Table of Contents Table of Contents General information ......................6 1.1. About this documentation ..................6 1.2. Structure of the safety notes ..................6 1.3. Rights to claim under limited warranty ..............7 1.4. Exclusion of liability ....................7 1.5. Other applicable documentation ................
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Table of Contents 4.4. Power connections ....................22 Connections for linear conveyors ..................25 Example 1 – Two-zone controller ................25 5.1. Example 2 – Single-zone controller ................ 26 5.2. Example 3 – Double-motor-roller, single-zone control ..........26 5.3. 5.4. Examples of invalid configuration ................
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Appendix A – Dimensions and Installation Instructions ..........88 9.1. ECC-DFC module dimensions ................88 Appendix B – Configuring the PC for Ethernet subnetworks ......... 90 10.1. IP addresses and subnetworks ................90 10.2. Configuration example ................... 91 Manual – ECC-DFC field bus controller...
Read the information in this documentation. This is a prerequisite for safe opera- tion. The products will only achieve the specified product characteristics and per- formance characteristics if these requirements are met. SEW-EURODRIVE as- sumes no liability for injury to persons or damage to equipment or property result-...
You must ensure that persons responsible for the system and its oper- ation and persons who work on the product on their own responsibility have read the entire documentation carefully and understood it. Consult SEW-EURODRIVE if anything is unclear or you require further information.
Safety notes 2.3. Target group Specialist for mechanical work All mechanical work must be carried out by a qualified specialist. Qualified spe- cialists in the context of this documentation are persons familiar with the design, mechanical installation, troubleshooting, and maintenance of the product and have the following qualifications: ...
Safety notes 2.5. Functional safety technology If the documentation does not expressly permit it, the product must not perform any safety functions without supervisory safety systems. 2.6. Transport Inspect the shipment for damage as soon as you receive the delivery. Inform the shipping company immediately about any damage.
In the event of deviations from normal operation, switch the product off. Possible deviations are increased temperatures, noise, or vibration, for example. Deter- mine the cause. Contact SEW-EURODRIVE if necessary. Mechanical blocking or product-internal safety functions may result in a motor standstill.
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Safety notes machine for safety reasons, first disconnect the product from the supply system and then start troubleshooting. Risk of burns: The product surface temperature can exceed 60 °C during opera- tion! Do not touch the product during operation. Let the product cool down before touching it. Manual –...
Introduction Introduction 3.1. The concept The ECC-DFC fieldbus controller that is used for conveyor belt control is a series of individual ECC-DFC modules that are connected to each other via Ethernet cabling in order to provide a complete solution for the function of motor rollers in conveyor systems.
Introduction 3.3. Characteristics of the ECC-DFC fieldbus controller During the installation and configuration of one or more ECC-DFC module(s), a range of operating characteristics and configurable properties of the ECC-DFC fieldbus controller are available, which are accessible via the ECShell engineer- ing software.
Introduction 3.4. Overview of the hardware ECC-DFC modules are designed such that they can be installed and integrated in the side frame of the conveyor belt. ECC-DFC modules can be used to control up to 2 motor roller zones of the con- veyor belt.
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Introduction [13] Button for module exchange Left connection – RJ45 Ethernet network connection between modules [14] Right connection – RJ45 Ethernet network connection between modules [15] [16] Removable IP54 cover for Ethernet connections [17] 1 x power wiring cable gland for degree of protection IP54, 2 x RJ45 protective casing for degree of protection IP54 INFORMATION The designations “left”...
Hardware connections Hardware connections 4.1. Left and right motor connections Both connections use a 4-pin M8 connector. Each connector is mechanically coded in order to ensure that alignment is correct when the connector is plugged Figure 3 M8 connector and ECR socket Manual –...
Hardware connections 4.2. Left and right sensor connections Figure 4 Sensor connector Each sensor connection is a standard M8 socket with the following pin assign- ment: Figure 5 Sensor connection Signal Description DC 24 V DC 24 V module supply I/O signal –...
