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IBS IP CDIO/R 24-8 IBS IP CDIO/R 24-8/SF Data Sheet INTERBUS Digital I/O Module for Use on Robots Revision C1 05/2000 Product Description The modules are designed as compact I/O units for use on robots. In the automotive industry in particular, they can be mounted directly on the welding transformer using Kempf terminal boxes. Features - IP 65 protection - Actuators and sensors are connected using 5-pos. female connectors - Electrical isolation of I/O and bus logic - Power supply for the bus logic and actuators provided via the hybrid cable Operation of both female connectors of one female connector pair (pairs: female connector 1 and 2, 3 and 4, 5 and 6 or 7 and 8): Ensure that there is a signal either at both female connectors only at pin 2 or at both female connectors only at pin 4. The simultaneous use of pin 2 and pin 4 is not permitted, as it may lead to incorrect signals. Use of pin 2 and pin 4 of one female connector: Ensure that the second female connector of the pair (pairs: female connector 1 and 2, 3 and 4, 5 and 6 or 7 and 8) remains unused. When using pin 2 and pin 4 of a female connector, the operation of the second female connector is not permitted, as it may lead to incorrect signals. 5221C1 522A0001 Figure 1: IBS IP CDIO/R 24-8... Phoenix Contact GmbH & Co. Postfach 1341 32819 Blomberg Germany 1 The IBS IP CDIO/R 24-8/SF module is a version of IBS IP CDIO/R 24-8 module. Differences are indicated in the data sheet. IBS IP CDIO/R 24-8 and IBS IP CDIO/R 24-8/SF modules are designed for use in a special installation remote bus in which the power supply for the module electronics and the actuators is carried as well as two wire pairs for additional signals. In the special application on a welding robot, these are signals CCR and SCM. The power supply for the bus logic (24 V DC) and for the actuators (24 V DC) is supplied to the robot controller in the hybrid cable and carried to the modules. R e m o te b u s S e n s o r 8 C C R S C M 2 4 V D C lo g ic s u p p ly P r o te c tiv e c a p U L 2 4 V D C a c tu a to r s u p p ly R o b o t c o n tr o lle r H y b r id c a (re m o te b w ith s u p p lo g ic a n d w e ll a s tw fo r a d d tio B A R C S e n s o rs / a c tu a to rs 7 b le u s b ra n c h ly fo r b u s a c tu a to rs a s o w ir e p a ir s n a l s ig n a ls ) R D E U S 2 U L 8 R C R D 7 8 6 3 1 S e n s o rs / a c tu a to rs 5 E U S 2 6 4 3 4 2 1 2 S e n s o rs / a c tu a to rs 5 IB S IP C D IO /R 2 4 -8 /S F R e m o te b u s B A S e n s o rs / a c tu a to rs IB S IP C D IO /R 2 4 -8 2 4 V D C lo g ic s u p p ly 2 4 V D C a c tu a to r s u p p ly R o b o t c o n tr o lle r 5 2 2 1 0 0 0 2 Figure 2: Electrical installation example for the IBS IP CDIO/R 24-8/SF module Both modules can only be operated using a controller board with Generation 4.x firmware. Cover unused female connectors with a protective cap to ensure IP 65 protection. 5221C1 Phoenix Contact GmbH & Co. Postfach 1341 32819 Blomberg Germany 2 Connector Pin Assignment O u tg o in g in s ta lla tio n r e m o te b u s O u tg o in g in s ta lla tio n re m o te b u s M a le c o n n e c to r 1 1 3 1 2 2 3 1 7 1 1 5 6 9 1 5 1 4 4 1 0 1 6 8 7 A s s e m b ly s id e C re s + 2 4 V 0 V + 2 4 V 0 V C C S S R D O D O D I D I O M e rv (+ (-U (+ (-U C R C R C M C M P E B S U L In c o m in g in s ta lla tio n r e m o te b u s 7 e d U S S 1 U S S 2 1 2 1 2 1 ) ) 2 ) ) T 9 1 0 1 1 6 4 1 3 2 1 2 1 7 1 3 1 4 5 1 5 1 6 7 y e llo w g re e n g ra y p in k b ro w n w h ite re d b lu e b ro w n b la c k b lu e re d b la c k p u r p le y e llo w /g r e e n 8 8 9 1 0 1 1 6 4 1 3 2 1 2 1 7 1 3 1 4 5 1 5 1 6 * P la c e s h ie ld in g in c o n n e c to r * C C R S C M C re s + 2 4 V 0 V + 2 4 V 0 V C C S S re s re s D O D O D I D I O M e rv (+ (-U (+ (-U C R C R C M C M P E e rv e rv e d U S S 1 U S S 2 1 2 1 2 In c o m in g in s ta lla tio n re m o te b u s 1 ) F e m a le c o n n e c to r 1 1 ) 2 ) ) 1 2 1 6 1 0 9 1 7 1 7 6 3 1 4 1 5 8 2 1 3 4 5 A s s e m b ly s id e e d e d P la c e s h ie