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Vahle DCS1-SMGM Instructions Manual

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TRANSLATION OF THE ORIGINAL INSTRUCTIONS
DCS1-SMGM CONTROL SYSTEM
SINGLE AXLE SMGM CONTROL
SYSTEM MANUAL
EN | V 1.04 | DCL 046

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Summary of Contents for Vahle DCS1-SMGM

  • Page 1 TRANSLATION OF THE ORIGINAL INSTRUCTIONS DCS1-SMGM CONTROL SYSTEM SINGLE AXLE SMGM CONTROL SYSTEM MANUAL EN | V 1.04 | DCL 046...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ..............Document history .
  • Page 3 TABLE OF CONTENTS ..............10 Communication .
  • Page 4 TABLE OF CONTENTS ..............19 Declaration .

  • Page 5: Document History

    DOCUMENT HISTORY DOCUMENT HISTORY Material number Version Edition Description/changes 1.01 08/2017 First issue 1.02 08/2018 Parameter „display“ modificated 1.03 12/2021 Added to parameter Drive - Brake opening time 1.04 01/2023 Added new CE Declaration of Conformity and UKCA Declaration of Conformity;...

  • Page 6: Abbreviations

    ABBREVIATIONS ABBREVIATIONS Deto Control System - Control DCSX mobile multi-axle control DCS1 mobile single-axle control Electrical overhead conveyor rail High frequency Industrial Ethernet PROFINET ETHERNET/IP Synchronous serial Interfaces SYSCAN System CAN bus Half cycle Power CAN bus / Rail bus /PowerCAN SMGM Slotted Microwave Guide Mini APOS optic...

  • Page 7: General

    GENERAL About these instructions These operating instructions enable the safe and efficient handling of our VAHLE products. This document is an integral part of the installation and must be kept accessible to operating and maintenance personnel in the immediate vicinity. The basic requirement for safe working is compliance with all specified safety instructions and instructions.

  • Page 8: Symbols

    GENERAL Symbols Safety instructions in this manual are identified by symbols. Each safety instruction begins with a signal word that indicates the severity of the hazard. The various types of warnings and safety instructions and their struc- ture are explained below. DANGER! The source of the hazard is described here.
  • Page 9 GENERAL NOTICE! This indicates a reference to another place in this text or another document. This combination of a symbol and a signal word indicates a reference to another place in this text or in a different document. ► The places in the text or references to other documents are identified here. TIPS AND RECOMMENDATIONS! ►...

  • Page 10: Copyright Protection

    We reserve the right to make technical changes to improve the usability and for further development. Customer service Paul Vahle GmbH & Co. KG Westicker Str. 52 Tel: +49 (0) 2307 704-0...

  • Page 11: Warranty

    If the operator independently performs repairs during the warranty period or has repairs performed by third parties. • If the product has been handled or maintained inappropriately. • If parts are used that are not original parts approved by Vahle. • If the information in this documentation is not observed.  ...

  • Page 12: Safety Instructions

    SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS Safety This section gives an overview of all important safety aspects relating to the protection of personnel as well as the safe use and fault-free operation. Other, task-specific safety instructions can be found in the sections on the individual phases of the product's life.

  • Page 13: Intended Use

    SAFETY INSTRUCTIONS Intended use DCS1 control systems are designed for the use on the mobile side of a rail guided automation system. Independent of the configuration, a multiplicity of sensors and actuators can be connected to the control sys- tems. The sensors and actuators are supplied by 24 V DC. The supply voltage of the DCS1 control system depends on the respective project planning and is typically in the following ranges: •...

  • Page 14: General Risks

    SAFETY INSTRUCTIONS General risks The following section describes residual risks that arise even if the product is used as intended. Observe the safety instructions listed here in the other sections of these instructions to reduce the risk of injuries or dam- age to property and equipment and to avoid dangerous situations.

  • Page 15: Danger From Electrical Energy

    SAFETY INSTRUCTIONS 4.3.1 Danger from electrical energy Perform the following safety work according to VDE 0105-100 (this work must be carried out by a qualified elec- trician, see chapter: "2 security"). Activate The required separation distances must be established. Secure against restart During work, a prohibition sign must be attached reliably on switching handles or drives of switches, control units, pressure and sensing devices, safety parts, circuit breakers that have been used to unlock a system part or that can be used to connect electricity.

