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PLC Programmable Logic Controllers for mobile work machines
PLCs for mobile work machines | 3
Table of contents
PLC Programmable Logic Controllers for mobile work machines
Völkel PLC – Common features 4
PLC short introduction 4
PLC hardware overview 6
Programming with CODESYS 8
Völkel‘s PLC-CD 9
Völkel‘s firmware 10
The BLM PLC 11
The HCX PLC 13
The HCY PLC 15
The BrainBox® PLC 19
BrainBox® – development accessories 25
The modular MMC PLC 26
MMC – development accessories 35
The MGD display 36
PLC housing and dimensions 38
Völkel PLC – Common features
The universally programmable controllers are intended for use in mobile work machines. They are all based on the proven Völkel Hardware Platform which provides four different basic types and a modular system. This is the means used by the controllers which complement each other‘s advantages with the benefits of free programming – according to the international stan-dard IEC 61131-3 and in the programming language C.
Performance features
Integrated current drivers for proportional solenoids Integrated drivers for analogue inputs, frequency inputs and
switch inputs Inputs and outputs diagnosis-capable Flexible use of the inputs and outputs due to
parameterisable controller configuration Expansion, connection via the CAN bus Equipped for remote diagnosis via modem Completed with an installable display
PLC short introductionThe PLCs from Völkel which are suitable for mobile use have at least on CAN interface for machine environment communication and an RS232 interface for commissioning and PC diagnosis. The software enables varied hardware use; the inputs and outputs can almost be configured as desired. The overview shows how many inputs and outputs can be used for special function – however not simultaneously.
BLM logic module 12 switch inputs
of which: 1 frequency input and 2 activation inputs for switching the safety relay
18 switch outputs
Standard HCX mobile controller 8 switch inputs 2 frequency inputs 6 analogue inputs 4 outputs with current regulation for proportional solenoids 2 switch outputs
4 | PLCs for mobile work machines
BLM
HCX
PLCs for mobile work machines | 5
Enhanced HCY mobile control 13 switch inputs (of which 10 are frequency inputs) 8 analogue inputs 6 outputs with current regulation for proportional solenoids 4 switch outputs 2 microprocessors 2 CAN interfaces
BrainBox® universal mobile controller 16 switch inputs 8 frequency inputs 8 analogue inputs 16 outputs with current regulation for
proportional solenoids 3 microprocessors 2 CAN interfaces
MMC modular PLCwith the modules MMC, MMA, MMD:
MMC master or slave 12 switch inputs 6 frequency inputs 8 analogue inputs 8 outputs with current regulation for proportional solenoids 2 CAN interfaces 8 switch outputs 8 PVG outputs
MMA analogue slave (analogue extension) 4 switch inputs 4 frequency inputs 4 analogue inputs 8 outputs with current regulation
for proportional solenoids
MMD digital slave (digital expansion) 16 switch inputs 18 switch outputs
MGD graphic-capable display for mobile hydraulic machines Visualisation of operating data 128 x 128 pixels LCD Contrast and brightness adjustable Installable
HCY
BrainBox®
MMC
MMA
MMD
MGD
PLC hardware overview
6 | PLCs for mobile work machines
BLM HCX HCY BrainBox®
Dimensions (HxWxD) in mm 152x150x56 152x150x56 152x150x56 188,5x160x52
Weight 650g 650g 700g 1050g
Surrounding temperature -40 ... +85°C -40 ... +85°C -40 ... +85°C -40 ... +85°C
Aluminium housing protection categories IP65, IP69K IP65, IP69K IP65, IP69K IP65, IP69K
Plug connections AMP, 42-pin AMP, 42-pin AMP, 42-pin AMP, 70-pin
Microcontrollers C167CR, 10MHz C167CR, 25MHz C167CS, 40MHz XC167CI, 40MHz
Safety microcontrollers ---- ---- C505CA, 16MHz 2x XC167CI, 40MHz
Program memories FLASH/
Source text memory1 in Kbytes
80/126 384/320 384/256 640/---
Data memory RAM1 in Kbytes 16 64 64 256
Parameter memory EEPROM
Remanent memory1 in bytes
256/5k 256/28k 256/6k 256/28k
Interfaces RS232, CAN 1x, 1x 1x, 1x 1x, 2x 1x, 2x
Supply voltage (DC) +5 ... +32V +8 ... +32V +8 ... +32V +8 ... +32V
Current consumption at 24V Approx. 80mA Approx. 60mA Approx. 160mA Approx. 190mA
Digital switch inputs 12 8 13+[8]* 16+[8]*
Frequency inputs [1]* 2 [10]* 8
Analogue inputs 0 ... 10V ---- 4+[2]* 8 8
Analogue inputs 0 ... 20mA ---- 2 [4]* [8]*
Switch outputs
(per maximum load)
18 (4A,∑25A) 2 (2A)+[4 (3A)]* 4 (3A)+[6]* (3A) [16]* (3A)
Proportional outputs
(per maximum load)
---- 4 (3A) 6 (3A) 16 (3A)
PVG outputs ---- ---- ---- ----
Sensor supply ---- 1 (5V) 1 (5V/8V) 2 (0 ... +10V)
Special features Standby operation
Safety relay
Safety microcontroller,
Safety relay
Multiple channel
Safety structure
[ ]* can be used if other inputs/outputs are reconfigured via software1 Free available
[ ]* can be used if other inputs/outputs are reconfigured via software1 Free available 2 Slave modules serve as a variable input and output extension for the MMC master.
