PCU 128 PNIO + PCU 48 PNIO are the name of the Process Control Units (PCU). Located in IPC switchboard, each PCU can handle up to 128 or 48 loops. The PCU is equipped with 2 different uplink communication ports:
Profinet – IO (PNIO)
Ethernet based RJ45 ports (Hub function) provide the link to PLC. All PLC based cyclic communication will be handled by this port´s. PNIO - IP address = TCP/IP address + 10, address response a ping
TCP / IP
1 Ethernet RJ 45 port is independent in hardware setup from PNIO interface, all acyclic TCP + UDP Ethernet communication for configuration, parameter and state information will be handled by this port. Ethernet address of 1st device = 10.XX.YY.232, address response a ping.
The Can Bus is provided on at the backplane connector on the right hand side of the PCU. Extension to Field CAN Bus only by CANBE or BE (-F) modules. The CAN Bus links all the remotes to the PCU.
Different type of modules handles the CAN Bus communication:
CANBE, CAN Bus interface module with repeater function. Is in use after the PCU to handle the maximum of 2 independent CAN Bus segments. Connection of Bus by CAN Bus SUB-D connectors. 2 different types:
with internal CAN Bus termination resistor
without internal CAN Bus termination resistor
BE, CAN Bus interface to extend the CAN Bus from the backplane connector to Sub-D Is in use after the PCU to handle 1 CAN Bus segment. Use 1 CAN Bus interface (SUB-D) on frontside. This module have no own address, is not an active CAN Bus member and will not be shown in the Flexotemp Manager configuration.
BE-F, CAN Bus interface to extend the CAN Bus from the backplane connector to ribbon cable Is in use after several Peripheral I/O modules to extend the CAN Bus by ribbon cable to HPC modules. This module have no own address, is not an active CAN Bus member and will not be shown in the Flexotemp Manager configuration.
CANBC, CAN Bus interface I/O header module
connection by 1 CAN Bus interface (SUB-D) to CAN network and extend the CAN Bus by backplane connector to I/O´s. This is the 1st module at remote, behind this module the peripheral I/O modules are lined up.
Input / Output modules are lined up after a PCU or CANBC module, linked by the backplane connector. Each module get a own unique CAN Bus address
Template:Notice bms
Different type of modules are avalible:
DO 08 R, output module with 8 dry relay contacts
DO 16, output module with 16 digital outputs (24VDC)
DIO 16 CI, module with 16 digital channels each may be configured as DI or DO (24VDC) equipped with current measurement interface
DIO 16 CI SPL, module with 16 digital channel éach may be configured as DI or DO (24VDC) equipped with current measurement interface and smart power limitation
AOI 04, analog output module with 4 channels outputs (0..10VDC / 4..20mA)
HPC 24, power output module with 24 outputs (max 7A / channel, half wave control technology) control the die bolt heaters.
PT 16, input module, equipped with 16pcs of 3-wire PT 100 inputs
TC 12, input module, equipped with 12 thermocouples inputs, type (K or J) can be adjusted
VC02 / VC 04, input – output module, valve positioning controller modules with 2 or 4 channels
CAN Bus cable type is a 2 x 0,64mm2, with flexible wires. The overall length of 1 CAN Bus segment should not exceed 250m. The cable is used in combination with the 90° CAN Bus connectors manufacturer "EPIC" (=Lapp) with and without diagnostic connector (diagnostic connector only at both ends of the bus segment) The connection points for field CAN Bus are located at different modules:
CANBE (repeater module, located right side of the PCU) links the CAN Bus to field 2 can bus segments can be handled, each segment support the maximum cable length.
BE (Bus connection module, extend the internal CAN Bus of the PCU to a sub –D plug) 1 CAN bus segment can be connected by SUB-D.
CANBC (uplink module, in field) here the field Can bus meet the remote I/O´s.
CAN Bus special cable is a ribbon type cable, it is used to extend the internal backplane I/O module CAN Bus by using the BE-F module to the HPC modules. The BE-F is the interface module from the backplan bus to ribbon cable.
CAN Bus Connection will be done by 90° connectors with screw terminals, on the CAN Bus cable sleeves need to be used
CAN Bus speed default speed setting is 250k, no change required.
CAN Bus addressing each device (excluding BE or BE-F) use a own CAN bus address for communication with PCU, this address is shown in the Flexotemp Manager project. The CAN Bus adresses need to be set at the CANBC modules only, all other modules receive the address at the bus initialisation procedure.
Rules for potential equalization and electrical noise discharging: (CAN bus will treated similar as other Fieldbus systems)
A single wire, 16mm2 ye-gr (multi conductor - flexible type) need to be routed with the bus cable to connect the 2 different bus locations (= independent shipping units, also in switchboard room).
If multiple bus systems are connected parallel only 1 wire is required.
