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MotionController GEL 8232
General information
MotionControllers of the serie GEL 823x are optimised for the rough environment of rotor hubs in wind turbines. The MotionController is a compact controller with CPU, LC display, key board, integrated PLC, fieldbus systems and multi axis control with a maximum of 6 controlled axes. A total of up to 64 axes can be controlled via the CAN bus (6 axes with feedback).
Additional inputs and outputs permit serveral CAN REMOTE I/Os with up to 64 inputs or outputs per node and up to 64 node addresses.
Hardware
- RAM: 1 MByte in total
- NVRAM: 8 kByte in total
- Flash: 1 MByte in total
- Free memory space: 256 kByte
Advantages
- Robust controller for up to 6 axes, not affected by shock and vibrations
- Extended temperature range -20 °C to +70 °C
- Open to all standard fieldbus systems
- High noise immunity due to galvanically isolated digitial and analogue inputs and outputs
- Short projecting times due to ready-made functional blocks and pre-configured inputs and outputs
Field of application
- Wind energy (onshore, nearshore, offshore)
- Harsh industrial environments
| Features | GEL 8230 | GEL 8231 | GEL 8232 |
|---|---|---|---|
| Digital inputs | 22 | 30 | 30 |
| Digital outputs | 15 | 15 | 15 |
| Analogue inputs | 1 | 3 | 3 |
| PT100 inputs | 0 | 4 | 4 |
| Analogue outputs | 3 | 3 | 3 |
| Coated electronics | yes | yes | no |
Description
Construction and design
The MotionController are delivered with or without Firmware. A device without firmware has a start-up screen function, which displays device information and copyright window. An existing firmware can be installed on the device.
Up to five different communication channels are available, enabling all conventional field bus systems (PROFIBUS-DP, DeviceNet,...) to be used with one interface. The field bus modules can be retrofitted or replaced at any time without modifying the PLC programme.
Connection is made fail-safe using coded terminal strips. The signal states on the digital input and output terminals can be checked via status indications on the rear side of the device. The status indicators are positioned above or under the terminal strips. Termination of CAN bus and serial inter- face is made using DIP switches on the rear side of the device.
Firmware
A menu-guided service programme with plain text is an integral part of the firmware. In this menu the axis can be configured userfriendly.
The menu structure and parameter setting depend on the firmware version. After switching on the device, the actual values for the axes and for the inputs and outputs are dis- played in different windows.
The menu is divided into the password protected configuration menu and freely accessible areas, e.g. stored failures memory, devide information and CAN bus status. The option texts and the limit values displayed for each parameter ensure easy and fast commisioning via the configuration menu.
Programming
Programming via the PLC is a further possibility to configure the MotionController. Using PLC programming, the display options and actual values may differ from the menus of the firmware.
The standard CoDeSys programming environment runs in parallel with the multiaxis control and offers full transparency for all parameters. Parametrization of all 6 axes is effected by a PC tool and offers menuguidance for comfortable setting of the usual parameters.
The standard programming environment in acc. with IEC 61131-3 includes a library of readymade and powerful technology functions for terminal programming and automatic motion control.
When the PLC start input I3.7 is low the operating parameters of the firmware are displayed. Ohterwise, the MotionController is displaying the PLC ouputs.
Integrated positioning controller
A positioning controller and the necessary hardware for up to six axes are already integrated in the controller. Therefore, no additional modules will be needed.
For the traversing of axes, the controller function library offers the following group of modules:
- Jog mode commands.
- Commands for automatic referencing.
- Positioning commands for servo drives (±10 V and CAN bus).
- Positioning commands for rapid feed/creep feed/stop axes
- Stop commands.
- Commands for setting and interrogating information such as the axis status.