No user software can be loaded to the slave modules.
MMCMaster | Slave2
MMC-Slave2
MMAMMC-Slave2
MMD
Dimensions (HxWxD) in mm 188,5x140x52 152x120x56 152x120x56
Weight 900g 600g 600g
Surrounding temperature -40 ... +85°C -40 ... +85°C -40 ... +85°C
Aluminium housing protection categories IP65, IP69K IP65, IP69K IP65, IP69K
Plug connections AMP, 70-pin. AMP, 42-pin. AMP, 42-pin.
Microcontrollers SAK XC2287, 80MHz SAK XC2287, 80MHz XC164CM, 40MHz
Safety microcontrollers ---- ---- ----
Program memories FLASH/
Source text memory1 in Kbytes
640/384 ----/---- ---/--- ---/---
Data memory RAM1 in Kbytes 256 ----/---- ---/--- ---/---
Parameter memory EEPROM
Remanent memory1 in bytes
256/6k ---- /---- ---/--- ---/---
Interfaces RS232, CAN,
Module bus
1x, 2x,
1x
---, ---
1x
----, ---
1x
Supply voltage (DC) +8 ... +32V +8 ... +32V +8 ... +32V
Current consumption at 24V Approx. 120mA Approx. 100mA Approx. 110mA
Digital switch inputs 22 8 16
Frequency inputs [6]* [4]* ----
Analogue inputs 0 ... 10V 4+[4]* 4 ----
Analogue inputs 0 ... 20mA [8]* [4]* ----
Switch outputs (per max. load) 8 (4A)+[8]* (3A) [8]* (3A) 14 (4A)+[4]*
Proportional outputs
(per maximum load)
8 (3A) 8 (3A) ----
PVG outputs [8]*
Sensor supply 1 (5V/8V/10V) 1 (5V/8V/10V) ----
Special features External watchdog,
Safety relay
External watchdog,
Safety relay
External watchdog,
Safety relay
MGD Display
139x139x37
680g
-20 ... +70°C
IP65
2xM12x1,5-pin
XC167CI, 40MHz
----
768/---
128
256/30k
1x, 1x
+8 ... +32V
Approx. 70mA
----
----
----
----
----
----
----
----
8 keys, 128x128 pixels
(0,5mm) LCD
PLCs for mobile work machines | 7
Programming with CODESYS
The control system application for the Völkel PLC isprepared using the IEC 61131-3 programming system (CODESYS) CODESYS is a full PLC development environment with a Windows screen. It basically consists of three parts:
Editors for the development of application codes
A compiler to translate the application for thecontrol system
Diagnosis and commissioning functions
Völkel PLC, CODESYS monitor
All IEC 61131-3 programming languages aresupported:
CFC – free graphic style Continuous Function Chart editor
FBD – Function Block Diagram – for visual support when programming procedures
COP – Contact Plan – for clear graphic depiction of the primary links
ST – Structured Text, the PLC high level language which is closely related to conventional programming languages such as PASCAL or C
SFC – Sequential Function Chart – expands the programming concept by a clear depiction of the program conditions and program status transitions
IL – Instructions List – as the common elementary language for all IEC 61131-3-compatible controllers
8 | PLCs for mobile work machines
PLCs for mobile work machines | 9
Völkel‘s PLC-CD
Contents
CODESYS programming system Version 2.3 (IEC 61131-3) Target files for all Völkel PLCs Software libraries 3S-CAN open libraries Sample projects Operating instructions
The Völkel software libraries Völkel PLC-CD | article number P1871
Library Description MM
C
Bra
inB
ox®
HC
Y
HC
X
BLM
MG
D
EEPROM Functions for access to the EEPROM (dealing with retain variables, automatic data
backup, testing checksums, direct writing and reading in the user area)
FILE CREATOR Function for creating a file in the controller‘s RAM, write and read access to the run-time
via the application software (can be read-out using the CODESYS programming screen)
VOELKEL Functions for the configuration of the RS232 interface, the CAN interface and for
reading-out information regarding firmware, hardware, serial number and CODESYS
project description
MMC Functions for diagnosis of the inputs and outputs (reading input voltage,
output current and status information)
3S-CANOPEN-
DEVICE
Implementation of a CANopen slave
3S-CANOPEN-
MANAGER
Basic library for CAN communication
3S-CANOPEN-
MASTER
Implementation of a CANopen master
3S-CANOPEN-
NETVAR
Treatment of network variables
BBX Functions for the operation of the error memory, for the online configuration of the
inputs and outputs or reading system status and input and output information for the
execution of special system functions such as triggering the safety cutoff, for example
HCYDIAG Functions for diagnosis of the inputs and outputs (reading input voltage,
output current and status information)
HCXDIAG Functions for diagnosis of the inputs and outputs (reading input voltage, output current
and status information)
BLMDIAG Functions for diagnosis of the inputs and outputs (reading input voltage, output voltage
and output current)
MGDLIB Functions for the configuration of the RS232 interface, the CAN interface and for
reading-out information regarding firmware, hardware, serial number and CODESYS
project description for setting background lighting and contrast for reading the supply
voltage and system temperature
KEYBOARD Functions for setting and analysing the keyboard (key FIFO, auto-repeat with
adjustable delay time and repeat rate)
HARDCOPY Function for the conversion and saving of the current display contents as a Windows
bitmap in the controller‘s RAM (can be read using the CODESYS program screen)
Völkel‘s firmware
The firmware supports the following functions:
10 | PLCs for mobile work machines
Function description MM
C
Bra
inB
ox®
HC
Y
HC
X
BLM
MG
D
Use of CAN network variables via standard CAN (11bit ID) and extended CAN (29bit ID) for easy information exchange between two or more controllers
Adjustable CAN end resistors
