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Pleiger Elektronik GmbH & Co. KG Fon +49 2324 398 333 D-58456 Witten ● Im Hammertal 51 Fax +49 2324 398 389 www.pleiger-elektronik.de [email protected]
PCM
Pleiger Control Modules
PCM series CM4
Manual Version 2016-09 - subject to modification -
• CM4 EHS Control Module
• CM4-D EHS Control Module
• CCM Conti Control Module
• RK 16/8 Relay-Card
• IO 8/8/4 IO-Module
• TII PT100 Modul
• BI Bus Interface
• PST Parameter-Setup-Tool
PCM
Pleiger Elektronik GmbH & Co. KG www.pleigerelektronik.de Fon +49 2324 398 333
PCM series CM4 Manual Version 2016-09
Contents
1 General information .................................................................................. 1 1.1 Transportation and storage instructions ........................................................................... 1 1.2 Installation and electrical connection ................................................................................ 1 1.3 Intervention into the component ........................................................................................ 1 1.4 Intended use ........................................................................................................................ 1 1.5 Not intended use ................................................................................................................. 1 1.6 Use in safety related vital functions................................................................................... 1 1.7 General safety advice ......................................................................................................... 2 1.8 Certificates and Approvals ................................................................................................ 2
2 Overview .................................................................................................... 3 2.1 Assembly ............................................................................................................................. 3
3 Assembly of the system ........................................................................... 5 3.1 Requirements of the installation site ................................................................................. 5 3.2 System overview and requirements................................................................................... 5 3.3 Controlling via mimic diagram ........................................................................................... 5 3.4 Commissioning hints .......................................................................................................... 6 3.5 Accessories ......................................................................................................................... 6
3.5.1 Adapting Cable ................................................................................................................ 6 3.5.2 Extension Cable ............................................................................................................... 7 3.5.3 Adapting Cable for RK 16/8 ............................................................................................. 7 3.5.4 Safety Advice Plate .......................................................................................................... 7 3.5.5 End Holder ....................................................................................................................... 7 3.5.6 Noise Suppression Filter .................................................................................................. 7 3.5.7 CM-ExE Capacitor Module ............................................................................................... 7 3.5.8 PST-C .............................................................................................................................. 8
4 EHS control module CM4 ......................................................................... 9 4.1 Operation ............................................................................................................................. 9
4.1.1 Wire break or short circuit detection of the Mimic Inputs ................................................ 10 4.2 Control functions .............................................................................................................. 10
4.2.1 Types of actuators ......................................................................................................... 11 4.2.2 Operation modes of the actuators .................................................................................. 12 4.2.3 Teach In ......................................................................................................................... 12
4.3 Start reports and self-test ................................................................................................. 13 4.4 Alarm output ...................................................................................................................... 13 4.5 Lamp test ........................................................................................................................... 13 4.6 Placing commands ............................................................................................................ 13 4.7 Wire break and short circuit detection ............................................................................ 13
4.7.1 Mimic Inputs ................................................................................................................... 14 4.7.2 Position feedback inputs ................................................................................................ 15
4.8 Terminal assignment ........................................................................................................ 16 4.8.1 Connecting Ex-Type actuators ....................................................................................... 17 4.8.2 Connecting spring close actuators with separate hydraulic power pack ......................... 17
4.9 Technical data ................................................................................................................... 17
5 EHS control module CM4-D .................................................................... 19 5.1 Control Functions ............................................................................................................. 19 5.2 Setup of extended operation mode .................................................................................. 19 5.3 Adjusting the operating time ............................................................................................ 20
5.3.1 Calibration of the operating time .................................................................................... 20
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PCM series CM4 Manual Version 2016-09
6 Conti Control Module CCM ..................................................................... 21
6.1 Operation ........................................................................................................................... 21 6.1.1 Status LED..................................................................................................................... 21 6.1.2 Position measurement ................................................................................................... 22 6.1.3 Position indication .......................................................................................................... 22
6.2 Calibration ......................................................................................................................... 22 6.3 Extended Operation Modes .............................................................................................. 23 6.4 Start reports and self-test ................................................................................................. 23 6.5 Alarm output ...................................................................................................................... 23 6.6 Lamp Test .......................................................................................................................... 23 6.7 Placing commands ............................................................................................................ 23 6.8 Analog Position Signal ..................................................................................................... 24 6.9 Behaviour in case of black out ......................................................................................... 24 6.10 Terminals ........................................................................................................................... 25 6.11 Interface to Flowmeter ...................................................................................................... 26 6.12 Technical data ................................................................................................................... 26
7 Relay Module RK 16/8 ............................................................................. 27 7.1 Indication ........................................................................................................................... 27 7.2 Operation ........................................................................................................................... 27 7.3 Jumper B1 ......................................................................................................................... 27 7.4 Counter function ............................................................................................................... 27 7.5 Operation mode: Digital inputs with off-delay ................................................................ 27 7.6 Terminal assignment ........................................................................................................ 28 7.7 Technical Data ................................................................................................................... 28
8 Input/output module IO 8/8/4 .................................................................. 29 8.1 Displays ............................................................................................................................. 29
8.1.1 Start messages and self-test .......................................................................................... 29 8.1.2 Lamp test ....................................................................................................................... 29
8.2 Adjusting the address ....................................................................................................... 29 8.3 Terminal assignment ........................................................................................................ 30 8.4 Technical data ................................................................................................................... 31
9 Input-/Output Module TII ......................................................................... 32 9.1 Display ............................................................................................................................... 32
9.1.1 Self-test and start-up indications .................................................................................... 33 9.1.2 Lamp test ....................................................................................................................... 33
9.2 Address Setting ................................................................................................................. 33 9.3 Terminals ........................................................................................................................... 34 9.4 Technical data ................................................................................................................... 35
10 Fieldbus interface BI, V2.7 ...................................................................... 36 10.1 Operation ........................................................................................................................... 36
10.1.1 Parameterisation of the fieldbus ..................................................................................... 36 10.1.2 Setting the address of CM (CM3, CM4, CM4-D, CCM) modules .................................... 36 10.1.3 Setting the address and operation mode of the RK 16/8 ................................................ 37 10.1.4 Skipping addresses ........................................................................................................ 38 10.1.5 Parameter Matching BI / CM4 ........................................................................................ 38 10.1.6 Display functions ............................................................................................................ 39 10.1.7 Start messages and self-test .......................................................................................... 40 10.1.8 Power management ....................................................................................................... 40 10.1.9 Setup of Quick Close Functions ..................................................................................... 41 10.1.10 Alarm output ................................................................................................................. 41 10.1.11 Lamp test ...................................................................................................................... 41 10.1.12 Bus Termination ............................................................................................................ 42
10.2 Terminal assignment ........................................................................................................ 42
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PCM series CM4 Manual Version 2016-09
10.3 Technical data ................................................................................................................... 43
11 BI Modbus interface (slave) .................................................................... 44 11.1 Modbus data model ........................................................................................................... 44
11.1.1 Fieldbus interface BI status, register 1, (read only) ........................................................ 44 11.1.2 CM3/4 status register (read only) ................................................................................... 45 11.1.3 CCM status register (read only) ..................................................................................... 46 11.1.4 IO status register (read only) .......................................................................................... 46 11.1.5 TII-status and input registers (read only) ........................................................................ 47 11.1.6 RK status register (read only) ........................................................................................ 47 11.1.7 Fieldbus interface BI remote control, register 142 (read/write) ....................................... 48 11.1.8 CM3/4 control register (read/write) ................................................................................. 48 11.1.9 CCM control register (read/write) ................................................................................... 49 11.1.10 IO control register (read/write) ...................................................................................... 49 11.1.11 TII-control register (read/write) ...................................................................................... 49 11.1.12 RK control register (read / write) ................................................................................... 50
11.2 Fieldbus Watchdog ........................................................................................................... 50 11.3 Extended Modbus Interface .............................................................................................. 50
11.3.1 Version Number Registers ............................................................................................. 51 11.3.2 Parameter Register ........................................................................................................ 51
11.4 Register summary ............................................................................................................. 52
12 BI Profibus DP interface (slave) ............................................................. 53 12.1 Profibus data model .......................................................................................................... 53
12.1.1 Fieldbus interface to superimposed control system (status words) ................................. 53 12.1.2 Superimposed control system to fieldbus interface (control words) ................................ 53 12.1.3 Data Valid Bit ................................................................................................................. 53
13 Secondary BI Module, passive mode .................................................... 54
13.1 Parameterisation of the secondary BI module ................................................................ 54 13.2 Fieldbus interface BI status, register 1 (read only) ......................................................... 54 13.3 Fieldbus interface BI remote control, register 142 (read/write) ...................................... 55 13.4 Operating redundant BI .................................................................................................... 55 13.5 Alarm output ...................................................................................................................... 55
14 Parameter Setup Tool (PST) ................................................................... 56 14.1 PST as local Bus Master ................................................................................................... 56 14.2 PST Main Menu .................................................................................................................. 57 14.3 “Address Setup” Menu ..................................................................................................... 57 14.4 „Parameter Setup“ Menu .................................................................................................. 58
14.4.1 Selecting the next or previous CM4 ............................................................................... 58 14.4.2 Selecting a Parameter ................................................................................................... 58 14.4.3 Changing the Parameter ................................................................................................ 58 14.4.4 The Actuator type........................................................................................................... 59 14.4.5 Timing Parameter .......................................................................................................... 59
14.5 Teach-In ............................................................................................................................. 59 14.6 Configuration ..................................................................................................................... 60
14.6.1 Copy and Paste ............................................................................................................. 61
15 PCM modules, available versions .......................................................... 62 15.1 CM3 .................................................................................................................................... 62 15.2 CM4 .................................................................................................................................... 62 15.3 BI ........................................................................................................................................ 62 15.4 IO 8/8/4 ............................................................................................................................... 62 15.5 TII ........................................................................................................................................ 62 15.6 RK 16/8 ............................................................................................................................... 62 15.7 CCM .................................................................................................................................... 62
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PCM series CM4
Manual Version 2016-09
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 responsibility of the user to perform a risk analysis 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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PCM series CM4
Manual Version 2016-09
1.7 General safety advice
The safety advices in this manual serve to avert dangers. They are placed prior to the description of a
potentially hazardous situation / work / practice. They are marked with a signal word and a pictogram.
They describe the kind and origin of the hazard and give instructions to avoid injury or damage to the
device or plant.
Signal words for safety advices
Signal word Severity of hazard
DANGER Signal word for an imminent danger with high risk, resulting in severe injuries or
death if not avoided
WARNING Signal word for a hazardous situation with medium risk, possibly resulting in severe
injuries or death if not avoided.
CAUTION Signal word for a hazardous situation with low risk, resulting in damaged to the de-
vice or the property or minor or medium injuries if not avoided.
NOTICE Signal word for important information to the product.
Pictograms
Warns of a general
hazard
Warns of an electrical
shock
Notice
1.8 Certificates and Approvals
PCM-modules meet the requirements of the following Directives:
• Directive 2014/90/EU on marine equipment
• DNV GL Guidelines VI-7-2
The following approvals apply:
• Type approval 26 092 – 05 HH by DNV GL
Certificates and approvals can be downloaded from our website or ordered from the manufacturer.
Technical Support:
+49 2324 398 333 [email protected]
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PCM series CM4
Manual Version 2016-09
2 Overview The system consists of the components: ART.NO.
• EHS control module CM4 9341100800
• EHS-Steuermodul CM4-D 934 1100 850
• EHS control module *CM3 9341100100, 140, 150, 160, 170, 180, 190
• Conti Control module CCM 9341100500
• Relay module RK 16/8 9341100400
• Input/output module IO 8/8/4 9341100300
• Pt100 Module TII 934 1100
• Fieldbus interface BI 9341100200 or 9341100250
• Parameter-Setup-Tool PST 934 1100 900
• Adapter PST-C 934 1100 950
Notice: If in this document any of the control modules CM3, CM4 or CCM are meant it will be
called CM.
*Notice: The control module CM3 is not recommended for new designs. It is described in a sepa-
rate manual version.
The EHS control module CM4 is for the control and monitoring of electro hydraulic swivel drives. Op-
eration can be carried out manually with the assistance of the control module operation elements, via
digital inputs and outputs of the control module and via a serial data connection to a supervisory con-
trol system. The CM4 control function can be adapted to the different actuator types by means of the
parameter setup tool PST. The CM4 is the successor of the CM3 und will replace the CM3 in future.
The CCM module is used to control centralized hydraulic actuators with analog hydraulic position
feedback. Those actuators use flowmeters with digital outputs that can directly be connected to the
CCM.
The RK16/8 module provides 8 relay outputs (normally open) and 16 digital inputs with opto-couplers.
This module is primarily used to control centralized hydraulic actuators. Up 4 double acting or 8 single
acting actuators can be operated by a single module.
The input/output module IO8/8/4 has 8 analog inputs, 8 digital inputs and 4 digital outputs and is for
monitoring and output of control signals. Link-up to a supervisory control system is carried out via a
serial data connection.
The PT100 module TII provides 6 Pt100 Inputs, 2 isolated current inputs 0/4..20mA and 2 isolated
4…20mA current outputs.
The fieldbus interface BI forms the interface between the bus protocol of the local module bus and the
fieldbus according to the Modbus RTU or Profibus DP standard. Furthermore, the fieldbus interface
acts as a monitor for all modules at the local bus and enables simple parameterisation of these mod-
ules.
2.1 Assembly
The modules BI, CM3, CCM, IO and TII are installed in a narrow, compact top-hat rail housing
(22.5x105x115, WxHxD). They are interconnected via a connector system in the top-hat rail and can
be removed from the system independently or re-applied without interfering with the function of the
overall system. The RK 16/8 module is installed in a flat top-hat rail housing (102x126x30) connected
to the local bus by means of a prefabricated connection cable.
The Parameter set-up tool is installed in a compact handheld case. It provides 5 push buttons and 4
line 20 char LCD display. It is connected to the PCM bus by means of a spiral cable with an RJ11 plug
that can be plugged onto the PST-C adapter module.
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The local bus connects all modules to a 24V supply voltage, a serial data bus and a common digital
control line used for lamp test. Up to 50 CM3 modules, 10 IO and 20 RK modules can be connected to
a fieldbus interface. If the devices are supplied via the top head rail, the power input shall be placed at
the side of the IO- and TII-modules or at the BI. CM- and RK modules may be place at a larger distance
or at the opposite site, respectively.
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3 Assembly of the system The system must only be installed, commissioned and calibrated by trained staff. The requirements of
the plant and the control system must be considered.
Electrical installations must only be carried out by electrically qualified persons.