Hardware connections 4.3. Left and right Ethernet connections Both connections are RJ45 sockets that correspond to the pin assignment of the Ethernet connection. In order to comply with degree of protection IP54, Ethernet cables must be equipped with protective sleeves. Figure 6 shows the used Ethernet cables with sleeves to protect the RJ45 con- nector at the Ethernet cables.
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Hardware connections In order to correctly fit the IP54 protective sleeve to the RJ45 connector, a special tool is required. Figure 9 shows a Phoenix Contact 2891547 FL IP 54 assembly tool. INFORMATION This tool is not included in the scope of delivery! Figure 9 shows a Phoenix Contact Ethernet switch 2891547 FL IP 54 assembly tool NOTICE! It is advisable for all Ethernet cables between the modules to be shielded.
Hardware connections 4.4. Power connections 4.4.1. IP54 installation Parts [12] and [17] as shown in figure 2 are not connected to the module when it is delivered but are supplied separately in the module box. These parts are needed in order to create a power wiring installation that is compliant with IP54. The power cables are routed through the cable gland [17].
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Hardware connections 4.4.2. Logic and motor roller current supply Each module of the fieldbus controller has separate power connections for the module logic and the motor, so that these can be supplied via separate current supply units. For example, the motor current supply can be switched off using an emergency stop system, so that all motors are de-energized.
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Hardware connections 4.4.3. Grounding of the current supply Regardless of whether the logic and the motor rollers have a shared or a sepa- rate current supply, the DC supply ground connections (“-”) must be connected. One of the two current supplies must have a grounded DC connection. Direct ground connection of more than one current supply DC connection must be avoided, since this can lead to unintentional ground loops.
Connections for linear conveyors Connections for linear conveyors The fieldbus controller is designed for linear conveyor operation in such a way that an auto configuration process runs, which is carried out by the ECShell engi- neering software. Before the auto configuration process can be carried out, each individual module of the fieldbus controller must be correctly connected to the assigned motor roll- ers and photo sensors in order to achieve the required operating results.
Connections for linear conveyors Example 2 – Single-zone controller 5.2. In this example, a single motor roller and a single photo sensor are connected to either the left or right interface area. The module controls the motor roller as an individual, independent logical conveyor belt zone.
Connections for linear conveyors The module will now attempt to act as a two-zone controller, even though only one motor roller is connected. INFORMATION These invalid configurations will not lead to the auto configuration function being aborted. The user will notice only the occurrence of faulty operation and/or unex- pected results.
Status displays Status displays The module status is indicated using several LEDs. With the exception of the Ethernet link and activity LEDs, all LEDs are multi-colored and context-sensitive. The different meanings of all LEDs are explained in the following table. The num- bers relate to the positions on the module;...
Status displays 6.3. Motors Indication Position LED status Description Left motor 2 and 3 Motor not running and no error found and right motor Illuminated Connection has been established green Illuminated If motor is running: Indicates current limiting. If the motor is in the idle state: Indicates that the motor is not correctly connected or is running hot Voltage supply is less than 18 V or above 30 V Slow...
Auto configuration of the linear conveyor Auto configuration of the linear conveyor The goal of auto configuration of ECC-DFC networked fieldbus controllers is to provide a simple and fast way of starting up a linear conveyor system. The func- tion of the ECC-DFC fieldbus controller for auto configuration requires the use of the ECShell engineering software on a PC that is connected to the network mod- ule that is the furthest upstream.
Auto configuration of the linear conveyor 7.3. Definition of the ECC-DFC Ethernet INFORMATION Important basic information about understanding IP addresses in the Ethernet network and subnetwork terms can be found in “Appendix B – Configuring the PC for Ethernet subnetworks”. The description in this section assumes that you have general knowledge of IP addresses and subnetworks.
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Auto configuration of the linear conveyor Figure 16 shows 4 modules as they have been installed on the conveyor belt immediately after unpacking. As soon as the auto configuration master deter- mines and the auto configuration procedure has been carried out, the IP ad- dresses of all 4 modules are configured as shown in figure 17.