Use of the RS232 interface in the user software, e.g. for controlling a printer
The proportional outputs are equipped with an integrated current controller. The current rate is provided directly in [mA]. The adjustable dither frequency hinders the solenoid valves from „sticking“. Alternatively, these outputs can also be operated as switch outputs
Proportional outputs can be alternatively configured as PWM outputs
Proportional outputs can be alternatively configured as frequency outputs
Proportional outputs can be alternatively configured as PVG outputs
Proportional outputs can be configured using parameterisable output characteristics with resting, trigger and maximum signal value as the current output
Frequency inputs incorporate reversible measurement ranges
Frequency inputs can alternatively be configured as switch inputs
Switch inputs can be operated using reversible pull down or pull up resistors
Switch inputs are evaluated in analogue form via parameterisable switching thresholds
Analogue inputs can be configured either as voltage or current inputs. They provide mea-surement values directly in [mV] or [µA]
Analogue inputs can be depicted using a parameterisable input characteristic for the value ranges 0...10,000 (pedal operation type) or -10,000...10,000 (joystick operation type
Analogue inputs can be configured for the ratiometric measurement of potentiometers
Visualisations prepared using CODESYS can be transferred directly to the controller and shown on the display. Comfortable parameter input via the controller keyboard can be linked to visualisation elements
Shaft encoder evaluation at frequency inputs
PLCs for mobile work machines | 11
The BLM is a controller which has the special capability as a performance module/ logic module to take over switching functions in mobile machines. Alternatively, the BLM is perfect for use as an input/output extension modu-le within a CAN bus system.
The BLM PLC combines the advantages of the proven BLM mobile control-ler and the advantages of free programming according to IEC 61131-3.
BLMPLC
BLM PLC – performance features
Activation inputs to switch the safety relay and to start the
microcontroller
Integrated drivers for frequency inputs and switch inputs
Capability to diagnose: voltage measurement for the inputs, electricity and voltage measurement for the outputs
Status LED
BLM PLC – connection diagram
The BLM PLC
BLM PLC | Article number P1896
BLM PLC – technical data
Dimensions (HxWxD) 152mmx150mmx56mm
Housing Aluminium housing with a ventilation membrane, powder-coated, black
Protection category IP65, IP69K (DIN 40050, DIN EN 60529)
Weight 650g
Temperature range -40 ... +85°C (housing)
Plug connections 1 42-pin connector, type AMP 1-0967280-1
Power supply (DC) UB = +5 ... +32V
Current consumption Approx. 80mA at 24V, standby <1,5mA
Microcontroller 1xC167CR, 10MHz
Program memory 512Kbyte flash EPROM
Data memory 128Kbyte RAM
Parameter memory 8Kbyte EEPROM
Interfaces 1xRS232, 1xCAN
Inputs 12 digital switch inputs with adjustable switching threshold. Alternative possibilities for use: 4 switch inputs with reversible pull down/pull up resistors, 4.7kΩ 8 switch inputs with pull-down, 4.7kΩ resistor 2 activation inputs for switching the safety relay and starting the microcontroller 1 frequency input, clamp W, up to 2kHz, switching thresholds at Uon 75% of UB, Uoff 25% of UB.
Outputs 18 switch outputs, each for a maximum of 4A, maximum allowable total current 25A. Analogue measurement of the output current in the range 0 ... +32V, Analogue measurement of the output current in the range 0 ... 4A.
Safety Microcontroller watchdog, reverse pole protection and reverse pole pro-tection.
EMC Road vehicles:Directive 72/245/EEC, ISO 10605ISO 7637-1, ISO 7637-2, ISO 7637-3
Construction machinery:DIN EN 13309, ISO 7637-3
Agricultural and forestry vehicles:Directive 75/322/EEC,DIN EN ISO 14982, ISO 7637-3
Article number P1896
12 | PLCs for mobile work machines
PLCs for mobile work machines | 13
The HCX PLC
The HCX PLC is a versatile universal control system for mobile applications.
The HCX mobile controller‘s hardware has been reliably tested in numerous mobile work machines. Thus it combines the advantages of the proven hardware platform with the advantages of free programming according to the international standard IEC 61131-3.
PLC
HCX PLC – performance features
Direct connection of proportional solenoids possible, current drivers are already incorporated in the operating system
Drivers for analogue inputs, frequency inputs and switch inputs are integrated
Outputs and analogue inputs diagnosis-capable
Status LED
HCX PLC – connection diagram
HCX PLC | Article number P1870
Dimensions (HxWxD) 152mmx150mmx56mm
Housing Aluminium with a ventilation membrane, powder-coated, black
Protection category IP65, IP69K (DIN 40050, DIN EN 60529)
Weight 650g
Temperature range-40 ... +85°C (housing)
Plug connections 1 42-pin connector, type AMP 1-0967280-1
Power supply (DC) UB = +8 ... +32V
Current consumptionApprox. 60mA at 24V
Microcontroller1xC167CR, 25MHz
Program memory1Mbyte flash EPROM
Data memory512Kbyte RAM
Parameter memory 32Kbyte EEPROM
Interfaces 1xRS232, 1xCAN
Inputs 8 digital switch inputs, pull down resistors 4.7Ω Switching thresholds Uon approx. 5,8V, Uoff approx. 3,7V
2 frequency inputs up to 4kHz
6 analogue inputs, 10bit, 0 ... +10V, of which 4 can also be used for 1 ...10kΩ Potentiometers with error recognition, 2 for 4 ... 20mA current measure- ment, 220Ω resistance to ground.