3.1 Requirements of the installation site
The following environmental conditions must be observed:
• The system must not be installed in hazardous areas.
• The system must be installed inside a closed control cabinet.
• During installation it is necessary to word with opened doors. Make sure that no dust can intrude.
In particular, metal dust and overspray must be restrained.
• The respective limits for environmental conditions as given in the technical data must be obeyed.
3.2 System overview and requirements
Certain boundary conditions must be adhered to during the assembly of the complete control systems
in order to ensure reliable and trouble free operation.
• Only a maximum of 50 CM, 10 IO8/8/4 (7 for Profibus DP) and 20 RK 16/8 modules are to be con-
nected to a fieldbus interface.
• The IO- and TII modules must be aligned left to the fieldbus interface BI. CM- and RK- modules
must be mounted on the right side of the BI.
• All 230VAC supplies must be fused with a 16A circuit breaker with B characteristic.
• The 24VDC supply may be connected several times to separate the supply for different systems
(etc. bilge, ballast). Each 24V supply is separately fused up to 4AT. All 0V supplies must be
connected directly to the same terminal. 0V supply is fused with a common 6AT fuse. For
the connection of the DC supply the BI (9, 10) or the plugs of the prefabricated cable sets must be
used.
• The local data bus and the lamp test control may be extended by means of prefabricated cable
sets. Up to 4 adapting cables and one extension cable may be used per BI module. The screen of
these cables must be connected to a PE terminal right beside the plug connector. The PE terminal
is also used to fix the modules on the rail mount.
• All control signals from and to the CM3 / CCM and IO 8/8/4 modules are supplied via the 24VDC
of the CM3 respectively the IO 8/8/4 modules. The control signals of the TII and RK may also be
connected to a separate supply.
• All cables leaving the control cabinet and being connected to the modules must be screened. The
screen must be connected extensively to the mounting plate. So-called “pigtails“, i.e. cables be-
tween the screen and a PE terminal, are not permissible.
3.3 Controlling via mimic diagram
The CM3 modules can be used without a fieldbus interface for applications in which the actuators are
controlled exclusively by a mimic diagram. The feeding-in of the 24VDC supply voltage is then via the
local bus connector pins 4 and 5. The voltage must have external fuse protection amounting to a max-
imum of 6A. Insofar as necessary, a 24VDC lamp test signal is also connected via the local bus con-
nector. The current consumption of this control input amounts to approx. 1mA per module.
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PCM series CM4
Manual Version 2016-09
3.4 Commissioning hints
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.
CAUTION
Material damage
Incorrectly connected drives or defective cables may cause damage of the CM mod-
ules or the OC feedback modules...
• To avoid this some tests must be performed before 24VDC or 230VAC supply is
turned on.
• Follow the instructions below.
1. 24VDC and 230VAC are completely separated from each other and from protective earth (PE),
e.g. the rail-hat. Therefore a high insulation resistance must be measured between those circuits.
The insulation resistance measurement should be
performed with an insulation resistance meter with 50
to 500VDC test voltage. The following minimum re-
sistance values must be achieved:
Using a standard multi-meter as a substitute may re-
sult in uncertain results. This measuring must be per-
formed during commissioning and should be re-
peated after any repair works on the cabling of the
actuators.
2. Please also check that pin 13 of the CM3 module, this is the position feedback input 4...20mA, is
connected only for those actuators that really use an analog position feedback signal.
3. Turn on 230VAC for a few devices only and check proper operation carefully before connecting
the next devices to 230VAC.
3.5 Accessories
For the proper installation of PCM systems the following accessories are required.
3.5.1 Adapting Cable
This cable is used if the 24VDC supply shall be feed several times. The length of the cable is app.
20cm must not be extended or replaced by a different cable. The modules are fixed on both sides of
the cable by means of an end holder that is fastened on the hat-rail. The right plug (4+5) must be con-
nected to 24VDC power
supply. Connect pin 4 to
the common 0V directly,
connect pin 5 to 24V fused
up to 4A.
Article-No: 9319710190
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1. 0VDC to PE 1 MOhm
2. 0VDC to L, N 1 MOhm
3. 24VDC to PE 1 MOhm
4. 24VDC to L, N 1 MOhm
5. N to PE 1 MOhm
6. L to PE 1 MOhm
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PCM series CM4
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3.5.2 Extension Cable
This cable is used to connect additional modules on a second hat-rail to the same BI module. Only
one cable can be used per BI module. The shield of the extension cable must be connected to the
hat-rail via PE terminals. These termi-
nals are also used to fix the modules
mechanically. The cable is app. 150 cm
long and must not be extended! If such
a cable is used the 24VDC power sup-
ply must be connected to the modules
separately.
Article-No: 9319710180
3.5.3 Adapting Cable for RK 16/8
This cable is required to connect one or
more relay modules to the local bus of BI,
CM3 or IO 8/8/4.
Article-No: 9319710330
3.5.4 Safety Advice Plate
This safety advice must be fixed at the hat-rail close by the installed
CM3 and CCM modules (at each hat-rail with CM3 / CCM).
Article-No: 9319932210
3.5.5 End Holder
The end holders are fixed to the hat-rail on the right side of the modules.
If the adapter cable is used one holder is also fixed on the left side of the
modules.
Article-No: 4639020830
3.5.6 Noise Suppression Filter
If a BI module is used on the bridge one filter must be inserted in the
common 24VDC supply of all modules (according GL-Rule EMC1:
Using on the bridge or on the open deck).
The current must not exceed 16A. The filter is screwed on the mount-
ing plate directly. A sufficient electrical and thermal contact to the
mounting plate must be ensured.
Article-No: 4470200050
3.5.7 CM-ExE Capacitor Module
To connect double acting actuators for explosion proof areas to a CM3
or CM4 module a capacitor module is required.
Article-No: 9311222810
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PCM series CM4
Manual Version 2016-09
3.5.8 PST-C
Connector module for the Parameter Setup Tool PST. On the
front side the PST-C provides a RJ11 socket for the easy con-
nection of a PST.
The PST shall be plugged onto the local bus at one of both
ends. It is recommended to equip each PCM system with a
PST-C that remains in the system permanently.
Artikel-Nr.:9341100950
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4 EHS control module CM4 The EHS control module CM4 is the successor of the CM3 control module. The major dif-
ferences are:
• All control functions and variants that have been implemented in special versions
of the CM3 are now integrated in the CM4.
• The electrical pump drive and the solenoid valve are now switched off from
mains completely.
• The plug X4 is completely touch protected (IP20). The concerning warning plate
is not required any longer.
• The inputs for limit switches and mimic command input can be parameterized in
such a way that wire break and short circuit can be detected.
• The quad DIP switches that have been used for the setup of the drive type as
well as the runtime potentiometer have been omitted. The necessary setup is
now done by means of separate setup tool the PCM-PST.
4.1 Operation
The EHS control module has several operating and display elements that enable manual on-site oper-
ation of the actuator.
switch „local - remote“
In position “local” the drive can be operated by means of the „close-0-
open“ switch. In position „remote” the can be operated using the digital
control inputs or the local serial bus.
button „close - 0 - open“
This button is used to operate the drive while the operating mode is „lo-
cal“. If the operation mode is “remote” pressing this button will indicate
the device and software version on the BI display.
Furthermore, operation of the local-remote switch causes the temporary display of the module ad-
dress on the fieldbus interface. In addition, these control elements are also used for the address set-
ting of the CM4.
Three LED (red, yellow, green) signalise the operating status of the actuator and the con-
trol module.
LED red LED green meaning
on off Drive in closed position
on blinking 1/s Drive in closed position, open command received
off blinking 1/s Drive is opening, closed position left
off on Drive in open position
blinking 1/s on Drive in open position, close command received
blinking 1/s off Drive is closing, open position left
blinking 2/s on / off Not closed within supervision time
on / off blinking 2/s Not opened within supervision time
blinking 2/s blinking 2/s No valid position on module start up
blinking 4/s blinking 4/s Illegal feed back
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PCM series CM4
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For drive type no. 10, 12, and 15 only:
blinking 1/2s off Command close, opened manually, open position not reached
blinking 1/2s on Command close, opened manually completely
The yellow LED serves to display the operating status of the control module.
LED yellow meaning
On No 230VAC power supply or fuse blown
off Power supply OK, no (valid) data on local bus
blinking Power supply OK, valid data on local bus but module is not addressed
flickering, dim Power supply OK, data exchange OK
4.1.1 Wire break or short circuit detection of the Mimic Inputs
If a short circuit or a wire break is detected the BI will indicate an invalid command error. Additionally
the red and green LED of the CM4 will show as special blinking indication. The red LED indicates
faults concerning the close input whereas the green LED indicates faults concerning the open input.
The blinking is overlaid the standard indication. Therefore the mimic input faults and the status indica-
tion is shown simultaneously.
Standard indication Indication if Break / Short t=
0,0s_______0,5s______1,0s_______1,5s_____
off flashing once a second __________-____________________-_________
permanently on fast Flickering _-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-
_-
off / on blinking normal off / fast flickering if on __________-_-_-_-_-_-_________-_-_-_-_-_-
off / on blinking fast off / fast flickering if on _____-_-_-_____-_-_-_____-_-_-_____-_-_-_
In the same way the green LED is used to indicate alarms concerning the mimic open command input.
4.2 Control functions
The control function that is required for the various types of actuators can be selected with the assis-
tance of the parameter setup tool PST. For this the transparent module cover flap must be opened.
To accept the new type the module has to be reset.
CAUTION
Damage to the device / malfunction of the actuators
It is absolutely necessary to adapt the control function to the type of actuator as other-
wise correct function of the actuator is not guaranteed and the actuator or the control
module can be damaged as the case may be.
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Type Actuator Type Operation Mode Required
Parameter
0 EHS double acting open / close Tr
1 EHS double acting step open / close Tr, Ta, Tb
2 EHS double acting open / step close Tr, Ta, Tb
3 MOV open / close Tr
4 EHS single acting, spring close open / close Tr
5 EHS single acting, spring open open / close Tr
6 EHS double acting % Tr
7 EHS double acting %Pos Tr, Ta, Tb
8 EHS single acting, spring close %Pos Tr, Ta, Tb
9 EHS single acting, spring open %Pos Tr, Ta, Tb
10 EHS single acting, spring close with hand wheel open / close Tr
11 EHS double acting with separate hydraulic unit open / close Tr
12 EHS spring close, electro-hydraulic override open / close Tr
13 EHS double acting, Ex-Type open / close Tr
14 EHS double acting, Ex-Type %Pos Tr, Ta, Tb
15 EHS single acting, spring close, hydraulic override open / close Tr
16 EHS spring close, separate hydraulic unit (Q) open / close Tr
17 EHS single acting, spring close open / step close Tr, Ta, Tb
18* EHS spring close, ExD3, hydr. override open / close Tr, Ta, Tb
19* service mode for type 18 %
20# EHS double acting, Ex-Type D3 %Pos Tr, Ta, Tb
99
* Function is only available in special version 9341100810 of CM4, see separate data sheet
# Function available in version 4.2 or higher
4.2.1 Types of actuators
Double-acting
This actuator actively opens and closes with activated drive motor. In the event of a power failure it
stops in the current position.
Single-acting, spring close
This actuator actively opens with activated drive motor. The closing procedure is carried out by spring
force. The actuator closes in the event of a power failure.
Single-acting, spring open
This actuator actively closes with activated drive motor. The opening procedure is carried out by
spring force. The actuator opens in the event of a power failure.
MOV, motor valve
This actuator behaves likes a double-acting actuator and contrary to this automatically turns the drive
motor off upon reaching the end position. The control module always leaves the current supply
switched on during normal operation. In case of any alarm the power is turned off.
Spring close, mechanical override with hand wheel
This actuator corresponds to a normal spring-close actuator, but can be opened manually with the as-
sistance of a hand wheel. This operating status is permitted and the control module will not report this
as an error. In order to re-close the manually opened actuator this must initially be completely opened
electrically. This function is carried out automatically by the control module.
Spring close, electro-hydraulic override with hand pump and lockable hand valve that can be
released electrically
The actuator operates like a standard spring close type but can manually be opened by means of a
manually operated valve and a hand pump. This operation mode is signalised at the CM4 module but
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is not indicated as a fault. The actuator may be closed again by the CM4 by powering the magnetic
valve of the EHS. This will open the manual operated valve again.
Spring close, hydraulic override with hand pump and separate hand valve
The actuator operates like a standard spring close type but can manually be opened by means of a
hand pump. Using the hand pump will open actuator and automatically prevent the oil from flowing
back to the tank. This operation mode is signalised at the CM4 module but is not indicated as a fault.
The actuator may be closed again manually by pressing a button or by the CM4 by starting the pump
for a few seconds.
Double acting, Ex-Type
The Ex-type actuator can only be operated in combination with the capacitor module (9311222810,
see also 4.8.1). The function equals a standard double acting actuator. This kind of actuator is availa-
ble with open/close and analog position indicator.
Separate Hydraulic Power Unit (Q)
Different actuators use a separate hydraulic power unit. Hydraulic unit and actuator are connected by
pipes. This allows operating such actuators in harsh environments like extreme temperatures or sub-
merged inside of tanks. This control function is optimized to operate such actuators. The spring close
actuator with separate hydraulic unit requires an external relay (see: 4.8).
4.2.2 Operation modes of the actuators
Operation mode: open / close
After the drive command has been given, e.g. by pushing the command key in the direction of ”close“,
the actuator will operate until the final position is reached or the maximum permissible operating time
is exceeded. The alarm output is activated if the operating time is exceeded and alarm status signal-
ised via the light-emitting diodes on the module.
Operation mode: open / step closing
To a large extent this operation mode corresponds to the open/close operation mode. Upon closing,
however, the actuator is repeatedly stopped briefly in order to extend the closing time. The pulse and
stop duration can be set up by the PST.
Operation mode: step opening / step closing
To a large extent this operation mode corresponds to the open/close operation mode. Upon closing
and opening, however, the actuator is repeatedly stopped briefly in order to extend the closing or
opening time. The closing and opening time can be parameterized by the PST
Operation mode: %
In this operation mode the actuator is only operated for as long as the command key is depressed or
the command is pending. The actuator can thus be stopped in any position. Only exception: Insofar as
either of the actuator limit switches is operated, the actuator is moved to the appropriate end position
when the key is released. This ensures that the actuator has actually moved completely to the end po-
sition if this is signalised by the end position switch. For example, this function is used for throttle
valves.
