BST-eltromat – Business Unit Tire

Logic module
BST ProLogic CPU 32x

Translation of the original

Operating Manual

BST eltromat International Bielefeld GmbH

Heidsieker Heide 53
33739 Bielefeld

Tel: 05206/999 – 0
Fax: 05206/999 – 999
Email: info@bst-international.com

This document may not be copied or accessed by a third party without our specific consent and even then the third party or
person to whom the copy is given must not use it improperly in any way whatsoever.
BST eltromat International Bielefeld GmbH

Logic module EDV-No.: MD.325.EN.02

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 Content 00

Table of contents

1 Description 1
1.1 Symbols Used in this Operating Manual 1
1.1.1 Warning Signs 1
1.2 General Information 2
1.3 Authorized Utilization 3
1.4 System Description 4
1.4.1 System Design 4
1.5 Safety Instructions 5
1.6 ESD Protection 6
1.7 Emissions 7
2 Technical Data 8
2.1 Environmental Conditions 8
2.1.1 Transport and Storage 8
2.1.2 Operation 8
2.2 Controller CPU 32x 8
2.3 Digital Input Module DI 16x 8
2.4 Digital Output Module DO 16x 9
2.5 Digital Input / Output Module DIO 88x 9
2.6 Analog I/O Module AIO 2+2x 10
2.7 Counter Module AOCIx 10
3 Transport / Storage 11
3.1 Transport 11
3.2 Storage 11
4 Layout 12
4.1 Controller CPU 32x 12
4.2 PSx Module 12
4.3 Interfaces 13
4.3.1 Serial Interfaces 13
4.3.2 CAN Interfaces 14
4.4 Digital Input Module DI 16x 19
4.5 Digital Output Module DO 16x 19
4.6 Analog I/O Module AIO 2+2x 20
4.7 Counter Module AOCIx 20
5 Status Indicators 21
5.1 Controller CPU 32x 21
5.1.1 Digital input module DI 16x 24
5.1.2 Digital output module DO 16x 24
5.1.3 Analog I/O module AIO 2+2x 25
5.1.4 Counter module AOCIx 25
6 Communication with the BST ProLogic CPU 32x 26
6.1 Setting up with RS 232 26
6.2 Setting up using TCP/IP
(only if the IP address is known) 28
6.3 Logging in 30
6.4 Data Transfer Using RS 232 (Not Using TCP/IP) 31
6.5 Data Transfer with TCP/IP via FTP (Windows Explorer) 33
6.6 Restart 33
6.7 Commands (Selection) 34
7 Battery 35
7.1 General Information 35
7.2 Battery Replacement 35

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8 Troubleshooting 37
8.1 Controller CPU 32x 37
8.2 Digital Input Module DI 16x 37
8.3 Digital Output Module DO 16x 37
8.4 Analog I/O Module AIO 2+2x 38
8.5 Counter Module AOCIx 38
9 Decommissioning 39

I Index

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1 Description
1.1 Symbols Used in this Operating Manual
1.1.1 Warning Signs

Symbols are used in this operating manual in order to clearly indi-

cate particularly important points.

Warning!

! You must obey this type of warning, in order to protect

yourself, as the operator, from bodily injuries arising
from mechanical movements.

Beware!
You must obey by this type of warning without fail, in
order to protect yourself, as the operator, from life
threatening injuries caused by electrical voltages.

Note
This symbol is used to point out additional useful tips,
which will help you to make optimum use of all of the
functions.

Attention!
Risk due to electrostatic discharge. Suitable protective
measures must be observed.

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 Description 1
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1.2 General Information

The start-up, maintenance and installation instruc-

! tions described in this operating manual must be
strictly adhered to!

The logic module BST ProLogic CPU 32x may be installed and
operated after first acquainting yourself with the appropriate op-
erating manual. This will help to avoid hazards and prevent
damage to the logic module due to improper installation or op-
eration.
This Operating manual, and particularly the safety instructions,
must be observed by all persons working on or with the
BST ProLogic CPU 32x logic module.
You must read, without fail, the safety instructions given in
Chapter 1.7 of this operating manual prior to starting the
installation and commissioning work!
Solely BST-eltromat staff or other persons specifically au-
thorized by BST-eltromat are permitted to modify or add to the
firmware of this control unit. Ignoring this warning might result in
the warranty rights being invalidated.
The settings and details shown in this operating manual (e.g. in
the display screens) are given as examples only, unless the text
explicitly states otherwise.
The latest version of the operating manual for the logic module
BST ProLogic CPU 32x can be obtained via the Internet in all
available languages under the following address:

http://www.bst-international.com

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 Description 1
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1.3 Authorized Utilization

The logic module BST ProLogic CPU 32x is a control unit that uses
user-specific software to control BST-eltromat systems and carries
out a data exchange with the customer control unit.

The logic module BST ProLogic CPU 32x is for fitting in another
machine or for combining with other machines to form a machine in
the sense of the directive 98/37/EC (machine directive). Start-up of
the system is forbidden until the user / operator has determined
that the machine, in which the system is installed, conforms to the
conditions of this directive.

BST-eltromat systems have been designed and built in accordance

with state-of-the-art standards and the recognized safety rules.
Nevertheless, use of the systems may constitute a risk to life and
limb of the user or of third parties or damage to the BST-eltromat
systems and other property. Therefore BST-eltromat systems are
only to be used if they are working correctly and in a technically
safe condition.