  • Page 16: Responsibilities Of The Operating Company

    SAFETY INSTRUCTIONS Responsibilities of the operating company Definition of the operating company The owner is listed in the order confirmation and has the following owner obligations: Owner obligations The system is put to commercial use. The owner of the system is therefore subject to laws and regulations on workplace health and safety.

  • Page 17: Personnel Requirements

    SAFETY INSTRUCTIONS Personnel requirements 4.5.1 Qualifications The tasks described in this manual present various requirements to the qualifications of the persons perform- ing them. WARNING! Hazard in case of insufficient qualification of personnel! Insufficiently qualified persons are unable to judge the risks when working on the sys- tem, which puts them and others at risk of severe or fatal injuries.

  • Page 18: Personal Protective Equipment

    SAFETY INSTRUCTIONS Personal protective equipment Every person who is instructed to work on the system or in the vicinity of the system (support personnel) must wear personal protective clothing/equipment for the suitable type of their work. Personal protective equipment has the purpose of protecting personnel against hazards to their health and safety at work. The owner is re- sponsible for ensuring that protective equipment is worn.

  • Page 19: Safety Devices

    SAFETY INSTRUCTIONS Safety devices WARNING! Danger from non-functional safety devices! Non-functional or disabled safety devices cause a risk of severe injuries or even death. ► Before beginning any work, verify that all safety devices are functional and in- stalled properly. ►...

  • Page 20: Conduct In Case Of Danger Or Accident

    SAFETY INSTRUCTIONS Conduct in case of danger or accident Precautions: • Have first-aid equipment (first-aid kit, blankets etc.) and fire extinguisher ready. • Maintain free access for emergency services vehicles. Conduct in case of accident: • Secure site of accident and call first aid personnel. •...

  • Page 21: Signage

    SAFETY INSTRUCTIONS Signage The following symbols and instruction signs are located in the work area. They relate to the immediate envi- ronment in which they are installed. DANGER! Danger of death due to electrical current! Contact with live parts can result in life-threating injuries. ►...

  • Page 22: Technical Data

    TECHNICAL DATA   TECHNICAL DATA Information Basis Description Conformity and approval 2014/35/EU Low voltage directive 2014/30/EU EMC directive Person and equipment protection Protection class EN60529 IP54 All plug connectors that are not in use must be closed with protective caps or blind plugs. The USB cover screw connection must be available.
  • Page 23 TECHNICAL DATA   Information Basis Description Operation EN60721-3-3 EN60721-3-7 Electrical Mains connection - X1 TT, TN (with grounded neutral Operation permitted without restrictions point) Motor connection - X2 Number of motor connections Length of the motor line < 5m from motor plug Line type shielded servo-cable, e.g.
  • Page 24 TECHNICAL DATA   Information Basis Description Storage capacity depending on the application Parameterization Interface USB (mini USB, type B, bushing) Usage Parameterizing, configuration, etc. Required software EHB tool  ...

  • Page 25: Dcs1 Control Systems

    DCS1 CONTROL SYSTEMS   DCS1 CONTROL SYSTEMS Application and use DCS1 control systems provide the control of the drive motors in automated, rail based systems. The digital in- puts and outputs (IO) are used to analyze a variety of sensors and actuate the actuators. The DCS1 control system series can in principle be differentiated by the type of communication.

  • Page 26: Mechanical Dimensions

    DCS1 CONTROL SYSTEMS   Mechanical dimensions Fig. 6-1 Dimensions DCS1 standard control systems up to 1.1 kW, dimensions in [mm] TIPS AND RECOMMENDATIONS! Information about the dimensions for DCS1 control systems with 1.5 kW converter An additional heat exchanger is mounted at the rear for DCS1 control systems with a 1.5 kW converter.

  • Page 27: Connections And Display Elements

    DCS1 CONTROL SYSTEMS   Connections and display elements Fig. 6-2 DCS1 control system (standard configuration, with the heat exchanger) 1: Motor connection 2: Cover of the USB configuration interface 3: Infrared interface 4: Display 5: On/off switch 6: Flange (IO) 7: Mains connection –...

