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Automation Technologies 3/2015

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Automation Technologies 3/2015


COMPONENTS AND SOFTWARE Intelligent power distribution: IO-Link in the DC 24V level Today, IO-Link technology is more and more frequently used in mechanical and plant engineering. This system-independent communications standard on the lowest field level is internationally specified in accordance with IEC61131-9. All the fieldbus systems established on the market, such as Profibus, Profinet, EtherCAT, Ethernet/IP can be implemented easily and profitably. In addition to the sensor and actuator components, which have been frequently used until now, for the first time, the DC 24V control voltage docks the control environment via IO-Link. About Company name: E-T-A Elektrotechnische Apparate GmbH Headquarters: Altdorf, Germany Turnover: € 90 m (2014) Group Employees: 414 (worldwide) Products: circuit breakers, power management systems and system solutions Key aspects of the success of IO-Link are bidirectional cyclic and acyclic transmission of diagnostic data. This ensures consistent data storage of device parameters, a reduction in cabling requirements and, compared to conventional bus systems, fewer requirements in engineering. An IO-Link system is configured in two basic steps. In the first step, the IO-Link master is integrated into the automation and control technology. Subsequently, the IO-Link devices are parametrised. The IO-Link master of the control system is placed either in the switch cabinet (IP20) or remotely in the field with higher protection type, e.g. IP65. It acts as a gateway between the IO-Link device and the higher level communication system (Profinet, Profibus-DP, EtherNet/IP. The various applications of IO-Link range from machine tools and packaging machines to conveyor technology systems. Continuous data channel The IO-Link connection of the ControlPlex Board SVS201-CP closes the previously existing gap between control system, sensors, actuators and the energy dis-

COMPONENTS AND SOFTWARE tribution in the DC 24V control voltage level. The ControlPlex system provides a continuous data channel for all cyclic process data and acyclic data for parameterisation and diagnostics of the entire DC 24V level. This will be a crucial requirement with regards to condition monitoring and energy management The system consists of the Power Board type SVS201-PWR with integrated wiring for up to a maximum of 16 load circuits, the electronic circuit breaker type ESX50D-S and the CPC10IO module for IO-Link communication (image 1). The electronic circuit breaker type ESX50D-S is equipped with integrated current limiting and a single turn-off characteristic for all load types. This ensures stable DC 24V control voltage without voltage drop in short-circuit or overload in a load circuit. Only the faulty current circuit is selectively shut down, whereas all other loads carry on running without failure. The ESX50D-S can also be reset remotely via IO-Link. The rated current setting in the range 1-10 A occurs either via IO-Link or with an “offline” rated current setting directly on the selector switch of the device. This reduces the number of different device types, as well as costs for logistics and spare parts storage. overcurrent protection power distribution internal device bus communication 01 Block diagram ControlPlex with IO-Link 02 Adjustable electronic circuit breakers ESX50D-S with IO-Link controller CPC10IO Easy implementation The entire system can be implemented very easily for switch cabinets even when production is running. The devices always operate autonomously as overcurrent protection, even without operation via the IO-Link connection (image 2). The device description file provided contains all the information on the CPC10IO IO-Link controller. The configuration tool of the IO-Link master, Simatic S7-PCT integrated in Step 7 is set up to 16 ESX50D-S safety breakers including rated current setting by modifying the turn-off and the switch-on after power-on. All status messages for the DC 24V system voltage, load current and load voltage go directly from the internal device bus ELBus to the IO-Link controller. In the IO-Link specification V1.1, three data transmission rates are specified for the IO-Link operating mode: COM 1 = 4.8 kBaud, COM 2 = 38.4 kBaud, COM 3 = 230.4 kBaud. An IO-Link master according to specification V1.1 supports all data transfer rates and automatically adapts to the the data transfer rate supported by the device. The IO-Link master receives the cyclic measured values and status information of 16 load circuits of the PLC bundled within 40 ms via a single port. Digital E/A modules or additional fieldbus couplers and the complex E/A wiring can therefore be omitted. Condition monitoring in the DC 24V level Important features for the user are the remote control capability for the single DC 24V load circuits and the setting of the switch-on delay and switch-off sequences for each software. Overloading of the power supply is avoided since the restart of the DC24V load is current-limited and runs sequentially. For the energy management of machinery and systems, during standstill and servicing a targeted switch-off of unnecessary loads and system parts is available. Ongoing analysis of the load currents, load voltage through the PLC is now also available within the framework of “Condition Monitoring” in the DC 24V level. Early deviations from normal operation, can be detected at an early stage and then planned and repaired based on actual conditions. AUTOMATION TECHNOLOGIES 3/2015


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