Bus termination is required at both ends of the bus segment at the CAN Bus cable. Details see: CAN_Bus in field setup
Acyclic Communication for the "specific controller" part PVSS and each PCU communicates on request directly by the TCP/IP protocol. After a request from PVSS has been sent to the PCU, the PCU response with a data stream which content the parameters of the zone.
Each PCU have his own internal webserver and webinterface. This Interface should be used only for maintanance issues only.
The Webserver response TCP/IP adress request in the browser.
Template:Notice bms
set CAN Bus addresses at CANBC modules in field according Flexotemp Manager project (should be similar E-drawings) by the 2 ID switches, the switches setting is in HEX format and is also shown in the Flexotemp Manager project.
The default adress step between the header modules (CANBC) may be 8 or 16.
After changing the address setting at CANBC a reconfiguration and new adress assignement to the submodules is requred, trigger it by pressing the CFG button for 5 sec.
use a 1:1 ethernet cable and connect the Template:KomNamRMT station directly to the PCU which you want to set the TCP/IP parameter
At lines with decentral electric you probably find the PCU's somewhere in the cabinets outside on the line. (eg. Die cabinet, TDO +TT1, MDO cabinet)
There you just take a direct connection to the TCP/IP port of the PCU
make sure you know:
PCU Name
TCP/IP address
Subnet mask
This information you can find in the Hardware configuration in the Simatic Manager
Start Flexotemp Manager
No Flexotemp Manager project required (you have no network access)
If there is still no result try to reset the PCU with following steps
Flexotemp IP Adress Backdoor
If you got problems in connecting to a Flexotemp PCU or it can't be recognized during the "Ethernet Scan", there is a trick to set it on a default IP.
The two coding switches on the PCU must be set to "F" with which the default IP Adress 192.168.0.220 is set to the PCU. Then if you are in the same IP range with your notebook you should be able to connect and configure the PCU.
After you have set the correct IP Adress via the Flexotemp Manager and downloaded it to the PCU, simply put the coding switches back to "0" and the communication takes place again over the "normal" configured IP range.
@PCU, use MSB and LSB to maintain a reset to factory settings:
for standard comissioning procedure use Flexotemp Manager at RMT station by Remote Desktop
Use Flexotemp Manager only for hardware checkup. In case the project is opened by the Flexotemp Manager, the file is locked and no writing access from PVSS possible.
Close Flexotemp Manager project anytime you don’t need it
Contact EECIBN@brueckner.com, request for firewall check for open ports for 1, 2, 3 on TCP as shown in the Ethernet setting
9.4 No communication by Ethernet from any network to PCU, (no webinterface, no Flexotemp Manager access, no scan result)[edit | edit source]
When the TCP/IP uplink is routed over the PCU onboard PNIO interface, connect PCU TCP/IP port (-X2) directly to plant network.
Background: in special PNIO interface panic situations, the PNIO interface may not forward the TCP/IP protocol
If the PCU is still not available with the flexotemp, you can try a communication without the CANBUS.
A failure in the CANBUS communication of the PCU or any other partner, can link to a miscommunication and the PCU can't be reached by the ProfiNet.
If the PCU (without CANBE Modul) can be reached by ping and the Flexotempmanager, you can reset the CANBus settings by pressing the "Config" button on each module in the loop for 5 seconds ( Reboot ). File:PSG CANBC.jpg
9.5 Communication to remote device missing, or failure message[edit | edit source]
After finishing the firmware update or project download device shown in Flexotemp Manager error messages:
as missing
offline
wrong firmware version
wrong module type
Following steps to rebuild and show real state in Flexotemp Manager:
run address scan from Flexotemp Manager (Project view) select header station (CANBC) of affected module and run address scan. A 2nd way to run the address scan is to trigger the process locally at CANBC by pressing the "CFG" button. File:Flexotemp IO Start Address scan.png
interface test, check the communication from PCU to affected module
After running a firmware update of an remote I/O module from Flexotemp Manager main window an error occurred and this module will not respond any more, follow the this steps:
select assigned CANBC module of the affected module direct in the project and start "start address scan"
check the response of affected I/O module: mark affected module in project view and perform "interface test"
after get a successful response of affected I/O module select at the module the "Firmware update"
9.7 HPC 24 internal cooling fan control and heatsink alarm handling[edit | edit source]
Internal heatsink cooling fan:
The internal cooling fan of the HPC 24 module can run with 3 different speed´s.
The fan starts when the heatsink temperature rises above 40°C with speed stage 1. When heatsink tempereature rises higter 70°C the fan run with 100% speed. Between this value the speed will be controlled.
Internal heatsink temperature observation:
The heatsink temperature will be observed, the 1st alert can be set manually in the project, default value = 60°.
A second, maximum alert is set in the internal software to 90°C, this value can not be modified. After reaching this value the module stops.
