SIGMA TEK ETV 1591-H User manual

ETV 1591-H
Control Panel
Date of creation: 02.04.2013
Version date: 24.03.2015
Article number: 13-230-1591-HE

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
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.

CONTROL PANEL ETV 1591-H
24.03.2015 Page 1
Control Panel ETV 1591-H
The control panel is an intelligent terminal for programming and visualization of automated
processes.
A touch screen serves as the input medium for process data and parameters. The output is
shown on a 15" XGA TFT color display.
To safely back up the data before the panel is shut down, an integrated UPS is used to
buffer the +24 V power supply.
The available interfaces can be used to exchange process data or configure the build-in
terminal. A SATA hard drive serves as the storage medium for the operating system, appli-
cation and application data.
With the integrated VARAN manager, the ETV 1591-H offers the possibility to construct a
high-performance VARAN system to operate for example, decentralized I/O modules, drive
systems or communication modules.

ETV 1591-H CONTROL PANEL
Page 2 24.03.2015
Contents
Technical Data.................................................................................5
1.1 Performance Data .........................................................................5
1.2 Electrical Requirements...............................................................6
1.3 Terminal.........................................................................................6
1.4 Environmental Conditions...........................................................6
1.5 15" XGA Display............................................................................7
1.6 Control Unit ...................................................................................7
1.7 Miscellaneous ...............................................................................7
2Mechanical Dimensions..........................................................8
3Chemical Resistance ..............................................................9
3.1 ASA Plastic Housing ....................................................................9
4Connector Layout..................................................................10
4.1 Front Connector..........................................................................10
4.2 Rear Connectors.........................................................................11
4.3 Applicable Connectors...............................................................13
5Uninterruptable Power Supply UPS.....................................14
5.1 Simplified Block Diagram ..........................................................14
5.2 Technical Data.............................................................................15
5.2.1 Electrical Requirements for the Battery Pack.................................... 15
5.2.2 Buffering after a +24 V Main Supply Failure ..................................... 16
5.2.3 Environmental Conditions................................................................. 16

CONTROL PANEL ETV 1591-H
24.03.2015 Page 3
5.2.4 Delivery Condition / Minimum Charge............................................... 16
5.3 UPS Operating Modes................................................................17
5.3.1 Switching to Battery Operation.......................................................... 17
5.3.2 Low Battery Charge Conditions ........................................................ 17
5.4 UPS Interface...............................................................................18
5.5 Using the Interface for the UPS.................................................18
5.5.1 Named-Pipe Read Functions............................................................ 19
5.5.2 Named-Pipe Write Function.............................................................. 26
5.6 Battery Charging Process..........................................................29
5.6.1 Time Specification............................................................................. 29
5.6.2 Measuring......................................................................................... 30
5.7 Battery Lifespan and Charge/Discharge Curve.......................31
5.7.1 Battery Lifespan................................................................................ 31
5.7.2 Self-Discharge .................................................................................. 32
5.7.3 Battery Charging Curve .................................................................... 33
5.7.4 Battery Discharging Process............................................................. 34
5.8 Battery Extension Cable ............................................................35
5.9 Battery Exchange........................................................................35
5.9.1 Exchange Battery Status .................................................................. 35
5.9.2 Exchanging the Battery..................................................................... 37
6Digital In and Outputs...........................................................38
6.1 General Information on the Digital Outputs.............................39
6.2 Disconnecting Inductive Loads.................................................40
6.3 Additional Protective Circuit .....................................................41
6.4 Wiring Guidelines for the Digital Outputs................................42

ETV 1591-H CONTROL PANEL
Page 4 24.03.2015
6.4.1 Connecting Inductive Loads.............................................................. 42
6.5 Wiring Guidelines for the Digital Inputs ...................................43
6.5.1 2-wire Initiators and Mechanical End Switches................................. 44
6.5.2 3-wire Initiators.................................................................................. 44
7Buffer Battery ........................................................................45
8Exchanging the Battery / Hard Drive ...................................46
9Cooling...................................................................................49
10 Mounting Instructions...........................................................49
11 Wiring Guidelines..................................................................50
11.1 Ground.........................................................................................50
11.2 Shielding......................................................................................50
11.3 ESD Protection............................................................................51
11.4 USB Interface Connections .......................................................51
12 Recommended Shielding for VARAN..................................52
12.1 Wiring from the Control Cabinet to an External VARAN
component...................................................................................53
12.2 Wiring Outside of the Control Cabinet .....................................54
12.3 Shielding for Wiring Within the Control Cabinet .....................55
12.4 Connecting Noise Generating Components............................56
12.5 Shielding Between Two Control Cabinets ...............................57
13 Cleaning the Touch Screen..................................................58

