EcoController GEL 8180

Camshaft gear

Technical Information Version 01.03

Internet: http://www.lenord.de Tel.: +49 (0)208 9963-0 Lenord, Bauer & Co. GmbH
E-Mail: [email protected] Fax: +49 (0)208 676292 Dohlenstrasse 32
46145 Oberhausen, Germany
Design, Construction

Design Characteristics
The camshaft gear is based on our EcoController and is ● Up to 64 tracks
designed for installation in a switch cabinet. It can be ● Up to 3584 variably adjustable cams
operated individually or cross-linked. At the core of the ● Up to 99 programmes
EcoController hardware is a fast 16-bit microprocessor and ● Input frequency-dependent displacement of cams
a powerful peripheral ASIC developed especially for the (dynamic cam)
demands of motion automation. The housing is made of
● Short cycle time, 300 µs without dynamic cams
sheet metal (Zincor).
The electronic camshaft gear has significant advantages ● Temporary lock of individual tracks or track groups
over mechanical solutions:
● short change-over times
● easy adjustment
● no operating cycle Example for path-dependent outputs
● no contact bouncing
● no mechanical wear 1
● no maintenance 2
3
Range of application 4
The electronic camshaft gear can be used wherever ●
●
mechanical solutions are to be replaced. ●

Examples for applications are: 64

● paper making machines, packaging machines and actual position
coiling machines 0 8192
● steel works and rolling mill technique
● presses and automatic punching machines
● materials handling and storing technique Digital inputs/outputs
In the basic version, the Controller has
● mechanical treatment machinery
● digital outputs
● digital inputs (connectors E2, E3 are not assigned)
Example for application:
Control of a bag filling machine All digital outputs operate with 24 V levels common in
In order for a machine to fill bags with granulate, 7 different industry. All digital outputs are short-circuit proof and
operations are necessary. They are repeated in a cycle (see protected against polarity reversal. The output status of 24
diagram). The position is recorded by an absolute encoder outputs can be displayed via 24 (programmable) LEDs.
(resolution 1°). The cams have power outputs. Up to 99
different programmes are available for various bag sizes and
types of granulate. Actual value acquisition
There are various encoder inputs available to record the
actual values of rotation, distance, or angle:
● one counting input for 5 V or 24 V incremental
encoders
● one SSI input for absolute encoders in Gray code
1 (13 bit/25 bit)
2
7
Communications interfaces
3 The controllers can easily be cross-linked with the aid of
6 two shunt-connected, 9-pin D-subminiature connectors.
1 Pick-up
Available are:
2 Check ● two RS 485 and one RS 422/485 communications
4 5 3 Open interfaces independent of one another
4 Fill (connector B1, B2)
5 Close
6 Seal ● one RS 232 interface (connector C)
7 Eject ● PROFIBUS DP (connector P)
● InterBus-S (connector I)

2 Lenord +Bauer DS22-8180(01.03)

 Field bus
Programming, Operation

Field bus GEL 8810 operator terminal

The input and output of process data (nominal/actual values) The GEL 8810 operator terminal with front dimensions of 160
and all control signals, as well as parametering can also be mm x 160 mm is designed for operation and observation in
carried out via the PROFIBUS or InterBus-S, which close proximity to the controller. The 18 mm x 18 mm quick
considerably reduces materials and wiring costs in com- stroke keys can be labelled with user-specific insertion
parison to conventional parallel communication. strips.
The PROFIBUS module is an intelligent interface RS 485 (1 The high-illumination, high-contrast display has an alpha-
line pair) that can transfer data in accordance with DIN E numeric LCD dot matrix display ( 4 x 20 characters, 8 mm
19245 part 3 (PROFIBUS DP). The maximum transfer rate is high) with LED background lighting. The self-explanatory
1.5 MBaud. An InterBus-S module according to DIN E 19258 display text (bilingual) uses menus to guide the user through
(2 line pairs) with the same functions may be used alternatively. the programming of functions and operating values. In
Connectors A2 and A3 are replaced by two 9-pin P connectors addition, there are also convenient editing features such as:
or I connectors. ● inserting cams or paths
● copying cams or paths, even outside of programmes
Programming ● deleting cams, paths, programs, units and the entire
The distribution of the 3584 cams between the programmes memory
and the paths can be determined by the individual user. ● scrolling through memory contents, etc.
Inputting the cams is carried out via the operator terminal.
With the EcoControllers, machine parameters and nominal
Still more convenient is using the BB 8180 „Operating +
value programmes can be edited or actual and nominal
Observing“ PC programme to edit, store and load the cams
values can be visualized.
into the controllers or to read them out from the controllers.
Of course the controllers can also be configured via this
programme.
The „Operating + Observing“ PC programme also allows
you to carry out communication with an individually operated
controller or with a complex controller network. An automatic
GEL 8810
backup function reads the data and configurations of all the
controllers that are cross-linked and independently generates
the files necessary for system management. The option of
saving data onto storage media allows for a better overview
of the diverse controller files. At the same time, the files can
also be printed out.