Any part found to be working incorrectly must be replaced immedi-

ately. Only original spare parts are to be used for this. Spare parts
obtained from third parties cannot be guaranteed to comply with the
design and manufacturing conditions and safety regulations. In this
case any guarantee claims for the BST-eltromat systems will be in-
validated.

Only qualified personnel who have been trained on the system are
allowed to undertake any work required on the BST-eltromat sys-
tems (such as installation, commissioning, operation, maintenance,
etc.).

Intended use also includes adhering to the instructions given in this

operating manual. Use for any purpose other than those mentioned
above is considered as contrary to the intended use. BST eltromat
International Bielefeld GmbH does not accept liability for any dam-
age resulting from this type of use.

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 Description 1
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1.4 System Description

1.4.1 System Design

The logic module BST ProLogic CPU 32x comprises a microcon-

troller (CPU 32x), a number of digital I/O modules (DI 16x and DO
16x), a number of analog I/O modules (AIO 2+2x), a number of
counter modules (AOCIx) and a power supply (PSx-module).

The modules must be arranged in the named sequence, if not in-

correct operation may occur.

The latest communication interfaces such as Ethernet TCP/IP for

networking and PC-MMI switch-on as well as for CANopen net-
works for the connection of field bus terminals predestines the logic
module for use in machines with distributed control structures.

The conditions of use and all external connections must conform to

the directives and specifications of VDE 0100 and 0110 or the Eu-
ropean Standards EN 60204 and EN 50178. The general EC ma-
chine directive or application-specific regulations originating from
VDE, TÜV and the Accident Prevention & Insurance Association
are likewise to be observed. In particular EMERGENCY OFF
equipment, limit and safety switches etc., must also be immediately
effective at the power supply of the respective units even if the
module itself has failed.

Microcontroller Digital Analog Counter- Power

CPU 32x IO-Module IO-Module Module Supply
(optional) (optional) (optional) PSx

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 Description 1
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The control has the following features:

- 32 Bit MPC 5200 micro controller
- 64 MByte SRAM
- 512 kByte CMOS, battery backed
- 16 MByte Flash PROM
- 1 serial interface
- 1 Ethernet TCP/IP interface
- 1 USB
- 1 SD-Card socket
- Watchdog
- 4 CAN interfaces

1.5 Safety Instructions

The safety relevant information in accordance with DIN EN ISO
13857, DIN EN 349 and the industry specific safety regulations
must be taken into consideration when installing the BST-eltromat
equipment in the production machine, these include:

There must be a safe distance between the BST-eltromat

equipment and the machinery already installed on-site,
such as machine panels, building structure, etc.
Connection lines between the individual system compo-
nents must be laid so that nobody can trip over them, free
from strain/tension and well anchored.
Ensure that there is sufficient free headroom. If the free
passage is restricted, the relevant building components
causing the restrictions must be padded and a danger
warning signs must be attached to them (yellow/black).
As a matter of principle, cable connections in BST-eltromat
systems may only be disconnected if the components are
no longer connected to the electricity supply. Any infringe-
ments will result in the warranty claim being invalidated.
Any transport safety devices that were used must be re-
moved prior to commissioning of BST-eltromat systems.

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 Description 1
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!
Only trained specialist personnel are permitted to
undertake the assembly, installation and commis-
sioning!

Only open the logic module if the power supply is

switched off.
If it becomes necessary to work on the open unit
while it is live, then only protection category IP 20
applies. There is an increased danger due to the
supply voltage!

Before starting work, ensure the equipment is elec-

trically isolated. To this end always carry out the fol-
lowing measures:

1. Switch off
2. Prevent switching back on.
3. Check the equipment is isolated.
4. Ground.
5. Cover or shield any adjacent parts that are still
live.

Only then you can carry out the relevant work.

Actuation movements will be undertaken by the ac-

! tuator even during function tests away from the pro-

duction machine and/or during commissioning.
The relevant safety arrangements must implement-
ed during function tests! Monitor the overall safety
concept of the production machine during commis-
sioning!

1.6 ESD Protection

Warning!
Risk of electro static discharge
(ESD = Electro Static Discharge).

The device contains ESD-sensitive electronic components.

Contact with electrostatically charged persons or objects, may
cause these components permanent damage, which may lead to
loss of performance, malfunctions or even destruction of the parts.

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 Description 1
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The housings of system components may only be opened in an

ESD-suitable work place (ESD work place as per DIN EN 61340-5-
1).

If no ESD-suitable work place is available, then ESD protective

measures must be implemented in accordance with DIN EN
61340-5-1, so that electrostatic charges are discharged in a con-
trolled manner.

If returning electronic components or modules, adhere to the rules

given in DIN EN 100 015 “Protection of electrostatically sensitive
components”. For transport, use only appropriate and correspond-
ingly labeled electrically conducting ESD packaging.

BST eltromat International Bielefeld GmbH will not be liable

for damage arising from the non-adherence to the ESD protec-
tive measures given here.

1.7 Emissions

The A-rated equivalent continuous sound level of the equipment is

less than 70 dB(A).

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 Technical data 2
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2 Technical Data
The following data are to be considered as thresholds, the exceed-
ing of which by and operator may lead to incorrect operation and
permanent damage.