Operation mode: %Pos
This operation mode is only used in connection with the issue of a command via a superimposed con-
trol system. In this case the superimposed control system prescribes the desired position of the valve
as a percentage and the control module automatically moves the valve into the target position. Devia-
tions from the target position not exceeding 2% are ignored by the module. This operation mode is al-
ways replaced by operation mode % during mimic diagram operation or local command input.
4.2.3 Teach In
To determine the parameters Tr, Ta and Tb a teach-in may be used. Please look at chapter 14.5.
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4.3 Start reports and self-test
Directly after the program has started up, the module displays the last “reset“ cause by illuminating
one or two LED briefly. The module subsequently carries out a short self-test. In the event that the
self-test is not carried out successfully, the yellow LED will start to flash.
Once the self-test has been carried out successfully, the normal status display will start up.
red yellow green Meaning
Start after complete power fail
Start after low voltage
Start after hardware or software reset
Start after runtime violation (watchdog)
Subsequently the module starts a short self-test. If this self-test fails the yellow LED starts blinking
while the red and green LED are turned off. Apart from that the CM4 has no function.
4.4 Alarm output
Once the self-test has been carried out successfully, the alarm output is closed initially. As soon as an
error occurs the output is opened. The output is not closed until the error is reset, e.g. by entering a
new drive command. Errors that will raise an alarm are:
• power supply failure 24VDC or 230VAC
• invalid or inadmissible position indications
• invalid signal levels at the feedback inputs (wire break or short circuit)
• invalid signal levels at the mimic command inputs (wire break or short circuit)
• timeout while closing or opening
When the special function „alarm out = local ctrl“ is activated the alarm relay is used to indicate the
position of the local-remote switch only and is not used for alarm purpose any longer.
4.5 Lamp test
Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied, the 3 LED
on the module are illuminated and in addition to this both report outputs “LED open” and “LED closed”
to the mimic diagram are activated.
4.6 Placing commands
Commands can be placed in three different ways:
• Using the open/close button while the operation mode is “local”
• Using the control inputs “CMD-close / CMD-open” while the operation mode is “remote”
• Using a command sent via the BI module while the operation mode is “remote”
NOTICE
Control inputs
As long as the command inputs are set they will overrule the commands sent via the BI
module.
4.7 Wire break and short circuit detection
The mimic inputs as well as the inputs for the feedback signals can be parameterized in such a way
that a wire break or a short circuit can be detected. The CM4 measures the signal voltage, calculates
the relation between supply voltage and signal voltage and finally compares the result with predefined
limits. The required signal voltages are adjusted by parallel and series resistor as usual.
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4.7.1 Mimic Inputs
Short |<|----
ON |<|----------------------------|>|
OFF |<|-------------------------|>|
Break --|>|
|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
U 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Break On Short
on threshold at Ub = 24V 1,9V 12,0V 22,3V
off threshold at Ub = 24V 2,2V 11,4V 22,0V
on threshold in % of Ub 7,9% 50,2% 92,8%
off threshold in % of Ub 9,4% 47,5% 91,6%
Resistor min. 10k - 1k
Resistor max. 35k - 5k
Recommended resistor 22k - 2k2
The tolerance of the threshold voltages is +- 500mV. The function of the break or short detection de-
pends on the inverted or non-inverted function of the mimic inputs.
Standard Command Input
The reaction of the CM4 on the four different input levels depends on the previous command state
and the duration of the input level.
Input Level curr. State Delay new Command Alarm
1 on off 0,2s on no
2 off on 0,2s off no
3 break on / off 2s same break
4 on / off break / short 10s on / off no
5 short on / off 2s same short
6 break / short short / break 10s same break / short
Input Level input voltage level according to the a.m. table
State current input state
Command command that results from current state and input signal
Alarm the break or short alarms are indicated by error number 4 and the alarm contact of the
CM4 additionally the bits 3 and 4 of the status byte are both set
additionally the local LED indicate the error by very fast blinking
e.g.
1. if the input level changes from Off to On, the new command is created with 0,2s delay.
5. if the input level changes from On or Off to Short the Short alarm will be raised with 2s delay,
whereas the command will stay unchanged
Inverted Command Input
If the inverted operation mode is set the meaning of the command input levels On and Off is inverted.
A low level will set the command whereas a high level will not. In case of a break level the alarm is
raised and also the command is set. This is the typical behavior of closed current circuits.
Input Level curr. State Delay new Command Alarm
1 off off 0,2s on no
2 on on 0,2s off no
3 break on / off 2s on break
4 off / on break / short 10s on / off no
5 short on / off 2s same short
6 break / short short / break 10s on / same break / short
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4.7.2 Position feedback inputs
Break |<|----
OFF |<|----------------------------|>|
ON |<|-------------------------|>|
Short---|>|
|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
U 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Break On Short
on threshold at Ub = 24V 22,0V 11,4V 1,9V
off threshold at Ub = 24V 21,7V 11.7V 2,2V
on threshold in % of Ub 91,7% 47,6% 7,8%
off threshold in % of Ub 90,4% 48,8% 9,2%
Resistor min. 10kΩ - 1kΩ
Resistor max. 35kΩ - 5kΩ
Recommended resistor 22kΩ - 2,2kΩ
The tolerance of the threshold voltages is +- 500mV.
A break or short is indicated to the BI as fault no. 3 (1 of N faults). Additionally the alarm contact
opens.
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4.8 Terminal assignment
CAUTION
Damage to the device / malfunction of the actuators
It is imperative to ensure that the supply voltage is not under any circumstances
applied to the local data bus. This may cause the destruction of all connected
modules.
Lower terminals, to the control system:
X1 (grey) pluggable
1 LED-open o Drive open, to mimic diagram
2 LED-closed o Drive closed, to mimic diagram
3 CMD-open i Command open, from mimic diagram
4 CMD-close i Command close, from mimic diagram
X2 (red) pluggable
5 N i Drive supply voltage 230VAC max. 3,15A
6 L i Drive supply voltage 230VAC max. 3,15A
7 Alarm a o Contact opens in case of error
8 Alarm b o Contact opens in case of error
Upper terminals, to the EHS:
X3 (grey) pluggable
9 FB-closed i Feedback closed, 0V = closed, internal pull up
10 FB-open i Feedback open, 0V = open, internal pull up
11 0V o DC power supply for position sensors
12 24V o DC power supply for position sensors
X4 (black) pluggable
13 FB- analog i Position signal (4..20mA) (optional)
14 N o Common power
15 L-close o Power output: pump close / solenoid valve / pump run
16 L-open o Power output: pump open / pump open / pump direction
Bus connector
1 Data A io Local data bus, rs485
2 Data B io Local data bus, rs485
3 lamp test i Lamp test input, 24V = lamps on
4 0VDC i Local power supply
5 +24VDC i Local power supply
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4.8.1 Connecting Ex-Type actuators
To operate Ex-type actuator (13 or 14) a capacitor module CM-ExE (9311222810) is required.
4.8.2 Connecting spring close actuators with separate hydraulic power pack
Such actuators require the control of the magnetic valve and also the hydraulic pump in both direc-
tions. Therefore a separate relay (contact: AC3, 230VAC, 6A, coil: 230VAC) is required.
Operation Pump open Pump close Solenoid Valve CM4 open CM4 close
a b c 16 15
1 open 1 - 1 1 1
2 keep open - - 1 - 1
3 closing, 80% of the runtime - - - - -
4 wait for closed feedback - 1 - 1 -
4.9 Technical data
Supply voltage DC 24V +30% -25%
Current requirement DC max. 40mA, plus external load*
Fuse DC self-resetting fuse, 500mA - 1100mA
Supply voltage AC 230V 20%
Fuse AC 2 x 3,15AT miniature fuse
Analog input position 4..20mA = 0..100%, deviation 1%, resistance249Ohm
Mimic output semiconductor high side switches, max. load 150mA, short
circuit proof
Size WxHxD 22,5mm x 105mm x 115mm
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Terminal type max. 2,5mm²
Operating temperature 0°C – 55°C
protection IP20
*The miniature fuses for AC power supply are accessible at the lower side of the cas-
ing. To exchange the fuses the casing has to be removed from the hat-rail. The fuse
holder can be opened by means of a screw driver.
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5 EHS control module CM4-D The EHS control module CM4-D is largely identical to the CM4. The major differences are:
• The CM4-D can’t be setup with the PST
• A setup via Modbus is also not possible
• Up to 16 actuator types can be selected by 4 switches
• Two additional operation modes can be selected by 2 further switches.
• The runtime is adjusted by means of a potentiometer
• The adjusting of the runtime poti is supported by a support function
• The timing parameters Ta und Tb are omitted and are replaced by default values
derived from the runtime setting.
• Wire break and short circuit detection of the mimic inputs and the feedback inputs
are omitted
5.1 Control Functions
The control function that is required for the various types of actuators can be selected with the assis-
tance of a quadruple switch in the front of the control module housing. For this the transparent mod-
ule cover flap must be opened. To accept the new type the module has to be reset.
CAUTION
Damage to the device / malfunction of the actuators
It is absolutely necessary to adapt the control function to the type of actuator as other-
wise correct function of the actuator is not guaranteed and the actuator or the control
module can be damaged as the case may be. Please select the correct control function
before turning on the CM4-D.
The actuator types 0…15 correspond to the CM4.
Typ Type of actuator Operation mode Runtime Switch
1 2 3 4
0 EHS double acting open / close 4s..260s 0 0 0 0
1 EHS double acting step open / close 4s..260s 1 0 0 0
2 EHS double acting open / step close 4s..260s 0 1 0 0
3 MOV open / close 4s..260s 1 1 0 0
4 EHS single acting, spring close open / close 4s..260s 0 0 1 0
5 EHS single acting, spring open open / close 4s..260s 1 0 1 0
6 EHS double acting % 4s..260s 0 1 1 0
7 EHS double acting %Pos 4s..260s 1 1 1 0
8 EHS single acting, spring close %Pos 4s..260s 0 0 0 1
9 EHS single acting, spring open %Pos 4s..260s 1 0 0 1
10 EHS single acting, spring close with handwheel open / close 4s..260s 0 1 0 1
11 EHS double acting with separated hydraulic unit open / close 4s..260s 1 1 0 1
12 EHS spring close, electro-hydraulic override open / close 4s..260s 0 0 1 1
13 EHS double acting, Ex-Type open / close 4s..260s 1 0 1 1
14 EHS double acting, Ex-Type %Pos 4s..260s 0 1 1 1
15 EHS single acting, spring close, hydraulic override open / close 4s..260s 1 1 1 1
Switch position 0= OFF, 1= ON
5.2 Setup of extended operation mode
The switches 5 and 6 of the above mentioned switch are used to select two additional operation
modes.
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Switch Extended operation mode
5 „no blink“, the mimic outputs, pin 1 and only indicate the state of the limit switches but do
not indicate the operation of the actuator or any error state.
6 “local override”, command input via mimic inputs and BI is possible even if local opera-
tion is switched on
These extended operation modes may also be set simultaneously.
5.3 Adjusting the operating time
The operating time of the actuator can be adjusted by means of a potentiometer on the front side of
the module. The transparent module cover flap must be opened for this. In general a fairly rough ad-
justment (-5% .. +25%) is sufficient whereby, if anything, the time should be assessed somewhat too
generously.
The operating time should only be determined exactly for actuators with a successive opening or clos-
ing function and in particular for actuators with the %Pos operation mode. A help function is integrated
into the control software for this purpose, allowing this to be very simple and reliable.
In case of a %Pos operation mode the runtime setting determines when the actuator is stopped while
it is approaching the nominal position. If the actuator stops too early and does not reach the nominal
position please increase the runtime a bit. On the other hand if the actuator overshoots the nominal
position please decrease the runtime.
5.3.1 Calibration of the operating time
• Set the operating time to maximum (r.h. limit stop).
• Move the actuator from the closed position to the open position by selecting the “local”
operation mode and pushing the command key in the direction of “open”.
• Once the actuator has opened completely, push the command key again in the direction of “open“
and hold depressed. Now slowly reduce the operating time until the red LED also starts blinking. If
both LED are blinking, the time has been adjusted correctly.
runtime
60
120180
2040 4
260
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6 Conti Control Module CCM The CCM is used to control centralized hydraulic actuators with analog position indication.
To measure the actuator’s position a flow meter with two 90° phase shifted binary signals is
used. The flow meter is inserted in the hydraulic pipe that is used to open the actuator.
The CCM fully controls the actuator including the solenoid valves. Operation can be done
by means of local switches, external devices like mimic push buttons or via a PCM-BI mod-
ule. The module provides the required power relays and the fuses to safely control the sole-
noid valves. The CCM uses the same address range as the PCM-CM modules. The casing
equals the one of the CM3. From a BI’s point of view the CCM behaves like a CM for EHS
with analog feedback.
The calibration of the CCM is done by teach-in. The module determines the volume of the
actuator as well as different compression volumes and the runtime of the actuator.
6.1 Operation
The CCM provides sev-
eral control and monitor-
ing devices for local oper-
ation of the actuator.
switch „local – remote“
In position “local” the actuator can be operated by means of the „close-
0-open“ button. In position remote the actuator can only be operated via
local bus or digital control inputs.
button „close – 0 – open“
In operation mode „local“ this button is used to control the actuator. In
operation mode “remote” the button is used to indicate the version of the
device respectively the software.
set button
Pressing this button in local operation mode will start the calibration
function. A transparent plastic cover protects the button against unin-
tended use.
The address setting of the CCM is done in the same way that is described for the CM3 (see also:
10.1.2).
6.1.1 Status LED
Three LED (red, yellow, green) signalise the operating mode of the actuator and the control
module.
LED red LED green Meaning
on off actuator in closed position
on blinking 1/s actuator in closed position, open command received
off blinking 1/s actuator is opening, left closed position
off on actuator in open position
blinking 1/s on actuator in open position, close command received
blinking 1/s off actuator is closing, left open position
blinking 2/s on / off while closing: final position not reached within supervision time
on / off blinking 2/s while opening: final position not reached within supervision time
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The yellow LED indicates the operating mode of the control module.
LED yellow Meaning
on missing coil supply voltage
off supply voltage OK, no valid data on local bus
blinking supply voltage OK, valid data on local bus but CCM not properly addressed
flickering supply voltage OK, local bus interface OK
6.1.2 Position measurement
A flow meter inserted in the hydraulic pipe that opens the actuator is used to determine the actual po-
sition of the drive. Several compression volumes are considered to determine the position as exactly
as possible.
As an incremental measuring is used referencing is required from time to time. Each time the final po-
sitions are reached, the actuator stops and the position is less than 3% or more than 97% the actual
position is set to 0% respectively 100%.