Auto configuration of the linear conveyor 7.4. Connect PC to the fieldbus controller network Connect the Ethernet connection of your PC to the auto configuration master using an Ethernet cable as shown in figure 18. Figure 18 Initial connection of a PC to the ECC-DFC subnetwork NOTICE! The PC must be connected directly to the network of the fieldbus controller.
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Auto configuration of the linear conveyor NOTICE! In order for the auto configuration process to work properly, the transported ma- terial must be removed from the entire conveyor line, and all photo sensors must be set so that none of them detect a load in their respective zone. Failure to comply with these conditions will lead to unexpected results.
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Auto configuration of the linear conveyor Figure 20 Topology view and initiation of auto configuration from selected nodes Note that in the topology view, the detailed information for each module is shown in RED if the module has not been configured. You can also select the module graphic from the topology view, right-click to display the context menu and initiate the auto configuration from there, as shown in figure 21.
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Auto configuration of the linear conveyor The node selected for auto configuration does not have to be the first module that is directly connected to the PC. The module at the other end of the line can also be selected as the auto configuration master, as shown in figure 22. Figure 22 Auto configuration from the node furthest away from the PC 7.5.1.
Auto configuration of the linear conveyor 7.6. Results of auto configuration 7.6.1. Normal results When the auto configuration procedure is complete, each module of the fieldbus controller is automatically restarted. If a module has been successfully configured and has been restarted, its module status LED flashes in green. INFORMATION Note that the duration of the auto configuration depends on the number of mod- ules to be configured.
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Auto configuration of the linear conveyor INFORMATION Note that another auto configuration request of some module or other in the fieldbus controller that is not the auto configuration master will not start another auto configuration procedure. The module concerned will detect that it is not the unit that is the furthest upstream and abort the procedure.
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Auto configuration of the linear conveyor 7.6.3. Single release mode/singulation (ZPA) Loads are normally transported from upstream to downstream zones in single release mode. A load that reaches the photo sensor of the final zone causes the motor in the final zone to continue running in order to transfer the load to the next conveyor or the next position.
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Auto configuration of the linear conveyor “Flex Zone” detection function 7.6.4. The fieldbus controller detects automatically if a box is longer than a zone length and automatically adapts the accumulation control so that the longer box then occupies two logical zones. This prevents the next upstream box from being transported into the longer box.
Auto configuration of the linear conveyor 7.7. Jam statuses The ECC-DFC detects two types of jam status: Sensor jam “No Arrival Jam” 7.7.1. Sensor jam If a load is still blocking the photo sensor in an upstream zone after an attempt has been made to transport the load to the next downstream zone, the controller detects a sensor jam.
Auto configuration of the linear conveyor 7.8. Network error In cases where the Ethernet network connection between the modules of the fieldbus controller is interrupted during operation, loads continue to be transport- ed and jam in the downstream zone that is furthest from the location where the network has been interrupted.
Auto configuration of the linear conveyor 7.11. Module replacement Proceed as follows to replace a fieldbus controller module: 1. Disconnect all module connections: Motor(s), network, photo sensor(s), hardware, and power. The order does not matter. 2. Connect the new module to the motor(s), sensor(s), hardware, network, and power. 3.
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Auto configuration of the linear conveyor Figure 28 Topology view and replacement of the selected node You can also replace a module by selecting the module graphic in the topology view, right-clicking it to display the context menu, and selecting “Replace this Node”...
ECShell engineering software ECShell engineering software 8.1. Introduction The ECShell engineering software is a PC-based application for configuring an ECC-DFC-controlled conveyor system. ECShell also makes it possible to modify preset module parameters. INFORMATION The previous sections describe how to install ECShell and perform the initial auto configuration.
ECShell engineering software 8.2. Options for configuring the IP address of a PC INFORMATION Note that the IP address of the PC does not have to belong to the same subnet- work as the fieldbus controller modules to perform the auto configuration with the ECShell engineering software.