  • Page 28: Type Code

    DCS1 CONTROL SYSTEMS   Type code TIPS AND RECOMMENDATIONS! Type code The type code shows DCS1 standard configurations. Fig. 6-3 Type code of DCS1 controllers  ...

  • Page 29: Displays

    DISPLAYS   DISPLAYS Control units series DCS1 include a two line OLED display (2x16 characters), which is used to display status and operating displays. Standard display Display Explanation Only for HW communication type! Currently issued frequency and the status of the inputs (HEX coded) Display Explanation...
  • Page 30 DISPLAYS   A transfer to the status display occurs after pressing the button [SCROLL]. Display Explanation Only for HW communication type! The state of the individual in- puts is displayed here. H12 represents the half cycle signal 1 and 2. + represents the positive, - represents the negative and x represents the full cycle.
  • Page 31 DISPLAYS   Display Explanation Only PCB communication type! Currently sent speed through PowerCAN. Display Explanation Only PCB communication type! Status display Display Explanation Only PCB communication type! RX signals Display Explanation Only PCB communication type! SYNC data Display Explanation Only PCB communication type! TX signals Display Explanation...
  • Page 32 DISPLAYS   Display Explanation Only SMGM communication type! Current acceleration and deceleration ramp. Display Explanation Only SMGM communication type! RX signals Display Explanation Only SMGM communication type! TX1 signals Display Explanation Only SMGM communication type! TX2 signals  ...
  • Page 33 DISPLAYS   A transfer to lower level takes place by pressing the button [MODE2]. The following can be found there: Display Explanation Operating minute counter Number of times that the control system was switched on.  ...
  • Page 34 DISPLAYS   Browsing through the individual pages takes place by pressing the button [SCROLL]. Display Explanation Error histogram - the last 10 errors are stored here. The upper line changes between error histogram and the real fault number with a relative time stamp referenced to the operating minutes. The lower line displays the error in plain text.

  • Page 35: Connections

    3 phases through the current rails. Data: Connection X1 Fig. 8-1 Connection X1 - supply voltage/half cycle communication Type Description Connection X1 VAHLE DETO plug field, 8 poles Line voltage 3/PE/PEN AC 360 ... 528V ±0% Mains frequency 45 ... 65Hz ±0% Function...

  • Page 36: Alternating Voltage With Smgm

    Mains connection of the DCS1 control system. The supply is provided with 3 phases through the current rails. Data: Connection X1 Fig. 8-2 Connection X1 - supply voltage Type Description Connection X1 VAHLE DETO plug field, 8 poles Line voltage 3/PE/PEN AC 360 ... 528V ±0% Mains frequency 45 ... 65Hz ±0% Function...

  • Page 37: Motor Connection

    CONNECTIONS   Motor connection Motor connection of the DCS1 control system. Data: Connection X2 Fig. 8-3 Connection X2 - motor connection Type Description Connection X2 Harting HAN10B, 10pole+PE, bushing Plug cycles > 100 Power Depending on the frequency con- verter used Frequency 0 ...

  • Page 38: Flange

    CONNECTIONS   Flange TIPS AND RECOMMENDATIONS! Information about the use of the flanges The selection of the flanges for the DCS1 control system series depends on the com- munication method used. The SA02 is used for the communication through half cycle and rail bus, while the SA06 flange is used for the SMGM communication.

