WatchDog pro

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WatchDog pro

Part Nr.: 090467

WatchDog pro


CONTENT

1. INTRODUCTION 4

2. ASSEMBLY 7

3. FUNCTIONING 8

4. INDICATORS on the Central Unit (CU) 10

4.1

Special cases - LED indicators on the

Central Unit (CU)

5. CIRCUIT DIAGRAMS 17

6.

SPECIFICATIONS for the

Central Unit (CU)

6.1 Power supply 18

6.2 Digital inputs 18

6.3 Relay outputs 19

6.4 RS232 communications interface 19

6.5 Remote bus 20

6.6 Mechanical design 20

6.7 Ambient conditions 20

6.8

Operator accessibility of terminals and

connectors

21

6.9 Memory 23

6.10 Data logger 23

6.11 Capturing internal values - measuring ranges 24

7. PROGRAMMING ENVIRONMENT 24

8. ACCESSORIES 28

12

18

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1. INTRODUCTION

These installation instructions describe the WatchDog pro

monitoring system’s devices.

These include:

- The Central Unit (CU),

- The expansion modules.

The aspects relevant to assembly, cabling and operation are

set out in this manual, which also contains additional explanations.

WatchDog pro may only be installed and operated by qualified

engineers. Special training in electronics is required for

installation and parameterizing. The local regulations, standards

and work instructions must be observed. They are not,

however, part of these installation instructions.

What is WatchDog pro:

WatchDog pro is a flexible, modular, programmable monitoring

and control system. It is employed to expand monitoring

relays and contactor controls.

WatchDog pro may not be used to replace safety-relevant

controls as demanded by IEC 61508, for instance, EMER-

GENCY-STOP crane or protective door controls.

WatchDog pro has been designed to be installed in a housing

or a switch cabinet. Command and alarm lines must also

be installed and enclosed when necessary in such a way so

as to prevent users from coming into contact with them.

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The following points must be observed before installation

work may be commenced:

- Ensure that the system (including measuring and control

circuits) is voltage-free

- Protect it from being switched back on again

- Confirm that the system is voltage-free

- Ensure that the system is earthed and short-circuited

- Neighbouring components that remain live must be

covered or cordoned off.

The following assembly instructions must be observed for

WatchDog pro:

Only staff qualified in accordance with EN 501101/2

(VDE 0105 Part 100) may intervene in this system.

Functional earthing ( ) must be connected to the protective

earth ( ) or potential equalization. This connection falls

within the responsibility of the person setting the system up.

Functional earthing is (Central Unit CU) internally connected

to the device’s earth (GND).

Connection and signal lines must installed in such a way that

inductive and capacitive interspersions do not negatively affect

the monitoring and control functions.

Automation engineering facilities and their control elements

must be fitted in such a way that they may be protected

against accidental operation.

In order to prevent cable or lead breakages on the signal

side from causing undefined states in the WatchDog pro system,

hardware and software precautions must be taken for

the input / output wiring.

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Ensure that the extra-low voltage output of the 24V power

supply is safely electrically insulated. Only mains equipment

that fulfils the requirements of IEC 60364-4-41 and

VDE 0100 Part 410 (HD 384.4.41 S2) may be used.

The galvanic isolation between the interfaces and inputs and

outputs may not be bridged.

Fluctuations and differences in the mains voltage from the

specified voltages may not exceed the tolerance limits specified

in the technical data. Otherwise, function failures and

dangerous conditions cannot be excluded.

EMERGENCY-STOP facilities as required by IEC/EN

60204-1 must remain functional in all operating conditions.

Releasing EMERGENCY-STOP systems may not restart the

system.

Measures must be implemented to enable programs interrupted

by voltage drops and power failures to restart properly.

No dangerous conditions may occur during such events,

even for short periods. EMERGENCY-STOPS should otherwise

be forced.

External measures that ensure or enforce safe states during

malfunctions or failures must be implemented in places

where automation errors may result in injuries or damage

(e.g. through independent limit switches, mechanical locks,

etc.).

Expansion modules with damaged bus connection cables

may not be taken into operation. The Central Unit’s front

panel or that of an expansion module may under no circumstances

be removed. Terminals that are not used (no symbol

on the front for the corresponding terminal) may not be wired

up. The local interface’s male header, the connector and the

ribbon cable may never come into contact with electrically

conducting components or liquids.

