Pleiger PCM Manual

Pleiger Elektronik
GmbH & Co. KG
PCM Pleiger Control Modules
Manual
CM3 EHS Control Module
IO 8/8/4 IO-Module
RK 16/8 Relay Module
CCM Conti Control Module
BI Bus Interface
Author: H. Vögler
Issue: 9/2011
- subject to modification -
Pleiger Elektronik GmbH & Co. KG

D-58456 Witten - Im Hammertal 51
D-58423 Witten - Postfach 32 63
Telefon (0 23 24) *3 98- 0
Telefax (0 23 24) 3 98- 3 89
Internet www.pleiger-elektronik.de
E-Mail info@pleiger-elektronik.de
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Contents
1 Overview ......................................................................................................................... 1
1.1 Assembly ...............................................................................................................................................1
2 EHS control module CM3 .............................................................................................. 2
2.1 Operation ...............................................................................................................................................2
2.2 Control functions ..................................................................................................................................3
2.2.1 Types of actuators.............................................................................................................................3
2.2.2 Operation modes of the actuators.....................................................................................................4
2.3 Adjusting the operating time ...............................................................................................................4
2.3.1 Calibration of the operating time .......................................................................................................5
2.4 Extended operation modes ..................................................................................................................5
2.4.1 Extended operation mode set-up......................................................................................................5
2.4.2 Displaying extended operation modes..............................................................................................5
2.6 Start reports and self test.....................................................................................................................5
2.7 Alarm output ..........................................................................................................................................6
2.8 Lamp test ...............................................................................................................................................6
2.9 Placing commands ...............................................................................................................................6
2.10 Terminal assignment ............................................................................................................................6
2.11 Technical data .......................................................................................................................................7
2.12 Connecting Ex-Type actuators ............................................................................................................7
3 Input/output module IO 8/8/4......................................................................................... 9
3.1 Displays..................................................................................................................................................9
3.1.1 Start messages and self test.............................................................................................................9
3.1.2 Lamp test ..........................................................................................................................................9
3.2 Adjusting the address ........................................................................................................................10
3.3 Terminal assignment ..........................................................................................................................10
3.4 Technical data .....................................................................................................................................11
4 Relay Module RK 16/8 .................................................................................................. 12
4.1 Indication .............................................................................................................................................12
4.2 Operation .............................................................................................................................................12
4.3 Jumper B1............................................................................................................................................12
4.4 Counter function .................................................................................................................................12
4.5 Technical Data.....................................................................................................................................13
5 Conti Control Module CCM.......................................................................................... 14
5.1 Operation .............................................................................................................................................14
5.1.1 Status LED ......................................................................................................................................14
5.1.2 Position measurement ....................................................................................................................15
5.1.3 Position indication ...........................................................................................................................15
5.2 Calibration............................................................................................................................................15
5.3 Extended Operation Modes................................................................................................................15
5.4 Start reports and self test...................................................................................................................16
5.5 Alarm output ........................................................................................................................................16
5.6 Lamp Test ............................................................................................................................................16
5.7 Placing commands .............................................................................................................................16
5.8 Analog Position Signal .......................................................................................................................16
5.9 Behaviour in case of black out ..........................................................................................................17
5.10 Terminals .............................................................................................................................................17
5.11 Interface to Flowmeter........................................................................................................................18
5.12 Technical data .....................................................................................................................................18
PCM – Manual Issue: 9/2011

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6 Fieldbus interface BI .................................................................................................... 18

6.1 Operation .............................................................................................................................................18
6.1.1 Parameterisation of the fieldbus .....................................................................................................18
6.1.2 Setting the address of the EHS-CM3 / CCM modules....................................................................19
6.1.3 Setting the address and operation mode of the RK 16/8................................................................20
6.1.4 Skipping addresses.........................................................................................................................20
6.1.5 Display functions .............................................................................................................................20
6.1.6 Start messages and self test...........................................................................................................21
6.1.7 Power management ........................................................................................................................21
6.1.8 Set-up of Quick Close Functions ....................................................................................................22
6.1.9 Alarm output....................................................................................................................................22
6.1.10 Lamp test ........................................................................................................................................22
6.1.11 Bus Termination ..............................................................................................................................22
6.3 Technical data .....................................................................................................................................23
7 BI Modbus interface (slave)......................................................................................... 24
7.1 Modbus data model ............................................................................................................................24
7.1.1 Fieldbus interface BI status, register 1, (read only) ........................................................................24
7.1.2 CM3 status register (read only).......................................................................................................25
7.1.3 CCM status register (read only) ......................................................................................................25
7.1.4 IO status register (read only) ..........................................................................................................26
7.1.5 Fieldbus interface BI remote control, register 142 (read/write).......................................................27
7.1.6 CM3 control register (read/write) ....................................................................................................27
7.1.7 CCM control register (read/write)....................................................................................................27
7.1.8 IO control register (read/write) ........................................................................................................28
7.1.9 RK status register (read only) .........................................................................................................28
7.1.10 RK control register (read / write) .....................................................................................................29
7.2 Fieldbus Watchdog .............................................................................................................................29
7.3 Register summary...............................................................................................................................30
8 BI Profibus DP interface (slave).................................................................................. 31
8.1 Profibus data model............................................................................................................................31
8.1.1 Fieldbus interface to superimposed control system (status words)................................................31
8.1.2 Superimposed control system to fieldbus interface (control words) ...............................................31
8.1.3 Data Valid Bit ..................................................................................................................................32
9 Secondary BI Module................................................................................................... 32
9.1 Parameterisation of the secondary BI module.................................................................................32
9.2 Fieldbus interface BI status, register 1 (read only) .........................................................................33
9.3 Fieldbus interface BI remote control, register 142 (read/write)......................................................33
9.4 Programming the fieldbus master.....................................................................................................33
10 Assembly of the system .............................................................................................. 34
10.1 Controlling via mimic diagram ..........................................................................................................34
10.2 Commissioning hints..........................................................................................................................34
10.3 Safety Advice.......................................................................................................................................35
10.4 Accessories .........................................................................................................................................35
10.4.1 Adapting Cable................................................................................................................................35
10.4.2 Extension Cable ..............................................................................................................................35
10.4.3 Adapting Cable for RK 16/8 ............................................................................................................35
10.4.4 Safety Advice Plate .........................................................................................................................36
10.4.5 End Holder ......................................................................................................................................36
10.4.6 Noise Suppression Filter .................................................................................................................36
10.4.7 CM-ExE Capacitor Module..............................................................................................................36
PCM – Manual Issue: 9/2011

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1 Overview
The system consists of the components:
• EHS control module CM3
• Input/output module IO 8/8/4
• Relay module RK 16/8
• Conti Control Module CCM
• Fieldbus interface BI
The EHS control module CM3 is for the control and monitoring of electro hydraulic swivel drives.
Operation can be carried out manually with the assistance of the control module operation elements,
via digital inputs and outputs of the control module and via a serial data connection to a supervisory
control system. The CM3 control function can be adapted to the different actuator types by means of
a quadruple switch.
The input/output module IO8/8/4 has 8 analog inputs, 8 digital inputs and 4 digital outputs and is for
monitoring and output of control signals. Link-up to a supervisory control system is carried out via a
serial data connection.
The RK16/8 module provides 8 relay outputs (normally open) and 16 digital inputs with opto-couplers.
This module is primarily used to control centralized hydraulic actuators. Up 4 double acting or 8 single
acting actuators can be operated by a single module.
The CCM module is used to control centralized hydraulic actuators with analog position feedback.
Those actuators use flowmeters with digital outputs that can directly be connected to the CCM.
The fieldbus interface BI forms the interface between the bus protocol of the local module bus and the
fieldbus according to the Modbus RTU or Profibus DP standard. Furthermore, the fieldbus interface
acts as a monitor for all modules at the local bus and enables simple parameterisation of these mod-
ules.
1.1 Assembly
The modules BI, CM3 / CCM and IO are installed in a narrow, compact top-hat rail housing
(22.5x105x115, WxHxD). They are interconnected via a connector system in the top-hat rail and can
be removed from the system independently or re-applied without interfering with the function of the
overall system. The RK 16/8 module is installed in a flat top-hat rail housing (102x126x30) connected
to the local bus by means of a prefabricated connetcion cable.
13 14 15 16
9 10 11 12
1 2 3 4
5 6 7 8
CM3 CCM IO 8/8/4 BI RK 16/8
The local bus connects all modules to a 24V supply voltage, a serial databus and a common digital
control line used for lamp test. Up to 50 CM3 modules, 10 IO and 20 RK modules can be connected
to a fieldbus interface. In doing so the IO modules must be aligned to the left of the fieldbus interface
and the CM3 and RK modules to the right of the fieldbus interface.
PCM – Manual subject to modification Issue: 9/2011 Page 1