  • Page 39: Sa06 - Flange For Smgm

    CONNECTIONS   8.3.2 SA06 - Flange for SMGM Fig. 8-4 Diagrammatic view of the flange SA06  ...
  • Page 40 CONNECTIONS   Sensor connections - digital interfaces Fig. 8-5 Sensor connection digital (X20) Type Description Connection X20 M12, A coded, 5 pole, bushing Plug cycles > 100 Contact AU (gold) Function Description Supply voltage +24VDC DIN 2 Digital input 2 Supply ground DIN 1 Digital input 1...
  • Page 41 CONNECTIONS   Fig. 8-6 Sensor connection digital (X21) Type Description Connection X21 M12, A coded, 4 pole, bushing Plug cycles > 100 Contact AU (gold) Function Description Supply voltage +24VDC DIN 3 (DOUT 1 optional)* Digital input 3 Supply ground DIN 4 Digital input 4 * Either the input DIN3 or the output DOUT 1 can be used.
  • Page 42 CAN low CAN_GND CAN mass not connected not connected TIPS AND RECOMMENDATIONS! Information about the connection line for the SYSCAN communication interface Only the Vahle system CAN bus cable DCS/BCC must be used for the connection of the communication interface!  ...
  • Page 43 CONNECTIONS   Sensor connection - serial interface Fig. 8-8 Sensor connection serial (X23) Type Description Connection X23 M12, A coded, 5 pole, bushing Plug cycles > 100 Contact AU (gold) Function Description Supply voltage +24VDC RS485_A Data Supply ground RS485_B Data not connected  ...
  • Page 44 CONNECTIONS   Data connector interface (for VAHLE data connector DS-VD) Fig. 8-9 Data connector interface Type Description Connection Card Edge 2x10Pin Data plug DS-VD NOTICE! Loss of the protection class IP54 as well as disturbances through interferences if the data connector is missing Damage of the control system as well as operating failures ►...

  • Page 45: Parameterizing Connection

    The USB interface permits the communication between APC and the VAHLY DCS1 control system. The USB in- terface can be used to change parameter values or to upload parameter sets. This is why the VAHLE EHB tool is required.

  • Page 46: Frequency Converter

    FREQUENCY CONVERTER   FREQUENCY CONVERTER NOTICE! Danger of destroying the frequency converter through wrong operating mode Destruction or damaging the frequency converter ► The frequency converter is not qualified for the permanent regenerative mode. Available frequency converters Frequency converter Power [kW] Identifier FU 0.75kW 0.75...

  • Page 47: Fu 0.75Kw

    FREQUENCY CONVERTER   FU 0.75kW Technical data Product key identification: B; Motor power ( 4 pole ASM): 0.75kW; Information for switching frequency 8kHz 3/PE AC 400V/480V 2/PE DC 565V Startup current Effective Peak peak Rated power (typical EHB application) Start-up current 70% [kW] 0.75 Typical motor power (4 pole ASM, star...

  • Page 48: Fu 1.10Kw

    FREQUENCY CONVERTER   FU 1.10kW Technical data Product key identification: C; Motor power ( 4 pole ASM): 1.10kW; Information for switching frequency 8kHz 3/PE AC 400V/480V 2/PE DC 565V Startup current Effective Peak peak Rated power (typical EHB application) Start-up current 70% [kW] Typical motor power (4 pole ASM, star [kW]...

  • Page 49: Fu 1.50Kw

    FREQUENCY CONVERTER   FU 1.50kW Technical data Product key identification: D; Motor power ( 4 pole ASM): 1.50kW; Information for switching frequency 8kHz 3/PE AC 400V/480V 2/PE DC 565V Startup current Effective Peak peak Rated power (typical EHB application) Start-up current 70% [kW] Typical motor power (4 pole ASM, star [kW]...

  • Page 50: Communication

    COMMUNICATION   COMMUNICATION 10.1 General The following communication options are available for VAHLE DSC1 control systems: • HW (Half cycle) • PCB (rail bus) • SMGM Overview communication methods Half cycle (HW) Rail bus (PCB) SMGM Transmission through contact wire...

  • Page 51: Smgm

    COMMUNICATION   10.2 SMGM 10.2.1 Basics The communication through SMGM (Slotted Microwave Guide Mini) is realized through a slotted waveguide, which was especially designed for this application. This method is suitable for complex control tasks. The ad- vantage is the higher transmission speed. Using the especially designed slotted waveguide make is possible to have a parallel operation to other industrial radio transmission processes, free of failures and interruptions.
  • Page 52 COMMUNICATION   The SMGM-BCC/DCS can be used when using a VAHLE DCS1 control system. Using this system it is possible that a stationary SMGM module supplies 2 segments with 15 participants each. The field bus is available 1 on 1 on the mobile side.