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The Central Unit (CU) provides internal device values (temperature,

battery voltage, MMC TM state). If necessary, the

user must ensure that these are properly monitored.

The safe operation of the real-time clock may only be ensured

with a battery voltage over 2.2 volts.

The MMC TM table 1) in the Central Unit (CU) contains detailed

technical information about communications with the Multi-

MediaCards TM tested and formatted by TELE. It may become

necessary to update this table 1) through the programming

environment to ensure that it is possible to work with cards

that become available in the future.

2. ASSEMBLY

WatchDog pro must be attached to a TS 35 profile rail in accordance

with EN 60715 (DIN rail). Always click the Central

Unit (CU) on the left while maintaining a distance (> 5 mm)

to other modules. The expansion modules must be installed

in rows on the right next to the Central Unit (CU) and connected

via the bus connector to the Central Unit (CU) or the

next module on the left. In the event that expansion modules

possessing greater currents are used, a distance (> 5 mm)

between the modules must be ensured (see corresponding

module data sheet). Only connect or disconnect the modules

when the power has been switched off (when the power supply

and input / output circuits are voltage-free).

1)

The MMC table is not required for CU-firmware revision 1.10 or higher!

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3. FUNCTIONING

Application-specific programs are stored and executed in the

Central Unit.

The LEDs provide information about the system’s current

operating states (error, operating mode, input and output

states, communications and data logger). The data logger

records plant and system data triggered by date or events

and saves it to an optional MultiMediaCard TM (MMC TM ).

The Central Unit’s (CU) operating mode

may be set with the mode selector as

follows:

Remote

Mode

RRun

RStop

Stop

Run

Stop The program is stopped. Access of the

programming environment to the Central Unit

(CU) is only possible to a limited degree.

RStop

RRun

Run

(Remote Stop) The program has been stopped

after a reset. Access of the programming environ

ment to the Central Unit (CU) is possible. The pro

gram may be started and stopped through the pro

gramming environment.

(Remote Run) The program will be started and

executed after a reset. Access of the programming

environment to the Central Unit (CU) is possible.

The program may be started and stopped

through the programming environment.

The program is being executed. A stopped program

will be started. Access of the programming

environment to the Central Unit (CU) is only possible

to a limited degree.

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A stopped program will be started when the mode is switched

from RStop to RRun.

A running program will be stopped when the mode is switched

from RStop to Stop.

The RESET key must be pressed for at least two seconds to

reset the Central Unit (CU).

The Central Unit (CU) is able to communicate with the programming

environment through the Mini DIN female connector.

Firmware, program modifications and MMC TM table 1) updates

may be installed through the programming environment.

Once the program has stopped, all relay outputs will be

switched to a safe state, i.e. they will become inactive, (13-

14; 23-24 on the Central Unit and 11-14; 21-24; 31-34 and

41-44 on the expansion module – G2DO4 R – are open and

the analog output of the G2AM4 M will be set to 0V).

1)

The MMC table is not required for CU-firmware revision 1.10 or higher!

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4. INDICATORS on the Central Unit (CU)

DI DI3 DI4

DI1 DI2

G4WDCU MMC

Central unit

SG

13 14

STX SRX

PC/Modem

U

Modem

UERR

Reset

Temp

DI1

ready

RS232

RB/LI

STOP RUN Remote Err I

Mode

RRun

RStop

Stop

DI2

DI3

DI4

Run

R1

R2

MMC

MMC - Flash Card busy

LI

Com HCom

GND

RB RB+ RBA RBB

24V 23 24

General:

Green U LED ON:

Error LED’s:

Red U ERR

LED flashing:

supply voltage is applied

Over-/undervoltage for the 24V

supply

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Red Err LED flashing:

Red Temp LED flashing:

Red >I RB/LI

LED flashing:

Operating mode:

Yellow Remote LED ON:

Green RUN LED ON:

Red STOP LED ON:

A critical error or a data logger

error has occurred

Temperature exceeded

permissibles range

Max. permissible supply

current exceeded on the local

interface or remote bus

Unrestricted communications

possible with the PC through

the RS232 interface

Program (including data

logger) is being executed

Program has been stopped

Inputs and outputs:

Yellow DI1...DI4 LEDs ON: Input active

Yellow R1, R2 LED ON: Output relay activated

Communication:

Green Modem LED ON: Status indicator –

communications modem

(see Point 4.1)