2.1 Environmental Conditions

2.1.1 Transport and Storage

Temperature range -20 °C to + 60° C

Temperature change max. 20 K/h
Relative humidity 8 % to 80 %; non-condensing
Shock (10 ms) max. 15 G
Vibration (5 to 100 Hz) max. 2 G
Air pressure 660 hPa to 1060 hPa

2.1.2 Operation

Temperature range 0 °C to + 60° C

Ventilation (air flow par- min. convection
allel to the PCB)
Temperature change max. 10 K/h
Relative humidity 20 % to 80 %; non-condensing
Shock (10 ms) max. 5 G
Vibration (5 to 100 Hz) max. 0.5 G
Air pressure 860 hPa to 1060 hPa
Place of installation In closed buildings
< 2000 m above sea level

2.2 Controller CPU 32x

Supply voltage +4.75 VDC to +5.25 VDC

Current consumption max. 600 mA DC
Power dissipation max. 3 W
Protection class IP20
Dimensions (H x W x D) 100 mm x 45 mm x 115 mm
Weight 240 g

2.3 Digital Input Module DI 16x

Supply voltage 5 VDC over local bus internal,

24 VDC external
Number of inputs 16 channels: “0” = -5 ... +5 VDC
“1” = +10 ...+30 VDC
Input current max. 11 mA for 30 V input signal

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 Technical data 2
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Threshold frequency > 1 kHz

Insulation voltage 500 V
Monitoring function Watchdog; thermal and short circuit pro-
tection
Protection class IP20
Dimensions (H x W x D) 100 mm x 22.5 mm x 115 mm
Weight 120 g

2.4 Digital Output Module DO 16x

Supply voltage 5 VDC over local bus internal,

24 VDC external
Number of outputs 16 channels
Output current 500 mA for 19 – 30 V external supply
Short circuit current short term, 2.5 A, max. module total
current: 8.1 A
Threshold frequency max. 250 Hz
Insulation voltage 500 V
Monitoring function Watchdog; thermal and short circuit pro-
tection
Protection class IP20
Dimensions (H x W x D) 100 mm x 22.5 mm x 115 mm
Weight 145 g

2.5 Digital Input / Output Module DIO 88x

Supply voltage 5 VDC over local bus internal,

24 VDC external
Number of inputs 8 channels: “0” = -5 ... +5 VDC
“1” = +10 ...+30 VDC
Input current max. 11 mA for 30 V input signal
Threshold frequency > 1 kHz
Number of outputs 8 channels
Output current 500 mA for 19 – 30 V external supply
Short circuit current short term, 2.5 A, max. module total
current: 8.1 A
Threshold frequency max. 250 Hz
Insulation voltage 500 V
Monitoring function Watchdog; thermal and short circuit pro-
tection
Protection class IP20
Dimensions (H x W x D) 100 mm x 22.5 mm x 115 mm
Weight 145 g

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 Technical data 2
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2.6 Analog I/O Module AIO 2+2x

Supply voltage 5 VDC over local bus internal,

24 VDC external
Sensor supply 24 V
In / outputs AIO 2+2U: -10 V ... +10 V
AIO 2+2I : 0 ... 20 mA
Resolution 16 Bit
Insulation voltage 500 V
Monitoring function Watchdog; thermal and
short circuit
protection
Protection class IP20
Dimensions (H x W x D) 100 mm x 22.5 mm x 115 mm
Weight 145 g

2.7 Counter Module AOCIx

Supply voltage 5 VDC over local bus internal,

24 VDC external
Current consumption 5 VDC: max. 132 mA
24 VDC: max. 50 mA
Digital inputs 4 channels, 24 VDC: max. 11mA
at 30 VDC
Analog output -10 V ... +10 V, max. 10 mA,
16 bit resolution
Protection class IP20
Dimensions (H x W x D) 100 mm x 22.5 mm x 115 mm
Weight 125 g

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 Transportation/Storage 3
1

3 Transport / Storage
3.1 Transport

The equipment will be shipped in accordance with the details stipu-

lated in the order:

completely assembled and connected in a BST-eltromat system

as component parts in standard cardboard boxes with cellular

lining material

The unit must only be transported when it is packed in the original

BST-eltromat transport packing.

BST eltromat International Bielefeld GmbH will not be liable

for damage to the logic module which is caused by incorrect
transport packaging!

3.2 Storage

If the components have been shipped as individual parts and will

not be fitted immediately, they must all be stored in a dry room pri-
or to assembly.

Storage conditions:
Temperature range -20 °C to + 60° C
Temperature change max. 20 K/h
Relative humidity 8 % to 80 %; non-condensing
Shock (10 ms) max. 15 G
Vibration (5 to 100 Hz) max. 2 G
Air pressure 660 hPa to 1060 hPa

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4 Layout
4.1 Controller CPU 32x

Designation Function
CAN1 RS232 Serial interface

WD 2 WD 1 C_GD C_H C_L PE

CAN1 CAN interface
4 CAN 1
3 Term 2 CAN2
CAN3 Drive interfaces
CAN3

CAN2

CAN4
Ethernet Ethernet TCP/IP interface
Local bus (socket)

Local bus (pin)

Local bus I/O interface

RS232
CAN4

USB USB port

SD card Slot for SD card
Ethernet

WDOG
LED 1
SD-Card

Status indicators;
LED 2 Meaning see point 5
USB

7 segment
WDOG
indicator
SD LED1
7 Segment Functional ground
LED2
indicator

4.2 PSx Module

24 V 0V

The controller CPU 32x and the PSx-module (power

supply) are connected to each other via the local bus
plug.
The power supply is connected to the appropriate ter-
minal. The plug connection is coded with pins to pre-
vent an incorrect connection.

