchanged.
The CCP 621 processor module is designed to be mounted in
the control cabinet. With the integrated VARAN manager, the
processor module offers the possibility to construct a high-
performance VARAN system to operate for example, decentralized I/O modules, drive sys-
tems or communication modules.
Compatibility
Completely PC-compatible. The CCP 621 works with standard PC BIOS; no SIGMATEK-
specific BIOS is therefore needed. LASAL is provided as the operating system.

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Contents
1Technical Data ........................................................................ 5
1.1 Performance Data.........................................................................5
1.2 Electrical Requirements...............................................................6
1.3 Standard Configuration................................................................6
1.4 Miscellaneous ...............................................................................7
1.5 Environmental Conditions...........................................................7
2Mechanical Dimensions......................................................... 8
3Mounting position................................................................... 9
4Connector Layout..................................................................10
4.1 Applicable Connectors...............................................................13
5Exchanging the microSD Card .............................................15
6Status Displays......................................................................16
7Display....................................................................................17
8CAN Bus Setup ......................................................................18
8.1 CAN Bus Station Number ..........................................................18
8.2 Number of CAN Bus Participants .............................................18
8.3 CAN Bus Data Transfer Rate.....................................................18
9Configuration of the Process Module..................................19

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10 CAN Bus Termination ...........................................................22
11 Wiring and Mounting Instructions .......................................23
11.1 Ground.........................................................................................23
11.2 Shielding......................................................................................24
11.3 ESD Protection............................................................................24
11.4 Mounting......................................................................................25
12 Working With and On the CCP 621......................................25
13 Process Diagram...................................................................26
14 System Boot Checkpoints....................................................27
15 Status and Error Messages..................................................28
16 Application Exceptions.........................................................36
16.1 SRAM and IRQ routines .............................................................36
16.2 SRAM and Consistency of Changed Data................................36
16.3 The File System Does Not Support Safe Writing via SRAM...36
16.4 Data Breakpoint ..........................................................................36
17 Note on SRAM Behavior.......................................................37
18 Recommended Shielding for VARAN..................................38
18.1 Wiring from the Control Cabinet to an External VARAN
component...................................................................................39
18.2 Wiring Outside of the Control Cabinet .....................................40

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18.3 Shielding for Wiring Within the Control Cabinet.....................41
18.4 Connecting Noise Generating Components............................42
18.5 Shielding Between Two Control Cabinets ...............................43

C-DIAS PROCESSOR MODULE CCP 621
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1 Technical Data
1.1 Performance Data
Processor
EDGE Technology X86 compatible
32-bit data bus
Clock frequency
800 MHz
Addressable I/O/P modules
VARAN bus: 65,280
CAN bus: 32
C-DIAS bus: 8
Internal I/O
no
Internal cache
32-kbyte L1 Cache
256-kbyte L2 cache
BIOS
AMI
Internal program and data memory
(DDR2 RAM)
128-Mbyte
Internal remnant data memory
512-kbyte (1)
Internal storage device
512-Mbyte microSD card
Interfaces
1x USB Host 2.0 (full speed 12 Mbit/s)
1x USB Device 1.1
1x Ethernet
1 x CAN
1x VARAN Out (Manager) (maximum cable length: 100 m)
1x C-DIAS
1x S-DVI interface for terminal (TFT display, USB)
Resolution 1024 x 768 pixels
Data buffer
yes
Status display
yes
Status LEDs
yes
Real-time clock
yes (buffering approximately 10 days)
(1) See chapter “Note on SRAM Behavior”

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1.2 Electrical Requirements
Supply voltage
+18-30 V DC
UL: Class 2 oder LVLC (1)
Current consumption of power
supply (+24 V)
typically 1100 mA
maximum 1300 mA
Inrush current
for a very short time (~20 µs): 30 A
Power supply on the C-DIAS bus
supplied by the CCP 621
Current load on C-DIAS bus
(power supply for I/O/P modules).
maximum 1.2 A
(1) Limited Voltage Limited Current
1.3 Standard Configuration
Ethernet 1
IP: 10.10.150.1
Subnet-Mask: 255.0.0.0
CAN bus
station: 00
baud rate: 01 = 500 kBaud
CAN bus on TAE
station: 00
baud rate: 01 = 500 kBaud
The CAN bus terminal is initialized by the FPGA and is limited in use!
Several CAN objects of the CAN bus are therefore not available.
Problems can arise if a control is connected to an IP network, which contains mod-
ules that do not run on a SIGMATEK operating system. With such devices, Ethernet
packets could be sent to the control with such a high frequency (i.e. broadcasts), that
the high interrupt load could cause a real-time runtime error or runtime error. By
configuring the packet filter (Firewall or Router) accordingly however, it is possible
to connect a network with SIGMATEK hardware to a third party network without trig-
gering the error mentioned above.
Des problèmes peuvent survenir si un automate est connecté à un réseau IP con-
tenant des modules qui ne fonctionnent pas sous un système d'exploitation
SIGMATEK. Avec de tels dispositifs, les paquets Ethernet peuvent être envoyés à
l’automate avec une fréquence tellement élevée (càd. diffusion), que les interruptions
ainsi générées peuvent provoquer une erreur d'exécution. En configurant d’une fa-
çon appropriée le filtre de paquets (pare-feu ou un routeur) il est toutefois possible
de connecter un réseau avec le matériel SIGMATEK à un réseau tiers sans déclench-
er l'erreur mentionnée ci-dessus.