  • Page 53: Interface Description

    COMMUNICATION   10.2.2 Interface Description The following description refers to the transmission through PROFINET. Data PLC to DCS1 Byte Description 0 ... 7 Speed specification LOW byte [1/10 mm per s] 0 ... 7 Speed specification HIGH byte [1/10 mm per s] Emergency stop Open brake Activate speed control...
  • Page 54 COMMUNICATION   Data from DCS1 to PLC 1. Telegram Byte Description 0 ... 7 Position LOW byte [mm] 0 ... 7 Position MIDDLE byte [mm] 0 ... 7 Position HIGH byte [mm] DIN 1 DIN 2 DIN 3 DIN 4 DIN 5 DIN 6 DIN 7...
  • Page 55 COMMUNICATION   2. Telegram Byte Description 0 ... 7 Mirroring query index PM data (preventive maintenance data) 0 ... 7 Queried PM data (preventive maintenance data) 0 ... 7 0 ... 7 0 ... 7 0 ... 7 0 ... 7 Vehicle number LOW byte 0 ...

  • Page 56: Layout And Function

    LAYOUT AND FUNCTION   LAYOUT AND FUNCTION 11.1 System overview External interfaces of a DCS1 control system Fig. 11-1 External interfaces of a DCS1 control system (schematic diagram) 1: Supply voltage from the current rail 2: Mobile vehicle/fastening location of the DCS1 control system 3: brake resistance 4: Motor 5: IR remote control: MC8/10M (maintenance/service)

  • Page 57: Commissioning

    COMMISSIONING   COMMISSIONING 12.1 Safety instructions for commissioning 12.1.1 Mechanical installation WARNING! Danger due to damaged products Accidents, severe injuries as well as property damages. ► Never install damaged products. Report damages immediately to the transport company. NOTICE! Danger due to connection to wrong mains voltage Damage or destruction of the device.

  • Page 58: Electrical Installation

    COMMISSIONING   12.1.2 Electrical installation Important information DANGER! Danger due to fatal electric shocks when working at energized lines Fatal or severe injuries ► The contacts of the wire connections (mains and motors) X1, X2, X3, X can carry life threatening voltages if the control system is connected to the mains. Therefore, disconnect the control system from the voltage before you perform any work at it.

  • Page 59: Emc

    COMMISSIONING   12.1.3 An EMC conforming installation is required to guarantee the flawless operation of VAHLE control systems on electric overhead conveyor rails. This includes: Install the motor line as described in the technical data. Install the motor connection line (U, V, W connections) separately from the sensor lines: •...

  • Page 60: Operating Modes

    Please ensure that the manual mode is only activated by authorized skilled employees. The VAHLE IR remote control MC8/10M (ident.-No.: 0777006/00) is required for manual mode. Additional information about the IR remote control can be found in section: “IR remote control MC8/10M“...

  • Page 61: Operation

    COMMISSIONING   12.2 Operation 12.2.1 First commissioning Before the first commissioning, please check: • whether the drives are undamaged. • the entire wiring (control system) for completeness, short circuit and ground faults. • whether the phases of the line voltage and the motors are connected correctly. •...

  • Page 62: Configuration/Parameterization

    Fig. 13-1 Connection of the DCS1 control system to the PC/laptop 2. Using a USB cable, USB mini connector type B - type A connector, connect the control system to the PC. 3. Start the VAHLE EHB tool and select the correct parameter set. Fig. 13-2 Start screen EHB Tool...
  • Page 63 CONFIGURATION/PARAMETERIZATION   Functions Buttons Description Read parameters The parameters stored on the control system will be downloaded to the PC. Write parameters The parameters “A” opened on the PC will be downloaded to the PC. Save in the file The parameters opened on the PC will be saved in a file (*.epar). Load from file A parameter file (*.epar) will be loaded from a file and will be opened.

  • Page 64: Parameterization

    ► Tool manual: EHB tool - DCS1 parameter description TIPS AND RECOMMENDATIONS! Configuration information about the VAHLE control systems During configuration, be aware of the respective type or the furnishings of your control system.  ...

  • Page 65: Overview Parameter Screen

    CONFIGURATION/PARAMETERIZATION   13.2.1 Overview parameter screen Overview parameter screen Fig. 13-3 EHB Configurator parameter screen 1: Parameter area 2: Adjustment area 3: Parameter will be visible after activation 4: Some settings must activated by clicking a checkbox.  ...