Green RS232 LED flashing: Communications through

the RS232 interface active

Yellow HCom LED flashing: Communications through

the high-speed bus active

Yellow Com LED flashing: Communications through

the standard bus active

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Data logger:

Green ready LED on:

Yellow busy LED on:

MMC TM Flash Card was

recognized, Central Unit is

ready for logging

Data is being logged

4.1 Special cases – LED indicators by the Central Unit

Communication with expansion modules:

Com /

HCom

t = 0,1s

Critical error:

Err t = 0,2s

Supply voltage exceeding permissible range:

U Err t = 0,2s

Temperature in the Central Unit (CU) exceeding permissible

range:

Temp t = 0,2s

Maximum permissible supply current on local interface or

remote bus too high:

I RB/LI

t = 0,2s

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Modem:

Modem is being initialized:

Modem t = 0,8s

Modem status PIN code blocked:

Modem t = 0,1s

Modem status OK:

Modem

on

Modem status – other error:

Modem t = 0,2s

Data logger

MMC TM type unknown (neither “data logger MMC TM ” nor

“Firmware MMC”):

ready

busy

off

t = 0,4s

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“Data logger MMC” recording active:

ready

on

busy

dependent

The duration that the busy LED remains on depends on the

number of logged values.

All MMC TM data files full:

ready

t = 0,1s

busy

off

Firmware update with MMC TM successfully completed:

ready

t = 0,1s

busy

on

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Formatting command is on the MMC TM it cannot be executed

in “RUN” mode:

Firmeware Update with MMC TM cannot be executed in

“RUN” mode:

ready

busy

off

t = 0,1s

MMC type or manufacturer not found in the MMC TM

table 1) :

Error in MBR (Master Boot Record) or boot sector on the

MMC TM :

Error formatting the MMC TM :

Wrong PIN code for firmware update with an MMC TM :

Error during firmware update with an MMC TM :

Error in the data structure with type “data logger MMC TM ”:

ready

busy

off

t = 0,2s

Err

t = 0,2s

1)

The MMC table is not required for CU-firmware revision 1.10 or higher!

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Formatting command previously written with “WatchDog pro

Data analyser” to MMC TM ; Central Unit on STOP!:

ready

off

busy

t = 15s

Formatting a 1 GB MMC TM takes around 15 seconds (busy

LED on). The MMC TM is formatted as soon the busy LED

switches off!

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5. CIRCUIT DIAGRAMS

Digital inputs:

DIGND +24V ... 100V DC / 24 ... 230V AC

Optional serial interface:

PC: GND RXD TXD

DI

DI3 DI4 13 14

DI1 DI2 SG STX SRX

RB

RB+ RBA RBB

Supply:

GND

24V

23

24

GND

24V DC

remote bus: GND A B

DI , DI1, DI2, DI3, DI4: Digital inputs 1 to 4

SG, STX, SRX: Optional serial interface

connection

13-14, 23-24: Programmable relay outputs

GND, , 24V: Supply voltage ( ) and GND are

internally connected

RB , RB+, RBA, RBB: Remote bus terminals

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6. SPECIFICATIONS for the Central Unit (CU)

6.1 Power Supply

Rated voltage:

24V DC

Terminals:

GND and 24V

( and GND are internally connected)

Tolerance: ± 10%

Rated consumption: 2.18VA typ.

Rated current:

91mA typ. at 24V

Max. supply current: 300mA

Ripple and noise: < 150mV PP

Duty cycle: 100%

Start-up time:

2.2s typ.

Drop-out voltage:

> 60% of the supply voltage

Current local interface: max. 1200mA

Cable length:

< 10m (CU to power supply)

6.2 Digital inputs

4 potential free voltage inputs with a common reference

point.

24V to 230V AC (48 ... 63Hz)

24V to 100V DC (input active)

Terminals:

DI , DI1, DI2, DI3, DI4

Switch point AC: 9.5V (typ.)

Switch point DC: 9.0V (typ.)

Input current: < 2mA AC/DC max.

