Device description
Contents
1. Inline Terminal ILT 24 230 DOR 4 HC Device Description GmbH Dresden Disclaimer Impressum This manual is intended to provide support for installation and usage of the device The information is believed to be accurate and reliable However SysMik GmbH Dresden assumes no responsibility for possible mistakes and deviations in the technical specifications SysMik GmbH Dresden reserves the right to make modifications in the interest of technical progress to improve our modules and software or to correct mistakes We are grateful to you for criticism and suggestions Further information device description available software can be found on our homepage www sysmik de Please ask for latest information SysMik disclaims all warranties in case of improper use or disassembly and software modifications not described in this document or when using improper or faulty tools Commissioning and operation of the device by qualified personnel only All applicable regulations have to be observed SysMik and the SysMik logo are registered trademarks of SysMik GmbH Dresden All other trademarks mentioned in this document are registered properties of their owners These and further trademarks are used in this document but not marked for better readability No part of this document may be reproduced or modified in any form without prior written agreement with SysMik GmbH Dresden Copyright 2007 by SysMik GmbH Dresden2. Connections 4 4 1 Circuit versions Load wiring Additional Defined Bipolar Advantages Disadvantages dropdelay inductive attenuation voltage limitation Diode Advantages x m easy implementation iB cost effective no critical sizing ur 75 lu large yes Up no small inductive voltage Disadvantages attenuation only via load an resistance large drop delay Series connection Advantages Diode Zener diode no critical sizing s Disadvantages medium to attenuation only above Uzp AN small yes gt no Last U Load do zp LN u P ss es Suppressor diode Advantages cost effective critical sizing L medium to yes Uzp yes limiting fast peaks A u small suitable for AC voltage Disadvantages attenuation only above Uzp Advantages high energy absorption medium t no critical sizing yes Uvpr yes suitable for AC voltage VDR small Disadvantages attenuation only above Uvpr Table 4 4 1 1 Circuit versions 12 ILT 24 230 DOR 4 HC Connections 4 4 2 RC Circuit Versions RC Series Circuit Load wiring Additional drop delay Defined inductive voltage limitation Bipolar attenuation Advantages Disadvantages RC combination o e Last Load yu medium to RC c small no Tab
3. in x 4 724 in x 2 815 in ith t Weight with connectors 230 g without connectors Operating mode 167 g process data operation with 1 byte Permissible operation 10 C to 55 C 14 F to 131 F temperature storage transport Permissible humidity 25 C to 85 C 13 F to 185 F 75 on average 85 occasionally non condensing oh operation Permissible 80 kPa to 106 kPa up to 2000 m 6562 ft above sea level air pressure storage transport 70 kPa to 106 kPa up to 3000 m 9843 ft above sea level Degree of protection IP20 according to IEC 60529 Inline connector Connection type spring clamp Rated cross section 0 2 mm to 1 5 mm AWG 24 16 Insulation stripping length 8 mm Deviation from Inline specification Permissible lowest operation temperature 10 C 14 F Mechanical requirements Vibration test sinusoidal vibrations according to IEC 60068 2 6 EN 60068 2 6 2g load 2 h for each space direction Shock test according to IEC 60068 2 27 EN 60068 2 27 2g load over 11 ms half sinusoidal wave three shocks in each space direction and orientation INTERBUS local bus Connection through data routing Transmission speed 500 kBaud Power consumption Communications power UL 7 5 V Current consumption at relays off 23 UL relays on 34 mA Power consumption a
4. relay 4 relay 3 relay 2 relay 1 Table 5 2 1 Structure of output process data byte Bit Command Description 6 5 4 00 0 set set relays 0 opened 1 closed 0 0 1 read back read back current logical relay state 01110 configuration 1 relay mode 0 monostable 1 bistable relay mode must be followed by configuration 2 confiquration 2 default state 0 opened 1 closed 0 111 merat state only effective for relays in monostable mode has to be sent after configuration 1 refresh of all relays coded in bit 0 1 010 configuration 3 bit 0 0 refresh off refresh bit 0 1 refresh every 120s bits 1 3 are reserved and must be 0 11011 1 1 0 reserved 11111 Table 5 2 2 Command field in output process data byte Input process data byte 7 6 5 4 3 2 1 0 error command relay 4 relay 3 relay 2 relay 1 Table 5 2 3 Structure of input process data byte The input process data byte mirrors the output byte except bit 7 which indicates an error when set 15 Communication 5 3 16 Set insufficient power supply for switching Configuration 2 command configuration 1 must be sent first Configuration 3 invalid parameter bits 1 3 not 0 Table 5 2 4 Possible error causes Description of Configuration Configuration example The terminal shall be configured as follows relay 1 monostable def