System requirements for the BB 8180 PC programme

● 80386 PC or higher (MS-DOS 3.30 or higher)
● 3.5" floppy disk drive and hard disk drive
● RS 232 interface slave slave slave slave
(controller 1) (controller 2) (controller 3) (controller 4)
If you are cross-linking several controllers, your PC requires
an RS 485 interface. If your PC does not have such an
interface, then we can offer you the following solutions:
● GEL 89010 V 24 / RS 485 converter incl. power supply
unit
Further information about the GEL 8810 operator terminal
● GEL 89011 V 24 / RS 485 converter with electrical
is available on a separate technical information.
signal isolation incl. power supply unit, GEL 8810
operator terminal

DS22-8180(01.03) Lenord +Bauer 3

Technical data

Supply voltage Serial interfaces 3

input 18 ... 30 V DC (UB) or Ser1 RS 485 or RS 232 C,
15 ... 23 V AC galvanically separated via
optocoupler
current consumption approx. 300 mA
Ser2 RS 422
output UB - 1 V
Ser3 RS 485
load current approx. 400 mA galvanically separated via
optocoupler
Counting inputs
Actual value range 0 ... 8,191 (max. 64 tracks)
logic level 24 V low: 0 ... + 5 V 0 ... 16,383 (max. 32 tracks)
high: +15 ... +30 V Number of axes 1
5V low: 0 ... +0.8 V
Number of cams 3,584
high: + 2.5 ... +5 V
input resistance 24 V > 2.5 kΩ Scan time 300 µsec + 150 µsec per
created group of dynamic
5V > 3 kΩ cams + 50 µsec for an SSI
input frequency < 200 kHz encoder
Climatic applicability class KWF (acc. to DIN 40040)
pulse width of zero signal 2.5 µs
relative humidity of air up to 95 %, no condensing
encoder supply 24 V approx. UB -1.5 V
(max. 26 V) operating temperature 0 °C ... 50 °C
5V 5 V + 5% stabilized with range
sense line storage temperature -20 °C ... +80 °C
SSI inputs range
EMC (observance of assembly instructions is mandatory)
data, cycle as per specification
RS 422 electromagnetic emissions acc. to EN 50081-1
cycle frequency approx. 375 kHz electromagnetic acc. to EN 50082-2
immunity
encoder supply UB - 1.5 V (max. 26 V)
The GEL 8180 is in strict conformity with Directive
Logic input (terminal strip) EMC 89/336/EEC of the European Union and is therefore
level low: 0 ... +5 V certified by the CE mark.
high: +15 ... +30 V Display
input resistance > 10 kΩ standard 2 LEDs
Logic output (terminal strip) option 24 LEDs signalizing the
Imax 300 mA, 8 outputs together switch position of inputs
max. 600 mA, sustained and outputs
short circuit-proof Housing
reaction time at overload > 1µs material sheet metal (Zincor)
voltage supply external 8 ... 30 V DC powder-lacquered black
fixture snap-on mounting on top
Digital output (cam 17 ... 64) hat rail as per DIN EN
outputs 2 x 24 50022-35 or simple
fastening with screws
Imax 20 mA per output: 200 mA weight approx. 1.2 kg
totally for all 48 outputs
voltage supply UB - 1 V Protection class IP 20

4 Lenord +Bauer DS22-8180(01.03)

 Z1 Z2
C B1 B2
Pin layouts
E2 A2

E3 A3

F H K

L1
L2
N G J

Connectors Z1, Z2 Connectors B1, B2

(counting inputs for an incremental enoder) (serial interfaces)

1 B1
0° 0 V1
6 + 5 / 24 V 1) 1
2
0° 2) 6
RxTx- ➀
7 RxTx+
sense 2) 2
3 7
90° Tx-
8 zero 3) 3
4 Tx+ 1)
90° 2) 8
Rx- ➁
9 zero 2) 4
5 Rx+
0V 9
Ri > 0,8 kW to 5 V 5
RxTx-
Ri > 10 kW to 24 V RxTx+ ➂
female 2)

female
1)
change with DIP switch (same voltage value as at N4, 26 V max.)
2) do not connect if not used B2
3)
alternative: sensor signal for reference fine function; if you use
1 0 V3
different voltage levels for the encoder (5 V) and the sensor (24 V)
adjust with DIP switch accordingly
➀ Ser 1: RS 485 with galvanical separation(PC etc.)
➁ Ser 2: RS 422/485 (daisy chaining EcoController)
E281047Z ➂ Ser 3: RS 485 with galvanical separation
(operator terminal GEL 8810)
1) switch on von RS 422 auf RS 485 mittels DIP switch
Connectors Z1, Z2 2) close DIP switch if several EcoControllers form
(actual value input for an absolute encoder) a cascade arrangement