Overload capacity: max. 264V AC / max. 115V DC

Underload:

min. 20.4V AC / min. 20.4V DC

(with active input)

Min. impulse length:

active: DC: 20ms / AC: 70ms (high latched)

inactive: DC: 30ms / AC: 30ms (low latched)

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Insulation rated voltage: 250V AC

Overvoltage category: III (in accord. with IEC 60664-1)

Rated surge voltage: 6kV

6.3 Relay outputs

2 potential free normally open contacts

Terminals: 13-14; 23-24

Rated voltage:

250V AC

Switching capacity: 750VA (3A / 250V AC)

Fusing:

3.15A fast acting

Mechanical life:

20 x 10 6 operations

Electrical life:

2 x 10 5 operations at

1000VA resistive load

Switching frequency: max. 6/min at 750VA

resistive load

Insulation rated voltage: 250V AC

Overvoltage category: III (in accord. with IEC 60664-1)

Rated surge voltage: 6kV

6.4 RS232 communications interface

Mini DIN female connector or optional through terminals.

Communications may never be effected through both simultaneously

(Mini DIN female connector and terminals)!

Terminals:

SG, STX, SRX

Data rate:

115.2 kBaud

Data rate tolerance with external device:

max. ± 1%

Cable length:

max. 2.5m (to the PC)

Premissible voltage to earth: max. 50V AC/DC

Premissible voltage data cables: max. ± 15V DC

Rated surge voltage:

800V

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6.5 Remote bus

Modules on an additional DIN rail may be controlled through

the remote bus and the remote bus coupling. Depending on

the cable used, this connection may be realized over several

hundred metres. Please refer to the remote bus coupling’s

data sheet.

Remote bus cable connection:

Terminals:

RB , (RB+), RBA, RBB

Current remote bus (RB+): max. 1500mA

6.6 Mechanical design

Self-extinguishing plastic housing, IP rating IP 20

Mounted on DIN-rail TS 35 according to EN 60715

Mounting position: any

Shockproof terminal connection according to VBG 4

(PZ1 required), IP rating IP20.

Tightening torque: max. 1Nm

Terminal connection:

1 x 0.5 to 2.5mm² with/without multicore cable end

1 x 4mm² without multicore cable end

2 x 0.5 to 1,5mm² with/without multicore cable end

2 x 2.5mm² flexible without multicore cable end

6.7 Ambient conditions

Ambient temperature:

-25 to +55°C

-25 to +40°C

(in accordance with UL 508)

-25 to +70°C

Storage temperature:

Transport temperature: -25 to +70°C

Relative humidity: 15% to 85%

(in accordance with

IEC 60721-3-3 class 3K3)

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Absolute humidity: 1g to 25g H 2

O/m 3

(in accord. with IEC 60721-3-3

class 3K3)

Pollution degree: 2 (in accord. with IEC 60664-1)

Vibration resistance: 10 to 55Hz 0.35mm

(in accord. with IEC 60068-2-6)

Shock resistance: 15g 11ms (in accord. with

IEC 60068-2-27)

6.8 Operator accessibility of terminals and connectors

The tables below indicate which terminals and connectors

may be touched by the operator during normal operation.

Connection definition:

Name Type No.

Terminals rated to

electric circuit

Digital input C 5 DI1, DI2, DI3, DI4, DI

Functional earth H 9

Power supply K 11 24V, GND

Remote bus supply K 11 RB+

Remote bus

data cables

Ar 2 RBA, RBB, RB

Local interface Al 1 male header

Serial interface Be 3

Mini DIN female

connector (RS232),

SG, STX, SRX

Output 1 D 6 13, 14

Output 2 D 6 23, 24

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No.

1

2

3

4

5

6

7

8

9

10

11

Type

Al

Ar

Be

Bi

C

D

E

F

H

J

K

Connection

Communications interface for local input / output expansion

devices

Communications interface for decentral input/output units

Open communications interface, open to external devices as well

Internal communications interface for peripheral assembly groups

Interface for digital and analog input signals

Interface for digital and analog output signals

Serial or parallel communications interface for data communications

with external devices

Interface for mains power supply

Interface for functional earthing

Input-/output interface for power supplies to sensors and actuators

Interface for auxiliary voltage output and auxiliary voltage input

Touchable by

the operator

YES

YES

YES

NO

NO

NO

YES

NO

YES

NO

NO

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6.9 Memory

Register:

Max. number of registers: 845

Max. number of permanent registers: 27

Max. number of permanent boolean registers: 128

Max. number of instructions: typ. 600

6.10 Data logger

The Central Unit (CU) will only accept such manufacturers

and types of MultiMediaCards TM that are included in the

MMC TM table 1) . The MMC TM table 1) is stored in the Central

Unit (CU). The MMC TM table 1) may be updated through the

programming environment. At the moment MMC‘s TM with storage

capacities of between 1GB and 2GB may be used.