  • Page 66: Parameter: General Information

    The other communication types, as shown in the following table, are only available af- ter prior analysis of the requirements or the existing system (in the portfolio) by VAHLE. Special hardware configurations are required for the communication types HW, PCB and SMGM.
  • Page 67 CONFIGURATION/PARAMETERIZATION   Parameter: “Parameter information” Parameter Selection Description Parameter version 0 ... 999 Parameter version number  ...
  • Page 68 CONFIGURATION/PARAMETERIZATION   Parameter: “Display” Parameter Selection Description Display language Display language: Deutsch Display language: English Display language: Spanish (currently not available) Screen saver display Active Screensaver active (To protect the display from aging, the connection screen saver is always active, to maintain compatibility with old versions, the parameter is preserved.) Screen saver settings Time until screen sav-...
  • Page 69 CONFIGURATION/PARAMETERIZATION   Parameter: “Data stick” Parameter Selection Description Data stick Check box Activate if a data stick is used. RF interface connec- Inactive Activation of the infrared data transmission (additional sta- tion tionery module required). Currently not available Active Production data con- Inactive Activate if production data must be stored on the stick.
  • Page 70 CONFIGURATION/PARAMETERIZATION   Parameter: MC 8/10M (IR remote control) WARNING! Danger due to switched off limit switches Accidents, severe injuries as well as property damages ► No limit switches are active in the infrared manual mode (except if it was set in advance)! ►...
  • Page 71 CONFIGURATION/PARAMETERIZATION   Parameter: “Manual mode links” Functions can be assigned here to the keys 1 ... 8 of the remote control. Parameter Selection Description Speed 0 ... 9 Speed selection forward/backward forward (right rotating field) backward (left rotating field) Brake Brake will be aerated Item Control system moves into the next stop position (only for...
  • Page 72 CONFIGURATION/PARAMETERIZATION   Parameter: “Timer” Parameter Selection Description Timer ON 0 ... 65000ms Setting of the switch-on delay for each input Timer OFF 0 ... 65000ms Setting of the switch-off delay for each input  ...
  • Page 73 CONFIGURATION/PARAMETERIZATION   Parameter: “Drive“ Parameter Selection Description Speed @ 50Hz 1 ... 20000 mm/s Speed settings at 50 Hz. The speed is used as the calcula- tion base for many functions of the control system in connec- tion with PowerCAN and the absolute distance measurement system (e.g.
  • Page 74 CONFIGURATION/PARAMETERIZATION   Parameter Selection Description Voltage controller Controller call-up in Frequency converter voltage controller is processed in the in- mode the interrupt (faster) terrupt (faster) Controller call-up in Frequency converter voltage controller is processed in the the polling polling (slower) Dead time 1.5/2/2.5/3...
  • Page 75 CONFIGURATION/PARAMETERIZATION   Parameter: “VAC” TIPS AND RECOMMENDATIONS! Information about the VAC operation The control system hardware DCS1 VAC (Vacuum Cleaner) is mandatorily required for the variant. Parameter Selection Description Check box Activate for control system type DCS1 VAC. Required minimum 0 ...

  • Page 76: Parameter: Smgm Control

    CONFIGURATION/PARAMETERIZATION   13.2.3 Parameter: SMGM control Parameter: “Communication” Parameter Selection Description Timeout time 0 ... 9999ms Timer for communication monitoring  ...
  • Page 77 CONFIGURATION/PARAMETERIZATION   Parameter: “Stop configuration” The behavior of the control system when using up to four collision initiators can be parameterized in the table stop configuration. Parameter Selection Description Input 1 1 ... 12 Number of the input used. Input 2 1 ...
  • Page 78 CONFIGURATION/PARAMETERIZATION   Parameter: “Positioning” The graphic “Positioning” can be found in section: “13.3 Positioning“ Parameter Selection Description Position offset moni- 0 ... 999999999mm (Graphic: Positioning “C”) toring target pos. Overtravel Positioning window 0 ... 255mm Positioning accuracy (graphic: Positioning “A”) Fine positioning 0 ...
  • Page 79 CONFIGURATION/PARAMETERIZATION   Parameter: “Speed controller” Parameter Selection Description Control type Absolute value sensor APOS optic is used for speed control Motor coder Incremental coder is used Controller cycle 0 ... 9999ms Cycle time of the controller Min. speed difference 0 ... 999mm/s The voltage controller becomes active if the measured speed target and actual is within these limits.