Outputs 1 power supply output, 5V for sensor supply, maximum 50mA
4 proportional solenoid outputs, maximum 3A, can also be used as switch outputs2 switch outputs, 2A maximum
Safety Microcontroller watchdog,Reverse pole protection and reverse pole protection.
EMC Road vehicles:Directive 72/245/EEC, ISO 10605ISO 7637-1, ISO 7637-2, ISO 7637-3
Construction machinery:DIN EN 13309, ISO 7637-3
Agricultural and forestry vehicles:Directive 75/322/EEC,DIN EN ISO 14982, ISO 7637-3
Article number P1870
HCX PLC – technical data
14 | PLCs for mobile work machines
PLCs for mobile work machines | 15
The HCY PLC
The HCY PLC is a universal control system for mobile hydraulic applications. Equipped with safety features and two CANinterfaces, the HCY controller is used in particular for complex tasks.It combines the advantages of the proven HCY mobile control system with the advantages of free programming according to IEC 61131-3.
PLC
HCY PLC – performance features
Direct connection of proportional solenoids possible, current drivers are already incorporated in the operating system
Drivers for analogue inputs, frequency inputs and switch inputs are integrated.
Extensive input and output peripherals, can be configured
individually, Outputs and inputs are diagnosis-capable
2 microcontrollers with reciprocal monitoring
Status-LED
HCY PLC – connection diagram
HCY PLC | Article number P1897
Dimensions (HxWxD) 152mmx150mmx56mm
Housing Aluminium with a ventilation, membrane, powder-coated, black
Protection category IP65, IP69K (DIN 40050, DIN EN 60529)
Weight 700g
Temperature range -40 ... +85°C (housing)
Plug connections 1 42-pin connector, type AMP 1-0967280-1
Power supply (DC) UB = +8 ... +32V
Current consumption Approx. 160mA at 24V (plus output current)
Microcontroller 1xC167CS, 40MHz
Program memory 1Mbyte flash EPROM
Data memory 512Kbyte RAM
Parameter memory 8Kbyte EEPROM
Safety microcontroller C505CA, 4MHz
Interfaces 1xRS232, 2xCAN
Inputs 4 digital switch entries with 4,7kΩ pull down/pull up- resistors. Switching thresholds which can be switched in pairs in the -5 ... +32V. Suitable as frequency inputs up to 10kHz. Also appropriate for Namur sensors due to 1kΩ pull down which can be additionally connected.6 digital switch inputs with 4,7kΩ pull down resistors of which 4 are suit- able as frequency inputs up to 4KHz with fixed switching thresholds: Uon = approx. 2,9V, Uoff = approx. 1,5V.
1 Rev sensor input pickup, fmax = 10kHz, signal level: Uss =400mV at 1kHz, becomes less sensitive at higher frequencies. Can alternatively be used as 2 digital switch inputs with 4,7kΩ pull down resistors.
1 Frequency input clamp W, fmax = 2kHz, Switching thresholds: Uon = 75% of UB, Uoff = 25% of UB, 4,7kΩ resistance to ground. Can also be used as a digital switch input.
4 analogue inputs for 0 ... +10V with 10bit resolution and 100kΩ input resistance. Can be configured as switch inputs.
HCY PLC – Technical data
16 | PLCs for mobile work machines
PLCs for mobile work machines | 17
HCY PLC – Technical data
Inputs 4 Current inputs, 4 ... 20mA, with 220Ω burden to ground and 10 bit resolution. Overload-protected. Reversible as analogue inputs with voltage range 0 ... +5V or 0 ... +10V with 10 bit resolution and 100kΩ input resistance. Can also be configured as switch inputs with 4,7kΩ pull down.
Outputs 6 Proportional solenoid outputs, each for a maximum of 3A.
4 Switch outputs, each for a maximum of 3A.
1 Power supply output with 5V or 8V for Namur sensors and potentiometers.
1 Safety relay for common cutoff of the 6 proportional outputs and the
4 switch outputs. The safety relay can be switched off using the safety microcontroller.
Safety Two microcontrollers with reciprocal monitoring, each with a microcontroller watchdog, double voltage regulation, double cycle generation, safetycut-off via relay,reverse pole protection and overvoltage protection.
EMC Road vehicles:Directive 72/245/EEC (e1-type approval))ISO 10605, ISO 7637-1, ISO 7637-2, ISO 7637-3
Construction machinery:DIN EN 13309, ISO 7637-3
Agricultural and forestry vehicles:Directive 75/322/EEC, DIN EN ISO 14982, ISO 7637-3
Article number P1897
HCY PLC functional safety
Safe control systems need safe hardwareand safe software.
Safe hardware:
2 microcontrollers to monitor each other reciprocally
Each microcontroller with separate voltage regulation,cycle operation and its own watchdog
Additional means of switching off using a safety relayaccording to the principle of closed circuit current
Monitoring the current supply andreverse measurement of all outputs
Safe software:
Reciprocal workflow monitoring due toconstant data exchange with checksum control
Checking ROM and RAM with read andWrite tests with checksum calculation with power ON.