The maximum continuous recording rate depends on the

maximum cycle time in normal mode. The maximum recording

rate is up to 50 messages per second. The memory

capacity is up to 100.000 messages per megabyte (e.g. 1GB

MMC permits up to 100.000.000 messages).

1)

The MMC table is not required for CU-firmware revision 1.10 or higher!

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6.11 Capturing internal values - measuring ranges

Temperature in the CU:

-40°C ... +100°C

Current remote bus:

0 ... 2A

Current local interface:

0 ... 2A

Supply voltage:

0 ... 30V

Battery voltage:

0 ... 4V

MMC state:

0 No errors

1 All MMC TM data files are full

2 MMC TM type or manufacturer not supported

3 Error in data structure on MMC TM

4 MMC TM root directory has been changed

(or ist invalid)

5 MMC TM not available resp. MMC TM not yet recognized

7. PROGRAMMING ENVIRONMENT

The WatchDog pro programming environment is a program

with which the WatchDog pro systems may be configured

and parameterized. A demo version may be downloaded

from www.tele-power-net.com. This version does not permit

communication with the Central Unit (CU). All other features,

however, remain fully functional.

The basic requirement is a PC with:

Windows 98/ME/2000/XP/Vista

The software requires the Microsoft.NET runtime environment

version 2.0, which may have to be installed as required.

This software is supplied with the programming environment,

but may also be downloaded from www.microsoft.com free

of charge.

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Create hardware configuration:

The required components must be dragged from the module

library to the hardware view. The module addresses must

then be specified and the inputs configured (measuring range,

transforming ratio, scaling). Each module must be assigned

its own address (1 to 99). These must be set on the

installed module with the address selector switch. One or

several modules may be deactivated by setting the address

to zero. It is only permitted to change address switch settings

when the power to the system has been disconnected (i.e.

when it is voltage-free).

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Create program:

Input values may be monitored, converted, compared with

each other and linked. Six libraries with various functions are

available.

The desired functions may be dragged from the function libraries

to the function list. Functions are described in the

function help screen. Registers, constants, measured values,

digital inputs or hardware outputs must be assigned to

the function inputs and outputs.

Note:

Some functions offer additional features which may be

accessed through „Show optional inputs“ or „Properties ...“

(right click on the function).

In order to enhance clarity within the WatchDog pro programming

environment during all project phases, the tasks have

been divided into three operating modes. The operating

mode may be set in the menu bar using drop down select

box. When the program is switched to simulation or online

mode, it will initially carry out a check for syntax errors. The

system will prevent modes from being changed until all errors

have been eliminated. Hardware configuration and function

list changes may only be feasible in programming mode.

No changes can be made to the program in the simulation

or online mode.

Some online commands (e.g. Refresh hardware), which

could be useful when creating the program, are also available

in programming mode.

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System simulation:

Projects may be simulated in simulation mode. The modules

input values may be changed and the output values as well

as interim values may be monitored when the program is

running in simulation mode. Thus allowing the functioning of

the monitoring systems to be checked even before the hardware

exists or has been installed.

Transfer and online application monitoring:

In online mode, the created program may be written to a

Central Unit (CU). This is effected by connecting the Central

Unit (CU) to the computer through Watch Dog pro COM

(WDP COM) (USB serial converter and RS232 interface cable).

The program may be read out from a Central Unit (CU)

or programs in the Central Unit (CU) may be compared with

those on the programming environment. When a program

is running, the control state, program execution, measured

values and register values may be monitored.

Input and output states as well as register states may be

forced to desired values during online mode when the Central

Unit (CU) is running.

Please refer to the online help for more detailed information

about the programming environment.

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8. ACCESSORIES

WDP SOFT

Parameterisation software

WatchDog pro programming environment on CD, running on

Windows 98/ME/2000/XP/Vista

MMC READER

MMC read out package

including Data analyser Software and MMC Card Reader

WDP COM

Communication equipment WatchDog pro

including USB serial converter and interface cable RS232

WDP GSM

WatchDog pro GSM package

including GSM Modem, data cable, antenna, power supply

unit and DIN-rail adapter

MMC 1GB

MultiMediaCard 1GB

formated memory card

MMC 2GB

MultiMediaCard 2GB

formated memory card

Subject to alterations and errors!

MultiMediaCard is a trademark of MultiMediaCard Association (MMCA).

MMC is a trademark of Infineon Technologies AG of Germany.

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