6.1.3 Position indication
Two 7 segments LED displays are used to indicate the current position of the actuator. The final posi-
tions are indicated as for “close” respectively for “open”. All intermediate positions are indi-
cated in percent ...
The decimal point of the lower digit flashes whenever the position value is referenced. A synchronous
blinking of both decimal points indicates that the position value has not yet been referenced after the
CCM was turned on. In this case the shown position value could be invalid if the position changed
while the CCM was turned off!
6.2 Calibration
After installation the CCM must be calibrated. During calibration the CCM calculates all parameters
concerning the actuator and the piping and stores these parameters in an internal non-volatile
memory.
NOTICE
Final position during calibration
During calibration, check that the actuator reaches both final positions.
The calibration run is started by pressing the SET button while the operation mode is set to “local“.
The calibration passes the following steps:
C Action End
1 actuator closes, valve b is on counter stopped
2 actuator stop, both valves off counter stopped and set to 0
3 actuator opens, valve b is on counter stopped and value > 500 incr.
4 actuator stop, both valves off counter stopped (counter value equals 100%
5 actuator closes, valve b is on counter stopped and counter value < 3%
6 actuator stop, both valves off counter stopped (counter = 0 )
7 actuator opens, valve a is on counter > 30%
8 actuator stop, both valves off counter stopped
9 actuator closes, valve b is on counter < 10%
A actuator stop, both valves off counter stopped
B actuator closes, valve b is on counter stopped
C actuator stop, both valves off counter stopped (counter = 0 )
The current step is indicated on the 7 segment display ....
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The calibration run can be terminated if the operation mode is set to remote. The calibration may be
started every time when opening the actuator is allowed. During calibration the operator has to make
sure that the actuator reaches the final positions completely.
6.3 Extended Operation Modes
Besides the default operation mode the CCM provides several extended modes. If the “set” button is
pressed for 3s while CCM is in “remote” mode the extended operation mode is shown. The upper digit
always shows . and the lower one a number. By means of the “open/close” switch the desired num-
ber can be selected. Each Bit in this number enables a certain mode. The default value is .
extended operation mode “local override“,
the inputs for the mimic push buttons are always enabled. This mode is required if the mimic
inputs are used for some safety functions that must be independent from the local / remote
switch.
extended operation mode “flow meter in pipe used to close the actuator”.
This mode is required if the flow meter is inserted in the pipe that is used to close the actuator.
Attention: During calibration run the actuator first starts opening and remains in open position
at the end of the test.
extended operation mode “very slow actuators”
this mode is required if very slow actuators are used. In this case the timeout periods are ex-
tended:
- close timeout and open timeout from 4 to 10 minutes
- calibration timeout from 10 to 20 minutes
extended operation mode “counter inhibit on lamp test”
In this operation mode the lamp test input has an additional function. When lamp test is set the
counter is blocked and no command can be entered, neither manually nor via serial interface.
The extended operation modes may also be combined. If for example you want to enable the “local
override” mode for “very slow actuators” you may add both numbers 1 and 4 and select mode .
6.4 Start reports and self-test
During start-up the CCM indicates cause of the last “reset“ on the 7 segments display and performs a
short self-test. If the self-test fails the yellow LED starts blinking.
6.5 Alarm output
After self-test is finished successfully the alarm contacts are closed. In case of a fault the contacts
open and are closed again if all faults have been removed. The alarm contacts are opened if:
• supply voltages 24VDC or 230VAC fail
• the runtime limit of the actuator is exceeded
• internal device fault
6.6 Lamp Test
Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied, the 3 LED
and all segments of the 7-segment display of the module are illuminated. The mimic outputs are
turned on. See also 6.3.
6.7 Placing commands
Commands can be placed in three different ways:
• Using the open/close button while the operation mode is “local”
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• Using the control inputs “CMD-close / CMD-open” while the operation mode is “remote”
• Sending a command via the PCM-BI module while the operation mode is “remote”
NOTICE
Control inputs
As long as the command inputs are set they will overrule the commands sent via the BI
module.
6.8 Analog Position Signal
The CCM provides an analog 4..20mA output. The current signal indicates the position of the actuator.
• 4mA = closed
• 20mA = open
The current output is not isolated to local 24V supply voltage. The max. resistance in the current load
must not exceed 180 Ohms. The deviation between analog output and 7 segment display may be up
to 2%. This output is intended to be connected to a position indication meter. It is not intended for con-
necting a supervisory control system.
6.9 Behaviour in case of black out
If the 24VDC supply of the module fails the current counter value is stored in an internal non-volatile
memory. If the supply voltage is turned on again the old counter value is restored. It is not possible to
capture counter pulses while the voltage is turned off.
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6.10 Terminals
CAUTION
Supply of solenoid valves
Connecting the AC-supply: Always plug in red connector last
Disconnecting the AC-supply: always pull red connector off first!
Lower terminals, control:
X1 (grey) pluggable
1 LED-open o drive is open, to mimic diagram
2 LED-closed o drive is closed, to mimic diagram
3 CMD-open i command open, from mimic diagram
4 CMD-close i command close, from mimic diagram
X2 (red) pluggable
5 24VDC / 230VAC L2 i solenoid valve supply voltage
6 0VDC / 230VAC L1 i solenoid valve supply voltage
7 Alarm a o contact opens in case of error
8 Alarm b o contact opens in case of error
Upper terminals, to the EHS:
X3 (grey) pluggable
9 Count A i counter input A, A prior to B means counting up
10 Count B i counter input B, B prior to A means counting down
11 0V o DC power supply for flow meter
12 24V o DC power supply for flow meter
X4 (black) pluggable
13 FB- analog o position signal (4..20mA), 4mA means closed
14 N o common terminal for solenoid valves
15 L-close o power output close
16 L-open o power output open
Bus connector
CAUTION
Damage to the device / malfunction of the actuators
It is imperative to ensure that the supply voltage is not under any circumstances
applied to the local data bus. This may cause the destruction of all connected
modules.
1 Data A io local data bus, rs485
2 Data B io local data bus, rs485
3 lamp test i lamp test input, 24V = lamps on
4 0VDC i local power supply
5 +24VDC i local power supply
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6.11 Interface to Flowmeter
Any flow meter connected to the CCM must comply with the following technical data:
Supply voltage 24V
Current consumption max. 100mA incl. counter, plus external load
Output signals 2 x rectangular signals 24VDC , 90° 20° phase shifted,
Pulse:Pause 1:1 10%
min. edge distance 80us, up to 3kHz pulse frequency
6.12 Technical data
supply voltage DC 24VDC
current requirement DC max. 65mA, incl. counter and analog output, plus external loads at
the mimic outputs
fuse DC self-resetting fuse, 500mA - 1100mA
supply voltage solenoid
valves
230VAC or 24VDC
fuse AC 2 x 1,25AT miniature fuse
analog position output 4..20mA = 0..100%, deviation 2%, max. burden resistance 180Ω
mimic open / close output solid state high side switches, max. load 150mA, short circuit proof
size WxHxD 22,5mm x 105mm x 115mm
weight approx. 160 g
terminal type max. 2,5mm²
operating temperature 0°C – 55°C
protection IP20
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7 Relay Module RK 16/8 The relay module provides 16 opto-decoupled digital inputs and 8 re-
lay outputs. The inputs are arranged in two groups with common 0V.
A jumper allows connecting both groups to the same 0V. The relay
outputs are designed as normally open contacts with one common
terminal. The common terminal is fused on-board. Standard fuse is
2AT, max. 10AT is allowed. The fuse is monitored. A voltage drop of
more than 100VAC will be indicated and signalled. The relay contacts
may switch up to 3A / 230V. A short cable with two plugs serves to
connect the RK 16/8 with each other.
7.1 Indication
The module is equipped with 24 LED for indication of the input and
output state. An additional yellow LED is used for status display.
- 16 green LED indicate the state of the digital inputs
- 8 yellow LED indicate the state of the digital outputs
The status LED indicates the data traffic on the local bus, a fuse fail and also assists the
user during setup of the module.
LED yellow meaning
on fuse fail, voltage drop on fuse > 100VAC
off no fuse fail, no data on the local bus
blinking no fuse fail, valid data on local bus but module is not addressed
flickering no fuse fail, communication on local bus is running
7.2 Operation
A push button is used to show and to setup the module address and operation mode. This function is
only available in conjunction with a BI module with software version 2.1 or higher. To set up the ad-
dress the BI must run in setup mode (see also: 10.1.3).
If BI is running in normal operation mode the push button is used to indicate the RK address. If the
button is pressed for more than 3s the software version of the RK is indicated instead of the address.
7.3 Jumper B1
If the jumper B1 is plugged on (default) the common 0V of both input groups are connected. In this
case only pin 9 of terminal X1 or X2 must be connected to 0V. If both input groups are connected to
independent supply voltages the jumper must be removed.
7.4 Counter function
To collect rapidly changing input values the RK provides a counter function for the input 1. Both rais-
ing and falling edges of the input signal are counted and stored in an 8 bit counter value. If the counter
reaches 255 it will be reset on the next edge of the input signal.
Each pulse must last at least 15ms. The counter value must be read frequently to detect a counter
overrun reliably. With pulse duration of 15ms the counter must be read at least every 15ms*255 =
3825ms.
7.5 Operation mode: Digital inputs with off-delay
If required the operation mode of the RK inputs can be changed in such a way that even a short high
level at an input is indicated as high signal for 0,9s. Hereby it can be ensured that even very short
events are captured. The set-up is described in chapter
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7.6 Terminal assignment
terminal X1:
1 digital input 1 i 24V DC
2 digital input 2 i 24V DC
… … i
8 digital input 8 i 24V DC
9 common 0V for 1-8 i common 0V
terminal X2:
1 digital input 9 i 24V DC
2 digital input 10 i 24V DC
... ... i
8 digital input 16 i 24V DC
9 common 0V for 9-16 i common 0V
terminal X3:
1 relay output 1 o normally open
2 relay output 2 o normally open
… … o
8 relay output 8 o normally open
9 common terminal o
terminal X5 and X6:
1 rs485 A i/o local data bus
2 rs485 B i/o local data bus
3 0VDC i/o power supply
4 24VDC i/o power supply
The RK 16/8 does not provide a lamp test input!
7.7 Technical Data
supply voltage DC 24V -25% +30%
current requirement DC max. 100mA
fuse DC Self-resetting fuse, 500mA - 1100mA
size WxHxD 22,5mm x 105mm x 115mm
terminal type max. 2,5mm²
Input voltage 24VDC
Threshold 6-12V, typ. 9V
Counter pulse length >= 15ms
Output voltage max. 230VAC
Output current max. 2A per output
Fuse default 2AT, max. 10AT
operating temperature 0°C – 55°C
protection IP20
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8 Input/output module IO 8/8/4 The IO module is an assembly group for registering analog and digital signals and for the
output of digital signals. All signal transmitters must be isolated, as this module does not
provide internal potential separation. Generally speaking, this is the case for temperature
and pressure sensors or limit switches, floating switches and dry relay contacts. Insofar as
this is not applicable, isolation amplifiers or isolating relays must be used.
This also applies correspondingly to the digital outputs that are designed as short-circuit
proof semi-conductor relays, dispensing 24V supply voltage.
8.1 Displays
The module has a total of 20 LED at its disposal to display the input or output status.
• 8 green LED indicate the status of the individual measured values.
green LED input signal meaning
on >=3.8mA and <=20.2mA valid measurement
blinking fast >20.2mA above range or short circuit
blinking slowly >0.2mA and <3.8mA below range
off <=0.2mA not used or wire broken
• 8 yellow LED indicate the status of the digital inputs.
• 4 red LED indicate the status of the digital outputs.
Furthermore, the LED are used to display any error status. In this connection the 4 lower and 4 upper
green LED flash alternately whilst the yellow LED indicate the error number from 1..8.
LED Error status Comment
1. address changed the address of the module was changed
2-7. reserved
8. module offline There is no data connection to the BI module
Alteration to the module address initially brings about the output of the “address changed“ error mes-
sage. This error message also brings about the display of the module address on the fieldbus inter-
face. The new module address is not accepted until the module has been re-started.
8.1.1 Start messages and self-test
Directly after the start of the programme the module displays the last reset cause by illuminating one
of the yellow LED briefly. The module subsequently carries out a short self-test. In the event that the
self-test is not carried out successfully, the two lowest green LED will start to flash.
Normal status display commences once the self-test has been carried out successfully (see above).
8.1.2 Lamp test
Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied the 8 green
and 8 yellow LED are illuminated. The red LEDs are not activated during the lamp test.
8.2 Adjusting the address
module address
switch
S1 S2 S3 S4
51 0 0 0 0
52 1 0 0 0
53 0 1 0 0
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The module address is adjusted with the
assistance of a quadruple switch. The
switch is to be found behind a transparent
cover flap.
The address range of the IO modules starts at 51 and fin-
ishes at 60.
The range beginning with setting 0101 is also mapped to
the addresses 51 to 56. In this case the state of the digital
input is hold for at least 0,9s. By this means even very
short events like pressing a push button can be detected
securely (Version B.6 and higher).
0= OFF, 1= ON
* state of digital inputs is hold for at least 0,9s
8.3 Terminal assignment
CAUTION
Damage to the device / malfunction of the actuators
It is imperative to ensure that the supply voltage is not under any circumstances
applied to the local data bus. This may cause the destruction of all connected
modules.