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2 EHS control module CM3

The EHS CM3 control module monitors and controls electro-hydraulic flap or valve actuators manu-
factured by Pleiger Maschinenbau. One control module is required for each actuator. The actuator
can be connected directly to the control module. The module is equipped with the necessary power
relays and actuator supply voltage fusing.
2.1 Operation
The EHS control module has several operating and display elements that enable manual on-site
operation of the actuator.
switch „local - remote“ In position “local” the drive can be operated by means of the „close-0-
open“ switch. In position „remote” the can be operated using the digital
control inputs or the local serial bus.
button „close - 0 - open“ This button is used to operate the drive while the operating mode is
„local“. If the operation mode is “remote” pressing this button will indi-
cate the device and software version on the BI display.
Furthermore, operation of the local-remote switch causes temporary display of the module address on
the fieldbus interface. In addition, these control elements are also used for the parameterisation of
the local bus (see also: 6.1.2).
Three LED (red, yellow, green) signalise the operating status of the actuator and the con-
trol module.
LED red LED green meaning
on off Drive in closed position
on blinking 1/s Drive in closed position, open command received
off blinking 1/s Drive is opening, closed position left
off on Drive in open position
blinking 1/s on Drive in open position, close command received
blinking 1/s off Drive is closing, open position left
blinking 2/s on / off Not closed within supervision time
on / off blinking 2/s Not opened within supervision time
blinking 2/s blinking 2/s No valid position on module start up
blinking 4/s blinking 4/s Illegal feed back
For drive type no. 10 only:
blinking 1/2s off Command close, opened manually, open position not reached
blinking 1/2s on Command close, opened manually completely
The yellow LED serves to display the operating status of the control module.
LED yellow meaning
on No 230VAC power supply or fuse blown
off Power supply OK, no (valid) data on local bus
blinking Power supply OK, valid data on local bus but module is not addressed
flickering, Power supply OK, data exchange OK
dim

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2.2 Control functions

The control function that is required for the various types of actuators can be selected with the
assistance of a quadruple switch in the front of the control module housing. For this the
transparent module cover flap must be opened. To accept the new type the module has to be
reset. type
ATTENTION: It is absolutely necessary to adapt the control function to the type of actuator as
otherwise correct function of the actuator is not guaranteed and the actuator or the
control module can be damaged as the case may be.
Switch
Typ Type of actuator Operation mode Runtime
1 2 3 4
0 EHS double acting open / close 4s..260s 0 0 0 0
1 EHS double acting step open / close 4s..260s 1 0 0 0
2 EHS double acting open / step close 4s..260s 0 1 0 0
3 MOV open / close 4s..260s 1 1 0 0
4 EHS single acting, spring close open / close 4s..260s 0 0 1 0
5 EHS single acting, spring open open / close 4s..260s 1 0 1 0
6 EHS double acting % 4s..260s 0 1 1 0
7 EHS double acting %Pos 4s..260s 1 1 1 0
8 EHS single acting, spring close % 4s..260s 0 0 0 1
9 EHS single acting, spring open % 4s..260s 1 0 0 1
10 EHS single acting, spring close with handwheel open / close 4s..260s 0 1 0 1
11 EHS double acting with separated hydraulic unit open / close 4s..260s 1 1 0 1
12# EHS spring close, hydraulic override open / close 4s..260s 0 0 1 1
13~ EHS double acting, Ex-Type open / close 4s..260s 1 0 1 1
14* EHS double acting, Ex-Type %Pos 4s..260s 0 1 1 1
15 not used
#
only for firmware version V2.0 or higher Switch position 0= OFF, 1= ON
~ only for firmware version V2.2 or higher
* only for firmware version V2.4 or higher
2.2.1 Types of actuators

Double-acting
This actuator actively opens and closes with activated drive motor. In the event of a power failure it
stops in the current position.
Single-acting, spring close
This actuator actively opens with activated drive motor. The closing procedure is carried out by spring
force. The actuator closes in the event of a power failure.
Single-acting, spring open
This actuator actively closes with activated drive motor. The opening procedure is carried out by
spring force. The actuator opens in the event of a power failure.
MOV, motor valve
This actuator behaves likes a double-acting actuator and contrary to this automatically turns the drive
motor off upon reaching the end position. The control module always leaves the current supply swit-
ched on during normal operation.
Spring close, mechanical override with handwheel
This actuator corresponds to a normal spring-close actuator, but can be opened manually with the
assistance of a handwheel. This operating status is permitted and the control module will not report
this as an error. In order to re-close the manually opened actuator this must initially be completely
opened electrically. This function is carried out automatically by the control module.

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spring close, hydraulic override with hand pump and separate hand valve
The actuator operates like a standard spring close type but can manually be opened by means of a
manual operated valve and a hand pump. This operation mode is signalised at the CM3 module but is
not indicated as a fault. The actuator may be closed by the CM3 by electrically opening the manual
valve again.
double acting, Ex-Type
The Ex-type actuator can only be operated in combination with the capacitor module (9311222810).
The function equals a standard double acting actuator. This kind of actuator is available with
open/close and analog position indicator.
2.2.2 Operation modes of the actuators

Operation mode: open / close
After the drive command has been given, e.g. by pushing the command key in the direction of ”close“,
the actuator will operate until the final position is reached or the maximum permissible operating time
is exceeded. The alarm output is activated if the operating time is exceeded and alarm status signal-
ised via the light-emitting diodes on the module.
Operation mode: open / step closing
To a large extent this operation mode corresponds to the open/close operation mode. Upon closing,
however, the actuator is repeatedly stopped briefly in order to extend the closing time. In this connec-
tion the closing time is extended by the set operating time, i.e. the closing time is approximately dou-
bled. The turn-on times of the actuator amount to at least 1 second. Depending on the operating time
the actuator is halted up to 20 times.
Operation mode: step opening / step closing
To a large extent this operation mode corresponds to the open/close operation mode. Upon closing
and opening, however, the actuator is repeatedly stopped briefly in order to extend the closing or
opening time. In this connection the closing or opening time is extended by the set operating time.
The turn-on times of the actuator amount to at least 1 second. The actuator is halted up to 20 times.
Operation mode: %
In this operation mode the actuator is only operated for as long as the command key is depressed or
the command is pending. The actuator can thus be stopped in any position. Only exception: Insofar
as either of the actuator limit switches is operated, the actuator is moved to the appropriate end posi-
tion when the key is released. This ensures that the actuator has actually moved completely to the
end position if this is signalised by the end position switch. For example, this function is used for throt-
tle valves.
Operation mode: %Pos
This operation mode is only used in connection with the issue of a command via a superimposed con-
trol system. In this case the superimposed control system prescribes the desired position of the valve
as a percentage and the control module automatically moves the valve into the target position. Devia-
tions from the target position not exceeding 2% are ignored by the module. This operation mode is
always replaced by operation mode % during mimic diagram operation or local command input.
2.3 Adjusting the operating time

The operating time of the actuator can be adjusted by means of a potentiometer on the front side of
the module. The transparent module cover flap must be opened for this. In general a fairly rough ad-
justment (-5% .. +25%) is sufficient whereby, if anything, the time should be assessed somewhat too
generously.

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The operating time should only be determined exactly for actuators with a successive opening or clos-
ing function and in particular for actuators with the %Pos operation mode. A help function is inte-
grated into the control software for this purpose, allowing this to be very simple and reliable.
2.3.1 Calibration of the operating time runtime

• Set the operating time to maximum (r.h. limit stop).
180
120 260
60
• Move the actuator from the closed position to the open position by selecting the “local” 40
20
4
operation mode and pushing the command key in the direction of “open”.
• Once the actuator has opened completely, push the command key again in the direction of “open“
and hold depressed. Now slowly reduce the operating time until the red LED also turns on. If both
LED are turned on, the time has been adjusted correctly.
2.4 Extended operation modes

The function of the CM3 module can be changed by setting several extended operation modes. This
feature is implemented from Version V2.0 upwards. Up to four extended operation modes can be set:
1. mimic inputs are active even in local operation mode
2. reserved
3. reserved
4. reserved
2.4.1 Extended operation mode set-up

Depending on the requested extended operation mode one or more type selector switches 1..4 must
be changed while the module is running. Now turn operation mode to “remote”.
• To set the extended operation push the command button to „close“ position until the yellow LED
starts flashing several times. The extended operation mode is set now.
• To reset the extended operation push the command button to „open“ position until the yellow LED
starts flashing several times. The extended operation mode is reset now.
ATTENTION: Do not forget to turn the type selector switches back to the original position.
2.4.2 Displaying extended operation modes

If at least one of the extended operation modes is set it will be displayed at the BI module if the
„close“ button is pressed in operation mode „remote“. If no extended operation mode is selected the
version number of the CM3 is displayed as usual.
If extended operation mode1 is set and the mode switch is turned to local mode the yellow lamps
starts flashing several times to indicate that mimc commands can overrule local commands.
2.5 Start reports and self test

Directly after the programme has started up, the module displays the last “reset“ cause by illuminating
one or two LED briefly. The module subsequently carries out a short self test. In the event that the
self test is not carried out successfully, the yellow LED will start to flash.
Once the self test has been carried out successfully, the normal status display will start up.