CONTROL PANEL ETV 1591-H
24.03.2015 Page 5
Technical Data
1.1 Performance Data
Processor
1.4 GHz Intel® Celeron B827E
Intel® Smart Cache
1.5 Mbytes
BIOS
AMI
SDRAM 50-DIMM 20-pin
2-Gbyte DDR3
SRAM
512-Kbyte
Internal storage device
100-Gbyte SATA HDD
Interfaces
5x USB 2.0, type A (high speed 480 Mbit/s)
2x Gbit Ethernet (RJ45)
1x VARAN Out (RJ45)
4x optically decoupled inputs
4x optically decoupled outputs
Internal interface connections and
devices
1x TFT LCD color display
1x touch
1x CF card socket
1x interface for connectable UPS
Display
Resolution
15" TFT color display
XGA, 1024 x 768 pixels
Control panel
5-wire touch screen (analog resistive)
Data buffer
yes
Signal generator
yes
Status LEDs
no
Real-time clock
yes (battery buffered)
Cooling
active (fan)

ETV 1591-H CONTROL PANEL
Page 6 24.03.2015
1.2 Electrical Requirements
Supply voltage
typically +24 V DC
minimum +20 V DC
maximum +30 V DC
Supply voltage (UL)
20-30 V DC (Class 2)
Current consumption
Power supply +24 V
1.25 A
(without externally connected devices / 100 % CPU load)
(WIN7 embedded) / 75 % brightness display)
Inrush current
maximum 28 A for 170 µs
The unit must be powered by a galvanically isolated source, which has a UL-certified
secondary fuse with a maximum rated current of
a) 4 A at voltages from 0..20 Vrms (0..28.3 Vp) or
b) 100 VA/Vp at voltages from 20..30 Vrms (28,3..42.4 Vp).
1.3 Terminal
Dimensions with battery
Dimensions without battery
358 x 313 x 109 mm (W x H x D)
358 x 313 x 81 mm (W x H x D)
Material
plastic housing: ASA
Weight
5.3 kg
1.4 Environmental Conditions
Storage temperature
-10 …+85 °C
Operating temperature
0 …50 °C
Humidity
10-90 %, non-condensing
EMC stability
EN 61000-6-2: EMC resistance
EN 61000-6-4: noise emission
Vibration tolerance
EN 60068-2-6
2-9 Hz: amplitude 3.5 mm
9-200 Hz: 1 g (10 m/s²)
Shock resistance
EN 60068-2-27
150 m/s²
Protection type
EN 60529
protected through the housing
front: IP54
rear panel: IP20

CONTROL PANEL ETV 1591-H
24.03.2015 Page 7
1.5 15" XGA Display
Type
15" TFT color display
Resolution
XGA, 1024 x 768 pixels
Color depth
18-bit (262 144 colors)
Pixel grid
0.297 mm x 0.297 mm
Active surface
304.128 mm x 228.096 mm
Backlighting
LED
Contrast
typically 700: 1
Brightness
typically 400 cd/m²
Angle CR > 10 from
left and right 80°, above and below 70°
1.6 Control Unit
Touch panel
analog resistive film-glass touch panel
Resolution
12-bit Controller (USB)
Connection technology
5-wire
1.7 Miscellaneous
Article number
12-230-1591-H
Operating system
Windows Embedded Standard 7
Project back-up
100-Gbyte SATA HDD
Hardware version
2.x
Standard
UL 508 (E247993)