Lower terminals (factory):
X1 (grey) pluggable
1 digital input 5 i 24V DC to 0V of supply voltage
2 digital input 6 i 24V DC to 0V of supply voltage
3 digital input 7 i 24V DC to 0V of supply voltage
4 digital input 8 i 24V DC to 0V of supply voltage
X2 (black) pluggable
5 digital output 1 o 24V DC to 0V of supply voltage
6 digital output 2 o 24V DC to 0V of supply voltage
7 digital output 3 o 24V DC to 0V of supply voltage
8 digital output 4 o 24V DC to 0V of supply voltage
Upper terminals (dockyard):
X3 (grey) pluggable
9 analog input 4 i 0 .. 20mA, to 0V DC
10 analog input 3 i 0 .. 20mA, to 0V DC
11 analog input 2 i 0 .. 20mA, to 0V DC
12 analog input 1 i 0 .. 20mA, to 0V DC
X4 (black) pluggable
13 analog input 8 i 0 .. 20mA, to 0V DC
14 analog input 7 i 0 .. 20mA, to 0V DC
15 analog input 6 i 0 .. 20mA, to 0V DC
16 analog input 5 i 0 .. 20mA, to 0V DC
54 1 1 0 0
55 0 0 1 0
56 1 0 1 0
57 0 1 1 0
58 1 1 1 0
59 0 0 0 1
60 1 0 0 1
51* 0 1 0 1
52* 1 1 0 1
53* 0 0 1 1
54* 1 0 1 1
55* 0 1 1 1
56* 1 1 1 1
addre
ss
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X6 (grey) pluggable
17 digital input 4 i 24V DC to 0V of supply voltage
18 digital input 3 i 24V DC to 0V of supply voltage
19 digital input 2 i 24V DC to 0V of supply voltage
20 digital input 1 i 24V DC to 0V of supply voltage
Bus connector
1 Data A io Local data bus, rs485
2 Data B io Local data bus, rs485
3 Lamp test i Lamp test input, 24V = lamps on
4 0VDC i Local power supply
5 +24VDC i Local power supply
8.4 Technical data
supply voltage DC 24V
current requirement DC max. 70mA, plus external load*
fuse DC Self-resetting fuse, 500mA - 1100mA
size WxHxD 22,5mm x 105mm x 115mm
terminal type max. 2,5mm²
operating temperature 0°C – 55°C
protection IP20
*Current via digital outputs
Analog inputs
range 0 (4) .. 20mA
resolution 12 Bit, 0 = 0mA, 4000 = 20mA, 4096 = 20,48mA
precision 0,4% of full range, typ. 0,2%
filter Median / low pass app. 200ms
shunt resistance 100 Ohm
overload protection self-resetting fuse 30 - 50mA per input (max. 30V)
Digital inputs
threshold app. 9,5V
input current app. 5mA
low pass filter app. 10ms
Digital outputs
output voltage 24VDC
output current, on max. 200mA per output, max. 400mA totally
output current, off <1mA
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9 Input-/Output Module TII The TII module is an electronic device for current and temperature measurement and ad-
ditionally provides two current outputs.
All analog inputs and outputs are isolated from 24V power supply but not isolated among
each other. The reference potential of all analog IO is the same. If separate potentials are
required separate TII modules must be used.
9.1 Display
The TII provides 11 LED to indicate the input or output state and the operation state.
• 6 green LED indicate the state of the 6 PT100 inputs.
green LED Input signal meaning
on permanently -10°C… +195°C valid measurement
blinking fast < -15°C range underflow or short circuit
off > 200 °C not connected or range overflow
• 2 yellow LED indicate the state of the analog inputs.
yellow LED Input signal meaning
on permanently >=3,8mA and <=20,2mA valid measurement
blinking fast >20,2mA range overflow, still valid
blinking slowly >0,2mA and <3,8mA range underflow, still valid
off <=0,2mA not connected, wire break or short circuit
blinking very fast < -0,1mA or
> 20,48mA
invalid measurement
• 2 red LED indicate the state of the analog current output.
red LED output signal meaning
on permanently 0,08mA … 20,48mA valid current output
blinking fast > 20,48mA burden resistance to high or
wire broken
off output value is 0
• 1 yellow LED indicates the module status.
Status-LED error meaning
starts blinking
during operation
address changed the address of the module has been changed
while TII is running
blinking directly
after start of TII
self-test error the self-test during start-up failed.
on permanently none normal operation
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9.1.1 Self-test and start-up indications
Step I: Right after turning on the TII the cause of the reset is indicated:
LED green Meaning
LED 1 flashes once Power-on Reset
LED 2 flashes once External Reset
LED 3 flashes once Brown-out Reset
LED 1 +
LED 3
may also flash simul-
taneously
Power-on Reset and Brown-out Reset may occur simultane-
ously. In this case both green LEDs 1 and 3 flash.
LED 4 flashes once Watchdog Reset
LED 5 flashes once JTAG Reset
Step II: Subsequently the module performs a short self-test (Flash and RAM). If the self-test fails the
yellow LED starts blinking.
Step III: After successful self-test the TTI software checks the calibration parameters for the analog
values. If one of the parameters is invalid the corresponding LED flashes once.
Between those test steps all LED are turned on simultaneously for a very short time. After all test have
finished successfully the normal status indication as described before starts.
9.1.2 Lamp test
The terminal 3 of the local bus is used as lamp test input. If this input is set to 24V all 11 LED of the
module turn on.
9.2 Address Setting
The module address is adjusted with the
assistance of a quadruple switch. The
switch is to be found behind a transparent
cover flap.
The address range of the TII modules starts at 51 and fin-
ishes at 60.
0 = OFF, 1 = ON
* The address settings 0101 to 1111 are reserved for fu-
ture use.
module address
switch
S1 S2 S3 S4
51 0 0 0 0
52 1 0 0 0
53 0 1 0 0
54 1 1 0 0
55 0 0 1 0
56 1 0 1 0
57 0 1 1 0
58 1 1 1 0
59 0 0 0 1
60 1 0 0 1
51* 0 1 0 1
52* 1 1 0 1
53* 0 0 1 1
54* 1 0 1 1
55* 0 1 1 1
56* 1 1 1 1
addre
ss
addre
ss
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9.3 Terminals
CAUTION
Damage to the device / malfunction of the actuators
It is imperative to ensure that the supply voltage is not under any circumstances
applied to the local data bus. This may cause the destruction of all connected
modules.
lower terminals:
X1 (grey) pluggable
1 GND - GND
2 PT100-1- T PT100, compensation
3 PT100-1+ T PT100, resistor
4 analog output 1 I 4...20mA
2 (black) pluggable
5 GND - GND
6 PT100-2- T PT100, compensation
7 PT100-2+ T PT100, resistor
8 analog output 2 I 4...20mA
X3 (grey) pluggable
9 GND - GND
10 PT100-3- T PT100, compensation
11 PT100-3+ T PT100, resistor
12 N.C. NC reserved for future use
upper terminals:
X4 (grey) pluggable
16 GND - GND
15 PT100-4- T PT100, compensation
14 PT100-4+ T PT100, resistor
13 analog input 1 I 4...20mA
X5 (black) pluggable
20 GND - GND
19 PT100-5- T PT100, compensation
18 PT100-5+ T PT100, resistor
17 analog input 2 I 4...20mA
X6 (grey) pluggable
24 GND - GND
23 PT100-6- T PT100, compensation
22 PT100-6+ T PT100, resistor
21 N.C. NC reserved for future use
Bus connector
1 Data A io Local data bus, rs485
2 Data B io Local data bus, rs485
3 Lamp test i Lamp test input, 24V = lamps on
4 0VDC i Local power supply
5 +24VDC i Local power supply
Bürde
I
Bürde
I
↑↑ T
↑↑ T
I
Quelle
↑↑ T
I
Quelle
↑↑ T
↑↑ T
↑↑ T
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9.4 Technical data
supply voltage DC 24V
current requirement DC max. 120mA
fuse DC self-resetting fuse, 500mA - 1100mA
size WxHxD 22,5mm x 105mm x 115mm
terminal type max. 2,5mm²
operating temperature 0°C – 55°C
protection IP20
Temperature inputs
range -10°C…190°C
resolution 0,1°C
precision ±1°C, typ. 0,5°C
filter low pass, average, 300ms
Sensor element PT100 (100 Ohm at 0°C)
Method of measurement 2-/3-conductor
Current inputs
range 0 (4)…20mA
resolution 11 Bit, 0 = 0mA, 4000 = 20mA, 4096 = 20,48mA
precision 0,4% of full range, typ. 0,2%
filter low pass, average, 300ms
shunt resistor 100 Ohm
overload protection self-healing fuse 30 - 50mA for each input (max. 30V)
Current outputs
range 4...20mA
resolution 8 Bit (12Bit internally) 0 = 0mA, 250 = 20mA
precision ±0,1mA, typ. ±0,05mA
burden resistance max. 400 Ohm
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10 Fieldbus interface BI, V2.7 For comfortable and reliable operation of the BI in combination with CM4 modules and the
PST setup tooI the BI V2.7 provides some additional functions:
• BI turns to passive mode if a PST wants to access the local bus
• BI provides a non-volatile memory to store the parameter sets all 50 CM4
• BI performs an automatic parameter matching between CM4 and BI
• BI provides an extended Modbus interface to transfer parameters and software
version numbers
The fieldbus interface serves to connect the control and IO modules to a superimposed
control system via a fieldbus. Furthermore, the module provides two control inputs and a
collective alarm output.
Two 7-segment displays and two push-buttons serve to parameterise the module and dis-
play system status.
Two fieldbus protocol variations are available:
• Modbus RTU, slave
• Profibus DP V0, slave
The choice of the fieldbus protocol is carried out via the parameterisation functions on the module.
The fieldbus lines are connected via terminal screws. Bus termination in accordance with the Profibus
standard can be activated via a miniature switch if required.
Note: The Profibus Interface is not available on BI modules with Art.No. 9341100250. Those BI only
provide Modbus RTU. If Profibus is selected anyhow an error message is indicated
10.1 Operation
Parameterisation of the module is carried out with the assistance of the “set“ and “prgm“ push-buttons.
The push-buttons are only accessible if the transparent lid on the module is opened. Display of the
chosen parameters is by means of two 7-segment displays.
10.1.1 Parameterisation of the fieldbus
Parameterisation of the fieldbus settings is only possible if the “prgm“ push-button is depressed for at
least 3s when switching on the module. After this all parameters must be entered in succession. The
“set“ key is always used to set the value and the “prgm“ key to accept the value. All parameters are
saved in a non-volatile memory.
Parameter sequence
Step Meaning Range of values Display (example)
1 Address, least significant digit x 0h … x Fh, x = any … … 2 Address, most significant digit 0 xh … F xh, x = any
3 Selection baud rate / protocol 4k8 / 9k6/ 19k2 / 38k4 / 56k / 57k6 /
76k8 / Profibus DP
Modbus only
4 Selection of parity none / odd / even . . . . . .
If the Profibus is chosen during step 3, step 4 is not applicable.
Automatic baud rate setting is generally used for the Profibus protocol. When the last parameter is en-
tered the module changes to normal operation.
10.1.2 Setting the address of CM (CM3, CM4, CM4-D, CCM) modules
The address of the CM control modules is adjusted with the assistance of the CM control elements.
Those modules do not provide separate address switches. Operation mode changeover on the CM
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module brings about the indication of the current module address on the fieldbus interface for the du-
ration of approx. 2 seconds.
As the address setting needs to be protected against unintentional alteration, it is necessary to
put the system in addressing mode. Addressing mode is set by pressing the “prgm” and “set”
keys on the BI simultaneously. This operation mode is shown as on the BI display. To leave
this mode just press both push buttons once more.
The CM3 module to be programmed is now switched to “remote“ operation mode. The lowest
available address on the local bus is now displayed by operating the command key in any di-
rection. An available address is an address to which no CM module will currently respond. The
two programming functions “delete“ and “accept“ are now available.
New modules are programmed in turn from left to right. Once programming has been completed the
fieldbus interface must be set to normal operation mode. For this both buttons are again pressed sim-
ultaneously.
NOTICE
Module address
The module address determines which register / data word is used by this actuator in
the data model of the fieldbus connection. If the address is not allocated as arranged,
the wrong valve will be activated. If possible, addressing should be carried out in such
a way that the address complies with the slot, i.e. that the 7th module, for example, is
given address no. 7.
10.1.2.1 Deleting the module address
If the command key is pushed in the direction of “open“ and the operation mode is then switched to
local while the command key is depressed, the module address is erased. The module is then no
longer visible for the fieldbus interface.
10.1.2.2 Accepting the lowest available address
If the command key is pushed in the direction of “close“ and the operation mode is then switched to
local while the command key is depressed, the module address is set to the lowest available address.
This new address can be displayed again by changing the operation mode.
10.1.3 Setting the address and operation mode of the RK 16/8
The address of the RK16/8 control modules is adjusted by means of the push button near the status
LED of the RK. If the button is pressed the module’s address is displayed at the BI. If the button is
pressed for more than 3s the module’s software version is displayed instead of the address.
As the address setting needs to be protected against unintentional alteration, it is necessary to
put the system in addressing mode. Addressing mode is set by pressing the “prgm” and “set”
keys on the BI simultaneously. This operation mode is shown as on the BI display. To leave
this mode just press both push buttons once more.
Now the push button of the appropriate RK must be pressed for some seconds. The status LED
first lights brightly and the turns off. The BI module now shows the lowest unused address for
an RK module in the range 61..80. As soon as the LED turns on again the button may be re-
leased. The RK is now programmed.
New modules are programmed in turn from left to right. Once programming has been completed the
fieldbus interface must be set to normal operation mode. For this both buttons are again pressed sim-
ultaneously.
NOTICE Module address
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The module address determines which register / data word is used by this actuator in
the data model of the fieldbus connection.
10.1.3.1 Deleting the module address
To erase the module address the button must be pressed again. As soon as the LED turns off the but-
ton must be released. The module address is erased now and the module becomes invisible for the
BI.
10.1.3.2 Stetting the operation mode:
If the button is kept pressed after the LED turns on again for at least 2,5s the LED starts blinking. This
indicates the activation of the extended operation mode. In this case the state of each digital input is
hold for at least 0,9s. By this means even very short events can be detected securely. The version
changes from .x to .x if this operation mode is turned on (Version D.4 and higher).
10.1.4 Skipping addresses
If necessary an address gap may be inserted at an arbitrary position. If the BI module is in “setup
mode” and the CM3 is set to “remote” operation, the lowest unused address is show when the close
button of the CM3 is pressed. Now the address may be increased by pressing the BI´s “Set” button or
decreased again by pressing the “Prgm” button. Only unused addresses are selected by the BI. This
setup, that means the number of address gaps, is also used for further addressing of the CM3 mod-
ules until the BI´s “setup mode” is left. (Remark: This function is only available for BI firmware version
V1.6 or higher).
Also addresses of the RK16/8 modules can be skipped. As soon as the lowest used address is shown
on the BI the “set” and “prgm” button can be used to modify the RK address.
10.1.5 Parameter Matching BI / CM4
If a BI and the connected CM4 start running after power-up the BI reads the parameter sets of all CM4
and compares them with their local copy. Make sure that the CM4 addresses are set properly. If there
are any deviations the following cases may occur.
State BI-Module State CM4-Module Reaction Action required
default parameter set valid parameter set BI copies parameter from CM4,
CM4 uses internal parameter
No
valid parameter set default parameter set BI sends parameter to CM4,
CM4 uses new parameter
No
valid parameter set
but differs from CM4
valid parameter set
but differs from BI
BI indicates PF and address of
CM4 alternating, CM4 uses in-
ternal parameter set
Yes
In the latest case a parameter conflict occurs. This may happen if both modules BI and CM4 have
been used in a different application before. This conflict is indicated by the BI display. There the char-
acters “PF” and a two digit number in the range 01…50 the CM4 address are shown rotationally. If
several of such conflicts are detected only the lowest address is shown.