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 Layout 4
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4.3 Interfaces

4.3.1 Serial Interfaces

The module has a serial interface conforming to the RS232 Stand-

ard via an RJ45 socket. The BST ProLogic programming environ-
ment, like the internal monitor, is operated via the RS232 interface
at 115 kBaud.
yellow
LED
RS232 plug pin assignments
RJ45
Pin

Pin Signal Pin Signal

green 1 DSR
LED
2 DCD
3 DTR
4 GND
5 RX
6 TX
7 CTS
8 RTS

Two LEDs integrated in the socket indicate the interface connec-

tion status.

Meaning of the LEDs for RS 232

RJ45

LED Signal

Yellow TX status, flickering light indicates data transmit

Green RX status, flickering light indicates data receive

Installation instruction

When connecting the serial interfaces used shielded cable. The

plug bodies must be made from metal or metalized plastic. The ca-
ble shielding is to be connected at both ends to the plug bodies.

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4.3.2 CAN Interfaces

4.3.2.1 CAN Interface CAN1

Pin The CAN1 interface  is galvanically isolated from the CAN2 inter-
4 3 2 1 faces  and fed via the CAN driver to the 4-pin connector.
1 The interfaces CAN2, CAN3  and CAN4  are fed to the
8-pin RJ45 plug (CAN3 and CAN4 are galvanically isolated).
WD 2 WD 1 C_GD C_H C_L PE
DIL 4 CAN 1
3 Term 2
switch The insulation voltage to the computer is 500 V. For all 4 CAN in-
terfaces, an internal terminating resistance of 120 Ohms is activat-
CAN3

CAN2

3 2
ed between CAN_H and CAN_L. This is activated via the ON posi-
tion of the four 2-pin DIL switches. The numbering of the switches
corresponds to the numbering of the CAN interfaces.
RS232
CAN4

A CAN high speed interfaces is implemented in accordance with

Ethernet

the ISO/DIS 11898 standard. The BST ProLogic CPU 32x can be
configured as a CAN master.
SD-Card

USB

CAN 1 plug pin assignments

WDOG

SD LED1 Pin Signal

LED2

1 PE
2 CAN_L
3 CAN_H
LED 1; LED 2
4 CAN_GND

Display of the operating states takes place using LED1 and LED2.

Meaning of the LEDs for CAN1

LED Signal
1 TX status, flickering light indicates data transmit
2 RX status, flickering light indicates data receive

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4.3.2.2 CAN Interfaces CAN2, CAN3, CAN4

The three CAN interfaces are drive interfaces, to which drives

can be connected that support at least the CANopen specification
DS 301.

yellow
Plug pin assignments CAN2, CAN3, CAN4
LED RJ45

Pin Signal Pin Signal

1 CAN_H 5 nc
Pin

2 CAN_L 6 nc
3 CAN_GND 7 CAN_GND
green
LED 4 nc 8 nc

Two LEDs integrated in each socket indicate the interface connec-

tion status.

Meaning of the LEDs for CAN2, CAN3, CAN4

RJ45

LED Signal
Yellow TX status, flickering light indicates data transmit
Green RX status, flickering light indicates data receive

CAN installation instructions

Twisted-pair shielded cables must be used for the data lines and
are to be routed away from the power cables. Where this is not
possible, use of double-shielded cable is recommended. The inner
shielding is insulated from the outer shielding and connected to a
ground connection.

The two ends of the bus lines are to be terminated with resistances
equal to the characteristic impedance of the cable. For twisted pair
cables, this is generally 120 Ω up to 1 MHz (0.25 W).

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4.3.2.3 Ethernet Interface

The Ethernet interface is implemented using an Ethernet plug - an

RJ45 connector. The cabling type is specified as 10BASE-T.
WD 2 WD 1 C_GD C_H C_L PE
The interface is for connection of a PC control unit or for connec-
4
3
CAN
Term
1
2 tion the control into a network.
CAN3

CAN2

Plug pin assignments

RJ45
RS232
CAN4

Pin Signal
Ethernet

1 TX+
SD-Card

USB

2 TX-
WDOG

SD LED1 3 RX+
LED2

4 nc
5 nc
6 RX-
7 nc
yellow
LED 8 nc

Two LEDs integrated in the socket indicate the interface connec-

Pin

tion status.

green Meaning of the LEDs for Ethernet

LED RJ45

LED Signal
Yellow Activity status,
indicates a data transfer via RX or TX
Green Connected status,
signals the result of the internal 10BASE-T link integ-
rity test. It illuminates as soon as an Ethernet connec-
tion exists.

The address of the Ethernet controller is set in the factory. It

is indicated on a sticker on the module.

Connection tip:
If a point-to-point connection is made between control and PC con-
trol unit, then a “cross-over” cable must be used.

