Description W

Service manual e

1. Instructions 2
2. Malfunctions 2
2.1 Possible problems 2
3. Incorrect setup operation 5
3.1 Reload parameter values 5
4. Replace soft ware 6
4.1 Spare parts delivery for E+L guiding systems 6
4.2 Function expansion to an existing guiding system 6
4.3 Function expansion to include oscillating mode 6
4.4 Retrofitting a digital coloured line sensor 6
4.5 Software replacement 6
5. CAN bus cards 8
5.1 Control card RK 40.. 8
5.2 Central processor ZC 40.. 9
6. Serial bus cards 10
6.1 Logic card LK 4002 10
6.2 Logic card LK 4010 10
7. Expansion cards 11
7.1 Analog card AK 4002 11
7.2 Power module PK 40.. 11
8. Technical Data 12
8.1 Analog card AK 40.. 12
8.2 Logic card LK 4002 12
8.3 Logic card LK 4010 12
8.4 Power unit PK 40.. 12
8.5 Control card RK 40.. 13
8.6 Central processor ZC 40.. 13

BEA--223497-E-02
Service manual

Explanation of symbols
➜ = jobs to be performed
= important information and instructions

This manual is designed as an aid to clearing simple malfunctions or

1. Instructions incorrect operation. Your E+L service engineers supply full support
for all problems.

Check and change parameter settings according to the parameter

2. Malfunctions list only (attached to the block diagram) and always note the set
parameter values. Group and device numbers (addresses) are
specified in the block diagram. If parameter settings have been
corrected, an intialisation run must be performed afterwards.

2.1 Possible problems (Note: X = place retainer; e.g. address X.6)

Problem / Malfunction possible causes recommended action

Operating voltage indicator Operating voltage not supplied Check voltages and electrical
+5 V DC does not go on. Power unit defective connections according to wiring
Line to CAN bus card broken diagram

Support beam does not move
(positioning drive)
mechanical defect
Operating voltage not supplied
Incorrectly set parameter in
device 6 and/or 7 (address X.6 / X.7).
..7. speed automatic = 0 mm/s
..8. speed manual = 0 mm/s
.1.1. motor current insufficient
Gears blocked
Call E+L service engineer.
Check electrical connections.
Check/changer support beam-guider
according to parameter list
Increase speed
Increase speed
Set motor current according to
type plate
Set motor current to double the nom.
value and perform initialisation run,
then set nominal current
(Process must not last longer
than 2 mins. - motor might other-
wise be destroyed!)

Actuating element does not move
(Actuator does not move)
mechanical defect
Operating voltage not supplied
Connection defective
Incorrectly set parameter in
device 5 (control card, address X.5)
..7. speed automatic = 0 mm/s
..8. speed manual = 0 mm/s
..9. pos. range +/- insufficient
.1.1. motor current insufficient
.1.5. control mode
Reference switch incorrectly mounted
Call E+L service engineer
Check electrical connections
Check plug connections
Check/change guider settings .
according to parameter list
Increase speed
Increase speed
Increase actuating range limits
Set motor current according to
type plate
Set correct operating mode
See act. element descr. for mounting