Attention: If a parameter conflict happens the user has to decide which parameter set is valid and
which one has to be erased that means replaced by the default set.
Usually this conflict will happen if one module has been replaced, either a BI or a CM4, by a module
that has been used in other applications before. In this case the parameter set of the replaced module
has to be erased by the user. This is done in the following way:
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BI The parameters are reset if the fieldbus setup menu is entered. The setting can be kept un-
changed. Keep the Prgm button pressed while the BI starts. Adjust the setting of the field bus
interface if necessary and finish the setup menu.
CM4 Turn the BI to setup mode by pressing both buttons of the BI simultaneously until the blinking
SU is indicated. Now set the address of the replaced CM4 in the usual way. All parameters of
the CM4 are reset now and subsequently restored by the copy stored in the BI when the sys-
tem is restarted the next time.
Hint: If the parameter of a CM4 cannot be restored in one of the above mentioned way the param-
eter setup tool PCM-PST must be used to restore them manually. The valid settings are men-
tioned in the electrical diagrams
10.1.6 Display functions
Various system data can be displayed for diagnosis purposes in connection with the “Set” and “Prgm”
keys of the fieldbus interface or the operation mode switches of the CM.
Display of a Parameter Conflict
From version 2.5 on a parameter conflict between BI and CM4 is indicated after start-up.
The two letters PF and the CM4 address are shown alternating. If several errors are de-
tected the latest one is indicated.
Indicate writing to EEPROM of the BI
From version 2.6 and higher the BI indicates the writing process to the EEProm memory that
means when the parameter memory is erased or written. As the number of read and write cy-
cles to this memory is limited a permanent display of E.E. indicates a malfunction.
Display of new command
If the BI receives a command for a certain CM via Modbus interface, the address of the CM is
indicated. Both decimal points are turned on if the command is passed to the CM. The indica-
tion is turned off if the CM starts executing the command.
Display of the Address of a CM4 module
Upon changing the operation mode (local – remote) of a CM its address is displayed for 2 sec-
onds via the 7 digit display of the BI ( = address 12). This function helps to check the correct
address setting.
Display of the CM software version
If the operation mode of the CM is remote and the open command button is pressed the ver-
sion number of the CM is shown on the BI display (. = Version 2.5). If the extended opera-
tion mode of a CM is set the extended operation mode is shown on the display if the close
command button is pressed.
Display of the lowest available address
The lowest available local address is displayed by pressing the set key of the fieldbus interface
(. = address 17). The address of the module in position 17 should be programmed as the
next CM4 module.
Display of modules that have failed
If a module does not respond to queries from the fieldbus interface for a certain period of time,
it moves to “offline“ status. The address of this module is then displayed for 3 seconds (.. =
address 13). The display of the address of the module that has moved to offline status can be
repeated at any time by pressing the “prgm” key. Displaying .. indicates that none of the
modules have gone offline.
Only the change to offline status is registered. If a module never answers after power up, it will
not be displayed.
Display of control inputs 1 and 2
If control input 1 or 2 is set, or output will appear on the display.
.
.
.
.
.
.
.
.
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Position indication of actuators with analog position feedback
If an actuator with analog position feedback is operated in „local“ mode the current position is dis-
played at the 7-segments display of the BI module. This indication is turned off a few seconds after
the actuator comes to a standstill. (Remark: This function is only available for BI firmware version V1.6
or higher).
Normal operation
If no status display is required, the display will change to (program execution).
Display LEDs
LED Modbus RTU Profibus DP
TxD red Transmit Data Error
RxD green Receive Data Data exchange
24V yellow supply voltage DC
10.1.7 Start messages and self-test
Directly after the programme has started up, the module displays the last “reset“ cause in the form of
two digits. The module subsequently carries out a short self-test. In the event that the self-test is not
carried out successfully, the red LED will start to flash. If Profibus DP is selected as fieldbus the red
LED indicates an error state while the error code is shown in the display. The error code F4 is dis-
played, when the BI module without Profibus interface is used but the parameter are set to Profibus
DP accidentally.
Once the self-test has been carried out successfully the version number of the software (x.y) is dis-
played briefly. The normal status display begins subsequently (see above).
10.1.8 Power management
The BI module provides a power management function to limit the 230VAC supply current. To avoid
that the high starting current of the drives blows the fuses the actuators are started successively al-
ways one drive every 100ms. Additionally the number of running drives that are connected to the
same fuse is limited (default 8). The current that is required to keep the magnetic valve of a single act-
ing drive closed is neglected. A motor valve is treated like an EHS even though the current is much
less.
If more than 8 actuators of a group connected to the same fuse get a command, the execution of this
command is delayed in such a way that not more than 8 actuators are running simultaneously. Up to 4
of such groups can be configured for each BI. The first group begins with the drive using the address
1 and ends with address A1, the second groups begins with A1+1 and ends with A2 and so on.
The default set up uses 2 groups:
• group 1: drive 1..25
• group 2: drive 26..50
• number of drives: 8
NOTICE
Fuse
In any case all modules of a group must be connected to the same fuse. The default
setting should only be changed in exceptional cases.
10.1.8.1 Configuring the power management
To configure the power management the „Set“ button must be pressed for at least 3s while the BI
starts up. The display will now show . By pressing the “Set” button the group number can be in-
creased. Pressing the “Prgm” button will select this group and the last address of this group is shown
in the display. The “Set” button may now be used to increment the last address. The highest value is
50, the lowest value is the last address of the preceding group plus one. Pressing the “Prgm” button
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once more will store the address and return to the group number display. If the last group (no 3) is
programmed or any group is programmed to address 50 the setup is finished.
From BI V2.2 the number of drives running at the same time can also be adjusted. Instead of leaving
the setup mode the number of drives is displayed in the lower digit while the upper digit shows a “.”.
The number can be changed using the “Set” button. Pressing the “Prgm” button will store the selected
number and leave the setup mode.
NOTICE
Addressing
The BI firmware secures that the last address of a succeeding group is always higher
than the last address of the preceding one. If this condition is not fulfilled the firmware
will adjust the addresses automatically.
10.1.9 Setup of Quick Close Functions
The control input E2 of the BI module is used to activate dif-ferent quick close functions. As soon as the input is set a close or open command is sent to all CM modules that are appropriately parameterised. This parameterisation is done in the setup mode of the BI module. At first the appropriate CM is selected by changing its operation mode. Afterwards the “Prgm” push-button is pressed. The present mode is now dis-played.
By pressing the „Set“ push-button the required mode is se-
lected and confirmed by pressing the “Prgm” push-button once more. The mode that is valid at pre-
sent is displayed with the decimal points turned on otherwise the decimal points are turned off.
This function must be repeated for all required CM. Press both push-buttons simultaneously to leave
the setup mode.
10.1.10 Alarm output
To begin with the alarm output is closed after the self-test has been carried out successfully. Cyclical
testing is carried out subsequently as to whether the modules connected to the local bus are working
accurately. If a module is not available (offline) or if a CM4 / CCM module reports a fault (e.g. timeout)
or is set to local operation mode, the alarm output will be opened. It will be closed again if the fault dis-
appears (e.g. CM4 is set to remote operation again).
10.1.10.1 Repeated alarming of new faults
If the alarm contact is open and an additional alarm occurs the alarm contact is closed for 3 seconds
and then opened again. In this way further alarms can be signalized. Alarms that occur within these 3s
period are also indicated by the next opening of the alarm relay contact.
10.1.11 Lamp test
Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied, the 3 LED
and all segments of the 7-segment display of the module are illuminated.
NOTICE
Compatibility
This function is implemented for compatibility purpose only and should not be used any
longer. Use mimic inputs instead.
.. none, no quick close function
.. close, if the operation mode is
„remote“
.. open, if the operation mode is
„remote“
.. emergency close in any case
.. emergency open in any case
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10.1.12 Bus Termination
If the BI module is placed at a physical end of the bus the bus cable has to be termi-
nated. This can be done by means of a miniature switch at the front of the module. If
both sliders are set to ON position the termination is turned on, if they are set to the op-
posite position the termination is turned off. All other settings are not allowed.
The bus termination is an active one and meets the Profibus standard.
10.2 Terminal assignment
CAUTION
Damage to the device / malfunction of the actuators
It is imperative to ensure that the supply voltage is not under any circumstances
applied to the local data bus. This may cause the destruction of all connected
modules.
Lower terminals
X2 (black) pluggable
1 PE Protective earth of the hat-rail
2 0V 0V of field bus interface
3 Field bus A io rs485 data
4 Field bus B io rs485 data
Upper terminals
X3 (grey) pluggable
5 E2 0V i Control input 2
6 E2 24V i Control input 2, opto
7 E1 0V i Control input 1
8 E1 24V i Control input 1, opto
X4 (black) pluggable
9 0V i DC power supply, max. 6A
10 24VDC i DC power supply, max. 6A
11 Alarm o Alarm output, opens in case of error
12 Alarm o Alarm output, opens in case of error
Bus connector
1 Data A io Local data bus, rs485
2 Data B io Local data bus, rs485
3 Lamp test i Lamp test input, 24V = lamps on
4 0VDC i Local power supply
5 +24VDC i Local power supply
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10.3 Technical data
supply voltage DC 24V
current requirement DC max. 50mA, plus external load*
control inputs 24V DC
alarm output Relay, 24V, 0,5A
size WxHxD 22,5mm x 105mm x 115mm
terminal type max. 2,5mm²
operating temperature 0°C – 55°C
Protection IP20
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11 BI Modbus interface (slave) The Modbus interface of the fieldbus interface serves to exchange data with a superimposed control
and visualisation system, hereinafter referred to as Modbus master. A register in both report direction
and control direction is used for every valve. Transmission is carried out via an RS485 connection.
The baud rate (4800-56000 baud), the parity (none, even, odd) and the Modbus address (1h..6Fh) can
be parameterised. The number off data bit is fixed to 8. One stop bit is used.
The fieldbus interface has a Modbus RTU interface (slave) and serves the following functions:
• 03 Read holding registers
• 06 Preset single register
• 16 Set multiple registers
This chapter describes the applied data model, i.e. the use and meaning of the individual registers of
the Modbus. This information is required for the preparation of the data model of the superimposed
control system and for the commissioning of the Modbus interface as the case may be. More detailed
information about the Modbus protocol may be obtained from .
11.1 Modbus data model
The data model described here complies with the program version 1.5 or higher.
The first register is always used to monitor the fieldbus interface itself. The following registers are
used for the CM3 and the IO modules.
In detail, the binary digits of the registers have the following meaning:
11.1.1 Fieldbus interface BI status, register 1, (read only)
Bit Meaning
Bit 0 CM3/4 fault, collective message
Bit 1 IO fault, collective message
Bit 2 reserved
Bit 3 control input E1 set
Bit 4 control input E2 set
Bit 5 control input „lamp test“ set
Bit 6 running in passive mode (see also: 13 !used only if secondary BI is connected)
Bit 7 RK16/8 fault, collective message
Bit 8..14 not used
Bit 15 live bit, changes state every 2s (*implemented in BI version V1.6 or higher)
CM3 fault collective message
This binary digit is set if at least one EHS-CM3/4 reports a fault.
IO fault collective message
This binary digit is set if at least one IO module reports a fault.
Fault on the local data bus
This binary digit is set if at least one module on the local bus replies to broadcast address 0 or if fur-
ther faults arise that cannot be allocated to a specific bus participant.
Control input E1 / E2 set
This binary digit is set if control input E1 / E2 has been set (24V).
Control input lamp test set
This binary digit is set if lamp test input has been set.
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11.1.2 CM3/4 status register (read only)
The CM3/4 status register includes the valve position and the valve error messages. The register
number depends on the module address (1-50).
Register number = module address + 1
(50 registers, from no 2 to no 51)
The lower-order byte of the register contains the position information:
Value Meaning
0..100 actual position of valves with analog position feedback
(128..228) most significant bit is set while drive is running (add128)
101 drive closed and in a standstill
102 drive neither open nor closed
103 drive open and in a standstill
105 drive in open position, close command received
106 drive in closed position, open command received
107 drive neither open nor closed while closing
108 drive neither open nor closed while opening
109 drive indicating closed position but is still running
110 drive indicating open position but is still running
111 unknown position
The higher-order byte of the register indicates the error messages:
Bit Meaning Remark
Bit 0 Error (Bit 0-2 binary)
Bit 1
0 = no error
Bit 2 1 = timeout while opening The error flags 1..3 stay set until the cause of the
error is removed or a new command is sent.
Runtime errors generally require resending a com-
mand
2 = timeout while closing
3 = invalid feedback
4 = invalid command
5 = error mimic input open Used with CM4 only
6 = error mimic input close
7 = not used
Bit 3 command close received via mimic input The bit is set as soon as the corresponding input
is set and reset when the input is released. In any
case the bit is set for at least 5s. If the close input
is activated the open input is assumed as deac-
tivated regardless of the physical input voltage. In
case of an activated wire break detection for the
mimic close and mimic open inputs the wire break
case is indicated by setting both bits 3 and 4 con-
currently.
Bit 4 command open received via mimic input
Bit 5 local / remote switch in local position
Bit 6 no AC supply (230VAC)
Bit 7 offline, no response on local bus
11.1.2.1 Combining error messages
The above mentioned error indications are very detailed. It is not necessary or even recommended to
display all error indications on a SCADA system. A useful combination of different error messages in
several groups is recommended.
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Example:
Group 1: runtime error = (error no equals 1) OR (error no equals 2)
Group 2: device error = (error no equals 3) OR (error no equals 4) OR (Bit6 is set)
Group 3: offline error = (Bit7 is set)
Group 2 and 3 may also be combined. Further fault analysis can be done by means of the LED of the
CM3 module.
Furthermore it is recommended that the SCADA control elements of an actuator are hidden or greyed
if the Bit5 is set.
11.1.3 CCM status register (read only)
The CCM status register includes the valve position and the valve error messages. The register num-
ber depends on the module address (1-50).
Register number = module address + 1
(50 registers, from no 2 to no 51)
The lower-order byte of the register indicates the position information:
Value Meaning
0..100 actual position of actuator in % / valve, 0 = closed, 100 = open
(128..228) while valve is moving the higher bit is set (+128)
While actuator is moving and also during calibration the most significant Bit in the position byte is set.