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2.6 Alarm output

Once the self test has been carried out successfully, the alarm output is closed initially. As soon as an
error occurs the output is opened. The output is not closed until the error is reset, e.g. by entering a
new drive command. Errors that will raise an alarm are:
• power supply failure 24VDC or 230VAC
• invalid or inadmissible position indications
• timeout while closing or opening
2.7 Lamp test

Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied, the 3 LED
on the module are illuminated and in addition to this both report outputs “LED open” and “LED closed”
to the mimic diagram are activated.
2.8 Placing commands

Commands can be placed in three different ways:
• Using the open/close button while the operation mode is “local”
• Using the control inputs “CMD-close / CMD-open” while the operation mode is “remote”
• Using a command sent via the BI module
Note: As long as the command inputs are set they will overrule the commands sent via the BI module.
2.9 Terminal assignment

Lower terminals, to the control system:
X1 (grey) pluggable
1 LED-open o Drive open, to mimic diagram
2 LED-closed o Drive closed, to mimic diagram
3 CMD-open i Command open, from mimic diagram
4 CMD-close i Command close, from mimic diagram
X2 (red) pluggable
5 N i Drive supply voltage 230VAC max. 3,15A
6 L i Drive supply voltage 230VAC max. 3,15A
7 Alarm a o Contact opens in case of error
8 Alarm b o Contact opens in case of error
Upper terminals, to the EHS:

X3 (grey) pluggable
9 FB-closed i Feed back closed, 0V = closed, internal pull up
10 FB-open i Feed back open, 0V = open, internal pull up
11 0V o DC power supply for position sensors
12 24V o DC power supply for position sensors
X4 (black) pluggable
13 FB- analog i Position signal (4..20mA) (optional)
14 N o Common power
15 L-close o Power output close
16 L-open o Power output open
Safety Advice: Always plug in red connector to connect AC supply voltage last and
always pull it off to disconnect AC supply voltage first! (see also 10.4)

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Bus connector
1 Data A io Local data bus, rs485
2 Data B io Local data bus, rs485
3 lamp test i Lamp test input, 24V = lamps on
4 0VDC i Local power supply
5 +24VDC i Local power supply
ATTENTION: It is imperative to ensure that the supply voltage is not under any circumstances
applied to the local data bus. This may cause the destruction of all connected
modules.
2.10 Technical data

Supply voltage DC 24V
Current requirement DC max. 40mA, plus external load*
Fuse DC self resetting fuse, 500mA - 1100mA
Supply voltage AC 230V ±20%
Fuse AC 2 x 3,15AT miniature fuse
Analog input position 4..20mA = 0..100%, deviation ±1%, resistance249Ohm
LED-open / -close semiconductor high side switches, max. load 150mA, short
circuit proof
size WxHxD 22,5mm x 105mm x 115mm
Terminal type max. 2,5mm²
Operating temperature 0°C – 55°C
protection IP20
*The current consumption of the feedback modules in the EHS, for example OC3 and the
currents emitted via the mimic diagram outputs X1, Pin1 and Pin2, must be added to the
current consumption of the module.
The miniature fuses for AC power supply are accessible at the lower side of the casing.
To exchange the fuses the casing has to be removed from the hat-rail. The fuse holder
can be opened by means of a screw driver.
2.11 Connecting Ex-Type actuators

PL56-03: 1~
PCM-CM3 6
CM-ExE
14 14 5 5
N
4 4
15 15
close 3 3
16 16 2 2 auxiliary winding
open
1 1
main winding
To operate an Ex-type actuator a capacitor module CM-ExE (see also: 10.4.7) is required.

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3 Input/output module IO 8/8/4

The IO module is an assembly group for registering analog and digital signals and for the output of
digital signals. All signal transmitters must be isolated, as this module does not provide internal poten-
tial separation. Generally speaking, this is the case for temperature and pressure sensors or limit
switches, floating switches and dry relay contacts. Insofar as this is not applicable, isolation amplifiers
or cutoff relays must be used.
This also applies correspondingly to the digital outputs that are designed as short-circuit proof semi-
conductor relays, dispensing 24V supply voltage.
3.1 Displays
The module has a total of 20 LED at its disposal to display the input or output status.
• 8 green LED indicate the status of the individual measured values.
green LED input signal meaning
on >=3.8mA and <=20.2 mA valid measurement
blinking fast > 20.2mA above range or short circuit
blinking slowly >0.2 mA and <3.8mA below range
off <=0.2mA not used or wire broken
• 8 yellow LED indicate the status of the digital inputs.

• 4 red LED indicate the status of the digital outputs.
Furthermore, the LED are used to display any error status. In this connection the 4 lower and 4 upper
green LED flash alternately whilst the yellow LED indicate the error number from 1..8.
LED Error status Comment
1. address changed the address of the module was changed
2-7. still free
8. module offline There is no data connection to the BI module
Alteration to the module address initially brings about the output of the “address changed“ error mes-
sage. This error message also brings about the display of the module address on the fieldbus inter-
face. The new module address is not accepted until the module has been re-started.
3.1.1 Start messages and self test

Directly after the start of the programme the module displays the last reset cause by illuminating one
of the yellow LED briefly. The module subsequently carries out a short self test. In the event that the
self test is not carried out successfully, the two lowest green LED will start to flash.
Normal status display commences once the self test has been carried out successfully (see above).
3.1.2 Lamp test

Terminal no. 3 on the local bus is used as a lamp test input. As soon as 24V are applied the 8 green
and 8 yellow LED are illuminated. The red LED are not activated during the lamp test.

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3.2 Adjusting the address

module switch The module address is adjusted with the assis-
address
address S1 S2 S3 S4 tance of a quadruple switch. The switch is to be
51 0 0 0 0 found behind a transparent cover flap.
52 1 0 0 0 The address range of the IO modules starts at 51
53 0 1 0 0 and finishes at 60.
54 1 1 0 0 The range beginning with setting 0101 is also mapped to
55 0 0 1 0 the addresses 51 to 56. In this case the state of the digital
56 1 0 1 0 input is hold for at least 0,9s. By this means even very
57 0 1 1 0 short events like pressing a push button can be detected
58 1 1 1 0 securely (Version B.6 and higher).
59 0 0 0 1
60 1 0 0 1
0= OFF, 1= ON
51* 0 1 0 1
52* 1 1 0 1 * state of digital inputs is hold for at least 0,9s
53* 0 0 1 1
54* 1 0 1 1
55* 0 1 1 1
56* 1 1 1 1

Lower terminals (factory):
X1 (grey) pluggable
1 digital input 5 i 24V DC to 0V of supply voltage
5 digital output 1 o 24V DC to 0V of supply voltage
Upper terminals (dockyard):
X3 (grey) pluggable
9 analog input 4 i 0 .. 20mA, to 0V DC
X6 (grey) pluggable

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Bus connector
3 Lamp test i Lamp test input, 24V = lamps on
modules.
3.4 Technical data

supply voltage DC 24V
current requirement DC max. 70mA, plus external load*
fuse DC Self resetting fuse, 500mA - 1100mA
terminal type max. 2,5mm²
operating temperature 0°C – 55°C
protection IP20
*Current via digital outputs
Analog inputs
range 0 (4) .. 20mA
resolution 12 Bit, 0 = 0mA, 4000 = 20mA, 4096 = 20,48mA
precision 0,4% of full range, typ. 0,2%
filter Median / low pass app. 200ms
shunt resistance 100 Ohm
overload protection self resetting fuse 30 - 50mA per input (max. 30V)
Digital inputs
threshold app. 9,5V
input current app. 5mA
low pass filter app. 10ms
Digital outputs
output voltage 24VDC
output current, on max. 200mA per output, max. 400mA totally
output current, off <1mA

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4 Relay Module RK 16/8

The relay module provides 16 opto-decoupled digital inputs and 8 relay outputs.
The inputs are arranged in two groups with common 0V. A jumper allows to
connect both groups to the same 0V. The relay outputs are designed as nor-
mally open contacts with one common terminal. The common terminal is fused
onboard. Standard fuse is 2AT, max. 10AT is allowed. The fuse is monitored. A
voltage drop of more than 100VAC will be indicated and signalled. The relay
contacts may switch up to 3A / 230V. A short cable with two plugs serves to
connect the RK 16/8 with each other.
4.1 Indication
The module is equipped with 24 LED for indication of the input and output state. An addi-
tional yellow LED is used for status display.
- 16 green LED indicate the state of the digital inputs
- 8 yellow LED indicate the state of the digital outputs
The status LED indicates the data traffic on the local bus, a fuse fail and also assists the user during
set-up of the module.
LED yellow meaning
on fuse fail, voltage drop on fuse > 100VAC
off no fuse fail, no data on the local bus
blinking no fuse fail, valid data on local bus but module is not addressed
flickering no fuse fail, communication on local bus is running
4.2 Operation
A push button is used to show and to set-up the module address and operation mode. This function is
only available in conjunction with a BI module with software version 2.1 or higher. To set up the ad-
dress the BI must run in set-up mode (see also: 6.1.3).
If BI is running in normal operation mode the push button is used to indicate the RK address. If the
button is pressed for more than 3s the software version of the RK is indicated instead of the address.
4.3 Jumper B1
If the jumper B1 is plugged on (default) the common 0V of both input groups are connected. In this
case only pin 9 of terminal X1 or X2 must be connected to 0V. If both input groups are connected to
independent supply voltages the jumper must be removed.
4.4 Counter function

To collect rapidly changing input values the RK provides a counter function for the input 1. Both rais-
ing and falling edges of the input signal are counted and stored in an 8 bit counter value. If the
counter reaches 255 it will be reset on the next edge of the input signal.
Each puls must last at least 15ms. The counter value must be read frequently to detect a counter
overrun reliably. With a puls duration of 15ms the counter must be read at least every 15ms*255 =
3825ms.

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4.5 Technical Data

current requirement DC max. 100mA
fuse DC Self resetting fuse, 500mA - 1100mA
Input voltage 24VDC
Threshold 6-12V, typ 9V
Counter pulse length >= 15ms
Output voltage max. 230VAC
Output current max. 2A per output
Fuse outputs default 2AT, max. 10AT
protection IP20

terminal X1:
1 digital input 1 i 24V DC
… … i
9 common 0V for 1-8 i common 0V
terminal X2:
... ... i
9 common 0V for 9-16 i common 0V
terminal X3:
1 relay output 1 o normally open
… … o
9 common terminal o
terminal X5 and X6:

1 rs485 A i/o local data bus
2 rs485 B i/o local data bus
3 0VDC i/o power supply
4 24VDC i/o power supply
The RK 16/8 does not provide a lamp test input!