ETV 1591-H CONTROL PANEL
Page 8 24.03.2015
2 Mechanical Dimensions

CONTROL PANEL ETV 1591-H
24.03.2015 Page 9
3 Chemical Resistance
3.1 ASA Plastic Housing
Solution
Visual Effect
Acetic acid (5 %) at 23 °C
None
Chromium acid solution (40 %) AT 23 °C
None
Citron acid solution (10 %) AT 23 °C
None
Hydrochloric acid (36 %) at 23 °C
None
Lactic acid (10 %) at 23 °C
None
Nitric acid (40 %) at 23 °C
None
Sulfuric acid (38 %) at 23 °C
None
Sulfuric acid (5 %)
None
Ammonia hydroxide solution (10 %) at 23 °C
None
Caustic soda (1 %) at 23 °C
None
Caustic soda (35 %) at 23 °C
None
Ethanol at 23 °C
None
Isopropyl Alcohol at 23 °C
None
Methanol at 23 °C
None
Iso-Octane at 23 °C
None
n-Hexane at 23 °C
None
Toluol at 23 °C
yes
Acetone at 23 °C
yes
Diethyl ether at 23 °C
yes
SAE 10W40 motor oil at 23 °C
None
Sodium carbonate solution (20%) at 23 °C
None
Sodium chloride solution (10%) at 23 °C
None
Sodium hypochloride solution (10%) at 23 °C
None
Zinc chloride solution (50 %) at 23 °C
None
Ethyl acetate at 23 °C
yes
Water at 23 °C
None

ETV 1591-H CONTROL PANEL
Page 10 24.03.2015
4 Connector Layout
4.1 Front Connector
X10, X11, X12: USB 2.0 (type A, high speed 480 Mbit/s)
The 3 front USB interface connections are designed for a maximum
total current of 500 mA!
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.
Pin
Function
1
+5 V_USB
2
D-
3
D+
4
GND

CONTROL PANEL ETV 1591-H
24.03.2015 Page 11
4.2 Rear Connectors
X1/X2: battery / supply
X3/X4: digital in / outputs
X1 - power plug
Pin
Function
1
+24 V DC DIG IOs
2
+24 V DC
3
GND
4
GND
X2 - battery
Pin
Function
1
NTC 1
2
Batt +
3
Batt -
4
NTC 2
X4 - Output
Pin
Function
1
output 1
2
output 2
3
output 3
4
output 4
X3 - Input
Pin
Function
1
input 1
2
input 2
3
input 3
4
input 4

ETV 1591-H CONTROL PANEL
Page 12 24.03.2015
X5/X6: Gbit Ethernet
n.c. = do not use
Problems can arise if a control is connected to an IP network, which contains mod-
ules that are not running with a SIGMATEK operating system. With such devices,
Ethernet packets could be sent to the control with such a high frequency (i.e. broad-
casts), 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 triggering the problems mentioned above.
For use in local networks only, not in
telecommunication circuits!
X7: VARAN Out
More information on the VARAN bus can be found in the VARAN bus specifications!
Pin
Function
1
RX +
2
RX -
3
TX +
4
n.c.
5
n.c.
6
TX -
7
n.c.
8
n.c.
Pin
Function
1
TX+ / RX+
2
TX- / RX-
3
RX+ / TX+
4
n.c.
5
n.c.
6
RX- / TX-
7
n.c.
8
n.c.

CONTROL PANEL ETV 1591-H
24.03.2015 Page 13
X8/X9: USB 2.0 (type A, full speed 12 Mbit/s) - bi-level
The 2 rear USB interface connections are designed for a maximum total
current of 500 mA!
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.
4.3 Applicable Connectors
USB: 4-pin, type A (downstream connector)
Ethernet: 8-pin RJ45
VARAN: 8-pin RJ45
Power supply: 4-pin Phoenix connector with spring terminals FMC1.5/4-ST-35
UPS: 4-pin Phoenix connector with spring terminals FMC1.5/4-ST-35
Digital IOs: 2 x 4-pin Phoenix connector with spring terminals FMC1.5/4-ST-35
The complete CKL 215 connector set is available from SIGMATEK under the article
number 12-600-215.
X8
Pin
Function
1
+5 V_USB
2
D0-
3
D0+
4
GND
X9
Pin
Function
1
+5 V_USB
2
D0-
3
D0+
4
GND

ETV 1591-H CONTROL PANEL
Page 14 24.03.2015
5 Uninterruptable Power Supply UPS
The complete ETV 1591-H panel consists of the actual ETV 1591-H function block and the
preceding UPS current supply (battery and electronics),
5.1 Simplified Block Diagram
The battery is charged with the connected +24 V main supply. The UPS is active when a
failure of the external +24 V main supply is detected. The UPS then provides the required
voltage to the ETV 1591 functional block from the rechargeable battery to enable a safe
shut down of the operating system.
Basic function of the UPS:

CONTROL PANEL ETV 1591-H
24.03.2015 Page 15
Circuit overview of the entire unit.
5.2 Technical Data
The technical data specifications for the UPS electronics and battery, such as voltage and
temperature ranges are discussed in the following chapters.
5.2.1 Electrical Requirements for the Battery Pack
Battery type
maintenance-free nickel-metal hybrid (NiMh) battery pack
Voltage
typically +14.2 V DC
minimum +12 V DC
maximum +18 V DC
Capacity
1100 mAh
Charging current
typically 55 mA
minimum 40 mA
maximum 70 mA
Discharging current
typically 2.00 A
minimum 0.00 A
maximal 3,00 A

ETV 1591-H CONTROL PANEL
Page 16 24.03.2015
5.2.2 Buffering after a +24 V Main Supply Failure
Buffer time
maximum 60 seconds1)
Battery deep discharge
protection
typically +12.3 V DC 2)
1) The battery-buffered supply is always deactivated after 60 seconds of continuous buffering.
2) The battery-buffered supply is deactivated at the deep discharge threshold to protect the battery from com-
pletely discharging.
5.2.3 Environmental Conditions
Battery storage tempera-
ture
-20 ... +60 °C
Battery operating tem-
perature
0 ... +50 °C 3)
3) Temperatures above and below this range are not allowed for the battery used, as it can be damaged.
5.2.4 Delivery Condition / Minimum Charge
The charge condition of the installed NiMh battery is not defined in the delivery con-
dition. The UPS must be charged for at least 5 hours before initial use to ensure the
proper function of the NiMh battery.
Procedure for rated operation:
Apply power to the ETV 1591-H (24 V)
Observe minimum charging time
No other activity or command required for the UPS

CONTROL PANEL ETV 1591-H
24.03.2015 Page 17
5.3 UPS Operating Modes
Limit at which the operating mode of the UPS is changed.
5.3.1 Switching to Battery Operation
The UPS monitors the main supply voltage in order to switch to battery operation when the
+24 V main supply fails. When a violation of the value limits is detected, the UPS switches
the source of the buffered supply from the +24 V main supply to the battery and back.
Operating Mode
Threshold
(hysteresis)
Meaning
Main supply OK
>19.4 V (±0.4 V)
The ETV 1591-H function block is powered by the +24 V supply.
The battery can be charged.
Main supply failure
<18.4 V (±0.4 V)
The ETV 1591-H function block is powered by the UPS battery.
Battery connected to a load.
5.3.2 Low Battery Charge Conditions
With the battery voltage measured under load, the low charge condition can be determined.
Contrary thereto, the charging or open circuit voltage cannot be evaluated. The voltage
under load is used for example, to immediately shut down Windows when a critical charge
condition is reached.
Status
Batter Voltage
(loaded)
Meaning
No critical status
>13.2 V
Battery normal.
Battery warning
≤13.2 V
The battery must be charged (recommended: >5 h)
The capacity of the battery is sufficient to safely shut down the
operating system (maximum 60 seconds).
Critical battery warning
≤12.8 V
The battery is has reached a very low charge, it is possible the less
than 60 seconds of buffering cannot be provided. Windows is
immediately shut down after a main power failure by the Windows
service "SigmatekUpsMonitor"
Battery critical
≤12.3 V
Deep discharge protection threshold of the battery. The UPS
deactivates the entire system so that the battery is not burdened
further.
The operating system is no longer shut down.

ETV 1591-H CONTROL PANEL
Page 18 24.03.2015
Critical states can occur:
With a new, uncharged battery
If the battery was not charged long enough
If too many consecutive discharges were performed successively
If the charging circuit is not functioning correctly
If the battery is defective
5.4 UPS Interface
The Windows service "SigmatekUpsMonitor“functions as the UPS interface. Sig-
matekUpsMonitor manages the communication with the UPS via RS232, the UPS configu-
ration, shutting down Windows and sending data to the application.
The SigmatekUpsMonitor Windows service must be used for the complete functional scope
of the UPS.
5.5 Using the Interface for the UPS
The Windows service and UPS are configured via a Named-Pipe server. The application
can configure the UPS and read data for the visualization with the following Pipe functions.
The connection to the Named-Pipe server is established through the name of the Pipe
server and the individual GUID (Globally Unique Identifier).
The name of the Pipe server with the following GUID:
UpsStateServer{A7AF64DE-35C1-4f90-B8B0-8AC24A92F39C}