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ECShell engineering software If the PC is configured so that it auto- matically receives an IP address, all you need to do is connect the PC as shown in figure 18. The IP address of the PC is configured so that the EC- Shell engineering software can be used.
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ECShell engineering software Starting ECShell If you have carried out the standard installation of ECShell, the program can be selected using “Start\All Programs\Industrial Software\ECShell”. If you chose a different storage location during the installation, start “ECShell.exe” from there. When you start ECShell for the first time, a window like the following one is dis- played, with deactivated status values and empty parameter check boxes.
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ECShell engineering software Proceed as follows to use the “Discover” function: 1. Press F2 in order to call up the “Advanced Dialog” function. Manual – ECC-DFC field bus controller...
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ECShell engineering software 2. Click the “Network Services” tab. If you have selected the “Network Services” tab, a window appears in which you not only see the connected modules but can also select modules whose IP address setting you would like to modify. Manual –...
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ECShell engineering software 3. Click “Discover” in this window. After you have clicked “Discover”, ECShell queries the network and displays a list of all modules that it finds, including the IP address, the serial number, and the current firmware of each module. The auto configuration master is the module with node 20.
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ECShell engineering software Method 2 – Modifying the PC to adapt to the auto configuration master 8.2.2. Since you now know the IP address of the auto configuration master, you can simply change the IP address configuration of the PC at this point so that it has access to the subnetwork of the auto configuration master.
ECShell engineering software INFORMATION The subnetwork concerned will no longer work from this point in time, since the IP address of its auto configuration master has been changed. You must now perform the auto configuration procedure again so that the IP addresses of all downstream modules are updated in order to match the address of the auto con- figuration master subnetwork.
ECShell engineering software which you would like to connect Node No. This is where you enter a range of nodes in which a connection is to be established. If entries are made in these fields, an update automatical- ly takes place. If you click “Refresh”, all of the other fields (3, 4 and 5) are also updated.
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ECShell engineering software In the example that is shown, only 10 nodes have been installed, but "12" was entered. After “Refresh” is clicked, two error messages are displayed one after the other. [-][+] The node value in the first field can be increased or decreased by clicking “+”...
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ECShell engineering software The current status of the selected connected module is displayed in the “Diagno- sis” window that opens. The window displays both the current status of the mod- ule and the zone status of the upstream and downstream connections of this module.
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ECShell engineering software Figure 31 Example of a module diagnosis window Sensor status – OFF means sensor is clear; ON means sensor is blocked Status of local upstream/downstream zone Status of zone upstream of module – “-“ means that no connection is config- ured Status of zone downstream of module Current status of connected motor –...
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ECShell engineering software An extremely useful function of the module diagnosis is the possibility of having the relevant parameters and the part number and serial number of the connected rollers displayed in a dialog window. As soon as the mouse is moved over the picture of the respective roller, the information is displayed;...
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ECShell engineering software 8.4.5. Selecting ZPA mode Singulation mode is the default configuration for all zones after the auto configu- ration procedure has been carried out. A description can be found in chapter “Singulation (ZPA)”. The ZPA modes that are available via ECShell are described in the following.
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ECShell engineering software As soon as the first box has passed the vicinity of the photo sensor, the gap timer starts. The next box arrives in the discharge zone and is stopped there until the gap timer has elapsed. When the gap timer has elapsed, the discharge zone is released and the train of boxes in all 10 upstream zones will start to move again simultaneously.
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ECShell engineering software NOTICE! Some aspects of material transport, such as the speed of the discharge convey- or and the weight of the load, must be carefully analyzed before using a T-bone configuration. Be sure to check the mechanical design and the load characteristics before start- ing up a T-bone arrangement.
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ECShell engineering software Figure 36 Two ECC-DFC T-bone example In order to configure a T-bone arrangement in such a way that it works properly, the “T-zone Accept Time” in the main window must be set to a non-zero value. This time value is the delay of the rollers in the accepting zone so that the up- stream sending zone can transport the load onto stationary rollers in the accept- ing zone.