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1.4 Miscellaneous
Article number
12-104-621
Hardware version
1.x
Project back-up
internally on the microSD card
Standard
UL 508 (E247993)
Approbations
cUL, UL
1.5 Environmental Conditions
Storage temperature
-10 ... +85 °C
Environmental temperature
0 ... +45 °C
Humidity
10 - 90 %, non-condensing
EMC stability
in accordance with EN 61000-6-2 (industrial area)
Shock resistance
EN 60068-2-27
150 m/s²
Protection type
EN 60529
IP20

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2 Mechanical Dimensions

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3 Mounting position
To ensure optimal cooling of the module, the CCP 621 must be mounted as shown (stand-
ing). For an angled mounting position, forced convection (cooling fan) must be used.
Top
Bottom

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4 Connector Layout

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X1: USB Host 2.0
It should be noted that many of the USB devices on the market do not comply with
USB specifications; this can lead to device malfunctions. It is also possible that
these devices will not be detected at the USB port or function correctly. Therefore, it
is recommended that every USB stick be tested before actual use.
Il faut souligner que la plupart des périphériques USB sur le marché ne sont pas
conformes aux spécifications USB, ce qui peut entraîner des dysfonctionnements de
l'appareil. Il est également possible que ces dispositifs ne seront pas détectés par le
port USB ou qu’ils ne fonctionnent pas correctement. Par conséquent, il est recom-
mandé que chaque clé USB soit testée avant l'utilisation sur l’automate.
X2: Ethernet
n.c. = do not use
X3: VARAN Out
More information on the VARAN bus can be found in the VARAN bus specifications!
Pin
Function
1
+5 V
2
D-
3
D+
4
GND
Pin
Function
1
TX+
2
TX-
3
RX+
4 - 5
n.c.
6
RX-
7 - 8
n.c.
Pin
Function
1
TX+ / RX+
2
TX- / RX-
3
RX+ / TX+
4 - 5
n.c.
6
RX- / TX-
7 - 8
n.c.

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X4: CAN Bus
X5: S-DVI (26-pin HD-D-Sub)
X6: USB Device 1.1
X7: Supply
Pin
Function
1
CAN A (CAN LOW)
2
CAN B (High)
3
CAN A (CAN LOW)
4
CAN B (High)
5
GND
6
n.c.
Pin
Function
Pin
Function
1
DVI1+
14
Shielded
2
DVI1
15
Shielded
3
DVI2+
16
Shielded
4
DVI2
17
Shielded
5
DVI3+
18
Shielded
6
DVI3
19
+24 V
7
DVIC+
20
+24 V
8
DVIC-
21
USB Ext. In+
9
Reserved
22
USB Ext. In-
10
GND
23
USB Ext. Out+
11
GND
24
USB Ext. Out-
12
Shielded
25
CAN A
13
Shielded
26
CAN B
Pin
Function
1
+5 V
2
D-
3
D+
4
n.c.
5
GND
Pin
Function
1
+24 V supply
2
GND
1 2
65

