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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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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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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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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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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


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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PCM series CM4


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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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


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.


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.


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).


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.


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.


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.


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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


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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PCM series CM4


4.8 Terminal assignment

CAUTION


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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PCM series CM4


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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PCM series CM4


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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PCM series CM4


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


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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PCM series CM4


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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PCM series CM4


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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PCM series CM4


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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PCM series CM4


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


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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PCM series CM4


• 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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PCM series CM4


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


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




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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PCM series CM4


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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terminal X1:

1 digital input 1 i 24V DC


… … i


9 common 0V for 1-8 i common 0V

terminal X2:



... ... i


9 common 0V for 9-16 i common 0V

terminal X3:

1 relay output 1 o normally open


… … o


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



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


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


CAUTION




modules.

Lower terminals (factory):

X1 (grey) pluggable

1 digital input 5 i 24V DC to 0V of supply voltage





5 digital output 1 o 24V DC to 0V of supply voltage




Upper terminals (dockyard):

X3 (grey) pluggable

9 analog input 4 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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PCM series CM4


X6 (grey) pluggable





Bus connector



3 Lamp test i Lamp test input, 24V = lamps on



8.4 Technical data

supply voltage DC 24V

current requirement DC max. 70mA, plus external load*

fuse DC Self-resetting fuse, 500mA - 1100mA




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




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



8 analog output 2 I 4...20mA

X3 (grey) pluggable

9 GND - GND



12 N.C. NC reserved for future use

upper terminals:

X4 (grey) pluggable

16 GND - GND



13 analog input 1 I 4...20mA


20 GND - GND



17 analog input 2 I 4...20mA

X6 (grey) pluggable

24 GND - GND



21 N.C. NC reserved for future use

Bus connector






Bürde

I

Bürde

I

↑↑ T

↑↑ T

I

Quelle

↑↑ T

I

Quelle

↑↑ T

↑↑ T

↑↑ T

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9.4 Technical data


current requirement DC max. 120mA

fuse DC self-resetting fuse, 500mA - 1100mA




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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PCM series CM4


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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PCM series CM4


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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PCM series CM4


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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PCM series CM4


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


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.


CAUTION




modules.

Lower terminals


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


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






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10.3 Technical data


current requirement DC max. 50mA, plus external load*

control inputs 24V DC

alarm output Relay, 24V, 0,5A




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).



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)


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


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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


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


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


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.


Register number = 2*(module address – 61) + 203


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).



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).



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


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.


Register number = (module address – 61) + 243


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


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



136-

140

up to

141 IO / TII analog input 8 / isolated current input

Reg.

No

Control-Register

Bit


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


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.

http://www.profibus.com/

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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


9341100800 Standard device as described in this manual.

9341100810 Special version for control function 18 and 19.

15.3 BI


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


9341100300 Standard device as described in this manual

15.5 TII



15.6 RK 16/8



15.7 CCM



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