The higher-order byte of the register indicates the error messages:
Bit Meaning Remark
Bit 0 error messages (Bit 0-2 binary)
Bit 1
0 = no error
Bit 2 1 = timeout while opening The error flags 1..4 stay set until the cause of the
error is removed respectively a new command is
sent. Runtime errors generally require resending a
command. Flag 3 is set on power up and is de-
leted when the counter is referenced the first time.
2 = timeout while closing
3 = reference run required
4 = invalid position counter value
5 = self-test error
6 = not used
7 = not used
Bit 3 command close received via mimic input The bits 3 and 4 are set as long as the corre-
sponding inputs are set. In any case the bit is set
for at least 5s. Bit 4 command open received via mimic input
Bit 5 local / remote switch in local position
Bit 6 no supply for solenoid valves (both 24VDC or 230VAC)
Bit 7 offline, no response on local bus
11.1.4 IO status register (read only)
The IO status registers contain the status of the analog and digital inputs of an IO module. An IO mod-
ule occupies a total of 9 registers. The register number depends on the module address.
The module addresses are in the range of 51 – 60.
Register number of the first register = 9*(module addresses -51) + 52
(90 registers, from no 52 to no 141)
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The first register contains the status of the 8 digital inputs in the lower-order byte and error messages
in the higher-order byte.
Bit Meaning
Bit 0..7 digital input 1..8 set
Bit 8 address was changed after last start up
Bit 9 error analog input 1..8
Bit 10 used internally
Bit 15 offline, no response on local bus
The following 8 registers contain one each of the 8 measured values as 12 binary digit value (0..20mA
= 0..4000 Incr.). A valid value must be even.
NOTICE
Valid values
An odd analog value indicates that the last measurement has not been updated be-
cause of an invalid measurement.
11.1.5 TII-status and input registers (read only)
A TII module always uses 9 registers. The first one is the status register. The TII-status register de-
scribes the state of the analog temperature inputs and current outputs of the TII module. The register
number depends on the modules address.
The TII address range is: 51 – 60.
Register number of the first register = 9*(module addresses -51) + 52
(90 registers, from no 52 to no 141)
Bit Meaning
Bit 0…1 analog output 1…2 not connected, wire break or burden resistance to high
Bit 2…7 PT100-[1…6] not connected, wire break or temperature not in measurement range
Bit 8 address was change since last start-up
Bit 9 error of any analog input
Bit 10…11 reserved
Bit 15 offline, no response on local bus
The following 8 registers contain one each of the 8 measured values (PT100: in 1/10 °C; 0..20mA =
0..4000 Incr.). A valid value must be even.
NOTICE
Valid values
An odd analog value indicates that the last measurement has not been updated be-
cause of an invalid measurement
11.1.6 RK status register (read only)
The RK status registers contain the status of the digital inputs and error flags of an RK module. An RK
module occupies a total of 2 registers. The register number depends on the module address.
The module addresses are in the range of 61 – 80.
Register number = 2*(module address – 61) + 203
(40 registers, from no 203 to no 241)
The first register shows the error flags in the lower byte and an 8 bit counter value in the upper byte.
Bit Meaning
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Bit 0 fuse is damaged
Bit 1 address button pressed
Bit 2 used internally
Bit 7 offline, no response at the local bus
Bit 8-15 8 Bit counter, all changes of input 1 are counted.
The second register shows the status of the 16 digital inputs.
Bit Meaning
Bit 0 digital input 1 (24V = Bit set
…
Bit 15 digital input 16 (24V = Bit set)
11.1.7 Fieldbus interface BI remote control, register 142 (read/write)
This register can be used by the Modbus master to control various functions of the fieldbus interface.
Bit Meaning
Bit 0 reserved
Bit 1 force BI to passive mode (see also: 13)
Bit 2…14 not used
Bit 15 Profibus data are valid (see also: 10.1.3.1) (implemented in BI version V1.6 or higher)
11.1.8 CM3/4 control register (read/write)
A CM3 control register is used to send a command to a valve. The register number depends on the
module address (1-50).
Register number = module address + 142
(50 registers, from no 143 to no 192)
Only the lower-order byte of the valve control register is used.
Value Meaning
0..100 position set point for %Pos drives
101 close drive
102 stop drive
103 open drive
104 acknowledge error, erase last command
111 commands by mimic diagram inputs only (not required any longer)
If command 111 is sent the BI completely passes control to the CM3/4 modules. The CM3 acts as if
there is no BI. Only old CM3 versions V1.6 or lower require this command to enable the mimic inputs
permanently. V1.7 and newer always react properly on mimic inputs in remote mode and do not re-
quire this command any longer.
Any command change will reset the errors 1..4. To force a command change the following way is sug-
gested:
Set the most significant bit of the command byte to indicate a new command. The CM3 / CCM
will react on this command immediately. The bit should be kept high for at least 1s and should
be reset afterwards.
Besides resetting error conditions restarting a command may be useful in certain applications like ac-
tuators that may be operated manually by hand wheel (override). If such a drive is closed by com-
mand and opened manually afterwards a repeated close command will close it again.
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example:
• send close command 128+101=229, actuator starts running, wait 1s, send close command
101
• actuator is closed
► actuator is opened manually
• send close command 128+101=229 once more , actuator starts running, wait 1s, send close
command 101
• actuator is closed again
11.1.9 CCM control register (read/write)
The CCM control register is used to send a command to the actuator. The register number depends
on the module address (1-50).
Register number = module address + 142
(50 registers, from no 143 to no 192)
Only the lower-order byte of the valve control register is used.
Value Meaning
0..100 position set point
101 close drive completely (same as 0)
102 stop drive
103 open drive completely (same as 100)
105 start calibration
111 commands by mimic diagram inputs only
NOTICE
Final position during calibration
During calibration the actuator will be completely opened and closed again. Make sure
that both final positions are reached.
If command 111 is sent, the CCM takes over the control from BI. The BI power management is no
longer effective. Commands sent via mimic inputs are always executed, independent from BI com-
mands.
Each command change resets error messages 1…4. For resetting without ´command change, the fol-
lowing procedure is executed.
11.1.10 IO control register (read/write)
The IO control register is used to set the 4 digital outputs of the IO 8/8/4 module. The register number
depends on the module address. The module addresses are in the range of 51 – 60.
Register number = (module address – 51) + 193
(10 registers, from no 193 to no 202)
Bit Meaning
Bit 0…3 digital output 1..4 set, outputs are reset if IO 8/8/4 goes offline
Bit 4…7 digital output 1..4 set, outputs stay on if IO 8/8/4 goes offline
11.1.11 TII-control register (read/write)
The TII-control register is used to set the 2 analog outputs of the TII module. The register number de-
pends on the module’s address.
Register number = (module addressee – 51) + 193
(10 registers, von no. 193 to no. 202)
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Bit Meaning
Bits 15…8 set point for analog output 1;
the output is set to 0 if the data connection between Modbus master and BI or be-
tween BI and TII is interrupted.
Bits 7…0 set point for analog output 2;
the output is set to 0 if the data connection between Modbus maser and BI or be-
tween BI and TII is interrupted.
example:
Register output 1 output 2
32FAh 4 mA 20 mA
upper or lower
byte of register output curent
00h <1 mA (off)
32h 4 mA
7Dh 10 mA
FAh 20 mA
FFh 20,48 mA (ca.)
11.1.12 RK control register (read / write)
The RK control register are used to control the relay outputs. Each module uses one register.
The register number depends on the module address.
The module addresses are in the range of 61 – 80.
Register number = (module address – 61) + 243
(20 registers, from no 243 to no 262)
Bit Meaning
Bit0…7 set relay output 1..8;
all outputs are reset if the data connection between PLC and PCM system fails
Bit8…15 set relay output 1..8;
all outputs keep the current state if the data connection between PLC and PCM sys-
tem fails
11.2 Fieldbus Watchdog
The BI Module permanently supervises the proper function of the Modbus (Profibus). The BI must re-
ceive at least one valid Modbus request every 5s otherwise the following functions will be carried out:
• A command 111 „enable mimic diagram inputs“ is sent to all CM3 modules.
• All control bits 0..3 of all IO8/8/4 are set to 0, that means that all outputs are reset
• All control bits 0..7 of all RK16/8 are set to 0, that means that all outputs are reset
We recommend starting a request at least every second. This function is implemented for the Profibus
protocol is the same way.
11.3 Extended Modbus Interface
Besides the formerly described Modbus registers the BI from version 2.5 on provides additional regis-
ters that can be used to read and write the parameter sets and to read the version number of all mod-
ules. Those registers are intended for diagnosis purpose mainly.
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11.3.1 Version Number Registers
For each PCM Module one register is provided were the BI writes the version number of the corre-
sponding PCM module. These 80 registers start at register number 400 and are read only registers.
Register Module
400 BI
401…450 CM3, CM4 with Addr. 1…50
451…460 IO8/8/4, TII with Addr. 51…60
461…480 RK16/8 with Addr. 61…80
11.3.2 Parameter Register
For each CM4 five registers are reserved that hold the CM4 operating parameters. These 250 regis-
ters start at register 500. Please keep in mind that the parameters are read from the BI memory and
not from the CM4.
CAUTION
Malfunction of the PCM system / Damage to the CM4 devices or actuators
These registers must not be written!
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11.4 Register summary
Reg.
No Status-Register
Bit
higher -order byte lower-order byte
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 BI status p Inputs Faults
2 CM status, module 1 messages Mo Mc Errors Position information
up to
51 CM status, module 50 messages Mo Mc Errors Position information
52
IO-status, module 51
TII-status, module 51
Error messages 8 <---digital inputs---> 1
Error messages T6 T5 T4 T3 T2 T1 IA2 IA1
53 IO / TII analog input 1 / PT100-1
54 IO / TII analog input 2 / PT100-2
55-
59
up to
60 IO / TII analog input 8 / isolated current input
to
133
IO-Status, Module 60
TII-Status, Module 60
Error messages 8 <---digital inputs---> 1
Error messages T6 T5 T4 T3 T2 T1 IA2 IA1
134 IO / TII analog input 1 / PT100-1
135 IO / TII analog input 2 / PT100-2
136-
140
up to
141 IO / TII analog input 8 / isolated current input
Reg.
No
Control-Register
Bit
higher -order byte lower-order byte
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
142 BI control V P R
143 CM control, module 1 control commands
up to
192 CM control, mod. 50 control commands
193 IO control, module 51 4<dig.outp.>1 4<dig.outp.>1
TII-control, Module 51 output value ch. 1 output value ch. 2
up to
202 IO control, module 60 4<dig.outp.>1 4<dig.outp.>1
TII-control, Module 60 output value ch. 1 output value ch. 2
Reg.
No.
Status-Register
Bit
higher -order byte lower-order byte
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
203 relay module 61 counter Error messages
204 16 <---digital inputs---> 9 8 <---digital inputs---> 1
up to
241 relay module 80 counter Error messages
242 16 <---digital inputs---> 9 8 <---digital inputs---> 1
Reg.
No.
Control-Register
Bit
higher-order byte lower-order byte
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
243 relay module 61 8 <-- digital outputs --> 1 8 <-- digital outputs --> 1
up to
262 relay module 80 8 <-- digital outputs --> 1 8 <-- digital outputs --> 1
not used =
Mo, Mc = indication of mimic command open / close
p = running in passive mode if set / P = force to passive mode
V = Data Valid Bit for Profibus / CM = CM3, CM4, CCM
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12 BI Profibus DP interface (slave) The Profibus DPV0 interface is available as an alternative to the Modbus and can be chosen via the
setup menu of the fieldbus interface (BI). Automatic baud rate identification is used. Baud rates be-
tween 9600 baud and 1.5 Mbaud are permissible. If required a bus terminator (in accordance with the
Profibus standard) can be connected via a miniature two-pole switch in the front of the housing.
The advanced V1 and V2 services are not available. Differing from the Profibus standard an inexpen-
sive screw-type terminal is used for the electrical connection instead of a sub-D connector. More de-
tailed information about the Profibus protocol may be obtained from the standard EN 50170 or from
the „Profibus Nutzer Organisation“ (PNO, www.profibus.com).
12.1 Profibus data model
For compatibility reasons the same data model is used as for the Modbus. 16 binary digit-wide data
words are used instead of the Modbus registers. On account of the maximum telegram length of 244
bytes a maximum of 7 IO- or TII modules can be used for the Profibus protocol. The data model is de-
scribed in the “PE_PCMV2.gsd“ GSD file (or newer versions). The meaning of the individual data
words corresponds to those in the registers for the Modbus protocol.
To avoid unnecessary data transfer the BI module is setup as a modular station. The following mod-
ules are available.
Module 1 BI, status & control, 1 word read, 1 word write
Module 2 5x CM3/CCM, status & control, 5 words read, 5 words write
Module 3 10x CM3/CCM, status & control, 10 words read, 10 words write
Module 4 1x IO8/8/4 or T-II, status & control, 9 words read, 1 word write
Module 5 1x RK16/8, status & control, 2 words read, 1 word write
Module 6 5x RK16/8, status & control, 10 words read, 5 words write
The module type 1 must always be inserted in first place. Next up to 50 CM3, 7 IO8/8/4 or T-II and 20
RK16/8 may be added.
12.1.1 Fieldbus interface to superimposed control system (status words)
Data word Meaning
1 Status field bus interface
1 each Status CM3, address 1..50
9 each Status IO 8/8/4, address 51..57
2 each Status RK 16/8, address 61..80
12.1.2 Superimposed control system to fieldbus interface (control words)
Data word Meaning
1 Command field bus interface
1 each Command CM, address 1..50
1 each Command IO 8/8/4, address 51..57
1 each Command RK 16/8, address 61..80
12.1.3 Data Valid Bit
Some Profibus DP masters keep on sending data even if the supervisory controller is stopped. In this
case all commands are set to 0. This is not suitable for PCM system. Therefore the highest Bit15 of
the control word of the BI is used as a „Data Valid Bit“. If this bit is not set the Profibus connection is
treated as invalid.
This Bit is used only if the Bit0 of the first Parameter Byte is set to 1, otherwise the data is always
treated as valid data. This function is only implemented in BI firmware version V1.6 or higher.
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13 Secondary BI Module, passive mode To achieve an improved availability of the field
bus connection (either Profibus DP or Modbus
RTU) an additional, secondary BI module may
be used. This secondary module is usually
running in passive mode permanently reading
the traffic on the local bus. Therefore it will al-
ways show the latest data of all modules con-
nected but it cannot and must not send any
command to the modules.