Technical data - integrated positioning controller
| Normal scan time | 1 ms per activated axis |
| Ramps | Linear ramp with adjustable jerk limination |
| Types of control | In binary from through the rapid feed/creep feed/stop function In analog from through the ±10 V interface In digital form through the CANopen interface |
| Controllable axes | 6 |
| In analog from through the ±10 V interface and, alternatively in binary from through the rapid feed/creep feed/stop function |
3 axis |
| In digital from through the CANopen interface | 4 |
Technical Data
| GEL 8230 | GEL 8231 | GEL 8232 | |
|---|---|---|---|
| Electrical data | |||
| Supply voltage VS | 19 to 30 V DC | ||
| Power consumption | 1 A max. (depending on interface) | ||
| Interfaces | |||
| Serial RS 232 | 2 (COM1/2), adjustable baud rate, for PC communication/pro- gramming; COM1: RS 232 C, COM2: RS 232 C or RS 422/485 |
||
| CAN bus | 2 x onboard (master / slave) | ||
| Field bus | 1 extension slot for PROFIBUS DP, InterBus-S or DeviceNet (others on request) |
||
| Inputs | |||
| Counting inputs | 6 x absolute SSI, power supply 24/5 V, 900/600 mA in total, clock frequency 125 kHz |
||
| Digital inputs (galvanically separated) | 24 V, green LED status indicators 22 | 30 |
||
| Analogue inputs (galvanically separated) | selectable alternatively 0 to 10 V or 0 to 20 mA 1 | 3 |
||
| PT100 inputs (galvanically separated) | -40 °C to +215 °C – | 4 |
||
| Outputs (galvanically separated) | |||
| Digital outputs | 9 x 24 V, 30 mA 6 x 24 V, 500 mA red LED status indicators |
||
| Analogue outputs | 3 x ±10 V, max. 10 mA, 2 mV resolution | ||
| PLC | |||
| Memory | programme: 256 KB / data: 128 KB / data backup: 128 KB / NV RAM: 4 KB |
||
| Programming | according to IEC 61131-3, CoDeSys environment | ||
| Ambient data | |||
| Protection class | front side: IP 65, rear side: IP 20 | ||
| Operating temperature | -20 °C to +70 °C | ||
| Storage temperature | -40 °C to +70 °C(1) | -30 °C to +70 °C | |
| Relative humidity of air | 95 %, non-condensing | ||
| EMC | EN 61000-6-2 and 4(2) | ||
| Vibration resistance (IEC 60068, 2-6) | 20 m/s2, 9 to 50 Hz | ||
| Display | |||
| Display | LCD 64x240 px with LED backlighting; visible area 133x39 mm |
||
| Housing | |||
| Material | galvanized sheet steel | ||
| Front panel | edge-protected aluminium | ||
| Weight | approx.1.7 kg | ||
| Valid for GEL 823xY001 to 823xY080 | |||
| Storage temperature | -30 °C to +70 °C | ||
Dimensional drawing
Dimensional drawing GEL 823x
Dimensional drawing mounting frame GK 2063
Overview
Front view
Rear side with connection overview
Connection assignment
Analogue and digital outputs for axis 1, 2 , 3 (terminal strips A1, A2, A3)
| A1 | A2 | A3 | Terminal | signal | function |
| ⊥ Q1 | ⊥ Q2 | ⊥ Q3 | 1 | GND | GND power supply for signals(1) |
| 2 | AnalogueX_Out- | Analogue GND(2) | |||
| QW10 | QW20 | QW30 | 3 | AnalogueX_Out+ | ±10 V |
| 24 V DC In | 24 VDC In | 24 V DC In | 4 | Vs | 24 VDC power supply signals(1) |
| QX1.0 | QX2.0 | QX3.0 | 5 | DAX.1 | 30 mA output(3) |
| QX1.1 | QX2.1 | QX3.1 | 6 | DAX.2 | 30 mA output(3) |
| QX1.2 | QX2.2 | QX3.2 | 7 | DAX.3 | 30 mA output(3) |
| QX1.3 | QX2.3 | QX3.3 | 8 | DAX.4 | 500 mA output |
| QX1.4 | QX2.4 | QX3.4 | 9 | DAX.5 | 500 mA output |
Digital inputs (terminal strips system: E1, axes 1 – 3: E2, E3, E4(4))
| PLC designation | Terminal | Signal | function | |||
| E1 | E2 | E3 | E4(4) | |||
| ⊥ I1 | ⊥ I2 | ⊥ I3 | ⊥ I4 | 1 | GND | Optocoupler supply(4) |
| IX1.0 | IX2.0 | IX3.0 | IX4.0 | 2 | DEX.1 | (3) |