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ECShell engineering software If the “Ignore Jam Sensor” check box has been activated, when the sensor is clear again, this 5-second delay is not used and the zone immediately switches back to automatic normal operation as soon as the sensor is clear. A similar situation applies to the Arrival Jam: If a load is moving from the up- stream to the downstream zone, the logic expects it to arrive in the downstream zone within the time set in the Jam Timer.
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ECShell engineering software INFORMATION If you are uncertain with regard to the motor type setting that is used, look this up in the motor roller documentation and check your application. Braking method The "Brake Method” drop-down menu contains all braking methods for motor rollers that are available for the ECC-DFC fieldbus controller.
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ECShell engineering software The following table describes the available braking methods for motor rollers: Method Description Normal Standard dynamic braking – the motor roller power circuit in the ECC-DFC is connected internally during the motor stop sequence in order to supply backwards-directed energy so that the rotor is braked.
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ECShell engineering software For example, the motor roller information in figure 32 shows that the nominal speed of the motor roller that is connected to the module is 60 m/min or 1 m/s. Entering a value of “1” for the speed and clicking “Set” sets the speed of the roll- er.
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ECShell engineering software Motor direction of rotation The direction of rotation can be chosen here, which is either clockwise (CW) or counter-clockwise (CCW). This setting is determined for each module based on the results of the auto configuration procedure. The term “Motor direction of rota- tion”...
ECShell engineering software 8.5. Advanced dialog The advanced dialog has already been mentioned in the section entitled “Use of the network help program”. The other selection options in this dialog window are described in the following. To call up the advanced dialog, simply press the following pushbuttons: ...
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ECShell engineering software Figure 38 Look Ahead function starts Figure 38 shows how a box passes the photo sensor of zone C and the module of zone B automatically adapts the speed to the previously configured Look Ahead speed. Activate the check box to enable the Look Ahead function for the selected node. Clicking “Set”...
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ECShell engineering software In this example, the slowed-down speed is proportional to 50% of 0.5 m/sec. De- tailed information about the “Slow Down” and “Fast Release Time” functions can be found in the pop-up window of the ECShell engineering software. Clicking “Set All”...
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ECShell engineering software Clicking the “Set” buttons for the Jam timer or the Run After timer results in the entered setting being downloaded to the respective zone of the selected node. Detailed information about the settings and functions of the Jam timer and the Auto Clear timer can be found in the pop-up window of the ECShell engineering software.
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ECShell engineering software 8.5.2. Upgrade The firmware help program can be accessed via the Upgrade tab. As time goes by, improvements and new functions are added to the product series. These must be loaded onto the modules via firmware upgrades. Firmware upgrades are files that are sent to you or made available for download- ing.
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ECShell engineering software Manual – ECC-DFC field bus controller...
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ECShell engineering software When the “Open” dialog window is displayed, navigate to the directory in which you have stored the firmware update file. Select this file and click “Open”. In this example, “Upload ALL” has been clicked, meaning that the firmware up- grade file is sent to all 6 nodes.
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ECShell engineering software When status of “Done” appears in the “Output” window for all nodes, the proce- dure is complete and you can close the Advanced dialog. Manual – ECC-DFC field bus controller...
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ECShell engineering software 8.5.3. Connections The Connections help program uses ECShell in order to instruct a certain module to establish a logical connection with another module that it would otherwise not have established during the auto configuration procedure. In applications with more than one subnetwork, the node of a subnetwork the is furthest downstream is logically linked with the node of another network that is the furthest upstream in this way.
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ECShell engineering software INFORMATION The following example requires the PC to have access to several subnetworks. More information can be found under Appendix B – configuring the PC for Ether- net subnetworks. Configuring node 192.168.27.25 1. First enter the correct subnetwork into the “Network IP” fields in the main window, plus the correct node that you would like to connect.