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4.3.2.4 USB Interface*

The USB interface conforms to the USB rev. 2.0 specification and
is capable of transmitting and receiving data at 12 Mbit/s (full
speed) or 1.5 Mbit/s (low speed).
4
3
WD 2 WD 1
CAN
Term
C_GD C_H C_L
1
2
PE
The USB interface is a type-A socket. The pin assignments corre-
spond to the USB standard. Only memory sticks are supported
CAN3

CAN2

which support USB bulk mode and are formatted with a FAT16 or
FAT32 file system. Moreover the memory stick may only have one
RS232
CAN4

partition.
Due to the large number of different memory sticks, it cannot be
Ethernet

guaranteed that any particular memory stick will function with BST
ProLogic CPU 32x.
SD-Card

USB

USB
WDOG

SD LED1
LED2
Pin assignment
Type A socket
Pin Signal
1 VCC
2 D-
3 D+
4 GND

Connection tip:
Use a high quality shielded cable to connect any external memory
media to the USB port. The cable length must not exceed 5 m.

4.3.2.5 SD Card*

The BST ProLogic CPU 32x has an SD card slot. An LED situated
beneath the slot indicates read/write access by flashing.
The maximum memory size of SD card supported is 2 Gbytes. The
4
WD 2 WD 1
CAN
C_GD C_H C_L
1
PE SD cards must be formatted with a FAT16 or FAT32 file system.
Term
Moreover the SD card may only have one partition.
3 2

Due to the large number of different SD cards, it cannot be guaran-

CAN3

CAN2

teed that any particular card will function with BST ProLogic CPU
32x.
RS232
CAN4

Ethernet
SD-Card

SD-Card
USB

WDOG

SD LED1
LED2

LED * not currently used in the BST-eltromat programs

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4.3.2.6 Watchdog

The module has a Watchdog switching circuit. This Watchdog cir-

Pin cuit is for control of the processor and switches off, if they are no
4 3 2 1 longer to be triggered, the outputs linked to it.

Watchdog (WDOG)
WD 2 WD 1 C_GD C_H C_L PE
Pin Signal
4 CAN 1
Term
3 2
1 Relay watchdog contact 1 (WD 1)
2 Relay watchdog contact 2 (WD 2)
CAN3

CAN2

3 nc
RS232
CAN4

4 nc

The watchdog status is indicated at the green LED WDOG.

Ethernet
SD-Card

Meaning of the LED WDOG

USB

On Status ok
WDOG

SD LED1 Off Error, watchdog has failed

LED2

The contacts WD1 and WD2 are connected via a relay contact, for
the scenario that watchdog activation is not successful. If the
LED watchdog triggers, the relay drops out.

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4.4 Digital Input Module DI 16x

0 V and 24 V power
supply

The digital input module can process up 16 opto-

decoupled 24 V signals. It is connected to the control
via the “local bus” plug.
Monitoring-LED
24V 24V 0V 0V for LIFE Check
LIFE 16 monitoring LEDs signal the input states.
24V

I1

I2
When connecting the supply voltage, monitor the cod-
I3 ed plug connection.
I4 Monitoring LEDs
Local Bus (socket)

I5 Input signals
I6

I7

I8

0V

24V
Local-Bus (pin)
I9

I 10

I 11

I 12
Monitoring LEDs
I 13
Input signals
I 14

I 15

I 16

0V

4.5 Digital Output Module DO 16x

0 V and 24 V
power supply
The digital output module can process up 16 opto-
decoupled 24 V signals. It is connected to the control
via the “local bus” plug.

16 monitoring LEDs signal the output states.

Monitoring-LED
for LIFE Check
24V 24V 0V 0V
LIFE
When connecting the supply voltage, monitor the cod-
24V ed plug connection.
O1

O2

O3

O4
Local Bus (socket)

Monitoring LEDs
O5
output signals
O6

O7

O8

0V

24V
Local-Bus (pin)
O9

O 10

O 11

O 12

O 13
Monitoring LEDs
O 14
output signals
O 15

O 16

0V

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 Layout 4
9

4.6 Analog I/O Module AIO 2+2x

0 V and 24 V Analog I/O module for every 2 analog I/O signals. The
power supply
10 V connection is a potentiometer reference voltage
(optional).

Monitoring-LED It is connected to the control via the local bus plug.

24V 24V 0V 0V for LIFE Check
LIFE
Ai1 When connecting the supply voltage, monitor the cod-
Ai1- ed plug connection.
SHLD

24V 2 analog
0V
inputs
Local Bus (socket)

Ai2+

Ai2-

SHLD

24V

0V

PE

10V Local Bus (pin)

10V

AGND

A01

AGND

SHLD
2 analog
A02
outputs
AGND

SHLD

4.7 Counter Module AOCIx

0 V and 24 V
power supply
The counter module is used for counting processes
running in real time. It is connected to the control via
the local bus plug.

24V 24V 0V 0V When connecting the supply voltage, check the coded
LIFE

REL
plug connection.
REL
Digital IN / Analog OUT

I1

I2

I3 4 digital inputs The encoder of the connections on the module is not

Local Bus (socket)

I4 currently used by BST-eltromat.