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5 Conti Control Module CCM

The CCM is used to control centralized hydraulic actuators with analog position indica-
tion. To measure the actuator’s position a flow meter with two 90° phase shifted binary
signals is used. The flow meter is inserted in the hydraulic pipe that is used to open the 13 14 15 16
9 10 11 12
actuator.
The CCM fully controls the actuator including the solenoid valves. Operation can be
done by means of local switches, external devices like mimic push buttons or via a
PCM-BI module. The module provides the required power relays and the fuses to safely
control the solenoid valves. The CCM uses the same address range as the PCM-CM3
modules. The casing equals the one of the CM3. From a BI’s point of view the CCM
behaves like a CM3 for EHS with analog feedback.
The calibration of the CCM is done by teach-in. The module determines the volume of
the actuator as well as different compression volumes and the runtime of the actuator.
1 2 3 4
5.1 Operation 5 6 7 8
The CCM provides several control and monitoring devices for local operation of the ac-
tuator.
switch „local – remote“ In position “local” the actuator can be operated by means of the „close-0-
open“ button. In position remote the actuator can only be operated via lo-
cal bus or digital control inputs.
button „close – 0 – open“ In operation mode „local“ this button is used to control the actuator. In
operation mode “remote” the button is used to indicate the version of the
device respectively the software.
set button Pressing this button in local operation mode will start the calibration func-
tion. A transparent plastic cover protects the button against unintended
use.
The address setting of the CCM is done in the same way that is described for the CM3 (see also:
6.1.2).
5.1.1 Status LED

Three LED (red, yellow, green) signalise the operating mode of the actuator and the control
module.
LED red LED green Meaning
on off actuator in closed position
on blinking 1/s actuator in closed position, open command received
off blinking 1/s actuator is opening, left closed position
off on actuator in open position
blinking 1/s on actuator in open position, close command received
blinking 1/s off actuator is closing, left open position
blinking 2/s on / off while closing: final position not reached within supervision time
on / off blinking 2/s while opening: final position not reached within supervision time

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The yellow LED indicates the operating mode of the control module.
LED yellow Meaning
on missing coil supply voltage
off supply voltage OK, no valid data on local bus
blinking supply voltage OK, valid data on local bus but CCM not properly addressed
flickering supply voltage OK, local bus interface OK
5.1.2 Position measurement

A flow meter inserted in the hydraulic pipe that opens the actuator is used to determine the actual
position of the drive. Several compression volumes are considered to determine the position as
exactly as possible.
As an incremental measuring is used referencing is required from time to time. Each time the final po-
sitions are reached (actuator stops) and the position is less than 3% or more than 97% the actual po-
sition is set to 0% respectively 100%.
5.1.3 Position indication

Two 7 segments LED displays are used to indicate the current position of the actuator. The final posi-
tions are indicated as CL for “close” respectively OP for “open”. All intermediate positions are indicated
in percent 1..99.
The decimal point of the lower digit flashes whenever the position value is referenced. A synchronous
blinking of both decimal points indicates that the position value has not yet been referenced after the
CCM was turned on. In this case the shown position value could be invalid if the position changed
while the CCM was turned off!
5.2 Calibration
After installation the CCM must be calibrated. During calibration the CCM calculates all parameters
concerning the actuator and the piping and stores these parameters in an internal non-volatile mem-
ory.
The calibration run is started by pressing the SET button while the operation mode is set to “local“.
The calibration passes the following steps:
1-2 close actuator and wait for a standstill
3-4 open actuator and wait for a standstill
5-6 close actuator once more and wait for a standstill
7-8 open actuator one third and wait for a standstil
9-A close actuator to app. 10% and wait for a standstil
B-C close actuator, wait for a standstill and store parameters
The current step is indicated on the 7 segment display C1...CC.
The calibration may be started every time when opening the actuator is allowed. During calibration
the operator has to make sure that the actuator reaches the final positions completely.
5.3 Extended Operation Modes

Besides the default operation mode the CCM provides several extended modes. If the “set” button is
pressed for 3s while CCM is in “remote” mode the extended operation mode is shown. The upper digit
always shows E. and the lower one a number. By means of the “open/close” switch the desired num-
ber can be selected. Each Bit in this number enables a certain mode. The default value is E0.

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E1 extended operation mode “local override“,

the inputs for the mimic push buttons are always enabled. This mode is required if the mimic
inputs are used for some safety functions that must be independent from the local / remote
switch.
E2 extended operation mode “flow meter in pipe used to close the actuator”.
This mode is required if the flow meter is inserted in the pipe that is used to close the actuator.
Attention: During calibration run the actuator first starts opening and remains in open position
at the end of the test.
E4 extended operation mode “very slow actuators”
this mode is required if very slow actuators are used. In this case the timeout periods are ex-
tended:
- close timeout and open timeout from 4 to 10 minutes
- calibration timeout from 10 to 20 minutes
The extended operation modes may also be combined. If for example you want to enable the “local
override” mode for “very slow actuators” you may add both numbers 1 and 4 and select mode E5.
5.4 Start reports and self test

During start-up the CCM indicates cause of the last “reset“ on the 7 segments display and performs a
short self test. If the self test fails the yellow LED starts blinking.
5.5 Alarm output

After self test is finished successfully the alarm contacts are closed. In case of a fault the contacts
open and are closed again if all faults have been removed. The alarm contacts are opened if:
• supply voltages 24VDC or 230VAC fail
• the runtime limit of the actuator is exceeded
• internal device fault
5.6 Lamp Test

and all segments of the 7-segment display of the module are illuminated. The mimic outputs are
turned on.
5.7 Placing commands

Commands can be placed in three different ways:
• Using the open/close button while the operation mode is “local”
• Using the control inputs “CMD-close / CMD-open” while the operation mode is “remote”
• Sending a command via the PCM-BI module while the operation mode is “remote”
Note: As long as the command inputs are set they will overrule the commands sent via the BI mod-
ule.
5.8 Analog Position Signal

The CCM provides an analog 4..20mA output. The current signal indicates the position of the actua-
tor.
• 4mA = closed
• 20mA = open

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The current output is not isolated to local 24V supply voltage. The max. resistance in the current load
must not exceed 150 Ohms. The deviation between analog output and 7 segment display may be up
to 2%. This output is intended to be connectd to a position indication meter. It is not intended for
connecting a supervisory control system.
5.9 Behaviour in case of black out

If the 24VDC supply of the module fails the current counter value is stored in an internal non-volatile
memory. If the supply voltage is turned on again the old counter value is restored. It is not possible to
capture counter pulses while the voltage is turned off.
5.10 Terminals
untere Klemmen, zur Steuerung:
X1 (grau) steckbar
1 LED-open o drive is open, to mimic diagram
2 LED-closed o drive is closed, to mimic diagram
3 CMD-open i command open, from mimic diagram
4 CMD-close i command close, from mimic diagram
X2 (red) pluggable
5 24VDC / 230VAC L2 i solenoid valve supply voltage
6 0VDC / 230VAC L1 i solenoid valve supply voltage
7 Alarm a o contact opens in case of error
8 Alarm b o contact opens in case of error
Upper terminals, to the EHS:

X3 (grey) pluggable
9 Count A i counter input A, A prior to B means counting up
10 Count B i counter input B, B prior to A means counting down
11 0V o DC power supply for flow meter
12 24V o DC power supply for flow meter
13 FB- analog o position signal (4..20mA), 4mA means closed
14 N o common terminal for solenoid valves
15 L-close o power output close
16 L-open o power output open
Safety Advice: Always plug in red connector to connect AC supply voltage last and
always pull it off to disconnect AC supply voltage first!
Bus connector
1 Data A io local data bus, rs485
2 Data B io local data bus, rs485
3 lamp test i lamp test input, 24V = lamps on
4 0VDC i local power supply
5 +24VDC i local power supply
modules.