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microSD Card
It is recommended that only storage media provided by SIGMATEK
(CompactFlash cards, microSD cards etc.) be used.
Order number for the 512-Mbyte EDGE microSD card: 12-630-051
The number of read and write actions have a significant influence on the
lifespan of the storage media.
Il est recommandé de n’utiliser que les supports de stockage approuvés par
SIGMATEK (compact flash, microSD, etc.).
Numéro de commande pour la carte microSD 512 Mo Edge est le: 12-630-051
Le nombre de cycles de lecture et d'écriture a l’influence notable sur la durée de vie
des supports de stockage.
4.1 Applicable Connectors
Connectors
Type
Wire Size
Max. Tightening Torque
X1
USB Type A
-
-
DR1969, SA25469:
RJ 45
-
-
X4
B2L 3.5/6
0.13 - 1.0 mm2
28 - 18 AWG (UL/CSA)
Spring terminal
X5
D-SUB high density
26-pin
-
-
X6
USB Type Mini-B
-
-
X7
FK-MCP 1.5/2-ST-3.5
0.14 - 1.5 mm2
28 - 16 AWG (UL/cUL)
Spring terminal
MC 1.5/2-ST-3.5
0.13 - 1.0 mm2,
30 - 16 AWG (UL),
28 - 16 AWG (CSA)
0.22 - 0.25 Nm
Pin
Function
1
DAT2
2
CD/DAT3
3
CMD
4
+3V3
5
Clk
6
GND
7
DAT0
8
DAT1

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Applicable Connectors
USB Device: 5-pin, type Mini-B
USB Host: 4-pin, type A
Ethernet:8-pin, RJ45
VARAN: 8-pin, RJ45
CAN Bus: 6-pin Weidmüller plug, B2L3, 5/6
Supply: 2-pin Phoenix plug with screw terminal technology MC 1.5/ 2-ST-3.5
2-pin Phoenix plug with spring terminal FK-MCP 1.5/ 2-ST-3.5
The complete C-DIAS CKL 031 connector set with spring terminals is available from
SIGMATEK under the article number 12-600-017.
S-DVI Cable
0.3 m
2 m
3 m
3.5
5 m
7 m
10 m
15 m
Art.No.: 05-950-003
Art.No.: 05-950-020
Art.No.: 05-950-030
Art.No.: 05-950-035
Art.No.: 05-950-050
Art.No.: 05-950-070
Art.No.: 05-950-100
Art.No.: 05-950-150
NOTE:
Connecting the S-DVI cable under voltage can damage the S-DVI interface; it is not
hot-plug capable.

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5 Exchanging the microSD Card
The microSD card is located under the LED cover.
To exchange the microSD card, carefully lift the LED cover.
The microSD card is located on the left side and can be
disengaged by lightly pressing on the card itself.
Remove the microSD card.

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6 Status Displays
Ethernet
LED
Color
Description
ACTIVE
Yellow
Lights when data is exchanged over Ethernet
Link
Green
Lights when the connection between the two PHYs is established
VARAN
LED
Color
Description
ACTIVE
Yellow
Lights when data is exchanged over the VARAN bus
Link
Green
Lights when the connection between the two PHYs is established
Control
LED
Color
Description
ERROR
Red
Lights when an error occurs (defective USV)
DCOK
Green
Lights when the power supply is OK

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7 Display
The CCP 621 processor module has a 2-digit decimal display (7-segment display) for the
following functions:
•When configuring the processor module, the parameters are shown in the display.
•If an error occurs while running the program or no valid user program is found, the dis-
play shows an error message. "Er" (error) and the error code thereby alternate in the
display. The same error code is also shown in the LASAL status line.
•While running the program, the display can be used to show digits using the system
variable _cpuDisplay. Valid values are 0 to 255; values over 99, however, are not
shown and the display remains dark.

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8 CAN Bus Setup
This section explains how to correctly configure the CAN bus. The following parameters
must first be set: Station number and data transfer rate.
8.1 CAN Bus Station Number
Each CAN bus station is assigned its own station number. With this station number, data
can be exchanged with other stations connected to the bus. In a CAN bus system however,
each station number can only be assigned once!
8.2 Number of CAN Bus Participants
The maximum number of participants on the CAN bus depends on the cable length, termi-
nation resistance, data transfer rate and the drivers used in the participants.
With a termination resistance of 120 , at least 100 participants are possible.
8.3 CAN Bus Data Transfer Rate
Various data transfer rates (baud rates) can be set on the CAN bus. The longer the bus line
is, the lower the data transfer rate that must be selected.
Value
Baud rate
Maximum length
00
615 Kbits/s
60 m
01
500 Kbit/s
80 m
02
250 Kbits/s
160 m
03
125 Kbits/s
320 m
04
100 Kbits/s
400 m
05
50 Kbits/s
800 m
06
20 Kbits/s
1200 m
07
1 Mbit / s
30 m
These values are valid for the following cable: 120 Twisted Pair.
Note: For the CAN bus protocol: 1 Kbit/ s = 1 kBaud.