1 E281047B
clock+
6 + 24 V 1)
2
clock-
7
3
data+ Connectors A2, A3
8
4 (data outputs)
data- tracks
9
5
0V connector A2 connector A3
1 17 41
female 14 18 42
2 19 43
15 20 44
1) change with DIP switch (same voltage value 3
as at N4, 26 V max.)
21 45
16 22 46
4 23 47
17 24 48
E281047S 5 25 49
18 26 50
6 27 51
19 28 52
7 29 53
Connector C 20 54
30
(serial interfaces RS 232 C) 8 31 55
21 32 56
9 33 57
22 34 58
10 35 59
RS 232 C 23 36 60
Ser1 11 37 61
1 24 38 62
12 39 63
6 nc 25
2 40 64
RxD 13 0 V1)
7 nc
0 V1)
3
TxD
8 nc
4
DTR
9 female
5 0V (identical with
0 V at B11) 1) alternative: +8 ... 30 V in case of
female external signal supply (programmable)

E281047C E281847A

DS22-8180(01.03) Lenord +Bauer 5

Pin layouts
1 1

1 2

7 + + * ) 4 ,

Connectors P Connectors I
(InterBus-S) 1 1
(two PROFIBUS ports connected in parallel)
5
9
4
8
3
7 GND1
2 /DI1
6 DI1
5 GND 1 /DO1
9 DO1
4 RxTx-
8 male
3 RxTx+
7 (galvanically separated)
2
6 +5 V
1 1 2

1 DO2
female 6
2 /DO2
7 DI2
3 /DI2
8 GND
Important! 4
9
The bus terminator GEL 89030 which is included in the scope 5 RBST
of supply must absolutely be plugged into connector P. +5 V

E281047P female E281047I

Terminal strip N Terminal strip F Terminal strip G

(supply voltage) (cam output) (control inputs)

1 ←~ voltage supply 1  0V 1 ← start

2 ← ~/+ 15 ... 23 V AC or 2 → track 1 2 ← /stop
+ 18 .. 30 V DC (UB)
3 ← - 3 → track 2 3 ← coarse reference
4 → + voltage output for the 4 → track 3 4 ← encoder simulation
signal encoders
5 → - ≈UB-1 V, max. 400 mA 5 → track 4
5 ← pause encoder simulation
6  nc 6 → track 5
6 ← 20 programme selection
7  nc 7 → track 6 binary BCD
7 ← 2 1
(continued at terminal
8  nc 8 → track 7
8 ← 22 strip J)
9  nc 9 → track 8
9  0 V (see terminal strip H)
10  nc 10 ← + 8 ... 30 V DC

E281825N E281825F E281825G

Terminal strip H Terminal strip J Terminal strip K

(cam output) (control inputs) (control outputs)
1 → track 9 1 ← track (group 1) 1  nc

2 → track 10 2 ← track (group 2) 2 → > Vmax

3 → track 11 3 ← track (group 3) 3 → < Vmin

4 → track 12 4 ← track (group 4) 4 → ⌬Ist>Max⌬

5 → track 13 5 ← track (group 5) 5 → ready

6 → track 14 6 ← track (group 6) 6 → calibrated

7 → track 15 7 ← track (group 7) 7 → started

8 → track 16 8 ← track (group 8) 8  nc

9 ← +8 ... 30 V DC 9  0V 9 ← +8 ... 30 V DC

G J
9  0 V (external supply) 9  0 V (external supply)
E281825H E281825J E281825K

6 Lenord +Bauer DS22-8180(01.03)

 Dimensioned drawings

EcoController GEL 8180 EcoController GEL 8180

for mounting on top hat rails for back panel mounting
79
90 74
140 5.5

approx. 80
41
82

65

166

184
172
104

40

E281136E E281136D

Mains transformator GEL 7923 Mounting plate GEL 7922

M4
» 118

top hat rail 35 mm

60
78

M4
» 65 » 71
5

50
60
20 0 20 0 0 115 230
60

7 6 5 4 3 2 1
20V 20V 115V
20VA 20VA 230V

50 X6203H E6101CH

Line filter GEL 7925

103
90
mains side

4.8

38.5
28

overall height 32

E6101AH

DS22-8180(01.03) Lenord +Bauer 7

Type code

actual value inputs

0 not mounted
A incremental counter input 24 V
B incremental counter input 5 V
S absolute SSI encoder
data input / output
0 not mounted
6 48 data outputs, 48 data inputs, 24 LEDs
8 InterBus-S
9 PROFIBUS DP
8180 A 0 _ 0 _ 0 0

PC software cable from operator terminal GEL 8810 to

Operating and Observing BB 8180 EcoController GEL 89019
connection cable RS 232C between PC
Accessories and EcoController GEL 89022
converter (V24/RS485) incl. supply unit GEL 89010 D-type subminiature adapter:
converter (V24/RS485) ● 25-pole male to 9-pole female GEL 89025
with galvanic signal separation ● 25-pole male to 25-pole female GEL 89026
incl. supply unit GEL 89011 ● 9-pole male to 9-pole female GEL 89027
cable from converter to EcoController GEL 89015 bus terminal connector (PROFIBUS DP) GEL 89030
cable from EcoController to EcoController mounting plate for mains transformer GEL 7922
● transmitter/receiver GEL 89016 SED mains transformer GEL 7923
● receiver/receiver GEL 89016 EED line filter with current-compensated chokes
250 V~ GEL 7925

Subject to technical modifications and typographical errors.

For the latest version please visit our web site : www.lenord.de.
8 Lenord +Bauer DS22-8180(01.03)