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5.11 Interface to Flowmeter

Any flow meter connected to the CCM must comply with the following technical data:
Supply voltage 24V
Current consumption max. 100mA
Output signals 2 x rectangular signals 24VDC , 90° ±20° phase shifted,
Pulse:Pause 1:1 ±10%
min. edge distance 80us, up to 3kHz pulse frequency
5.12 Technical data

supply voltage DC 24VDC
current requirement DC max. 65mA, incl. counter and analog output, plus external load
fuse DC self resetting fuse, 500mA - 1100mA
supply voltage solenoid 230VAC or 24VDC
valves
fuse AC 2 x 1,25AT miniature fuse
analog position output 4..20mA = 0..100%, deviation ±2%, max. burden resistance 150Ω
mimic open / close output solid state high side switches, max. load 150mA, short circuit proof
protection IP20
6 Fieldbus interface BI
The fieldbus interface serves to connect the control and IO modules to a
superimposed control system via a fieldbus. Furthermore, the module provides two
control inputs and a collective alarm output. The module and the local bus are
supplied with 24VDC.
Two 7-segment displays and two push-buttons serve to parameterise the module and
display system status.
Two fieldbus protocol variations are available:
• Modbus RTU, slave
• Profibus DP V0, slave
The choice of the fieldbus protocol is carried out via the parameterisation functions on the module.
The fieldbus lines are connected via terminal screws. Bus termination in accordance with the Profibus
standard can be activated via a miniature switch if required.
Note: The Profibus Interface is not available on BI modules with Art.No. 9341100250. Those BI only
provide Modbus RTU. If Profibus is selected anyhow an error message F4 is indicated
6.1 Operation
Parameterisation of the module is carried out with the assistance of the “set“ and “prgm“ push-
buttons. The push-buttons are only accessible if the transparent lid on the module is opened. Display
of the chosen parameters is by means of two 7-segment displays.
6.1.1 Parameterisation of the fieldbus

Parameterisation of the fieldbus settings is only possible if the “prgm“ push-button is depressed for at
least 3s when switching on the module. After this all parameters must be entered in succession. The

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“set“ key is always used to set the value and the “prgm“ key to accept the value. All parameters are
saved in a non-volatile memory.
Parameter sequence
Step Meaning Range of values Display (example)
1 Address, least significant digit x 0h … x Fh, x = any 0 … F
2 Address, most significant digit 0 xh … F xh, x = any 1 … F
3 Selection baud rate / protocol 4k8 / 9k6/ 19k2 / 38k4 / 56k / 57k6 / 4 9 1 3 5 5 7 D
76k8 / Profibus DP 8 6 9 8 6 7 6 p
Modbus only
4 Selection of parity none / odd / even P. P. P.
n. O. E.
If the Profibus is chosen during step 3, step 4 is not applicable.
Automatic baud rate setting is generally used for the Profibus protocol. When the last parameter is
entered the module changes to normal operation.
6.1.2 Setting the address of the EHS-CM3 / CCM modules

The address of the CM3 / CCM control modules is adjusted with the assistance of the CM3 / CCM
control elements. Those modules do not provide separate address switches. Operation mode
changeover on the CM3 / CCM module brings about the indication of the current module address on
the fieldbus interface for the duration of approx. 2 seconds.
As the address setting needs to be protected against unintentional alteration, it is necessary to
S put the system in addressing mode. Addressing mode is set by pressing the “prgm” and “set”
U
keys on the BI simultaneously. This operation mode is shown as SU on the BI display. To leave
this mode just press both push buttons once more.
The CM3 / CCM module to be programmed is now switched to “remote“ operation mode.
0 The lowest available address on the local bus is now displayed by operating the com-
2 mand key in any direction. An available address is an address to which no CM3 / CCM
module will currently respond. The two programming functions “delete“ and “accept“ are
now available.
New modules are programmed in turn from left to right. Once programming has been completed the
fieldbus interface must be set to normal operation mode. For this both buttons are again pressed si-
multaneously.
PLEASE NOTE: The module address determines which register / data word is used by this actuator
in the data model of the fieldbus connection. If the address is not allocated as arranged, the wrong
valve will be activated. If possible, addressing should be carried out in such a way that the address
complies with the slot, i.e. that the 7th module, for example, is given address no. 7.
6.1.2.1 Deleting the module address

If the command key is pushed in the direction of “open“ and the operation mode is then switched to
local while the command key is depressed, the module address is erased. The module is then no
longer visible for the fieldbus interface.
6.1.2.2 Accepting the lowest available address

If the command key is pushed in the direction of “close“ and the operation mode is then switched to
local while the command key is depressed, the module address is set to the lowest available address.
This new address can be displayed again by changing the operation mode.

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6.1.3 Setting the address and operation mode of the RK 16/8

The address of the RK16/8 control modules is adjusted with by means of the push button S1 of the
RK. If the button is pressed the module’s address is displayed at the BI. If the button is pressed for
more than 3s the module’s software version is displayed instead of the address.
As the address setting needs to be protected against unintentional alteration, it is necessary to
S put the system in addressing mode. Addressing mode is set by pressing the “prgm” and “set”
U
keys on the BI simultaneously. This operation mode is shown as SU on the BI display. To leave
this mode just press both push buttons once more.
6 Now the push button S1 of the appropriate RK must be pressed for some seconds. The
1 status LED first lights brightly and the turns off. The BI module now shows the lowest un-
used address for an RK module in the range 61..80. As soon as the LED turns on again
the button may be released. The RK is now programmed.
New modules are programmed in turn from left to right. Once programming has been completed the
fieldbus interface must be set to normal operation mode. For this both buttons are again pressed si-
multaneously.
PLEASE NOTE: The module address determines which register / data word is used by this actuator
in the data model of the fieldbus connection. If the address is not allocated as arranged, the wrong
valve will be activated. If possible, addressing should be carried out in such a way that the address
complies with the slot, i.e. that the 7th module, for example, is given address no. 7.
Stetting the operation mode:
If the button is kept pressed after the LED turns on again for at least 2,5s the LED starts blinking. This
indicates the activation of the extended operation mode. In this case the state of each digital input is
hold for at least 0,9s. By this means even very short events can be detected securely. The version
changes from D.x to E.x if this operation mode is turned on (Version D.4 and higher).
6.1.3.1 Deleting the module address

To erase the module address the button must be pressed again. As soon as the LED turns off the
button must be released. The module address is erased now and the module becomes invisible for
the BI.
6.1.4 Skipping addresses

If necessary an address gap may be inserted at an arbitrary position. If the BI module is in “set-up
mode” and the CM3 is set to “remote” operation, the lowest unused address is show when the close
button of the CM3 is pressed. Now the address may be increased by pressing the BI´s “Set” button or
decreased again by pressing the “Prgm” button. Only unused addresses are selected by the BI. This
set-up, that means the number of address gaps, is also used for further addressing of the CM3 mod-
ules until the BI´s “set-up mode” is left. (Remark: This function is only available for BI firmware version
V1.6 or higher).
Also addresses of the RK16/8 modules can be skipped. As soon as the lowest used address is shown
on the BI the “set” and “prgm” button can be used to modify the RK address.
6.1.5 Display functions

Various system data can be displayed for diagnosis purposes in connection with the “Set” and “Prgm”
keys of the fieldbus interface or the operation mode switches of the CM.
Display of the address of a CM3 module
1. Upon changing the operation mode (local – remote) of a CM3 its address is displayed for 2
2 seconds via the 7 digit display of the BI (1.2 = address 12).

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Display of the lowest available address

1 The lowest available local address is displayed by pressing the set key of the fieldbus interface
7. (17. = address 17). The address of the module in position 17 should be programmed as the
next CM3 module.
Display of modules that have failed
1. If a module does not respond to queries from the fieldbus interface for a certain period of time,
3. it moves to “offline“ status. The address of this module is then displayed for 3 seconds (1.3. =
address 13). The display of the address of the module that have last moved to offline status
can be repeated at any time by pressing the “prgm” key. Displaying 0.0. indicates that none of the
modules have gone offline.
PLEASE NOTE: Only the change to offline status is registered. If a module never answers after
power up, it will not be displayed.
Display of control inputs 1 and 2
If control input 1 or 2 is set, E1 or E2 output will appear on the display.
Position indication of actuators with analog position feedback
If an actuator with analog position feedback is operated in „local“ mode the current position is dis-
played at the 7-segments display of the BI module. This indication is turned off a few seconds after
the actuator comes to a standstill. (Remark: This function is only available for BI firmware version
V1.6 or higher).
Normal operation
If status display is not necessary, the display will switch to PE. (program execution).
Display LEDs
LED Modbus RTU Profibus DP
TxD red Transmit Data Error
RxD green Receive Data Data exchange
24V yellow supply voltage DC
6.1.6 Start messages and self test

Directly after the programme has started up, the module displays the last “reset“ cause in the form of
two digits. The module subsequently carries out a short self test. In the event that the self test is not
carried out successfully, the red LED will start to flash. If Profibus DP is selected as fieldbus the red
LED always indicates an error while the error code is shown in the display.
Once the self test has been carried out successfully the version number of the software (x.y) is dis-
played briefly. The normal status display begins subsequently (see above).
6.1.7 Power management

The BI module provides a power management function to limit the 230VAC supply current. To avoid
that the high starting current of the drives blows the fuses the actuators are started successively al-
ways 0ne drive each 100ms. Additionally the number of running drives that are connected to the
same fuse is limited (default 8). The current required to keep the magnetic valve of a single acting
drive closed is neglected. A motor valve is treated like an EHS even though the current is much less.
If more than 8 actuators of a group connected to the same fuse get a command, the execution of this
command is delayed in such a way that not more than 8 actuators run simultaneously. Up to 4 of
those groups can be configured for each BI. The first group begins with the drive using the address 1
and ends with address A1, the second groups begins with A1+1 and ends with A2 and so on.
The default set up uses 2 groups:

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• group 1: drive 1..25

• group 2: drive 26..50
• number of drives: 8
6.1.7.1 Configuring the power management

To configure the power management the „Set“ button must be pressed for at least 3s while the BI
starts up. The display will now show . By pressing the “Set” button the group number can be in-
creased. Pressing the “Prgm” button will select this group and the last address of this group is shown
in the display. The “Set” button may now be used to increment the last address. The highest value is
50, the lowest value is the last address of the preceding group plus one. Pressing the “Prgm” button
once more will store the address and return to the group number display. If the last group (no 3) is
programmed or any group is programmed to address 50 the set-up is finished.
From BI V2.2 the number of drives running at the same time can also be adjusted. Instead of leaving
the set-up mode the number of drives is displayed in the lower digit while the upper digit shows a “n.”.
The number can be changed using the “Set” button. Pressing the “Prgm” button will store the selected
number and leave the set-up mode.
PLEASE NOTE: The BI firmware secures that the last address of a succeeding group is always
higher than the last address of the preceding one. If this condition is not fulfilled
the firmware will adjust the addresses automatically.
6.1.8 Set-up of Quick Close Functions