W page 2

Problem / malfunction
Actuator moves in one direction only
and stops
Actuator motor direction of rotation
incorrect
Initialisation run not possible
(is not initiated)
Act. element does go into center pos.
(Centering)
Actuator moves in one direction only
in manual mode
Act. element does not move in
manual mode
Actuator moves in one direction only
in automatic mode
Motor leads mixed up
possible causes
Initialisation run not performed
Ref. switch activated several times
(several switch points - CAN LED flashes)
Incorrectly set parameter in
device 5 (address X.5)
.1.2. motor direction
Incorrect connection to actuator
(e.g. motor line mistaken)
Motor direction of rotation is wrong
Reference switch incorr. mounted / defect
Incorrectly set parameter in
device 5 (address X.5)
..9. pos. range +/- insufficient
.1.1. motor current insufficient
Ref. switch activated several times
(several switch points - CAN LED flashes)
Reference switch incorr. mounted / defect
Incorrectly set parameter in
device 5 (address X.5)
.1.6. zero offset
Mechanical defect
Ref. switch incorrectly mounted
Motor leads mixed up
A/B incremental encoder lines mixed up
Incorrectly set parameter in
device 5 (control card, address X.5)
..8. speed manual = 0 mm/s
Initialisation run not performed
Incorrectly set parameter in
device 5 (address X.5)
..9. pos. range +/- insufficient
.1.1. motor current insufficient
Mechanical defect
Ref. switch incorrectly mounted
A/B incremental encoder lines mixed up
Sensor signal incorrect /not supplied
Service manual
recommended action
Perform initialisation run
(see command station DO description)
Check ref. switch mounting
Check/change parameter setting
according to parameter list
(0 = normal / 1 = inverted)
Check connections
Check/change motor direction of rot.
Check reference switch
Check/change parameter setting
according to parameter list
Increase actuating range limits
Set motor current according to
type plate
Check reference switch mounting
Check reference switch
Check/change parameter setting
according to parameter list
Set offset to 0.0
Call E+L service engineer.
See act. element descrip. for mounting
Check/change guider settings
according to the parameter list
Increase speed
Perform initialisation run
Check/change parameter settings
according to parameter list
Increase actuating range limits
See motor current according to
type plate
Call E+L service engineer
See act. element descrip.for mounting
Check sensor function according to
sensor description
W page 3
Service manual
Problem / malfunction
Actuator does not move in
automatic mode
Actuating path is not symmetrical
CAN LED does not go on
CAN LED lights up red
CAN LED flashes continuously
1 x green and 1 x red
(unknow hardware)
CAN LED flashes continuously
1 x green and 2 x red
(max comp reached)
CAN LED flashes continuously
1 x green and 3 x red
(no link defined)
CAN LED flashes continuously
1 x green and 4 x red
EEprom overflow
Operating or function keys on
command station have no effect
W page 4
possible causes
Incorrectly set parameter in
device 5 (control card, address X.5)
..7. speed automatic = 0 mm/s
..9. pos. range +/- insufficient
.1.1. motor current insufficient
Sensor signal incorrect /not supplied
Guider not enabled
Initialisation run not performed
Actuator not centered
Actuator is mounted off-center
Actuator goes to its mechanical stops
no +24 V DC voltage supply
no software in the appropriate
CAN bus card
CAN bus card defective
Malfunction on the CAN bus card or
interrupted CAN bus line
No CAN terminating resistor connector
unknown hardware
serial bus card defective or no
serial bus terminating resistor connector
Reference switch activated several times
(several switch points)
more serial bus cards /devices
than allowed attached to the CAN bus card and check CAN bus connections
(generally max. 8).
internal error
Memory overflow in the EEPROM
Key is disabled via key filter
(key filter parameter).
recommended action
Check/change guider settings
according to parameter list
Increase speed
Increase actuating range limits
Set motor current according to
type plate
Check sensor function according to
sensor description
Close guider enable contact
Perform initialisation run
Consult E+L service engineer
Reposition actuator
Reduce actuating range limits in
.9. pos. range +/-
Check voltage supply
Plug in EPROM
Replace CAN bus card
Check all bus connection according
to the block diagram
Check hardware components.
Disconnect all serial bus cards one
after another then reconnect until the
error occurs again - last card to
be reconnected possibly defective.
Check terminating resistor connector
Check reference switch mounting
Reduce no. of serial bus cards/devices
according to block diagram
(consult E+L service engineer).
---
Reduce no. of serial bus cards
Consult E+L service engineer
Enable key via Hex code in
key filter parameter (see command
station DO description)