5. INST UM E user manual or the Inline system manual for your bus system especially the notes on the low voltage area ILT 24 230 DOR 4 HC 5 Safety Notes 3 4 Special Features of the Terminal The terminal can be used to switch loads up to 230 V Note The terminal interrupts the potential jumpers Uy Us GND 24 V area or L and 120 V 230 V areas If required these supply voltages must be resupplied provided using an appropriate power terminal after the relay terminal Switching loads in the 230 V area To switch voltages outside the SELV area an AC area must be created corresponding to the installation instructions and notes provided in the user manual AN Operation on an AC network Operate the terminal from a single phase on an AC network Switching voltages that are not available in the segment A relay terminal can be used to switch voltages that are not available in the segment in which the terminal is located e g switching 230 V AC within a 24 V DC segment In this case place a distance terminal before and after the terminal see Order Information The isolating distances between the individual areas are thus maintained See also Connection examples in chapter 4 3 ILT 24 230 DOR 4 HC Connections 4 Connections Bild 4 1 Terminal connections Indicator Color Descriptiong D green Bus diagnost
6. SysMik GmbH Dresden Tel 49 0 351 4 33 58 0 Bertolt Brecht Allee 24 Fax 49 0 351 4 33 58 29 01309 Dresden E Mail sales sales sysmik de E Mail support service sysmik de Germany Homepage http www sysmik com 2 ILT 24 230 DOR 4 HC Inhalt Inhalt 3 2 3 3 3 4 4 4 1 4 2 4 3 4 4 4 4 1 4 4 2 4 4 3 5 5 1 5 2 5 3 6 7 ILT 24 230 DOR 4 HC Overview Order Information Safety Notes Safety Notes for Inline Terminals Used in Areas Outside the SELV Area AC Area Correct Usage Installation Instructions and Notes Special Features of the Terminal Connections Wiring Guidelines Terminal Assignment Typical Terminal Arrangement Interference Suppression Measures on Inductive Loads Switching Relays Circuit versions RC Circuit Versions Switching Large AC CD Loads Communication Programming Data Configuration data Process Data Structure Description of Configuration Technical Data Literature a a N 11 12 13 14 15 15 15 16 17 22 Overview Order information 1 Overview The four channel relay terminal ILT 24 230 DOR 4 HC is designed for use within the modular Inline I O system of Phoenix Contact Features electrically isolated connections for 4 actuators rated current 10 A at single outputs up to 16 A with derating inrush current 30 A max inrush current 20 ms 80 A Safe isolation according to EN 50178 low power
7. ault state opened relay 2 monostable default state closed relays 3 4 bistable refresh off Step Process data Explanation 1 OUT 2Chex configuration 1 relay mode relays 3 and 4 bistable 2 wait for IN 2Chex wait for confirmation 3 OUT 32hex configuration 2 default state relay 2 closed 4 wait for IN 326 wait for confirmation 5 OUT 40hex configuration 3 refresh off 6 wait for IN 40nex wait for confirmation Table 5 3 1 Example of configuration sequence The relay terminal saves the configuration in a nonvolatile memory EEPROM It is therefore not necessary to configure the terminal anew following a loss of power supply or a bus reset The configuration is written to EEPROM when the power supply starts to fail and only if the configuration data has actually changed Even multiple configuration changes do not lead to an EEPROM write cycle as long as the supply voltage is stable Note Each EEPROM cell has an endurance of at least 100 000 write cycles This is approximately equivalent to 13 write cycles daily over a period of 20 years Note If there are relays in bistable mode their switching state is also written to EEPROM when the power supply fails provided that the current state is different from the previously saved one ILT 24 230 DOR 4 HC Technical Data 6 Technical Data General data Housing dimensions width x height x depth 48 8 mm x 120 mm x 71 5 mm 1 921