The control input E2 of the BI module is used to activate differ-
n.o. none, no quick close function
ent quick close functions. As soon as the input is set a close or
open command is sent to all CM3 modules that are appropri- C.L. close, if the operation mode is
„remote“
ately parameterised. This parameterisation is done in the set-
up mode of the BI module. At first the appropriate CM3 is se- O.P. open, if the operation mode is
lected by changing its operation mode. Afterwards the “Prgm” „remote“
push-button is pressed. The present mode is now displayed. E.C. emergency close in any case
By pressing the „Set“ push-button the required mode is se- E.O. emergency open in any case
lected and confirmed by pressing the “Prgm” push-button once more. The mode that is valid at pre-
sent is displayed with the decimal points turned on otherwise the decimal points are turned off.
This function must be repeated for all required CM3. Press both push-buttons simultaneously to leave
the set-up mode.
6.1.9 Alarm output

To begin with the alarm output is closed after the self test has been carried out successfully. Cyclical
testing is carried out subsequently as to whether the modules connected to the local bus are working
accurately. If a module is not available (offline) or if a CM3 / CCM module reports a fault (e.g. timeout)
or is set to local operation mode, the alarm output will be opened and not closed until the fault has
been removed and the alarm acknowledged on the CM3 module.
6.1.10 Lamp test

and all segments of the 7-segment display of the module are illuminated.
6.1.11 Bus Termination

If the BI module is placed at a physical end of the bus the bus cable has to be termi-
nated. This can be done by means of a miniature switch at the front of the module. If
both sliders are set to ON position the termination is turned on, if they are set to the

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opposite position the termination is turned off. All other settings are not allowed.
The bus termination is an active one and meets the Profibus standard.

Lower terminals
1 PE Protective earth of the hat-rail
2 0V 0V of field bus interface
3 Field bus A io rs485 data
4 Field bus B io rs485 data
Upper terminals
X3 (grey) pluggable
5 E2 0V i Control input 2
6 E2 24V i Control input 2, opto
7 E1 0V i Control input 1
8 E1 24V i Control input 1, opto
9 0V i DC power supply, max. 6A
10 24VDC i DC power supply, max. 6A
11 Alarm o Alarm output, opens in case of error
12 Alarm o Alarm output, opens in case of error
Bus connector
3 Lamp test i Lamp test input, 24V = lamps on
applied to the local data bus. This leads to the destruction of all connected
modules.
6.3 Technical data

current requirement DC max. 50mA, plus external load*
control inputs 24V DC
alarm output Relay, 24V, 0,5A
Protection IP20

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7 BI Modbus interface (slave)

The Modbus interface of the fieldbus interface serves to exchange data with a superimposed control
and visualisation system, hereinafter referred to as Modbus master. A register in both report direction
and control direction is used for every valve. Transmission is carried out via an RS485 connection.
The baud rate (4800-76800 baud), the parity (none, even, odd) and the Modbus address (1h..6Fh) can
be parameterised. The number off data bit is fixed to 8. One stop bit is used.
The fieldbus interface has a Modbus RTU interface (slave) and serves the following functions:
• 03 Read holding registers
• 06 Preset single register
• 16 Set multiple registers
This chapter describes the applied data model, i.e. the use and meaning of the individual registers of
the Modbus. This information is required for the preparation of the data model of the superimposed
control system and for the commissioning of the Modbus interface as the case may be. More detailed
information about the Modbus protocol may be obtained from www.modbus.org.
7.1 Modbus data model

The data model described here complies with the program version 1.5 or higher.
The first register is always used to monitor the fieldbus interface itself. The following registers are
used for the CM3 and the IO modules.
In detail, the binary digits of the registers have the following meaning:
7.1.1 Fieldbus interface BI status, register 1, (read only)

Bit Meaning
Bit0 CM3 fault collective message
Bit1 IO fault collective message
Bit2 Fault on the local data bus
Bit3 control input E1 set
Bit4 control input E2 set
Bit5 control input „lamp test“ set
Bit6 running in passive mode (see also: 9 !use only if secondary BI is connected)
Bit7..14 not used
Bit15 live bit, changes state every 2s *
*implemented in BI version V1.6 or higher
CM3 fault collective message
This binary digit is set if at least one EHS-CM3 reports a fault.
IO fault collective message
This binary digit is set if at least one IO module reports a fault.
Fault on the local data bus
This binary digit is set if at least one module on the local bus replies to broadcast address 0 or if fur-
ther faults arise that cannot be allocated to a specific bus participant.
Control input E1 / E2 set
This binary digit is set if control input E1 / E2 has been set (24V).
Control input lamp test set
This binary digit is set if lamp test input has been set.

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7.1.2 CM3 status register (read only)

The CM3 status register includes the valve position and the valve error messages. The register num-
ber depends on the module address (1-50).
Register number = module address + 1
(50 registers, from no 2 to no 51)
The lower-order byte of the register contains the position information:
Value Meaning
0..100 actual position of valves with analog position feedback
(128..228) most significant bit is set while drive is running (add128)
101 drive closed and in a standstill
102 drive neither open nor closed
103 drive open and in a standstill
105 drive in open position, close command received
106 drive in closed position, open command received
107 drive neither open nor closed while closing
108 drive neither open nor closed while opening
109 drive indicating closed position but is still running
110 drive indicating open position but is still running
111 unknown position
The higher-order byte of the register indicates the error messages:

Bit Meaning
Bit 0: error message 0 = no error
Bit 1: (Bit 0-2 binary) 1 = timeout while opening
Bit 2: 2 = timeout while closing
3 = invalid feedback
4 = invalid command
5 = self test error
6..7 = not used
Bit 3: command close received via mimic input*
Bit 4: command open received via mimic input*
Bit 5: local / remote switch in local position
Bit 6: no AC supply (230VAC)
Bit 7: offline, no response on local bus
The error flags 1..4 stay set until the cause of the error is removed or a new command is sent. Run-
time errors generally require resending a command.
*These status bit are implemented in CM3 firmware V1.9 or higher. The bit is set as soon as the cor-
responding input is set and reset when the input is released. In any case the bit is set for at least 5s.
7.1.3 CCM status register (read only)

The CCM status register includes the valve position and the valve error messages. The register num-
ber depends on the module address (1-50).
The lower-order byte of the register indicates the position information:

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Value Meaning
0..100 actual position of actuator / valve, 0 = closed, 100 = open
128..228 actual position while valve is moving
While actuator is moving and also during calibration the most significant Bit in the position byte is set.
The higher-order byte of the register indicates the error messages:

Bit Meaning
Bit 0: error message 0 = no error
Bit 1: (Bit 0-2 binary) 1 = timeout while opening
Bit 2: 2 = timeout while closing
3 = reference run required
4 = invalid command
5 = self test error
6..7 = not used
Bit 3: command close received via mimic input*
Bit 4: command open received via mimic input*
Bit 5: local / remote switch in local position
Bit 6: no supply for solenoid valves (both 24VDC or 230VAC)
The error flags 1..4 stay set until the cause of the error is removed respectively a new command is
sent. Runtime errors generally require resending a command. Flag 3 is set on power up and is de-
leted when the counter is referenced the first time.
The bits 3 and 4 are set as long as the corresponding inputs are set. In any case the bit is set for at
least 5s.
7.1.4 IO status register (read only)

The IO status registers contain the status of the analog and digital inputs of an IO module. An IO
module occupies a total of 9 registers. The register number depends on the module address.
The module addresses are in the range of 51 – 60.
Register number of the first register = 9*(module addresses -51) + 52
The first register contains the status of the 8 digital inputs in the lower-order byte and error messages
in the higher-order byte.
Bit Meaning
Bit 0..7: digital input 1..8 set
Bit 8: address was changed after last start up
Bit 9: error analog input 1..8
Bit 10: used internally
The following 8 registers contain one each of the 8 measured values as 12 binary digit value
(0..20mA = 0..4000 Incr.). A valid value must be even.
Attention: An odd value indicates that the last measurement has not been updated because of an
invalid measurement.

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7.1.5 Fieldbus interface BI remote control, register 142 (read/write)

This register can be used by the Modbus master to control various functions of the fieldbus interface.
Bit Meaning
Bit0 reserved
Bit1 force BI to passive mode (see also: 9)
Bit2..14 not used
Bit15 *Profibus data are valid (see also: 8.1.3)
*implemented in BI version V1.6 or higher
7.1.6 CM3 control register (read/write)

A CM3 control register is used to send a command to a valve. The register number depends on the
module address (1-50).
Only the lower-order byte of the valve control register is used.
Command Meaning
0..100 position set point for %Pos drives
101 close drive
102 stop drive
103 open drive
104 acknowledge error, erase last command
111 commands by mimic diagram inputs only
If command 111 is sent the BI completely passes control to the CM3 modules. The CM3 acts as if
there is no BI. Only old CM3 versions V1.6 or lower require this command to enable the mimic inputs
permanently. V1.7 and newer always react properly on mimic inputs in remote mode and do not re-
quire this command any longer.
Any command change will reset the errors 1..4. To force a command change the following way is sug-
gested:
Set the most significant bit of the command byte to indicate a new command. The CM3 / CCM
will react on this command immediately. The bit should be kept high for at least 1s and should
be reset afterwards.
Beside resetting error conditions restarting a command may be useful in certain applications like ac-
tuators that may be operated manually by hand wheel (override). If such a drive is closed by com-
mand and opened manually afterwards a repeated close command will close it again.
example:
• send close command 128+101=229, actuator starts running, wait 1s, send close command
101
• actuator is closed
► actuator is opened manually
• send close command 128+101=229 once more , actuator starts running, wait 1s, send close
command 101
• actuator is closed again
7.1.7 CCM control register (read/write)

The CCM control register is used to send a command to the actuator. The register number depends
on the module address (1-50).