Problem / malfunction
All displays on the command station
light up red
Setup parameters cannot
be changed
Setup cannot be quit
3. Incorrect setup
operation
3.1 Reload parameter values
Service manual
possible causes recommended action
Connectors X 1and X 2 on relevant Check connectors on operator panel
operator panel RT 4... mixed up RT 4...
"Display parameter" only, e.g. see parameter list
software version
Setup editor disabled see command station DOdescription
DIP switch S 2.8 = on (DIP switch S 2.8 = off) and/or
expanded setup is not selected Select expanded setup (enter 42 in
parameter ..3. , change parameter )
Incorrect operation Isolate guider voltage
Attention: changed parameter values
are thus stored.
When quitting the setup editor (setup mode / expanded setup
mode) via a reset or isolating the guider voltage, changed para-
meters are stored.
If the parameters are changed such as to impair guider function, the
E+L basic setting can be loaded again. If setup operation was incor-
rect however, the E+L basic setting may already be overwritten and
the guider cannot continue to operate error-free in this situation. In
this event, the "default values" must be loaded and the guider re-pa-
rameterized with the aid of the parameter list.
First load the E+L basic setting, if you have no success with
this, load the default values and re-parameterize the guider.
Load E+L basic setting
➜ Select expanded setup mode
➜ Load the E+L basic setting; select parameter ..2. reset settings
and set the number 1, change parameter (see parameter list).
➜ Perform guider reset; select parameter ..3. start service, set the
number 1 and change parameters.
Load default values
➜ Select expanded setup mode
➜ Load default values; select parameter ..2. reset settings and set
the number 2, change parameters (see parameter list).
➜ Perform guider reset; select parameter ..3. start service and set
the number 1, change parameters.
W page 5
Service manual
4. Replace soft
ware
4.1 Spare parts delivery for
E+L guiding systems
4.2 Function expansion to an
existing guiding system
4.3 Function expansion to
include oscillating mode
4.4 Retrofitting a digital colou-
red line sensor
4.5 Software replacement
W page 6
Re-parameterizing
➜ Select expanded setup mode
➜ Set the values specified in the parameter protocol in all parame-
ters.
If the system was not designed by E+L, set the values specified in
the "value" column in all parameters in the parameter list.
➜ Perform guider reset; select parameter ..3. start service, set the
number 1 and change parameters.
The software for E+L guiders and the appropriate E+L components is
in principle downwardly compatible i.e. components with current and
older software can be combined. The old function scope is retained,
extended functions of the new software have no bearing in this case.
On support beam VS 353. both RK control cards must always
have the same software. This means that when the software is
changed, both programme memories must be replaced. We
however also recommend that you replace the software in the ma-
ster device (address X.5).
In the case of function expansions to existing guiding systems, the
programme memories in the master device (address X.5) and in all
componnts affected by the function expansion must be replaced
(same software status).
Function expansions should be performed by E+L only!
When expanding function to include oscillating mode on VS 3530 the
software status must be current in command station DO 002., in
the web guider (master device, address X.5) and in support beam
VS 3530 (in both control cards, address X.6 und X.7).
If a web guiding system is retrofitted with a digital coloured line sen-
sor, both command station DO and control card RK in the master de-
vice must be equipped with the current software.
The following are required:
- control block diagram
- descriptions of all affected components
- parameter lists
- programme memory (EPROM with new software)
- appropriate tools
 Service manual

Programme memories (EPROM with software) are located on all RK

control cards and ZC central processors (see block diagram). Which
programme memory belongs to which device can be read from the
software number (see adhesive label on the EPROM).
Software RK 4...... control card programme memory
(act. element / master device +supp. beam)
Software ZC 4...... central processor programme memory
(command stations and interfaces)
Replace programme memory as follows:
- Enter all parameter values of the "old" programme memory in the
parameter lists (see block diagram for address).
- Switch off mains voltage.
Socket - Remove old programme memory carefully and insert the new pro-
gramme memory correctly. The notches on the socket and
EPROM must match (visual checking of connections).
- Switch the mains voltage back on.
- Select expanded setup mode (see CAN bus, serial bus and setup-
RK4002-0001U_ZL editor or command station DO.. descriptions).
- Select parameter ..3. in the master device (address X.5) and set
EPROM
the number 99, then change parameters.
Software number
- Check the addresses of the attached devices, such as sensors,
support beam etc. in the new programme memory. The addresses
are specified in the block diagram and parameter list.
- Enter the parameter values you have noted in the new program-
me memory (changed device).
Web guider initialisation run - Perform web guider initialisation run and if featured, perform su-
port beam initialisation run (see CAN bus, serial bus and setup-
+ editor descriptions).
- Select manual mode and check the direction of rotation and end
+ position display.
- Select sensors and set automatic mode. Then check the web gui-
Support beam initialisation run der function.
+ - Commission the new components such as remote display DO ac-
cording to the description and perform further parameter settings
as necessary (see parameter list and description).
+

W page 7
Service manual

Every CAN bus card has its own address which is specified in the
5. CAN bus cards block diagram of systems designed by E+L. Setting is performed on
all CAN bus cards via DIP switch S 2.
The address is made up of two parts:
- the group number from 0 to 7
- the device number from 1 to F (hex)
Example: address 0.5 0 = group number
5 = device number
Each address must be assigned once only! ! The settings on
the DIP switch are in binary code form.