ld in g in c o n n e c to r T h is ju m p e r n e e d o n ly b e in s e r te d if a n o th e r IB S C o n s ta n t c u r r e n t r e g u la tio n S e c o n d a r y c ir c u it m o n ito r in g d e v ic e fo llo w s 5 2 2 1 0 0 0 4 Figure 3: Connector pin assignment for the hybrid cable - Do not mix up the terminals, as this may damage the electronics. - Place the individual braided shields together and ensure the shield is fitted according to the manufacturers instructions. Mounting the Installation Remote Bus P r o te c tiv e c a p fo r s e n s o r/a c tu a to r c o n n e c to rs O u tg o in g in s ta lla tio n re m o te b u s In c o m in g in s ta lla tio n re m o te b u s 5 2 2 1 A 0 0 8 Figure 4: Mounting the connecting cables 5221C1 Phoenix Contact GmbH & Co. Postfach 1341 32819 Blomberg Germany 3 Connection of Inputs and Outputs The I/O from each two channel connector is wired together in an X shape (see Figure 5). This means that there are two inputs/outputs available at one female connector. The input/output signal of the affected channels is available at pin 4, the signal of the corresponding channel is at pin 2. If pin 2 is used (sensor or actuator with two signals), only one female connector may be connected per pair of channels. The corresponding female connector must remain unused and should be covered. F e m a le c o n n e c to r N F e m a le c o n n e c to r N + 1 3 1 4 5 3 D I/D O N 0 V 2 2 In te rn a l + 2 4 V 0 V In itia to r s o c k e ts 1 , 3 , 5 a n d 7 4 5 1 + 2 4 V D I/D O N + 1 In itia to r s o c k e ts 2 , 4 ,6 a n d 8 5 2 2 1 A 0 0 3 Figure 5: Channel pair 2 P in 1 + 2 4 V D C + 2 4 V D C + 2 4 V D C + 2 4 V D C + 2 4 V D C P in 3 0 V 0 V 0 V 0 V P in 4 IN /O U T B it 0 IN /O U T B it 1 IN /O U T B it 2 P in 2 IN /O U T B it 1 IN /O U T B it 0 IN /O U T B it 3 S u p p ly 1 In p u t/ O u tp u t C o n n e c tio n n u m b e r a n d p o s itio n 3 4 5 6 In p u t/ O u tp u t w ith 1 s ig n a l w ith 2 s ig n a ls S e n s o r o r a c tu a to r Table 1: Location and pin assignment of sensor/actuator sockets 7 8 + 2 4 V D C + 2 4 V D C + 2 4 V D C 0 V 0 V 0 V 0 V IN /O U T B it 3 IN /O U T B it 4 IN /O U T B it 5 IN /O U T B it 6 IN /O U T * B it 7 IN /O U T B it 2 IN /O U T B it 5 IN /O U T B it 4 IN /O U T * B it 7 IN /O U T B it 6 P in 5 P o s itio n o f th e c o v e re d c o n n e c to r ( w h e n P in 2 is u s e d ) 5 2 2 1 A 0 0 6 * In the IBS IP CDIO/R 24-8 module, channel 8 can be used in the same way as the other channels. In the IBS IP CDIO/R 24-8/SF module, channel 8 is used only as an input and is permanently connected to the terminal block on the back of the module. It cannot be used as an additional input nor as an output. This also means that there is no output signal at pin 2 of channel 7. Depending on the connector pin assignment, only the output or the input can be used for each channel. 5221C1 Phoenix Contact GmbH & Co. Postfach 1341 32819 Blomberg Germany 4 Additional Signals On the IBS IP CDIO/R 24-8/SF module, additional signals can be carried from the back of the module via spring-clamp terminals. For the special application on a welding robot, this involves the following signals: - Temperature of the welding transformer - Signal for constant current regulation (CCR) - Signal for secondary circuit monitoring (SCM) Permanently connected to input 8 Looped directly into the hybrid cable Looped directly into the hybrid cable Signal CCR is used to control the welding current. It is passed on to the welding controller by the welding transformer. The input for the thermostatic switch is permanently connected to input 8. 1 3 0 m m ( 1 .1 8 1 in .) 1 1 m m ( 0 .4 3 3 in .) 