DCOM

AO 1
analog output
ACOM

Local Bus (pin)

Encoder

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 Status indicators 5
5

5 Status Indicators
5.1 Controller CPU 32x

On the module alongside the 3 status LEDs is a 7 segment indica-

tor which, dependent on the operating condition, indicates the cur-
rent status and any errors possibly occurring in the module.
Status LEDs

A distinction is made between the boot-up phase and operation.

Boot-up phase
The following indicators appear in this phase.

Indication Meaning
Hardware initialization

RAM test

Initialization completed

Loading of firmware from flash into RAM

Firmware loaded

Firmware started

Operation
When starting the firmware, the following indications appear.

Indication Meaning
Processor initialization

Software initialization

Operating system initialization

Task and mailbox initialization

I²C hardware initialization

File system initialization

Local bus initialization

Hardware check

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 Status indicators 5
5

Any errors that may occur during the boot-up are indicated by the
sequential error numbers shown below (with 2 characters/sec).

Indication Meaning
E01 RAM error
E02 Checksum error in the boot loader
E05 Unrecognized FPROM type
E06 Error when loading the firmware from FPROM
E07 Error when starting the firmware
E88 Processor exception

Status indication in normal operation

If the control successfully passes from the boot-up phase to the
operating state, the following flashing and indication pattern ap-
plies.

In this respect, the individual segments of the 7 segment indicator

are allocated in accordance with the following arrangement:

LED Meaning/task
a PLC program
b Service
c Fine interpolator
d Central control
e Interpreter
f Interpolator
g Ethernet communication
h Pulse in the interpolator rhythm

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 Status indicators 5
5

Any errors during operation are indicated according to the following

indication pattern.

The indicator shows the pattern sequentially with 2 characters / se-

cond.

Indication Meaning/task
E104 I²C initialization has failed
E105 EEPROM initialization has failed
E106 RTC initialization has failed
E107 Voltage failure at the real time clock, time invalid
F001 Missing segment in freemem
F002 Invalid segment in freemem
F003 Invalid argument in PutMsg
F004 Unexpected task end
F005 Initialization error during timer initialization
F101 System initialization (tasks) failed
F102 System initialization (ports) failed
F103 Error when initializing ZST task
F201 Error when initializing monitor task
F301 Error when initializing PLC task step 1
F302 Error when initializing PLC task step 2
F303 Recursive PLC_PRG call
F701 Error when initializing LPDMA task
F702 Error when initializing NET task
H202 Battery for CMOS and RTC buffering is almost
discharged (warning is repeated at 10 second
intervals)
E88xx- Processor exception xx at address yyyyyyyy with
yyyyyyyy- stack pointer zzzzzzzz
zzzzzzzz

The letters in the table have the following meanings:

F ... : Fatal
E ... : Error
H ... : Information

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 Status indicators 5
5

5.1.1 Digital input module DI 16x

There are 21 monitoring LEDs available on the input module.

16 LEDs indicate the input states and one LED is responsible for
the LIFE check.

Input LEDs: There is one LED indicator for each input.

It indicates the presence of the 24 V signal at the
corresponding terminal. The LED illuminates if
the voltage is applied to the input.

LIFE-LED: The LIFE-LED indicates the module function

state. The following display pattern applies to the
different operating conditions:

LED Meaning
On Module status reported at the local bus
Off Module status not reported at the local bus

5.1.2 Digital output module DO 16x

There are 21 monitoring LEDs available on the output module.

16 LEDs indicate the output states and one LED is responsible for
the Life check.

Output LEDs: There is one LED indicator for each output.

This LED receives its current directly from the
output of the respective switch and therefore en-
ables visual checking of the switching state.
The LED illuminates if the voltage is applied to
the output.

LIFE-LED: The LIFE-LED indicates the module operating

state. The following display pattern applies to the
different operating conditions:

LED Meaning
On Module status reported at the local bus
Off Module status not reported at the local bus

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 Status indicators 5
5

5.1.3 Analog I/O module AIO 2+2x

On the analog I/O module AIO 2+2x there is a LIFE-LED, which

visually represents the operating state.
The following display pattern applies to the different operating con-
ditions:

LED Meaning
On Module status reported at the local bus
Off Module status not reported at the local bus

5.1.4 Counter module AOCIx

The counter module AOCIx has 10 monitoring LEDs. 4 LEDs indi-

cate the digital input states and one LIFE-LED visually represents
the operating state. The following display pattern applies to the dif-
ferent operating conditions:

LED Meaning
On Module status reported at the local bus
Off Module status not reported at the local bus

The remaining modules LEDs have no function. They are not used
for this application.

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 Communication 6
9

6 Communication with the BST ProLogic CPU 32x

6.1 Setting up with RS 232
1. Connect the PC and BST ProLogic CPU 32x with the BST-
eltromat null-modem cable.
2. Start the HyperTerminal.

3. Select the name for the connection - e.g. ProLogic RS232

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 Communication 6
9

4. Select the COM port - generally COM1

5. Make the connection settings for the COM port

Use the following settings:

Bit/s : 115200
Data bits: 8
Parity: none
Stop bits: 1
Flow control: Hardware or none

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 Communication 6
9

6.2 Setting up using TCP/IP (only if the IP address is known)

1. Connect the PC and BST ProLogic CPU 32x with the BST-
eltromat null-modem cable.
2. Start the HyperTerminal.

3. Select the name for the connection - e.g. ProLogic IP

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 Communication 6
9

4. Select TCP/IP.

5. First enter the IP address of the BST ProLogic CPU 32x and
then port number 23.

The subnet mask of the PC and the BST

ProLogic CPU 32x must match the IP ad-
dresses used.