Example: group number 0, device number 5, setup editor free

S 2. 1 2 3 4 5 6 7 8
1234
1234 Disable setup editor (master device):
1234
ON
1234
1234 S 2.8 on = setup editor disabled
OFF 1234 S 2.8 off = setup editor free

Binary value:
1 2 4 8 1 2 4
Device number (e.g. B. 5) : Group number (e.g. 0) :
DIP switch S 2.1 - S 2.4 DIP switch S 2.5 - S 2.7
DIP switch S 2

5.1 Control card RK 40..
The control card converts all signals required for controlling into an
appropriate corrective signal for a DC actuator. The motor current is
also monitored.
Depending on the control card task, various connectors are assi-
gned (see diagram and illustration at top of page 9).

Connectors
Magnetic incremental
encoder signals
X1 Supply voltage 20 to 30 V DC.
M X2 DC actuator and magnetic incremental encoder.
X2
X3 Command station for web offset RE..
DC actuator actuating
signal X4 Reference switch and external signals e.g. "Guider stop"
X5 CAN bus interface RS 422 for digital sensor.
X6 CAN bus interface RS 422 for digital sensor.
Optical incremental
encoder signals X7 CAN bus interface for CAN bus compatible E+L components
X 10 e.g. a further RK control card
M
X2 X8 Analog card AK 4.., for connecting analog sensors
Actuating signal
DC actuator X9 Serial bus components from E+L such as operator panel RT.
X 10 Optical incremental encoder
Connector X 2 and X 10
X 11 Power unit PK for increasing the output power to 100 W.

LEDs
H1 +5 V operating voltage available.
H2 Current controller for DC actuator active.

W page 8
 Service manual

X9 X8 Most common addresses on the DIP switch:

Guider (master device) 0.5 (hex)
Right support beam 0.6 (hex)
Left support beam 0.7 (hex)
X7
EPROM 5 0
S 2. 1 2 3 4 5 6 7 8
X6 X4 ON

OFF

Binary value:1 2 4 8 1 2 4
H1 DIP switch
S 2.1 bis S 2.8 6 0
X3
X5 S 2. 1 2 3 4 5 6 7 8
H2
ON

OFF
X 11 X 10 X2

7 0
S 2. 1 2 3 4 5 6 7 8
X1 ON

OFF

Control card RK 40..

5.2 Central processor ZC 40.. The ZC 40.. central processor is a CAN bus controller and is located
in DI interfaces and DO command stations (see diagram).

Connections
X1 Supply voltage 20 to 30 V DC.
X2 Serial bus components from E+L such as operator panel RT.
X3 CAN bus interface
X4 System bus (processor bus), connection for E+L expansion
cards e.g. ARCNET interface

LEDs
H1 Operating voltage of +5 V available

Example:
X4 Address on DIP switch 1.E (hex)
X1
E 1
S 2. 1 2 3 4 5 6 7 8
ON

EPROM OFF
DIP switch
S 2.1 bis S 2.8 Binary value:1 2 4 8 1 2 4

H1 X3 X2

W page 9
Service manual

Logic card LK 40..serves as an input-output module (I/O-Port) for

6. Serial bus cards transferring commands or reading values in and out.

LK 4002 connections
6.1 Logic card LK 4002 X1 Supply voltage 0 V DC
8 digital inputs
X2 Supply voltage 20 to 30 V DC
8 digital outputs
X3 serial bus ("In"). Connection to CAN bus card ZC 40..
X4 serial bus ("Out"), E+L components such as operator panel RT
or further logic cards.

LK 4002 LEDs
H9 Internal supply voltage of +5 V DC
H 10 Supply voltage of 20 - 30 V DC
H 1 to H 8 (digital inputs)
Input 1 to 8 (H 1 to H 8); go on when logical "1" set
H 11 bis H 18 (digital outputs)
Output 1 to 8 (H 18 to H 11); go on when logisch "1" set
LK 4010 connections

LK 4002 LK 4010

LED's LED's
X3

X1 X3

X2
X1 X4
X2

6.2 Logic card LK 4010 X1 serial bus ("In"). Connection to CAN bus card ZC 40..
X2 4 digital inputs and 0 V DC (ground reference)
X3 serial bus ("Out"), E+L components such as operator panel RT
or further logic cards.