8. consumption due to bistable relays 3 different operating modes configurable for each output communication on local bus via process data indicators for diagnostics and status Modes of operation monostable default state opened delivery status The contact is opened when power supply or bus communication fails This is the behaviour of a normal make contact monostable default state closed The contact is closed when power supply or bus communication fails This behaviour is similar to a break contact but the control via the process data is not inverted The command Set always closes contact x if bit relay x is set independent of the operation mode bistable The contact holds its current state when power supply or bus communication fails 2 Order Information IB IL 24 230 DOR 4 HC PA terminal with four relay outputs complete with connectors and labelling fields Accessories 1225 100250 04 2 Inline distance terminal complete with IB IL DOR LV SET PAC connectors and labelling fields 1 set 2 1225 100491 01 8 pieces Table 2 1 Order Information 4 ILT 24 230 DOR 4 HC Safety Notes 3 1 3 2 Safety Notes Safety Notes for Inline Terminals Used in Areas Outside the SELV Area AC Area Only qualified personnel may work on Inline terminals in the AC area Qualified personnel are people who because of their education experience and instruction and their kno
9. cy range spectral elements reaching several MHz with a large amount of power To prevent such arcs from occurring the contacts loads must be fitted with protective circuits In general the following protective circuits can be used contact protective circuit load protective circuit combination of both protective circuits LN H LN U al I Je ET Fig 4 4 1 Contact protective circuit A load protective circuit B If sized correctly these circuit versions do not differ greatly in their effectiveness In principle safety equipment should intervene directly at the source of the interference The following points speak in favor of a load protective circuit When the contact is open the load is electrically isolated from the operating voltage It is not possible for the load to be activated or to stick due to undesired operating currents e g from RC elements Shutdown voltage peaks cannot be coupled in control lines that run in parallel Phoenix Contact provides protective circuit solutions in the form of terminals or electronic housing see CLIPLINE or TRABTECH catalogs Additional information is available on request In addition to this today the majority of contactor manufacturers offer diode RC or varistor elements that can be snapped on For solenoid valves connectors with an integrated protective circuit can be used ILT 24 230 DOR 4 HC 11
10. cycles per time of output n lin load current of output n Dn duty ratio of load current on output n D ton x fn Safety devices None Error messages to higher level control system Peripheral error in case of I O supply voltage Uana failure Air and creepage distances according to EN 50178 VDE 0109 VDE 0110 Isolating distance Air distance Test voltage Relay contact bus logic O 4 kV 50 Hz 1 min Contact contact 035205 1 1 kV 50 Hz 1 min Contact PE oe 1 kV 50 Hz 1 min Table 6 1 Technical data ILT 24 230 DOR 4 HC 21 Literature 7 22 Literature 1 2 3 4 User manual IL SYS INST UM E Automation Terminals of the Inline Product Range Phoenix Contact Phoenix Contact order no 2698737 User manual IB IL SYS PRO UM Configuring and Installing the INTERBUS Inline Product range Phoenix Contact Phoenix Contact order no 2743048 www phoenixcontact com www sysmik de ILT 24 230 DOR 4 HC
11. ductive load an effective protective circuit must be provided otherwise the service life of the system will be reduced considerably To prolong the life of the terminal as much as possible when using lamp loads or capacitive loads the current peak must not exceed 30 A when the load is switched on Switching Large DC Loads In DC operation a relay can only switch a relatively low current compared with the maximum permissible alternating current This maximum DC value is also highly dependent on the voltage and is determined in part by design conditions such as the contact distance and contact opening speed A non attenuated inductive load further reduces the values for switching currents The energy stored in the inductance can cause an arc to occur which forwards the current via the open contacts Using an effective contact protection circuit almost the same currents can be switched as for an ohmic load and the service life of the relay contact is the same ILT 24 230 DOR 4 HC Communication 5 1 5 2 ILT 24 230 DOR 4 HC Communication Programming Data Configuration data Attribute value ID code BF hex 1 91aez Length code 81 Input address area 1 Byte Output address area 1 Byte Parameter channel PCP 0 Byte Register length bus 1 Byte Table 5 1 1 INTERBUS programming data configuration data Process Data Structure Output process data byte 7 6 5 4 3 0 command