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 Communication 6
9

6.3 Logging in

6. a) a password in requested by the TCP/IP application after log-

ging in:

b) this request is not made with the RS 232 application

The following data are required for the login:

- User: ‘admin’, PWD: ‘clavis’ for kernel version V1.20.beta1
- User: ‘admin’, PWD: ‘expert’, or ‘wizard’ for the others

7. Pressing ‘?’ generates the prompt ‚>‘

8. Entering help causes the possible input commands to be dis-

played

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 Communication 6
9

6.4 Data Transfer Using RS 232 (Not Using TCP/IP)

Receive files from the BST ProLogic CPU 32x:

To be able to receive files, the file folder must first be specified.

This occurs in the menu: [Transmit ► File receive].

To do this press the Search button and select the target folder.

! Confirm the setting with Close (do not press Receive).

The cursor can be seen in an editing window.

Input of a question mark ‘?’ “activates” the software module. It re-
sponds with the input prompt ‘>’

Once the target path is set, the editor can be used to indicate to
the BST ProLogic CPU 32x logic module that a file is to be trans-
mitted to the target folder. This is implemented with the command:

SZ [file name]

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 Communication 6
9

E.g. [dir] is used to display the directory for the BST ProLogic
CPU32x logic module:

Transmit files to the BST ProLogic CPU 32x:

Any files can be sent to the logic module via the menu option
[Transfer ► file send]

To do this press the Browse button and select the file to be sent.

To send, press the Send button.

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 Communication 6
9

6.5 Data Transfer with TCP/IP via FTP (Windows Explorer)

1. Enter the IP Address of the BST ProLogic CPU 32x.

2. Login

When logging in the login data is requested (identical to those

in chapter 6.3)

3. Transfer data

Transfer the files using standard Windows commands (copy &

paste), e.g. Activation code or files for a service case.

6.6 Restart
After new software is installed, the command ‘reboot’ is used to
restart the BST ProLogic CPU 32x and start the loaded PLC pro-
gram.

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 Communication 6
9

6.7 Commands (Selection)

dir Shows the directory (contents) for a selected unit.

del Deletes the specified data from the specified unit.
cd Changes the selected unit or indicates the selected unit.
format Formats the current unit and in so doing deletes any files present in it. The unit name
must be specified.
sz pattern Transmits the specified files from the current selected unit via the Z modem transfer to
the PC>
rz This command is implicitly sent by the connected terminal to the logic module by select-
ing ‘send files” and serves to transmit the files to the currently selected unit. The
ZMODEM protocol must be selected for transmission.
reboot Resets the logic module. To activate boot monitor, the ‘!’ key must be pressed afterwards
help Shows the help page with the program commands.
ts nr Activate selected traces (TRACE SET)
tr nr Deactivate selected traces (TRACE RESET)
tc Deactivate all traces (TRACE CLEAR)
tl List all traces (TRACE LIST)
di nr Display PLC inputs (HEX)
do nr Display PLC outputs (HEX)
dm nr Display PLC inputs (HEX)
dp nr Indicate field values
wp nr = value Change field values
tim Display cycle and running times
vmon V24 interface monitor for UNIT-A. ASCII codes (hex) can be output separated with blank
characters, for those characters that should not be displayed.
canstat Display CAN-bus loading
zy command Cyclically implement the specified monitor command.
ver Display version string
rdobj node obj Reads an entry from the CANopen directory (CAN1)
rdobj node obj Writes an entry to the CANopen object directory (CAN1)
canconf Shows the internal configuration of the CANopen unit. Configuration of the output:
tx/rxpdo NodeID/Pdo-No.: handle CobID Length IO-Offset Swapping Profilno.
ipconf Network parameter configuration for the Ethernet interface.

Note:

The file *.PRG contains the PLC program. The name must conform
to the DOS 8.3 naming format and only one *.PRG file may be in-
stalled on the BST ProLogic CPU 32x. The remaining files are
needed for internal purposes.

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 Battery 7
2

7 Battery
7.1 General Information

Battery service life is dependent on the mains operating time and

the ambient temperature. The theoretical service life at an ambient
temperature of 23°C is approximately 7 years; in the worst case
(extremely high or low temperatures), the battery lasts for about
0.5 years. Reliable operation is guaranteed by constant monitoring
of the remaining battery capacity. The control will indicate when
battery replacement is necessary.
During battery replacement, voltage supply to the CMOS-RAM is
via a special capacitor. To prevent RAM data loss, the battery re-
placement should be completed within 15 minutes (time between
removal of the discharged battery and insertion of a new battery).

7.2 Battery Replacement

A type CR 2430 battery is used. When using additional aids to

change the battery, ensure they are made from non-conducting
material. If conducting material is used, short-circuits may occur.

1. Unlock both sides of the locking mechanism with a suitable tool

(e.g. screwdriver) by pushing down.

Press in the latches

(Latch)

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 Battery 7
2

2. Pull out the casing upper part and PCBs from the casing lower
part.

PCBs Casing upper part

3. Push out the battery with a suitable tool (non-conducting).

Battery

Ensure that the new battery is pushed up to the stop in the holder!