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Only the lower-order byte of the valve control register is used.
Command Meaning
0..100 position set point
101 close drive completely (same as 0)
102 stop drive
103 open drive completely (same as 100)
104 acknowledge error, erase last command
105 start calibration
111 commands by mimic diagram inputs only
Commands 104 and 111 are used for compatibility to older CM3 versions only.
Attention: During calibration the actuator will be completely opened and closed again. The operater
has to make sure that the actuator completely reaches both final positions.
7.1.8 IO control register (read/write)

The IO control register is used to set the 4 digital outputs of the IO 8/8/4 module. The register number
depends on the module address. The module addresses are in the range of 51 – 60.
Register number = (module address – 51) + 193
Bit Meaning
Bit 0..3: digital output 1..4 set, outputs are reset if IO 8/8/4 goes offline
Bit 4..7: digital output 1..4 set, outputs stay on if IO 8/8/4 goes offline
7.1.9 RK status register (read only)

The RK status registers contain the status of the digital inputs and error flags of an RK module. An
RK module occupies a total of 2 registers. The register number depends on the module address.
Register number = 2*(module address – 61) + 203
The first register shows the error flags in the lower byte and a 8 bit counter value in the upper byte.
Value Meaning
Bit 0: fuse is damaged
Bit 1: address button pressed
Bit 2: used internally
Bit 7: offline, no response at the local bus
Bit 8-15 8 Bit counter, all changes of input 1 are counted.
The second register shows the status of the 16 digital inputs.
Value Meaning
Bit 0: digital input 1 (24V = Bit set)
…
Bit 15: digital input 16 (24V = Bit set)

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7.1.10 RK control register (read / write)

The RK control register are used to control the relay outputs. Each module uses one register.
The register number depends on the module address.
Register number = (module address – 61) + 243
Value Meaning
Bit 0..7: set relay output 1..8;
all outputs are reset if the data connection between PLC and PCM system fails
Bit 8..15: set relay output 1..8;
all outputs keep the current state if the data connection between PLC and PCM system
fails
7.2 Fieldbus Watchdog

The BI Module permanently supervises the proper function of the Modbus (Profibus). The BI must re-
ceive at least one valid Modbus request every 5s otherwise the following functions will be carried out:
• A command 111 „enable mimic diagram inputs“ is sent to all CM3 modules.
• All control bits 0..3 of all IO8/8/4 are set to 0, that means that all outputs are reset
• All control bits 0..7 of all RK16/8 are set to 0, that means that all outputs are reset
We recommend to start a request at least every second. This function is implemented for the Profibus
protocol is the same way.

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7.3 Register summary

Reg. Status-Register higher -order byte lower-order byte
No Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 BI status p Inputs Faults
2 CM3/CCM status, module 1 messages Errors Position information
up to
51 CM3/CCM status, module 50 messages Errors Position information
52 IO status, module 51 Error messages 8 <---digital inputs---> 1
53 analog input 1
54 analog input 2
55-
up to
59
60 analog input 8
up to
133 IO status, module 60 Error messages 8 <---digital inputs---> 1
134 analog input 1
135 analog input 2
136-
up to
140
141 analog input 8
Reg. Control-Register higher -order byte lower-order byte
No Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
142 BI control V P R
143 CM3/CCM control, module 1 control commands
up to
192 CM3/CCM control, mod. 50 control commands
193 IO control, module 51 4<dig.outp.>1 4<dig.outp.>1
up to
202 IO control, module 60 4<dig.outp.>1 4<dig.outp.>1
Reg. Status-Register higher -order byte lower-order byte
Nr. Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
203 relay module 61 counter Error messages
204 16 <---digital inputs---> 9 8 <---digital inputs---> 1
up to
241 relay module 80 counter Error messages
242 16 <---digital inputs---> 9 8 <---digital inputs---> 1
Reg. Control-Register higher-order byte lower-order byte
Nr. Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
243 relay module 61 8 <-- digital outputs --> 1 8 <-- digital outputs --> 1
up to
262 relay module 80 8 <-- digital outputs --> 1 8 <-- digital outputs --> 1
not used =
p = running in passive mode if set (see also: 9.2)
P = force to passive mode (see also: 9.3)
V = Data Valid Bit for Profibus ( see also:8.1.3)

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8 BI Profibus DP interface (slave)

The Profibus DPV0 interface is available as an alternative to the Modbus and can be chosen via the
set-up menu of the fieldbus interface (BI). Automatic baud rate identification is used. Baud rates be-
tween 9600 baud and 1.5 Mbaud are permissible. If required a bus terminator (in accordance with the
Profibus standard) can be connected via a miniature two-pole switch in the front of the housing.
The advanced V1 and V2 services are not available. Differing from the Profibus standard an inexpen-
sive screw-type terminal is used for the electrical connection instead of a sub-D connector. More de-
tailed information about the Profibus protocol may be obtained from the standard EN 50170 or from
the „Profibus Nutzer Organisation“ (PNO, www.profibus.com).
Note: The Profibus Interface is not available on BI modules with Art.No. 9341100250. Those BI only
provide Modbus RTU. If Profibus is selected anyhow an error message F4 is indicated
8.1 Profibus data model

For compatibility reasons the same data model is used as for the Modbus. 16 binary digit-wide data
words are used instead of the Modbus registers. On account of the maximum telegram length of 244
bytes a maximum of 7 IO modules can be used for the Profibus protocol. The data model is described
in the “PE_PCM_2.gsd“ GSD file. The meaning of the individual data words corresponds to those in
the registers for the Modbus protocol.
To avoid unnecessary data transfer the BI module is set-up as a modular station. The following mod-
ules are available.
Module 1 BI, status & control, 1 word read, 1 word write
Module 2 5x CM3/CCM, status & control, 5 words read, 5 words write
Module 3 10x CM3/CCM, status & control, 10 words read, 10 words write
Module 4 1x IO8/8/4, status & control, 9 words read, 1 word write
Module 5 1x RK16/8, status & control, 2 words read, 1 word write
Module 6 5x RK16/8, status & control, 10 words read, 5 words write
The module type 1 must always be inserted in first place. Next up to 50 CM3, 7 IO8/8/4 and 20
RK16/8 may be added. Please keep in mind that the number of data bytes both read and write must
not exceed 244.
8.1.1 Fieldbus interface to superimposed control system (status words)

Data word Meaning
1 Status field bus interface
1 each Status CM3, address 1..50
9 each Status IO 8/8/4, address 51..57
2 each Status RK 16/8, address 61..80
8.1.2 Superimposed control system to fieldbus interface (control words)

Data word Meaning
1 Command field bus interface
1 each Command CM3, address 1..50
1 each Command IO 8/8/4, address 51..57
1 each Command RK 16/8, address 61..80

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8.1.3 Data Valid Bit

Some Profibus DP masters keep on sending data even if the supervisory controller is stopped. In this
case all commands are set to 0. This is not suitable for PCM system. Therefore the highest Bit15 of
the control word of the BI is used as a „Data Valid Bit“. If this bit is not set the Profibus connection is
treated as invalid.
This Bit is used only if the Bit0 of the first Parameter Byte is set to 1, otherwise the data is always
treated as valid data. This function is only implemented in BI firmware version V1.6 or higher.
9 Secondary BI Module +24V

To achieve an improved availability of the field
bus connection (either Profibus DP or Modbus 0V
RTU) an additional, secondary BI module may
be used. This secondary module is usually prim. sec.
running in passive mode permanently reading IO BI CM3 CM3 CM3 CM3 BI
the traffic on the local bus. Therefore it will al- 1 1 2 3 ...
ways show the latest data of all modules con-
nected but it can not and must not send any
command to the modules.
Whether a BI runs in passive or active mode
depends on its priority on the local bus. Al- primary bus
ways the BI with the highest priority becomes secondary bus
active. The priority depends on the following
conditions:
Priority Condition
3 primary module, field bus connection to supervisory control is working properly
3 primary module, running in set-up mode
2 secondary module, always
1 primary module, no field bus connection and no set-up mode
If the field bus connection of the primary module fails the priority of this module is reduced to 1 and
therefore the primary module becomes passive whereas the secondary module becomes active. Be-
cause a BI running in set-up mode needs full access to the local bus the priority of the primary BI is
set to 3 if set-up mode is turned on. To use the secondary BI in set-up mode the fieldbus connection
of the primary BI must be interrupted during set-up.
The secondary BI should preferably be mounted on the right side of the CM3 modules. The control
inputs E1 and E2 are connected in parallel to the primary BI if used at all.
9.1 Parameterisation of the secondary BI module

The address setting is the only difference between primary and secondary BI. If both BI are con-
nected to separate field busses they both may (and preferably should) use the same real fieldbus ad-
dress.
The secondary BI module is set to a fieldbus address “real address + 80h”. That means that the sec-
ondary BI with the fielbus address 1 is set to address 1+80h = 81h.
ATTENTION: All functions described here are available only in software version 2.0 or higher!