Various possibilities to monitor the inputsand outputs (e.g. recognition of cable breaks andshort circuits)
Plausibility checks for important parameters by logical combination and checking limit values
Structural diagram:
18 | PLCs for mobile work machines
HCY
Input
level
Output
level
Mainmicrocontroller
Softwaresafety module
Hardwarewatchdog
Safety microcontroller
Softwaresafety module
Hardwarewatchdog
Data exchange Errorstorage
Safety relay
Supply
Supply
+
Reversemeasurement
PLCs for mobile work machines | 19
The BrainBox® PLC
The BrainBox® PLC is a universal controller for use in complex controlling tasks with safety functions in mobile hydraulics. It has a second, independent cutoff means and can be freely programmed according to IEC 61131-3.
BrainBox® PLC – performance features
Three microcontrollers (Infineon XC 167), each with an independent supply unit and means of communication for reciprocal monitoring
Independent master controller for the application program for redundant processing of the data received, e.g. from connected sensors and actuators
Two controllers which work independent of the master CPU, drive the outputs and process the input signals and are equipped with extensive Völkel firmware and the safety software
Direct connection of proportional solenoids possible, current drivers are already incorporated in the operating system
Drivers for analogue inputs, frequency inputs and switch inputs
All outputs and inputs can be diagnosed
In put and output peripherals provide diverse configuration options
2 CAN interfaces
Brain Box® PLC | article number P1898
BrainBox®
PLC
BrainBox® PLC connection diagram
20 | PLCs for mobile work machines
PLCs for mobile work machines | 21
BrainBox® PLC functional safety
The BrainBox® is equipped to control safety-relevant functions and can assume safety tasks up to Safety Inte-grity Level (SIL) 2 according to IEC 61508, or category 3 according to EN 954-1.
Comprehensive test and monitoring routines recognise errors in the redundant assembled hardware and bring the system into a safe state via independent switching means. A safe condition is defined as the condition of an output with a safety function without energy.
Safe control systems need safe hardware and safe soft-ware.
Safe hardware:
3 microcontrollers for clear task splitting and reciprocal monitoring
Each microcontroller with separate voltage regu-lation, cycle operation and its own watchdog
Sensors and actuators can be connected redun-dant and evaluated independently
Independent means of shutdown with double-poleswitched outputs
Additional output shutdown possibilities using themaster CPU
Inputs and outputs diagnosis-capable
Comprehensive safety measurements below sys-tem level
Individual, independent performance semicon-ductor components per output
Reverse battery protection, overvoltage protection,no components plugged-in
Safe software:
Comprehensive system tests each time after switching on
Dual channel signal processing with comparisons
Reciprocal workflow monitoring due topermanent data exchange
Monitoring all inputs and outputs during operation
Plausibility checks of safety-critical parameters
Safe communication with checksums and frame counters
CAN 2
CAN 1
RS232
MasterMicrocontroller
I / OMicrocontroller
part A
I / OMicrocontroller
part B
Parametermemory
Switchinputs
Frequencyinputs
Analogueinputs
Parametermemory
Temperaturesensor
Supply
Parametermemory
Datamemory
Programmemory
Voltagemonitor
Supply
Switchinputs
Frequencyinputs
Analogueinputs
Temperaturesensor
Supply
Voltagemonitor
Proportionaloutputs,
plus
&
Sensor supply
Proportionaloutputs,
plus
Sensor supply
&
Safetyshutdowns,earthed
Safetyshutdowns,earthed
BrainBox® PLC block diagram
22 | PLCs for mobile work machines
PLCs for mobile work machines | 23
BrainBox® PLC – technical data
Dimensions (HxWxD) 188,5mmx160mmx52mm
Housing Aluminium with a ventilation membrane, powder-coated, black
Protection category IP65, IP69K (DIN 40050, DIN EN 60529)
Weight 1kg
Temperature range -40 ... +85°C (housing)
Plug connections 1x70-pin multiple plug, AMP 1-963484-1
Power supply (DC) UB = +8 ... +32V
Current consumption Maximum allowable total current: 32A
Microcontroller 3xC167CI, 40MHz (1 master processor, 2xI/O processors)
Program memoryMaster processor internal: 256Kbyte flash-EPROM, external: 1Mbyte flash-EPROMI/O processor internal: 256Kbyte flash-EPROM
Program memoryMaster processor internal: 12Kbyte RAM external: 1MByte RAMI/O processor internal: 12KByte RAM
Parameter memory Master processor 32Kbyte EEPROMI/O processor 32Kbyte EEPROM
Interfaces 1 x RS232, maximum baud rate: 115 Kbauds2 x CAN 2.0B, maximal baud rate: 1Mbaud
Inputs16 Digital switch inputs (4 groups each with 4 inputs) Can be configured by group: pull up, pull down or Namur 4,4kΩ pull down/pull up resistors, 1kΩ resistor for Namur sensors. Adjustable switching thresholds in the range between 0 ... +32V.