12. fill the condition la l2 132 142 lt 400 Example What max current is acceptable at 50 C and what current is allowed at the other three outputs The diagram shows an allowed load current of max 14 A This leaves for the other outputs 400 A 14 A 400 196 204 Therefore even a second output could be loaded with 14 A and the other two otputs with 2 A each 14 AY 2 2 196 A 4 A 4 A 204 Alternatively in case of equal load on the remaining three outputs these could each carry a maximum current of 204 2 3 68 2 8 2 A DC load breaking capacity In case of DC loads the max DC load breaking capacity may further limit the max allowed current 300 200 resistive load _ 100 gt 5 50 gt 40 O Q 30 20 10 0 1 0 2 0 5 1 2 5 10 20 DC current A ILT 24 230 DOR 4 HC Technical Data Power dissipation Equation to calculate the power dissipation in the terminal Paus Pret PL Paus 0 5 W Paz 66 mWs x f f fa f4 li x Dy li x Do li x Ds li x Dj x 0 006 Q Where Pet total power dissipation of the terminal Psus power dissipation through bus operation Pug power dissipation through switching relays P power dissipation through the load current via the contacts fh switching frequency
13. ics Status indication of output bes yellow LED on contact closed Table 4 1 Local diagnostic and status indicators Terminal point Assignment 1 2 2 2 common contact 1 3 2 3 1 4 2 4 closing contact Table 4 2 Terminal assignment Terminal points not defined in table 4 2 must not be used ILT 24 230 DOR 4 HC 7 Connections Local bus U ANA L U Protocol chip F LED uC Microcontroller Current limiter EEPROM EEPROM T Energy storage X Relay driver cu bistabile relay Fig 4 2 Functional overview 4 1 Wiring Guidelines For load currents of more than 8A it is strongly recommended to use 2 wires 2x 1 5 mm in parallel Single wire connection is allowed too observing the derating conditions but the correct connectors have to be used included in delivery These connectors are internally connected between terminal points 1 2 and 2 2 1 3 and 2 3 1 4 and 2 4 The load current should be evenly distributed when using two wires in parallel This means both connections should have the same resistance The following measures apply equal wire cross section of 1 5 mm copper equal wire length equal number of additional contact points Attention If the internally connected terminal points 1 3 2 3 1 4 2 4 are used as a terminal block the current of each te
14. l shall switch a 230 V load within a 24 V area or vice versa separation terminals are necessary On the other hand if the relay terminal is used to switch the same voltage as in the adjoining area no additional separation terminals are needed Because the relay terminal interrupts the voltage jumpers Uy Us and GND in 24 V areas or L and N in 120 V or 230 V areas these voltages have to be re supplied using an apropriate power terminal after the relay terminal if required Note On AC networks operate the terminal from a single phase only To use several phases separate areas have to be built using separation terminals one area for each phase ILT 24 230 DOR 4 HC Connections 4 4 Interference Suppression Measures on Inductive Loads Switching Relays Each electrical load is a mix of ohmic capacitive and inductive elements Depending on the proportion of the elements switching these loads results in a larger or smaller load on the switch contact In practice loads are often used with a large inductive element such as contactors solenoid valves motors etc Due to the energy stored in the coils voltage peaks of up to a few thousand volts may occur when the system is switched off These high voltages cause an arc on the controlling contact which may destroy the contact through material vaporization and material migration This pulse which is similar to a square wave pulse emits electromagnetic pulses over a wide frequen
15. le 4 4 2 1 RC series circuit Sizing C Li caa 4 R 0 2x Capacitor Resistor RC Parallel Circuit With Series Diode Additional Defined drop delay inductive voltage limitation Load wiring yes Bipolar attenuation Advantages HF attenuation due to energy absorption suitable for AC voltage level independent attenuation compensating reactive current Disadvantages exact sizing required high inrush current Advantages Disadvantages RC combination with diode B Last medium to Load Use small no no Advantages HF attenuation due to energy absorption level independent attenuation current reversing not possible Disadvantages exact sizing required only suitable for DC voltage Table 4 4 2 2 RC parallel circuit with series diode Sizing C Li cad 4 x 0 2 X Rtoad Capacitor Resistor ILT 24 230 DOR 4 HC 13 Connections 4 4 3 Switching Large AC CD Loads 14 Switching Large AC Loads When switching large AC loads the relay can be operated up to the corresponding maximum values for the switching voltage current and power The arc that occurs during shutdown depends on the current voltage and phase relation This shutdown arc switches off automatically the next time the load current passes through zero In applications with an in