4. Once you have replaced the battery, reassemble in reverse se-

quence.

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 Troubleshooting 8
2

8 Troubleshooting
8.1 Controller CPU 32x

See the description of the LED flashing and display pattern in

chapter 5 “Status indicators“, Point 5.1.

8.2 Digital Input Module DI 16x

Problem Possible cause Action

Module does not work
LIFE-LED does not illuminate
LIFE-LED illuminates, no in-
put-LED in spite of the signal
24 V signal is present, input
LED illuminates, but the signal
is further processed as ‘0’
Local bus contacts are not correct
24 V power input to the power
supply module is missing
Internal module error
Internal 24 V short circuit, module
has switched off
Signal is not present
Input parameterized using inverse
logic
Check the module
Check the 24 V supply
Replace the module
Remove the short cir-
cuit, wait a few seconds
Check the signal at the
module
Check the parameteriza-
tion

8.3 Digital Output Module DO 16x

Problem Possible cause Action

Module does not work
LIFE-LED does not illuminate
Local bus contacts are not correct Check the module
24 V power input to the power Check the 24 V supply
supply module is missing
Internal module error Replace the module
Internal 24 V short circuit, fuse Replace the module
has tripped

LIFE-LED illuminates, no out-
put-LED in spite of the signal
24 V signal is present, output
is ‘0’, output LED does not
illuminate, but the signal is
present
Signal is not present Check the signal at the
module
CAN bus input is parameterized Check the parameteriza-
using inverse logic tion

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2
8.4 Analog I/O Module AIO 2+2x
Problem
Module does not work
LIFE-LED does not illuminate
8.5 Counter Module AOCIx
Problem
Module does not work
LIFE-LED does not illuminate
Logic module
BST ProLogic CPU 32x
Troubleshooting 8
Possible cause Action
Local bus contacts are not correct Check the module
24 V power input to the power Check the 24 V supply
supply module is missing
Internal module error Replace the module
Internal 24 V short circuit, fuse Replace the module
has tripped
Possible cause Action
Local bus contacts are not correct Check the module
24 V power input to the power Check the 24 V supply
supply module is missing
Internal module error Replace the module
Internal 24 V short circuit, fuse Replace the module
has tripped
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 Decommissioning 9
1

9 Decommissioning
Decommissioning (scraping) of the system must be carried out to-
gether with the entire machine.

The necessary procedures must be prepared by the manufacturer

of the machine. You must take into consideration that the control
system is generally considered to be an electrical / electronic de-
vice, which must be disposed of in accordance with the current le-
gal requirements.

You may also be able to return the system to BST eltromat International
Bielefeld GmbH. The corresponding agreement must be made first.

Index
Analog I/O module AIO 2+2x ........................... 20
Status indicator............................................ 25
Authorized use ................................................... 3
Battery replacement ........................................ 35
Cable connections ............................................. 5
Communication with the BST ProLogic CPU 32x
......................................................................... 26
Commands .................................................. 34
Data transfer using TCP/IP ......................... 33
Data transfer with RS 232 ........................... 31
Logging in .................................................... 30
Restart ......................................................... 33
Setting up using TCP/IP .............................. 28
Setting up with RS 232 ................................ 26
Controller CPU 32x
Status indicator............................................ 21
Counter module AOCIx ................................... 20
Status indicator............................................ 25
Decommissioning ............................................ 39
Digital input module DI 16x.............................. 19
Status indication .......................................... 24
Troubleshooting........................................... 37
Digital output module DO 16
Status indicator............................................ 24
Digital output module DO 16x ......................... 19
Electrostatic discharge ...................................... 6
Emissions .......................................................... 7
Environmental conditions
Operation ....................................................... 8
Transport and storage ............................. 8, 11
ESD ................................................................... 6
ESD protection .............................................. 6
Firmware
Firmware adding............................................ 2
Interfaces ......................................................... 13
CAN
CAN1 ........................................................ 14
CAN2 ........................................................ 15
CAN3 ........................................................ 15
CAN4 ........................................................ 15
Ethernet....................................................... 16
SD card ....................................................... 17
serial ............................................................ 13
USB ............................................................. 17
Watchdog .................................................... 18
Layout
CPU 32x ...................................................... 12
PSX module ................................................ 12
Operating manual
Use .................................................................2
Operating Manual
Symbols .........................................................1
Protection category ............................................6
Safety instructions ......................................... 2, 5
Status indication
Digital input module DI 16x ......................... 24
Status indicator
Analog I/O module AIO 2+2x ...................... 25
Controller CPU 32x ..................................... 21
Counter module AOCIx ............................... 25
Digital output module DO 16 ....................... 24
Storage ............................................................ 11
System design ....................................................4
Technical data ....................................................8
Analog I/O module AIO 2+2x ...................... 10
Controller CPU 32x ........................................8
Counter module AOCIx ............................... 10
Digital input module DI 16x ............................9
Digital output module DO 16x ........................9
Transport ......................................................... 11
Troubleshooting............................................... 37
Analog I/O module AIO 2+2x ...................... 38
Controller CPU 32x ..................................... 37
Counter module AOCIx ............................... 38
Digital input module DI 16x ......................... 37

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