8 Frequency inputs, fmax = 10kHz Configurable: pull up, pull down or Namur. 4,4kΩ pull down/pull up resistors. 1kΩ resistor for Namur sensors. Respectively two frequency inputs can be used as shaft encoders. Adjustable switching thresholds with a range of -5 ... +32V. Also usable as digital switch inputs or as ordinary analogue inputs. 8 analogue inputs Current inputs, 4 ... 20mA with 220Ω burden to ground and 10 bit resolution. Overload-protected. Reversible as analogue inputs with voltage 0 ... +5V or 0 ... +10V with 10 bit resolution and an input resistance >100kΩ.
Outputs 16 proportional outputs, each current-regulated for a maximum of 3A. Can also be used as switch, PWM or frequency outputs.
4 switching ground contacts for proportional solenoid outputs (the ground contacts from four proportional solenoids are combined and connected to a ground connection).
2 voltage supply outputs (adjustable 0 ... +10V) for sensors and potentiometers, 300mA.
2 analogue grounds for sensor and potentiometer connection.
Safety Three microcontrollers with watchdogs and reciprocal monitoring.Triple voltage regulation and cycle generation.Double-pole switched outputs (high side and low side).Shutdown of the outputs using the master CPU possible.Reverse pole protection, overvoltage protection.
EMC Road vehicles:Directive 72/245/EECISO 10605, ISO 7637-1, ISO 7637-2, ISO 7637-3
Construction machinery:DIN EN 13309, ISO 7637-3
Agricultural and forestry vehicles:Directive 75/322/EEC, DIN EN ISO 14982, ISO 7637-3
Industrial use:DIN EN 61000-6-2, DIN EN 61000-6-4
Article number P1898
24 | PLCs for mobile work machines
BrainBox® PLC – technical data
PLCs for mobile work machines | 25
BrainBox® test box/simulation box
When developing the software, the test box/simulation box provides help.
The integrated sensors and actuators enable important software tests,accelerating development. External sensors and actuators can also beconnected.
For commissioning, the test box is plugged directly into the BrainBox® and connected via the service lines (provided within the scope of delivery). If an RS232 connection is made to the PC, all the BrainBox® outputs and inputs can already be operated.
The control functions at the inputs and outputs and the requiredparameters can be optimised systematically using the test box. The simulation reduced the software test on the machine itself and makes it more meaningful.
Brain Box® test/simulation box | article number P1851
Die BrainBox with a test/simulation box
BrainBox® development accessories
Operating and display elements
The modular MMC PLC
The MMC, the modern PLC for mobile work machines, is a control unit consisting of a basic controller (master) and extension modules (slaves). The size of the control unit can easily be scaled individually.Depending on the inputs and outputs required, the number of modules in the system can be varied.
At the same time, the MMC acts externally in the control environment like one single controller.The extension modules are connected at operating system level and is therefore especially easy: the system identifies new models automatically via their connector coding.
modulbus
MMC modular PLC – performance features
The modular MMC controller provides one master and three different types of extension (slaves):
MMC Master
MMA analogue slave primarily with analogue inputsand outputs
MMD digital slave with digital inputs and outputs
MMC slave with a mix of inputs and outputs A maximum of three Typ MMA, three type MMD and one type MMC extensions are allowed in one system. The largest possible stage of extension consists of one master and five slaves. The modular PLC communicates via a CAN bus and can be freely programmed according to IEC 61131-3 or in C.
26 | PLCs for mobile work machines
PLCs for mobile work machines | 27
MMC modular PLC – usable inputs and outputs
MMC modular PLC – safety structure
Microcontroller with an internal watchdog Additional external watchdog with a time window Microcontroller and external watchdog, each with separate voltage
regulation and cycle generation Additional means of switching off using a safety relay according to the principle of closed circuit current
Reverse measurement of all outputs Activation input for direct supply and shut-down of the microcontroller,watchdog and safety relay
MMC, MMA and MMD structural diagram
Activation input
supplyPower
supplyPower
Watchdogwith a
time window
Outputlevel
Microcontroller
Hardware- watchdog
UB load
Reversemeasurement
Safety relay
Inputlevel
MMC master or slave MMA analogue slave MMD digital slave
Analogue inputs 8 4 —
Frequency inputs 6 4 —
Digital switch inputs 12 4 16
Proportional inputs 8 8 —
PVG outputs 8 — —
Switch outputs 8 — 18
CAN interfaces 2 — —
RS232 interfaces 1 — —
MMC – connection diagram
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PLCs for mobile work machines | 29
MMA – connection diagram
MMD – connection diagram
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PLCs for mobile work machines | 31
MMC master/slave – technical data
Dimensions (HxWxD) 188,5mmx140mmx52mm
Housing Aluminium housing with a ventilation membrane, powder-coated, black
Protection category IP65, IP69K (DIN 40050, DIN EN 60529)
Weight Approx. 900g
Temperature range -40 ... +85°C (housing)
Plug connections 1 70-pin connector, type AMP 1-963484-1
Power supply (DC) UB = +8 ... +32V
Current consumption Approx. 160mA at 12V, maximum allowable total current: 25A
Microcontroller 1xInfineon SAK XC2287, 80MHz
Program memory768Kbyte flash EPROM1Mbyte flash EPROM (external)
Data memory83Kbyte RAM (internal)1Mbyte RAM (external)
Parameter memory 8Kbyte EEPROM
Interfaces 1xRS232, maximum baud rate: 115Kbauds3xCAN 2.0B, maximum baud rate: 1Mbaud
Inputs 12 switch inputs of which four are individually reversible between pull up and pull and eight fixed with pull down.4,2kΩ pull down/pull up resistors.Adjustable switching thresholds in the range between 0 … +32V.