Whether a BI runs in passive or active mode
depends on its priority on the local bus. Al-
ways the BI with the highest priority becomes
active. The priority depends on the following
conditions:
Priority Condition
4 Parameter Setup Tool if active
3 primary module, field bus connection to supervisory control is working properly
3 primary module, running in setup mode
2 secondary module, always
1 primary module, no field bus connection and no setup mode
NOTICE
Parameter Setup Tool
The Parameter Setup Tool PST always gets priority 4 and supersedes all BI modules.
If the field bus connection of the primary module fails the priority of this module is reduced to 1 and
therefore the primary module becomes passive whereas the secondary module becomes active. Be-
cause a BI running in setup mode needs full access to the local bus the priority of the primary BI is set
to 3 if setup mode is turned on. To use the secondary BI in setup mode the fieldbus connection of the
primary BI must be interrupted during setup.
The secondary BI should preferably be mounted on the right side of the CM modules. The control in-
puts E1 and E2 are connected in parallel to the primary BI if used at all.
13.1 Parameterisation of the secondary BI module
The address setting is the only difference between primary and secondary BI. If both BI are connected
to separate field busses they both may (and preferably should) use the same real fieldbus address.
The secondary BI module is set to a fieldbus address “real address + 80h”. That means that the sec-
ondary BI with the fieldbus address 1 is set to address 1+80h = 81h.
NOTICE
Compatibility
All functions described here are available only in software version 2.0 or higher!
13.2 Fieldbus interface BI status, register 1 (read only)
One entry is added to this register. As long as the BI is running in passive mode all data are valid but
no command will be sent to the modules.
Bit Meaning
IO
prim.BI
CMCMM
CMCMM
1 21
sec.BI
CMCMM
3 ...
+24V
0V
primary bus
secondary bus
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Bit6 running in passive mode
13.3 Fieldbus interface BI remote control, register 142 (read/write)
One entry is added to this register. For test purpose the BI can be forced into passive mode. The sec-
ondary BI will than change to active mode.
NOTICE
Passive mode
Only one single BI must be set to passive mode.
Bit Meaning
Bit6 force BI to passive mode
13.4 Operating redundant BI
Both master interface settings should be (but don’t have to be) identical. If two separate bus cables
are used even the slave addresses may and should be the same. The master software should treat
both BIs as well as the connected modules identically. There is no need to send commands to the
passive BI as this BI can’t send commands to the connected modules. Anyhow you may do so if it is
more convenient. The passive flag in the BI status register should be indicated to the user. Of course
both masters must poll the primary and the secondary BIs permanently. Otherwise a failure of the sec-
ondary bus may not be noticed.
For test purpose the master should be able to stop polling the primary bus. In this case the secondary
BI must indicate that it turned to active state a few seconds later. If turning off the primary master is
not possible the primary BI can be forced to passive mode by setting the corresponding bit in the con-
trol register.
13.5 Alarm output
The alarm output of the passive BI is always closed that means an alarm is never signalised. The ac-
tive BI behaves like a standard BI.
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14 Parameter Setup Tool (PST) The Parameter Setup Tool (PST) is a small handheld device
equipped with a four line LCD display and five buttons. By means of a
spiral cable with a RJ11 plug it can be plugged in the PST-C con-
nector module and thus connected with the local PMC bus. The PST
is supplied by the local bus and has full access to the local data bus
and to the connected CM4 modules. Of course the CM4 must be ad-
dressed in the usual way either using a BI or the PST.
Note: If a BI module is used together with CM4 and PST the soft-
ware version of this BI must be V2.7 or higher. Otherwise the
functions described here are not or only partially available.
The PST may be used in combination with one or two BI.
14.1 PST as local Bus Master
CAUTION
Control system loses control function
As soon as a submenu is selected, the PST changes to active mode as bus master.
The supervising control system can no longer control the modules.
• Changes and parameterization must only be carried out by trained staff.
• Bear in mind any consequence that may occur when the control system has no in-
fluence and possibility of intervention on the system
• After finishing your work, select the main menu or disconnect the PST from the bus.
The PST may be connected to a running system and doesn’t interfere with the normal function of the
system. But if any sub-menu of the PST is called the BIs become passive and the PST acts as a Bus
master. The lower decimal points of the BIs turn on and indicate the passive state.
If parameters are sent to a CM4 module they will also be sent to the BIs and stored in a non-volatile
memory. In this way the parameter set can automatically be restored if a CM4 has to be replaced.
All CM4 are permanently requested by the PST in the same way a BI would do. All other PCM mod-
ules like IO 8/8/4 or RK 16/8 are not served by the PST. The output signals of those modules are re-
set if this function is used.
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14.2 PST Main Menu
PCM Set-Up Tool V1.2
Pleiger Elektronik
1: Parameter set-up
2: Address set-up
If the PST is plugged in it shows the main menu. As long as the PST shows this main menu it has no
access to the local Bus of the PCM system and the system operates as usual.
This menu is used to call one of two functions, either to set the CM addresses or to change the CM
parameter. Use the arrow keys ▲ and ▼to select the desired function and call the function by press-ing the OK-Button. Alternatively pressing the arrow key ▲ for a longer time will call function 1.
(Notice: The PST distinguishes two ways of pressing a button, a short click on a button lasting less
than 0,7s and pressing the button for more than 0,7s. The short click has the meaning OK or
Acknowledge whereas a long press means escape or abort.)
As soon as one of the sub menus is selected, the PST takes control to the local Bus and all BI turn
passive and do not communicate to the connected modules.
NOTICE
Terminating setup
If the PST is no longer needed, select the main menu or disconnect the PST from the
local Bus.
The PST automatically returns to the main menu if none of the five buttons is pressed
for 3 minutes (from version 1.1 on only)
14.3 “Address Setup” Menu
This function serves to set or change the address of a CM4 module. The way to set an address is sim-
ilar to the BI in setup mode.
address set ??
first free addr. 1
address offset 0
new address 1
Turn CM4 to remote mode and then press the open / close command switch to show some more in-
formation about this node.
address set Vx.y aa
The version of the CM4 software Vx.y as well as the module address „aa“ are displayed. If no address
is set „no“ is displayed.
first free addr aa
The lowest unused address is shown here. Usually this address will be used for the selected node.
address offset aa
If the lowest free address is not desired for the selected node the user can adjust the desired address
by pressing the arrow keys▲ / ▼to change the address. Addresses that are already in use will be
skipped.
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new address aa
This is the address value that will be used for this node if the operation mode switch is changed to lo-
cal while the command button is press into close position.
Long press the OK-Button to leave the address setup menu.
14.4 „Parameter Setup“ Menu
The parameter setup menu can be called in two different ways.
1. Select menu in the main menu and press the OK-Button
2. Press the arrow up key ▲ long.
CM4 V4.2 ID 7 Typ: 0
Tr: 50 Ta: 0 Tb: 0
Configuration: 00000
dbl acting o/c
• The first line shows the module kind, the software version of the module, the address (ID) and
the actuator kind in form of a number.
• The second line shows the actuator’s run-time and if additional timing parameters are required
the parameter Ta and Tb. The meaning of those parameters depends on the actuator kind.
• The third line shows the module configuration in form of a 5-digit number.
• The last line is used to add some comments that further describe the meaning of the selected
parameter.
Long press the OK button to return to the main menu again.
14.4.1 Selecting the next or previous CM4
By pressing the arrow key▼long the CM4 with the previous address is selected while pressing the ar-
row key▲ for at least 1s the CM4 with the next higher address is selected. If a CM4 module is found
the parameters of this module are displayed.
Hint: To select any CM4 module simply change its operation mode from remote to local. The se-
lected module starts blinking
14.4.2 Selecting a Parameter
First of all use the arrow keys to select the desired parameter and then press the OK Button to change
to the edit mode. The cursor now changes its appearance. Instead of a blinking cursor an underscore
is shown. A hint text for this parameter is shown in the last line.
14.4.3 Changing the Parameter
The up / down arrow keys are used to increase or decrease the value, the left / right arrow keys are
used to select the digit that shall be changed.
If the desired value of the parameter is set press the OK button shortly to confirm this parameter and
to send it to BI and CM4. The edit mode is left and the selection mode is turned on again. The appear-
ance of the cursor changes to a blinking cursor again.
If the modified parameter value shall be discarded in edit mode just press the OK button long. The edit
mode will be left but the parameter value stays unchanged.
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14.4.4 The Actuator type
The actuator type replaces the setting of the quad DIP switch of the CM3. This parameter defines the
required control function for the actuator. Currently the functions 0…18 are defined for the CM4 mod-
ule. The types 0…15 are almost identical to the corresponding types of the CM3. Furthermore a so
called default type is defined and used as works setting or if a parameter set is erased. A parameter
set is erased whenever the modules address is set or changed. The default type is indicated by “*0”
and cannot be chosen by the user.
14.4.5 Timing Parameter
The parameter Tr defines the runtime of the actuator. In general a fairly rough adjustment (-5% ..
+30%) is sufficient whereby, if anything, the time should be assessed somewhat too generously. The
range is 0s … 520s. This parameter is used to calculate the supervision time:
Ts = 1,2*Tr + 6s
and the follow-up time:
Tf = 0,1*Tr + 2s
Actuators with operation mode %Pos
Parameter Ta defines the distance between target position and stop position in % while closing.
Parameter Tb defines the distance between target position and stop position in % while opening.
Double acting actuators with successive closing or opening
Parameter Ta defines the pulse time in 0,1s and parameter Tb defines the pause time in 0,1s. On
closing the first pulse lasts Tr/2. On opening the actuator begins with start stop operation and contin-
ues until the sum of all pulses are > Tr/2. Then the actuator moves to open position without further
stops. (Hint: current version continues stepping until actuator is open).
Single acting actuators with successive closing
Parameter Tr equals the runtime from close to open position. Opening is done without stopping. Pa-
rameter Ta defines the runtime from open to close position. Tb is the desired runtime for closing.
While closing the actuator starts with a step that lasts Ta/2 and then continues stepping with smaller
steps while the pulse time is at least 1s and not more than 10 pulses are used to close the actuator
completely. The number of pulses and the final runtime depends on the current actuator speed.
14.5 Teach-In
The CM4 from version 4.1 provides a Teach-In function to determine the timing parameter Tr, Ta and
Tb in an easy and reliable way. The meaning of the timing parameter depends on the actuator type,
as mentioned before.
The Teach-In function is started if:
• The parameter Tr has been set to 0 and the open command is set in local operation mode or
• The CM4 is selected by the PST and the open command is set in local operation mode
The actuator first opens completely, stays in open position for a few s and then closes again. If an an-
alog position indication is used the actuator stops at 30% while opening and also while closing. Finally
the parameter are calculated, stored in EEProm and are also sent to the BI. The BI once indicates
E.E. for a second. If a BI is used the version must be 2.6 or higher, otherwise the BI will indicate a pa-
rameter fault PF.
For actuators that close or open successively the pulse and pause time is set in such a way that the
total close time is doubled. That means that the pause time is twice as high as the pulse time. It is at-
tempt to set the times in such a way that 10 steps are required for the last 50% and each pulse takes
at least 1s. When the actuator is opened stepwise the step mode is uses for the whole movement.
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The Teach-In can be terminated by pressing the close button or by changing the operation mode to
remote. As long as the parameter Tr = 0 the Teach-In can be started again as mentioned before.
14.6 Configuration
The configuration of the module is defined by a 5 digit number. The advantage of such a number is that it can easily be added to the documentation and checked at a glance. Besides the address and the actuator type the configuration is added to the wiring diagram. In most cases the default value „00000“ will be used.
This table helps to find the correct configuration number.
1. local options Options for local operation + alarm options0 standard standard, alarm contact opens on error1 local override mimic operation allowed in local mode2 alarm out = local ctrl alarm contact opens on local operation3 loc over + alarm = local ctrl combining 1 and 2
2. feedback input open / close position indication inputs0 standard standard1 wire break detection wire break detection on2 short detection short circuit detection on3 break + short detection both on
3. mimic ouputs mimic outputs0 mimic out standard standard, blinking while running1 mimic out no_blink mimic outputs = feedback input
4. mimic input open mimic input open0 standard standard1 wire break detection wire break detection on2 short detection short circuit detection on3 break + short detection short circuit and wire break detection on4 inverted input inverted, 0V means input is set5 break + inverted inverted + wire break detection6 short + inverted inverted + short detection7 all all three special function set
5. mimic input close mimic input close0 standard standard1 wire break detection wire break detection on2 short detection short circuit detection on3 break + short detection short circuit and wire break detection on4 inverted input inverted, 0V means input is set5 break + inverted inverted + wire break detection6 short + inverted inverted + short detection
0 0 0 0 0 7 all all three special function set
Parameter Input level Alarm Command
0 standard break Off Off
low Off Off
high Off On
short Off On
3 break On Off
break+short low Off Off
high Off On
short On Off
4 break Off On
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The reaction of the CM4 on the mimic input level depends on the parameter setting. The behaviour of the command inputs close and open is identi-cal.
14.6.1 Copy and Paste
Long press the arrow key ► to copy all parame-
ters of the latest parameter set that has been confirmed to the selected node. Long press the arrow
key ◄ to replace all parameter of the selected node by default values.
inverted low Off On
high Off Off
short Off Off
7 break On On
Inverted+ low Off On
break+short high Off Off
short On Off
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15 PCM modules, available versions CM3 modules should no longer be used for new installations. This applies particularly to special ver-
sions xx110 to xx180.
15.1 CM3
CM3 is no longer recommended for new installations!
Article number Function
9341100100 Standard device as described in this manual if not otherwise mentioned
9341100110 CM3 with control functions for hydraulic actuators with 24V solenoid valves (see
separate manual)
9341100120 CM3 for spring close actuators with separated hydraulic unit (separate manual)
9341100140 Like standard device but extended operation mode 1+2 is already set
9341100150 Like standard device but extended operation mode 1+3 is already set
9341100160 Device with wire break detection and extended operation mode 1+2 is already set
9341100170 Device with wire break detection and extended operation mode 1+4 is already set
9341100180 Like standard device but extended operation mode 1 is already set
9341100190 Standard device but mimic outputs indicate drive position only, without blinking
15.2 CM4
Article number Function
9341100800 Standard device as described in this manual.
9341100810 Special version for control function 18 and 19.
15.3 BI
Article number Function
9341100200 Standard device as described in this manual, provides Modbus + Profibus inter-
face
9341100250 Simplified version, provides Modbus interface only
15.4 IO 8/8/4
Article number Function
9341100300 Standard device as described in this manual
15.5 TII
Article number Function
9341100600 Standard device as described in this manual
15.6 RK 16/8
Article number Function
9341100400 Standard device as described in this manual
15.7 CCM
Article number Function
9341100500 Standard device as described in this manual