| IX1.1 | IX2.1 | IX3.1 | IX4.1 | 3 | DEX.2 | (3) |
| IX1.2 | IX2.2 | IX3.2 | IX4.2 | 4 | DEX.3 | (3) |
| IX1.3 | IX2.3 | IX3.3 | IX4.3 | 5 | DEX.4 | (3) |
| IX1.4 | IX2.4 | IX3.4 | IX4.4 | 6 | DEX.5 | (3) |
| IX1.5 | IX2.5 | IX3.5 | IX4.5 | 7 | DEX.6 | (3) |
| IX2.6 | IX3.6 | IX4.6 | 8 | DEX.7 | (3) | |
| IX2.7 | IX3.7 | IX4.7 | 9 | DEX.8 | (3); SPS Start für I3.7 | |
Analogue inputs terminal strip E5(4) (PT100)
| E5 | PLC | Termial | Signal | function |
| Analogue4_In- | 1 | /AE 1.4 | GND | |
| Analogue4_In+ | IW54 | 2 | AE 1.4 | PT100 |
| Analogue5_In- | 3 | /AE 1.5 | GND | |
| Analogue5_In+ | IW55 | 4 | AE 1.5 | PT100 |
| Analogue6_In- | 5 | /AE 1.6 | GND | |
| Analogue6_In+ | IW56 | 6 | AE 1.6 | PT100 |
| Analogue7_In- | 7 | /AE 1.7 | GND | |
| Analogue7_In+ | IW57 | 8 | AE 1.7 | PT100 |
Analogue inputs terminal strip E6 (current / voltage)
| E6 | PLC | Termial | Signal | function |
| Analogue1_In- | 1 | /AE 1.1 | Signal- | |
| Analogue1_In+ | IW61 | 2 | AE 1.1 | Signal+ |
| Analogue2_In- | 3 | /AE 1.2 | Signal-(4) | |
| Analogue2_In+ | IW62 | 4 | AE 1.2 | Signal+(4) |
| Analogue3_In- | 5 | /AE 1.3 | Signal-(4) | |
| Analogue3_In+ | IW63 | 6 | AE 1.3 | Signal+(4) |
Each input can be switched from current to voltage input by a jumper (current 0 to 20 mA / voltage 0 to 10 V). Delivery state: current input
Connection assignment
Power supply ( 24 V; terminal strip V)
| Terminal | Signal | Function |
| 1 | GND (Z) | GND (encoder) |
| 2 | GND | GND |
| 3 | 24 V DC | Logic power supply |
| 4 | 24 V DC (Z) | Encoder power supply (terminal strips Z1, Z2, Z3) |
Encoder inputs (actual–value for axis 1, 2 or 3; terminal strip Z1, Z2, Z3)
| Klemme | Signal | SSI encoder A | SSI encoder B | Function |
| 1 | GND (Z) | x | x | GND encoder(1) |
| 2 | +5 V DC Out | UZ | UZ | 5 V encoder power supply(1), internally regulated to 5 V |
| 3 | +24 V DC Out | UZ | UZ | 24 V encoder power supply(1) |
| 4 | CLK_SSI+ | x | x | Differential clock signal for encoder A and B |
| 5 | CLK_SSI- | x | x | |
| 6 | Data_SSI_A + | x | - | Differential data signal for encoder A |
| 7 | Data_SSI_A - | x | - | |
| 8 | Data_SSI_B + | - | x | Differential data signal for encoder B |
| 9 | Data_SSI_B - | - | x | |
| 10 | Ref_N + | (x) | Reference signal N | |
| 11 | Ref_N- | (x) |
Serial interface connector C1
CAN bus interface (terminal strip C2)
| Terminal | Signal |
| 1 | GND (C) |
| 2 | CAN 1_H |
| 3 | CAN 1_L |
| 4 | |
| 5 |
Termination of CAN bus by dip switch
Type code and Accessories
Type code
Accessories
Mounting accessories
Accessories
Mounting accessories
Mounting accessories
| Item number | Description |
| GEL 89043 | Counter plug set |
| BG 4622 | 14 hex screws M3 x 10, 14 cable bride, 2 earting terminals, 14 toothed lock washers |
| BG 4623 | 6 hex screws M4, 6 washers, 6 spring washers, 2 earthing terminals |
| GK 2063 | Mounting frame: 6 hex screws M3 x 10 and 6 toothed lock washers |
Fieldbus accessories
| Item number | Description |
| GEL 89022 | Connection cable RS 232 C between PC and MotionController |
| GEL 89130 | Fieldbus module (PROFIBUS-DP) |
| GEL 89131 | Fieldbus module (InterBus-S) |
| GEL 89132 | Fieldbus module (DeviceNet) |
| GEL 89133 | Fieldbus module (Ethernet) |
Documentations
| Item number | Description |
| CD GEL 823x_- | CD-ROM GEL 823x without firmware, including manuals as pdf-files |
| CD GEL 823x_200 |
CD-ROM GEL 823x with firmware version 200, including manuals as pdf-files |
| on request | User manual GEL 823x in German or English (DIN A5, printed) |