6 frequency inputs, fmax = 10kHzSwitching between pull up and pull down possible in a group of four as well as twice individually.4,1kΩ pull down/pull up resistors.Two pairs can respectively alternatively be used as one shaft encoder input.Commonly adjustable switching thresholds for a group of four as well as twice individually in the -0,2 …+18V range.Can also be used as digital switch inputs with adjustable switching thresholds in the 0 … +32V range.
8 analogue inputs Current inputs, 4 ... 20mA with 220Ω burden to ground and 10 bit resolution. Overload-protected. Reversible as analogue inputs with a voltage range of 0 ... +5V or 0 … +10V with 10bit resolution and 100kΩ input resistance. 4 of which are reversible as switch inputs with 4,1kΩ pull down.
MMC master/slave – technical data
32 | PLCs for mobile work machines
Outputs 8 proportional solenoid outputs, each current-regulated for a maximumof 3A.Can also be used as switch outputs. Can also be switched individuallyas PVG outputs.
8 switch outputs1 power supply output for sensors and potentiometers (switchable bet
ween 5V, 8V und 10V)for sensors or potentiometers.
Safety Microcontroller watchdog, Safety cut-off via an external watchdog and relay. Reversepole protection and overvoltage protection.
EMC Road vehicles: Directive 72/245/EEC, ISO 10605, ISO 7637-1, ISO 7637-2, ISO 7637-3
Construction machinery: DIN EN 13309, ISO 7637-3
Agricultural and forestry vehicles:Directive 75/322/EEC, DIN EN ISO 14982, ISO 7637-3
Industrial use: DIN EN 61000-6-2, DIN EN 61000-6-4
Mechanical, climatic Load capacity
Cold: DIN EN 60068-2-1Dry heat: DIN EN 60068-2-2Oscillation: DIN EN 60068-2-6Temperature change: DIN EN 60068-2-14Shock: DIN EN 60068-2-27Permanent shock: DIN EN 60068-2-29Damp heat: DIN EN 60068-2-30Free falling: DIN EN 60068-2-32
Article number MMC master: P2175MMC slave: P2227
PLCs for mobile work machines | 33
MMA slave – technical data
Dimensions (HxWxD) 152mmx120mmx56mm
Housing Aluminium housing with a ventilation membrane, powder-coated, black
Protection category IP65, IP69K (DIN 40050, DIN EN 60529)
Weight 600g
Temperature range -40 ... +85°C (housing)
Plug connections 1 42 pin connector, type AMP 1-0967280-1
Power supply (DC) UB = +8 ... +32V
Current consumption Approx.. 150mA at 12V, maximum allowable total current: 25A
Microcontroller 1xInfineon SAK XC2287, 80MHz
Program memory 768Kbyte flash EPROM (internal)
Data memory 83Kbyte RAM (internal)
Parameter memory 8Kbyte EEPROM
Interfaces 1xCAN 2.0B, maximum baud rate: 1Mbaud
Inputs 4 switch inputs Switching between pull up and pull down possible in a group of two as well as
twice individually. 4,2kΩ pull down/pull up resistors. Adjustable switching thresholdsin the range between 0 ... +32V.
4 frequency inputs, fmax = 10kHz Switching between pull up and pull down possible in a group of two as well as twice individually. 4,1kΩ pull down/pull up resistors. Respectively two frequency inputs can be used as a shaft encoder input. Adjustable switching thresholds with a range of -0,2 ... +18V. Can also be used as digital switch inputs with adjustable switching thresholds in the 0 ... +32V range.4 analogue inputs Current inputs, 4 … 20mA with 220Ω burden to ground and 10 bit resolution.
Overload-protected Reversible as analogue inputs with voltage range 0 ... +5V or 0 ... +10V with 10 bit resolution and 100 kΩ input resistance.4 coding inputs, distinguishing 10 device addresses.
Outputs 8 proportional solenoid outputs, each current-regulated for a maximum of 3A. Can also be used as switch outputs.
1 power supply output (switchable between +5V, +8V und +10V) for sensors and potentiometers.
1 analogue ground for sensor and potentiometer connection.
Safety, EMC,Mechanical, clima-tic load capacity
As the MMC master
Article number P2177
MMD slave – technical data
34 | PLCs for mobile work machines
Dimensions (HxWxD) 152mmx120mmx56mm
Housing Aluminium housing with a ventilation membrane, powder-coated, black
Protection category IP65, IP69K (DIN 40050, DIN EN 60529)
Weight 600g
Temperature range -40 ... +85°C (housing)
Plug connections 1 42 pin connector, type AMP 1-0967280-1
Power supply (DC) UB = +8 ... +32V
Current consumption Approx. 160mA at 12V, maximum allowable total current: 25A
Microcontroller 1xXC164CM, 40MHz
Program memory 128Kbyte flash EPROM (internal)
Data memory 8Kbyte RAM (internal)
Parameter memory 8Kbyte EEPROM
Interfaces 1xCAN 2.0B, maximum baud rate: 1Mbaud
Inputs 16 switch inputs, 4 of which are in a group reversible between pull up and pull down. 8 fixed with pull down. 4 more individually reversible as an alternative to switch outputs. 4,2kΩ pull down/pull up resistors. Adjustable switching thresholds in the range between 0 ... +32V.
4 Coding inputs Distinguishing 10 device addresses.
Outputs 18 Switch outputs, each for a maximum of 4A, 4 of which are reversible as switch inputs.