  • Page 80: Positioning

    CONFIGURATION/PARAMETERIZATION   13.3 Positioning Fig. 13-4 Graphic presentation positioning process and positioning monitoring (schematic) Positioning process (arrows indicate driving direction) I: Braking point (calculated braking distance based on speed and deceleration) II: Fine positioning (presented enlarged) - Para: “Correction value theoretical brake point” III: Brake point for target positioning IV: Target position 1: Driving speed...

  • Page 81: Malfunctions

    MALFUNCTIONS   MALFUNCTIONS 14.1 Safety information about malfunctions WARNING! Risk of injury in case of improper troubleshooting! Improper troubleshooting may cause serious injuries or property damage. ► Ensure sufficient installation space before beginning any work. ► Switch off power supply, verify that the system is free of voltage, and secure against switching back on.

  • Page 82: Troubleshooting

    MALFUNCTIONS   14.3 Troubleshooting 14.3.1 General The error messages for the DCS1 control system are differentiated depending on the communication method. The communication methods are: • Half cycle (HW) • Rail bus (PCB) • SMGM TIPS AND RECOMMENDATIONS! Information about troubleshooting and fault clearance The occurrence of an error always results in an immediate stop of the motor control! The triggered error messages depend on the application or the parameterizing of the control.

  • Page 83: Error Messages Smgm

    MALFUNCTIONS   14.3.2 Error messages SMGM Fault Fault number* Cause Resolution F001 overcurrent 0x01 Overload through continuous Check the drive dimension- current that is inadmissibly too ing, check the settings high. The rated motor current is incorrectly set. F002 Overtemp. 0x02 Theinternal temperature of the Lower the ambient tempera-...
  • Page 84 MALFUNCTIONS   Fault Fault number* Cause Resolution F029 BCR not ready 0x1C Position reader initialization tim- Check cabling, exchange eout, not ready fo operation barcode reader message from position reader, conection interrupted, Position reader defective F032 ID Range 0x20 Carrier number is too big, bus Check parameters identifier wrong parametrized F033 ID changed...

  • Page 85: Return/Repair

    Information about the repair approach The repair approaches within and outside of the warranty are identical. If the control system is defective, then it must be sent to VAHLE for repair. Please contact the VAHLE customer service (see section “3.5 Customer service“).

  • Page 86: Accessories

    ACCESSORIES   ACCESSORIES 15.1 IR remote control MC8/10M Fig. 15-1 MC8/10M Designation Description Ident .-No. MC8/10M Infrared remote control for mobile DCS control sys- 0777006/00 tems; Recommended for service - manual mode operation; required batteries: 3x alkaline AAA, 1.5V (not includ- ed in scope of delivery) WARNING! Danger due to inactive limit switches in manual mode...
  • Page 87 ACCESSORIES   Button Function Note Switching to manual mode If the button is pressed for longer than 2 sec, the control system switches to IR manual mode. If the option is selected with enter- ing the vehicle number, then it must be entered additionally.

  • Page 88: Data Connector Ds-Vd

    ACCESSORIES   15.2 Data connector DS-VD Fig. 15-2 DS-VD Designation Description Ident .-No. DS-VD Data connector for the storage of the control param- 10010330 eters; required for operation  ...

  • Page 89: Software Ehb Tool

    15.3 Software EHB tool Fig. 15-3 EHB tool Designation Description Ident .-No. EHB tool Software tool for the parameterizing of the DCS con- trol systems; tool is required for the parameterizing of the system; * As download from the VAHLE home page  ...

  • Page 90: System Can Bus Cable For Dcs/Bcc

    ACCESSORIES   15.4 System CAN bus cable for DCS/BCC TIPS AND RECOMMENDATIONS! Information about the use of the system CAN bus cables For the DCS1 control system series, the system CAN bus cables are used for the com- munication type SMGM. Fig.

  • Page 91: Maintenance

    MAINTENANCE   MAINTENANCE The main aim of this section is to maintain the system’s target condition and operational capability. By avoiding malfunctions and unplanned downtimes, regular maintenance can increase the utilization rate. Efficient plan- ning of maintenance work and material is a prerequisite. In order to carry out safe maintenance by appropri- ately trained personnel, the following instructions must be observed: DANGER! Danger of death due to electrical current!