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ECShell engineering software The procedure is now half-way through. Then instruct the downstream module to accept the load from the upstream module, as described in the following. Manual – ECC-DFC field bus controller...
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ECShell engineering software Configuring node 192.168.25.20 1. First enter the correct subnetwork into the “Network IP” fields in the main window, plus the correct node that you would like to connect. In this case, xxx.xxx.xxx.20 is node 1 for this special subnetwork. 2.
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ECShell engineering software 8.5.4. Network Services The Network Services window is used both for checking for reachable networks and also for setting the IP address of a selected module. For more information, refer to the "Use of the network help program" section. 8.5.5.
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ECShell engineering software In this example, the left-hand pin 2 has been set as a “Wake up” input for the upstream zone of the module, and the right-hand pin 2 has been set as a “Lane Full” interface for the downstream zone. Note that the green arrows specify the zone (UP or DOWN) that has been as- signed to the function of the left or right pin 2.
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ECShell engineering software In this example, the same functions have been retained for pin 2, but this time the arrow has been selected that points diagonally from right-hand pin 2 to the up- stream zone (UP). This leads to a situation whereby the setting for pin 2 (“Lane Full Interface”) is applied to the upstream zone rather than the downstream zone.
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ECShell engineering software In this example, a typical zone “handshake” has been set for the upstream zone of the module. The left-hand pin 2 signal is the input that “wakes up” the zone and the right-hand pin 2 signal is an output that indicates that the upstream zone is occupied.
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ECShell engineering software In this example, a typical zone “handshake” has been set for the downstream zone of the module. The right-hand pin-2 signal is the input that instructs the re- lease of the downstream zone, and the left-hand pin 2 signal is an output that indicates that the downstream zone is occupied.
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ECShell engineering software In this dialog, you can also invert the meaning of the electrical signal by activating the “Invert” check box for one or both of the pins. Since the “Invert” check box is selected for both pin signals in the example that is shown, the respective func- tions are not activated until the signal has been electrically switched off.
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ECShell engineering software 8.5.7. Flex Zone ECC-DFC modules detect automatically if a box is longer than a zone length and automatically adapt the accumulation control so that the longer box occupies two logical zones. This prevents a collision between the following box and the longer box.
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ECShell engineering software 8.5.9. Extensions The “Extensions” tab allows you to extend individual zones or multiple zones into a “Master” zone or subordinate them to such a zone. To do this, go to the up- stream or downstream node of the module that you would like to extend and se- lect “This module (current node) is an extension of the downstream or upstream module (node up to which you would like to extend the current node)”.
Appendix A – Dimensions and Installation Instructions Appendix A – Dimensions and Installation Instructions 9.1. ECC-DFC module dimensions Manual – ECC-DFC field bus controller...
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Appendix A – Dimensions and Installation Instructions Dimensions in mm Manual – ECC-DFC field bus controller...
Appendix B – Configuring the PC for Ethernet subnetworks Appendix B – Configuring the PC for Ethernet subnetworks 10.1. IP addresses and subnetworks In order to connect to a network and/or use and control a conveyor system with several subnetworks, a certain amount of knowledge about Ethernet IP address- es is required.
Appendix B – Configuring the PC for Ethernet subnetworks Figure 41 Available subnetworks for each typical subnet mask value As you can see, it is possible to configure the PC using simple subnet mask val- ue manipulation so that it recognizes several networks. 10.2.
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Appendix B – Configuring the PC for Ethernet subnetworks INFORMATION The structure of the ECC-DFC IP addresses is designed such that the final octet (DDD) of all modules is greater than or equal to 20 and less than or equal to 240. This means that 36 valid addresses (256 - 220 = 36) are left free in the same subnetwork for other devices such as PCs and PLC controllers.
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Appendix B – Configuring the PC for Ethernet subnetworks When you click Properties, the “Internet Protocol (TCP/IP) Properties” window appears. In this example it has been as- sumed that an IP address has been as- signed to your PC by your office network. This is also indicated by the fact that the text fields in this window have been deac- tivated.
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