2 2 1 5 2 2 1 0 0 0 7 Figure 6: Terminal block on the back of the module Table 2: Terminal assignment for the terminal block Terminal Signal 1 Initiator supply UINI 2 IN 8 3 GND 4 Constant current regulation 1 (CCR1) 5 Constant current regulation 2 (CCR2) 6 Secondary circuit monitoring 1 (SCM1) 7 Secondary circuit monitoring 2 (SCM2) In the IBS IP CDIO/R 24-8 module, this terminal block is not provided and signals CCR and SCM are looped through from the incoming to the outgoing remote bus. 5221C1 Phoenix Contact GmbH & Co. Postfach 1341 32819 Blomberg Germany 5 Programming Data Table 3: The most important data for programmers ID code 3dec (03hex) Length code 81hex Input address area 1 byte Output address area 1 byte PCP address area 0 bytes Register length on the bus 1 byte 54 mm (2.13 in.) 33 mm (1.30 in.) 18,5 mm (0.73 in.) Housing Dimensions 48 mm (1.89 in.) 3 mm (0.19 in.) 13 mm (0.51 in.) 2 22 mm (0.87 in.) 1 87 mm (3.42 in.) 4 8 mm (0.31 in.) 3 Æ 6 4,5 mm (0.18 in.) 5 Æ 8 150 mm (5.91 in.) 7 73 mm (2.87 in.) UL BA RC RD E US2 3 mm (0.19 in.) 62 mm (2.44 in.) 20,5 mm 14 mm (0.55 in.) (0.81 in.) 5221A005 Figure 7: Housing dimensions for the IBS IP CDIO/R 24-8/SF module The IBS IP CDIO/R 24-8 module has the same housing dimensions, but does not have an opening and seal on the back. 5221C1 Phoenix Contact GmbH & Co. Postfach 1341 32819 Blomberg Germany 6 Technical Data General Data Type Ambient temperature - Operation - Storage/transport Humidity - Operation - Storage/transport Degree of protection Electrical isolation between Housing - Dimensions (length x width x height) IBS IP CDIO/R 24-8, IBS IP CDIO/R 24-8/SF 0°C to 55°C (32°F to 131°F) -25°C to 70°C (-13°F to 158°F) 75%, no condensation 95%, no condensation IP 65, when installed, unused slots should be covered with a protective cap - I/O - Bus logic with a test voltage of 500 V AC, 1 min 150 mm x 54 mm x 48 mm (5.906 in. x 2.126 in. x 1.890 in.) Supply Voltages Bus voltage US1 Nominal voltage 24 V DC Permissible range 18.5 V DC to 30.5 V DC (ripple included) Ripple 3.6 Vpp Current consumption Approximately 120 mA plus initiator current The voltage US1 is looped through and can be tapped off at the connector for the outgoing remote bus. The maximum continuous current is 4.5 A. Initiator voltage UINI Nominal voltage US1 minus 1 V Current consumption 40 mA total current for all inputs (5 mA per input) Protection by fuses Electronic overload/ short circuit protection Actuator voltage US2 Nominal voltage 24 V DC Permissible range 18.5 V DC to 30.5 V DC (ripple included) Ripple 3.6 Vpp Current consumption 3.5 A, maximum (IBS IP CDIO/R 24-8/SF) 4.0 A, maximum (IBS IP CDIO/R 24-8) The voltage US2 is looped through and can be tapped off at the connector for the outgoing remote bus. The maximum continuous current is 7.0 A. INTERBUS Interface Interface type Connection technology Connector pin assignment 5221C1 Two-wire installation remote bus; Differential signal lines, twisted in pairs IP 65 circular connector See Figure 3 Phoenix Contact GmbH & Co. Postfach 1341 32819 Blomberg Germany 7 Digital Inputs Number of inputs Electrical isolation Input voltage - Permissible range 0 signal - Permissible range 1 signal Input current Permissible residual current 0 signal Delay time 0 -> 1 Delay time 1 -> 0 7+1 (IBS IP CDIO/R 24-8/SF) 8 (IBS IP CDIO/R 24-8) Yes, for bus logic Test voltage 500 V AC, 50 Hz, 1 min. According to DIN 19240 -30 V to +5 V +13 V to +30 V 5 mA at 24 V, typical 1.5 mA 3 ms, typical 3 ms, typical Digital Input for Thermostatic Switch (for IBS IP CDIO/R 24-8/SF Only) The digital input for the thermostatic switch of the welding transformer is on the back of the module and can be accessed through the ground plate. It is permanently connected to input 8. Connection method Spring-clamp terminal 0.13 - 0.5 mm2 (26 - 20 AWG) Digital Outputs Number of outputs Min. output voltage at nominal current Nominal current per channel Concurrent channel derating Derating Protective functions Short circuit current protection Limitation of the voltage induced on circuit interruption Protection against ground connection interruption Max. leakage current at 0 signal Electrical isolation 8 (IBS IP CDIO/R 24-8) 7 (IBS IP CDIO/R 24-8/SF) US2 minus 1 V 0.5 A electronically short circuit-proof 0.5 All outputs can be on at maximum current without exceeding housing maximum power dissipation. Electronic short circuit protection Free running circuit