Safety, EMC,Mechanical, climaticload capacity
As the MMC master
Article number P2176
PLCs for mobile work machines | 35
MMC – development accessories
Test and simulation boxes
The MMC test and simulation boxes for masters and slaves support the software development. Its integrated sensors and actuators enable testing and optimisation of the input and output functions and the parameterisation like on a real machine.
Optionally, external sensors and actuators can be connected. The simulation replaces functional software tests on the machine and leads to fast, convincing results. This considerably reduces actualcommissioning.
To set up the test environment, the controller is plugged into the correct simulation box which is connected via the servicelines provided and an RS232 connection is made to the PC.Now all inputs and outputs are available for simulation.
MMA test box/simulation box | article number P2198
MMD test box/simulation box | article number P2199
MMC test box/simulation box | article number P2197
MMA with test box/simulation box
MMD with test box/simulation box
MMC with test box/simulation boxt
The MGD display
The MGD PLC is a graphics-capable LC display which serves for the display and input of operating data. MGD is particularly suitable for the installation in mobile-hydraulic machines (instrument panels or electrical control panels).
MGD – performance features
Eight keys fir input and operation
The front panel, made of antireflection coated mineral glass, ensures good visibility without reflections and high scratch resistance
Brightness and contrast can be individually adapted
Freely programmable according to IEC 61131-3, with the programming system CODESYS.
CAN interface for communication with the machine environment
RS232 interface to the PC
X1•4
X1•5
X1•1
X 2 •5
X 2 •4
X 2 •1
X1•2
X1•3
graphicdisplay128 x 128
MGD display| article number P1943
MGD – connection diagram
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PLCs for mobile work machines | 37
MGD technical data
Dimensions front panel/housing (HxWxD)
139mmx139mmx4mm/95,5mmx109,5mmx37mm
Housing front panel/reverse side Anodised aluminium/stainless steel, with a ventilation membrane
Protection category IP65
Weight 680g
Temperature range -20 ... +70°C
Plug connections 2 5-pin, built in male connectors, type M12x1
Power supply (DC) +8 ... +32V
Current consumption Approx. 70mA at 24V
Microcontroller 1x XC167CI, 40MHz
Program memory1024Kbyte flash EPROM (external)256Kbyte flash EPROM (internal)
Data memory1024Kbyte RAM (external)12Kbyte RAM (internal)
Parameter memory 32Kbyte EEPROM
Interfaces 1xRS232, 1xCAN
Foil keyboard 8 embossed keys
Display128x128 pixels LCD module (diagrammable) LED backlighting
Visible image size (WxH) 73mmx73mm
Pixel size 0.5mmx0.5mm
Pixel spacing 0.05mm
Brightness/contrast Adjustable by software
Safety Microcontroller watchdog,overvoltage protection, reverse pole protection
EMC Directive 72/245/EEC, Directive 75/322/EEC,DIN EN 13309, ISO 7637, DIN EN 14982
Article number P1943
Housing, common features
All PLC housing from Völkel is specially designed for the extreme operating conditions for mobile applications and has both a mechanically and climati-cally high capacity. The protection category IP65 protects effectively against the infiltration of dust and water jets, protection category IP69K provides wide-ranging protection when cleaning using high-pressure cleaners. The ventilation membrane hinders that damp condenses in the inside of the housing.
Some of the housing includes an LED on the front panel which provides information regarding the operating status.
BLM, HCX and HCY housing
Due to their common hardware platform, the housing dimensions are identi-cal. Special feature: installed LED for status display.
PLC housing and dimensions
150
mm
123 mm
152
mm
5,5 mm
205
mm
108 mm
138
mm
36 mm
56 mm
130
mm
12,5
mm
5,5 mm 138 mm
38 | PLCs for mobile work machines
PLCs for mobile work machines | 39
Aluminium with a ventilation membranepowder-coated, black,protection systems IP65, IP69K
193
mm25
5 m
m
160
mm
175 mm
136
mm
12,5
mm
5,5 mm
175
mm
188,
5 m
m
32 mm
52 mm
5,5 mm
BrainBox® housing
Aluminium with a ventilation membranepowder-coated, black,protection systems IP65, IP69KSpecial feature: LED for status display
235
mm
173
mm
140
mm
5,5 mm
5,5 mm
175
mm
188,
5 m
m
32 mm
52 mm
175 mm
116
mm
12,5
mm
MMC housing
40 | PLCs for mobile work machines
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Aluminium with a ventilation membranepowder-coated, black,protection systems IP65, IP69KSpecial feature: LED for status display
123 mm
152
mm
5,5 mm
175
mm
108 mm
138
mm
36 mm
56 mm
120
mm
5,5 mm 138 mm
100
mm
12,5
mm
MMA and MMD housing
MGD housing
Front panel: anodised aluminiumReverse side: stainless steel, with a ventilation membraneProtection category: IP65Special feature: planned for fitting
139 mm
95 mm
109,
5 m
m
139
mm
6 m
m
37 m
m
49 m
m
42 | PLCs for mobile work machines
Völkel Mikroelektronik GmbH Otto-Hahn-Straße 30 48161 MünsterGermany
Tel. +49 [0]2534.9731-0 Fax +49 [0]2534.9731-10
Further information regarding our other products and our company are available under www.voelkel.de
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| X
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2013
0412
© 2013 Völkel Mikroelektronik GmbH | Status: 04.2013