  • Page 92: Safety Information About Repairs

    MAINTENANCE 16.1 Safety information about repairs DANGER! Before beginning any work, ensure that the system is free of voltage and remains so for the duration of the work. Observe the safety instructions in the section 4 Safety in- structions! WARNING! Risk of injury due to improperly performed maintenance work! Improper maintenance can result in serious personal injury or property damage.

  • Page 93: Transport And Storage

    TRANSPORT AND STORAGE TRANSPORT AND STORAGE 17.1 Safety instructions for transport and storage NOTICE! Damage due to improper transport or storage. Improper transport or storage may cause significant property damage! ► Storage temperature: see „Technical Data" ► Storage location: Indoors, dry, no exposure to chemicals. ►...

  • Page 94: Disassembly And Disposal

    Errors during the removal or replacement of components may cause life-threatening situations or significant property damage ► Observe the safety instructions before beginning any removal work. CAUTION! All accessories must be checked for wear. Only defect-free parts may be reused. ► Use only genuine VAHLE spare parts.  ...

  • Page 95: Disposal

    DISASSEMBLY AND DISPOSAL 18.2 Disposal General information Current national local regulations are decisive for disposing / recovering (recycling) assemblies, machines and systems. NOTICE! Danger from incorrect disposal / operator responsibility Risk of environmental damage / loss of valuable raw materials ►...
  • Page 96 DISASSEMBLY AND DISPOSAL Manufacturer's obligation to provide information (according to ElektroG, Germany) Options for the return, disposal and recovery (recycling) of old devices • The latest, valid guidelines, laws and regulations on site apply. • The operator, as a professional user of the products, is responsible for properly disposing or recycling of (old) products.

  • Page 97: Declaration

    Diese Erklärung beinhaltet keine Zusicherung von Eigenschaften. Die Sicherheitshinweise der mitgelieferten Produktdokumentationen sind zu beachten. Kamen, 07.09.2022 Michael Heitmann Bereichsleiter Qualitätsmanagement Paul Vahle GmbH & Co. KG · Postfach 1720 · D-59172 Kamen · Tel. 02307/704-0 · Fax 02307/704-444 · eMail: info@vahle.de  ...
  • Page 98 The safety hints mentioned in the product documentation must be followed. Kamen, 08.09.2022 Michael Heitmann Manager Testing, Services & Quality Management Paul Vahle GmbH & Co. KG · Postfach 1720 · D-59172 Kamen · Tel. 02307/704-0 · Fax 02307/704-444 · eMail: info@vahle.de  ...

  • Page 99: Declaration Of Conformity (Ukca)

    The safety hints mentioned in the product documentation must be followed. Kamen, 21.10.2022 Michael Heitmann Director Quality Management Paul Vahle GmbH & Co. KG · Postfach 1720 · D-59172 Kamen · Tel. 02307/704-0 · Fax 02307/704-444 · eMail: info@vahle.de  ...

  • Page 100: Repair Note

    Other abnormalities? When does the error oc- cur? Student / Temporary? Notice The General Terms and Conditions (GTC) of Paul Vahle GmbH & Co. KG apply. The terms and conditions are accepted with order confirmation. Contract award Signature, Date _____________________________________________,_________________...

  • Page 101: Index

    INDEX INDEX Activate 13 Communication types 48 Connection to the PC 60 60 Determine absence of voltage 13 Dimensions of the DCS1 control system 24 Display status and operation 27 Electrically qualified person 15 EMC 57 EMERGENCY STOP device 56 Error messages 80 External interfaces 54 First commissioning 59...
  • Page 102 INDEX safety aspects 10 Safety information 7 Software EHB tool 87 Switch on again 13 Switch-on sequence 59 Symbols 6 System CAN bus cable DCS/BCC 88 Technical condition 14 Transport 91 Unloading 91 Vehicle number 61  ...
  • Page 103 Paul Vahle GmbH & Co. KG Westicker Str. 52 D–59174 Kamen Tel.: +49 (0) 2307/704-0 E-Mail: info@vahle.de www.vahle.com Technical Documentation...

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