LK 4010 LEDS
H5 internal supply voltage of +5 V DC
H 1 bis H 4 (digital inputs)
input 1 to 4 ( H 1 to H 4), go on when logical "1" set

W page 10
 Service manual

7. Expansion
cards
7.1 Analog card AK 4002 Analog card AK 4002 features two analog-digital converters which
convert analog sensor signals into pulse width-modulated signals.

Connections
X2 X1 X 1 and X 4
Connection to sensor (if not assigned, connect jumper as indi-
X5 X4 cated in diagram).
H2 H1
X 2 and X 5
Connection to sensor (if not assigned, connect jumper as indi-
cated in diagram)
X3
X3 Connection to control card RK 40..
F1

LEDs
H1 Operating voltage +12 V DC supplied.
H2 Operating voltage -12 V DC supplied.

Overload protection
F1 If the output voltage of ±12 V is shorted out or overloaded,
thermostatic switch F 1 shuts off the output voltage. Once the
malfunction has been cleared and the thermostatic switch coo-
led down, analog card AK 4002 is operational again.

7.2 Power module PK 40.. Power module PK 40.. is an additional power unit for control card
RK 40.. and is used to increase the overall output power of a digital
guider to 100 W.

Connections
X1 Supply voltage 24 V DC.
X2 DC actuator AG.. and connection to control card RK 40.. termi-
nal X 2
X4 Connection to control card RK 40.. terminal X 11.

LEDs
H1 Operating voltage +5 V DC supplied.
H2 Current controller for DC actuator active.

W page 11
Service manual

Supply voltage AK 4002 20 to 30 V DC

8. Technical Data
Output voltage 2 x ±12 V DC
(Sensor supply voltage)
8.1 Analog card AK 40.. Output current maximum 0.5 A
Signals
Input signal 2 x ±10 V
Output signal 2 x +5 V (PWM)

8.2 Logic card LK 4002 Internal supply voltage +5 V DC

External supply voltage 20 - 30 V DC
including residual ripple
External current input
per LK 4002 maximum 4 A (8 x 0.5 A)
Potential-free inputs
Input voltage
with signal "1" 20 - 30 V DC
Input voltage
with signal "0" < 3 V DC
Input current maximum 10 mA
Potential-free outputs
Output voltage
with signal "1" supply voltage - 1 V
Output current per output maximum 0.5 A
Ambient temperature 0 - 50° C

8.3 Logic card LK 4010 Internal supply voltage +5 V DC

Potential-free inputs
Input voltage
with signal "1" 20 - 30 V DC
Input voltage
with signal "0" < 3 V DC
Input current maximum 10 mA

8.4 Power unit PK 40.. Supply voltage

including residual ripple 20 to 30 V DC
Current input maximum 3.5 A
Power input
depending on output loading maximum 85 W
Output voltage 22 V pulse width-modulated
Output power
with additional heat sinks maximum 50 W
Output power in conjunction
with control card RK 4002 maximum 100 W
Heat sink 2.5 W / K

W page 12
 Service manual

8.5 Control card RK 40.. Supply voltage

including residual ripple 20 to 30 V DC
Power input
(depending on output loading) 30 W to 100 W
Output voltage ±22 V (PWM)
(pulse width-modulated)
Output power
without additional heat sinks maximum 20 W
with additional heat sinks maximum 50 W
with external power module maximum 100 W
Protection class IP 00

8.6 Central processor ZC 40.. Supply voltage 20 to 30 V DC

Current input maximum 0.5 A
CAN bus
CAN bus level + 5 V (potential-free)
CAN baud rate 250 KBaud
Serial interface
Serial interface level 5V
Synchronous baud rate 1.3 MBaud
Technical data subject to modification without notice

W page 13
 Erhardt + Leimer GmbH
Postfach 10 15 40
D-86136 Augsburg
Telefon (0821) 24 35-0
Telefax (0821) 24 35-666