16. lel compensated 7 UF 1 2 x 58 W typ 50 000 cycles typ 50 000 cycles Energy saving lamps with conventional ballast 40 x 25 W typ 40 000 cycles Energy saving lamps with electronic ballast 3x18 W typ 40 000 cycles Electrical motor 250 V AC 16 A cos 0 6 typ 85 000 cycles compressor 230 V lon peak lt 21 A lor 3 5 cos 0 5 typ 230 000 cycles ILT 24 230 DOR 4 HC Technical Data 16 4 14 4 Maximum switching current depending on temperature all outputs simultaneous and with equal currents 12 4 10 4 a a x Current 30 35 40 45 50 Ambient temperature C 55 60 Connection 2x 1 5mm Connection 1x 1 5mm 18 4 16 14 4 Maximum switching current of a single output depending on temperature 12 4 10 4 Max current in A L 30 35 40 45 50 Ambient temperature in C 55 60 In case of unsymmetric loads a higher current is acceptable on single outputs The following conditions have to be fulfilled double wire connection 2x 1 5 mm in case of currents gt 8 A the maximum current must not exceed the value from the diagram above ILT 24 230 DOR 4 HC 19 Technical Data 20 the load currents of the separate outputs have to ful
17. rminal point must not exceed 8 A 8 ILT 24 230 DOR 4 HC Connections 4 2 Terminal Assignment 1 2 3 4 179 O 2 3 O M I 44 24 2 24 11 2 14 21 12 22 a 22 12 2 12 22 main contact OO OC main contact 13 23 13 23 13 23 13 23 D ODIO OO CO OO OG N O contact z en ao N O contact SO OO OO OG Fig 4 2 1 Terminal assignment 4 33 Typical Terminal Arrangement Fig 4 3 1 Switching 24 V within a 24 V area 1 24 V area consisting of station head and I O terminals 2 relay terminal in the 24 V area 3 24 V area consisting of power terminal and I O terminals ILT 24 230 DOR 4 HC Connections 10 Fig 4 3 2 Switching 230 V within a 24 V area 1 24 V area consisting of station head and I O terminals 2 relay terminal separated from the 24 V area by Inline separation terminals 3 24 V area consisting of power terminal and I O terminals Figures 3 3 1 and 3 3 2 illustrate the two basic types of application with and without separation terminals Separation terminals must be used to ensure the required safety clearance between different voltage areas of an Inline station for example between 230 V AC and 24 V SELV If the relay termina
18. t relays off 0 17 W UL relays on 0 26 W I O supply voltage Uana 24 V DC Current consumption at Uana Power consumption at UANA 10 mA max 55 mA when switching duration approx 25 ms per switched relay max 0 46 W ILT 24 230 DOR 4 HC Technical Data 18 Connection method potential routing Number 4 Contact material AgSnO Limiting continuous current at maximum ambient temperature 8 A single wire connection 1 5 mm 10 A double wire connection 2x 1 5 mm Maximum switching voltage 253 V AC 250 V DC Maximum switchin power 4000 VA Minimum load 12 V 100 mA Peak inrush current 20 ms 80A Max switching without load 60 cycles minute frequency at nominal load 6 cycles minute Bounce time typ 2 ms Operate release time typ 5 ms 4 ms Common potentials all contacts electrically isolated Mechanical life Examples of electrical life typ 30 10 cycles 1150 W 230 V AC 5A lon 75 A Small load 24 V DC 100 mA 2310 cycles Ohmic load 250 V AC 16 A typ 100 000 cycles Incandescant lamp 20 000 cycles Incandescent lamp 1000 W 250 AC 4A typ 80 000 cycles Incandescant lamps 250 V AC 5x 60W typ 500 000 cycles Fluorescent lamps not or serial compensated 14 x 58 W typ 50 000 cycles Fluorescent lamps duo circuit 7 x 2 x 58 W Fluorescent lamps paral
19. wledge of relevant standards regulations accident prevention and service conditions have been authorized by those responsible for the safety of the plant to carry out any required operations and who are able to recognize and avoid any possible dangers Definitions of skilled workers according to EN 50110 1 1996 Note The instructions given in this data sheet as well as in the user manual IL SYS INST UM E 1 or the Inline system manual for your bus system must be strictly observed during installation and startup Technical modifications reserved Correct Usage The terminal is only to be used within an Inline station as specified in this data sheet as well as the IL SYS INST UM E user manual or the Inline system manual for your bus system SysMik accepts no liability if the device is used for anything other than its designated use Dangerous contact voltage Please note that there are dangerous voltages when switching circuits that do not meet SELV requirements Only remove and insert the AC terminals when the power supply is disconnected When working on terminals and wiring always switch off the supply voltage and ensure it cannot be switched on again Installation Instructions and Notes Install the system according to the requirements of EN 50178 Use grounded AC networks Inline AC terminals must only be operated in grounded AC networks Read the user manual Observe the installation instructions and notes in the IL SYS
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