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9.2 Fieldbus interface BI status, register 1 (read only)

One entry is added to this register. As long as the BI is running in passive mode all data are valid but
no command will be sent to the modules.
Bit Meaning
Bit6 running in passive mode
9.3 Fieldbus interface BI remote control, register 142 (read/write)

One entry is added to this register. For test purpose the BI can be forced into passive mode. The
other BI will than change to active mode.
Bit Meaning
Bit1 force BI to passive mode
9.4 Programming the fieldbus master

Both master interfaces should be (but don’t have to be) identical. If two separate bus cables are used
even the slave addresses may be the same. The master software should treat both BIs including the
CM3 and IO8/8/4 identically but all commands sent to the BI running in passive mode are ignored.
The passive flag in the BI status register should be indicated to the user. Of course both masters
must poll the primary and the secondary BIs permanently. Otherwise a failure of the secondary bus
may not be noticed.
For test purpose the master should be able to stop polling the primary bus. In this case the secondary
BI must indicate that it turned to active state a few seconds later. If turning off the primary master is
not possible the primary BI can be forced to passive mode by setting the corresponding bit in the con-
trol register.

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10 Assembly of the system

Certain boundary conditions must be adhered to during the assembly of the complete control systems
in order to ensure reliable and trouble free operation.
• Only a maximum of 50 CM3 / CCM, 10 (7 for the Profibus DP) IO and 20 RK modules are to be
connected to a fieldbus interface.
• The IO modules must be aligned to the left and all other modules must be aligned to the right of
the fieldbus interface. RK modules must be mounted on the very right side of all other modules.
• All 230VAC supplies must be fused with max. 16A B characteristic.
• The 24VDC supply may be connected several times to separate the supply for different systems
(etc. bilge, ballast). Each 24V supply is separately fused up to 4AT. All 0V supplies must be
connected directly to the same terminal. 0V supply is fused with a common 6AT fuse. For
the connection of the DC supply the BI (9, 10) or the plugs of the prefabricated cable sets must be
used.
• The local data bus and the lamp test control may be extended by means of prefabricated cable
sets. Up to 4 adapting cables and one extension cable may be used per BI module. The screen of
these cables must be connected to a PE terminal right beside the plug connector. The PE termi-
nal is also used to fix the modules on the rail mount.
• All control signals from and to the CM3 / CCM and IO 8/8/4 modules are supplied via the 24VDC
of the CM3 respectively the IO 8/8/4 modules.
• All cables leaving the control cabinet and being connected to the modules must be screened. The
screen must be connected extensively to the mounting plate. So-called “pigtails“, i.e. cables be-
tween the screen and a PE terminal, are not permissible.
10.1 Controlling via mimic diagram

The CM3 modules can be used without a fieldbus interface for applications in which the actuators are
controlled exclusively by a mimic diagram. The feeding-in of the 24VDC supply voltage is then via the
local bus connector pins 4 and 5. The voltage must have external fuse protection amounting to a
maximum of 6A. Insofar as necessary, a 24VDC lamp test signal is also connected via the local bus
connector. The current consumption of this control input amounts to approx. 1mA per module.
10.2 Commissioning hints

Incorrectly connected drives or defective cables may cause damage of the CM3 modules or
the OC3 feedback modules. To avoid this some tests must be performed before 24VDC or
230VAC supply is turned on.
1. 24VDC and 230VAC are completely separated from each other and from protective earth (PE),
e.g. the rail-hat. Therefore a high insulation resistance must be measured between those circuits.
The insulation resistance measurement should be
performed with an insulation resistance meter with 50 1. 0VDC to PE 1 MOhm
to 500VDC test voltage. The following minimum resis- 2. 0VDC to L, N 1 MOhm
tance values must be achieved: 3. 24VDC to PE 1 MOhm
Using a standard multi-meter as a substitute may re- 4. 24VDC to L, N 1 MOhm
sult in uncertain results. This measuring must be per- 5. N to PE 1 MOhm
formed during commissioning and should be repeated
6. L to PE 1 MOhm
after any repair works on the cabling of the actuators.

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2. Please also check that pin 13 of the CM3 module, this is the position feedback input 4..20mA, is
connected only for those actuators that really use an analog position feedback signal.
3. Turn on 230VAC for a few devices only and check proper operation carefully before connecting
the next devices to 230VAC.
10.3 Safety Advice

The plate beside shows an important safety advice and
CM3 Safety Advice
must be fixed at the top-hat rail right beside the installed
Always plug in CM3 modules.
red connector last
and pull it off first! If CM3 modules are mounted on different top-hat rails
(AC supply voltage) one plate has to be fixed at each rail.
Pay attention to this safety advice during any kind of work on the pluggable screw terminals!
10.4 Accessories
For the proper installation of PCM systems the following accessories are required.
10.4.1 Adapting Cable

This cable is used if the 24VDC supply shall be feed several times. The length of the cable is app.
20cm must not be extended or replaced by a different cable. The modules are fixed on both sides of
the cable by means of an end holder that is fastened on the hat-rail. The right plug (4+5) must be
connected to 24VDC weiß weiß
1 1
power supply. Connect pin 2
braun
grün
2
braun
grün
3 3
4 to the common 0V di-
b
4 4
5 5
rectly, connect pin 5 to
24V fused up to 4A.
Article-No: 9319710190
10.4.2 Extension Cable

This cable is used to connect additional modules on a second hat-rail to the same BI module. Only
one cable can be used per BI module. The shield of the extension cable must be connected to the
hat-rail via PE terminals. These termi-
nals are also used to fix the modules
5
mechanically. The cable is app. 150 cm 4 e lb
+g
long and must not be extended! If such 1

we
iß
3
2
gr
ün
bra
un
2 rau
n
a cable is used the 24VDC power sup-

b we
1 iß
3 grü
n+g
elb
4
ply must be connected to the modules 5
separately.
10.4.3 Adapting Cable for RK 16/8

This cable is required to connect one or
more relay modules to the local bus of BI,
CM3 or IO 8/8/4.
Artikel-Nr.: 9319710330

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10.4.4 Safety Advice Plate

This safety advice must be fixed at the hat-rail close by the installed
CM3 modules (at each hat-rail with CM3).
10.4.5 End Holder

The end holder are fixed to the hat-rail on the right side of the modules. If
the adapter cable is used one holder is also fixed on the left side of the
modules.
10.4.6 Noise Suppression Filter

If a BI module is used on the bridge one filter must be inserted in the
common 24VDC supply of all modules (according GL-Rule EMC1:
Using on the bridge or on the open deck).
The current must not exceed 16A. The filter is screwed on the mount-
ing plate directly. A sufficient electrical and thermal contact to the
mounting plate must be ensured.
10.4.7 CM-ExE Capacitor Module

To connect double acting actuators for explosion proof areas to a CM3
module a capacitor module is required.

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PCM Pleiger Control Modules

Pleiger Elektronik GmbH & Co. KG

PCM – Manual Issue: 9/2011

6 Fieldbus interface BI .................................................................................................... 18

PCM – Manual Issue: 9/2011

CM3 CCM IO 8/8/4 BI RK 16/8

PCM – Manual subject to modification Issue: 9/2011 Page 1

2 EHS control module CM3

PCM – Manual subject to modification Issue: 9/2011 Page 2

2.2 Control functions

2.2.1 Types of actuators

PCM – Manual subject to modification Issue: 9/2011 Page 3

2.2.2 Operation modes of the actuators

2.3 Adjusting the operating time

PCM – Manual subject to modification Issue: 9/2011 Page 4

2.3.1 Calibration of the operating time runtime

2.4 Extended operation modes

2.4.1 Extended operation mode set-up

2.4.2 Displaying extended operation modes

2.5 Start reports and self test

PCM – Manual subject to modification Issue: 9/2011 Page 5

2.6 Alarm output

2.7 Lamp test

2.8 Placing commands

2.9 Terminal assignment

Upper terminals, to the EHS:

PCM – Manual subject to modification Issue: 9/2011 Page 6

2.10 Technical data

2.11 Connecting Ex-Type actuators

PCM – Manual subject to modification Issue: 9/2011 Page 7

PCM – Manual subject to modification Issue: 9/2011 Page 8

3 Input/output module IO 8/8/4

• 8 yellow LED indicate the status of the digital inputs.

3.1.1 Start messages and self test

3.1.2 Lamp test

PCM – Manual subject to modification Issue: 9/2011 Page 9

3.2 Adjusting the address

3.3 Terminal assignment

PCM – Manual subject to modification Issue: 9/2011 Page 10

3.4 Technical data

PCM – Manual subject to modification Issue: 9/2011 Page 11

4 Relay Module RK 16/8

4.4 Counter function

PCM – Manual subject to modification Issue: 9/2011 Page 12

4.5 Technical Data

4.6 Terminal assignment

terminal X5 and X6:

PCM – Manual subject to modification Issue: 9/2011 Page 13

5 Conti Control Module CCM

5.1.1 Status LED

PCM – Manual subject to modification Issue: 9/2011 Page 14

5.1.2 Position measurement

5.1.3 Position indication

5.3 Extended Operation Modes

PCM – Manual subject to modification Issue: 9/2011 Page 15

E1 extended operation mode “local override“,