PROCESSOR MODULE DCC 080

Processor module DCC 080

with 8 digital inputs
6 digital outputs
1 analogue input 0-10 V
1 analogue output 0-10 V

The DCC 080 processor module executes the control program

and constitutes a major part of the automation system. Digital
and analogue inputs and outputs are integrated in this module.
An internal power supply provides power to the processor
module so no further components are necessary.

Technical data
Performance data

Processor INTEL386EX

Addressable I/O/ P modules 8

Internal I/O yes

Instruction execution time typically 0.3 µs minimum 0.094 µs

Internal program storage (Flash-PROM) 40 kByte

Internal program storage (SRAM) 112 kByte

Internal data storage (SRAM) 124 kByte

Interfaces 1 x RS 232
1 x CAN

Data preservation Lithium battery

Status display no

Status LED´s yes

Real time clock yes

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Electrical requirements

Supply voltage 18 – 30 V DC

Supply voltage current consump- typically 200 mA maximum 500 mA

tion

Supply to DIAS bus +5V

Current drawn at the DIAS bus maximum 700 mA

(Supply of the I/O/ P modules)

Connection requirements

Required terminal module DKL 091 (Article number: 05-024-091)

Mechanical coding | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 |

Connection technique 48 pole spring terminal strip 3 row

20 pole ribbon connection

Miscellaneous

Article number 05-700-080

exchange type: 05-700-080-2
Module identification at the 16#C0
DIAS Bus

Hardware version 1.x – 5.x

Standardization UL (E247993)

Environmental conditions

Storage temperature - 20 – + 85 °C

Operating temperature 0 – + 60 °C

Humidity 0 – 95 %, without condensation

EMV stability in accordance with EN 50082- part 2 (industrial)

Resistance to shocks EN 60068-2-27 150 m/s²

Protective system EN 60529 IP 20

NOTE: The interface adapter cable is required for programming

(order no. 05-901-011)

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Specifications of the digital inputs

Number 8
Input voltage + 24 V typical + 30 V maximum
Signal level Low: < +8 V High: > +14 V
Switching threshold + 11 V typical

Input current
5 mA at + 24 V
(input set to „High“)
Input filter input 1 – 3 : 25 µs input 4 – 8 : 100 µs
Counter function input 1 at 2
Counter frequency 3 kHz maximum
Inputs for interrupts input 3
Status display green LEDs

Specifications of the digital outputs

Number 6
Supply voltage 18 – 30 V DC
Protection against short circuiting output 1 – 4: YES output 5 – 6: NO
Maximum permissible constant current per output 1 – 4: 1 A output 5 – 6: 0.5 A
channel
Maximum total current on all 6 channels
5A
(at 100 % operating time)
Voltage drop across supply
<1V
(output switched on)
Residual current in output (output switched < 1 mA
off)
Switch-on delay time
< 150 µs
(output „Low“ -> „High“)
Switch-off delay time
< 150 µs
(output „High“ -> „Low“)
Status display yellow LEDs

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Specifications of the analogue inputs

Number 1
Range 0 – 10 V DC
Measured value 0 to 1000 an open input delivers an invalid value
Resolution 10 Bit
Transformation time per channel < 14 ms
Input resistance > 1 MΩ
Input filter 100 ms 3rd order low-pass filter
Precision ±5%
Reference output + 10 V / ± 1 %
Current-carrying capacity of the reference
4 mA
output

Specifications of the analogue output

Number 1
Output signal 0 – 10 V DC
Output value 0 to 127
Resolution 7 Bit
Transient time < 50 µs
Loadability ≥100 kΩ
Protection against short circuiting yes
Precision of analogue output ±2%

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Interfaces
RS232 and CAN

DKL 091

20 19
1 16

20 pin connector

2 1

3 row terminalblock

20 pole PCB header connections

Pin Function Pin Function

1 CAN A 2 CAN B
3 not assigned 4 not assigned
5 not assigned 6 not assigned
7 not assigned 8 +5V
9 GND 10 not assigned
11 not assigned 12 not assigned
13 Rx 14 RTS
15 Tx 16 CTS
17 not assigned 18 not assigned
19 GND 20 not assigned

In addition, the CAN bus comes out of the 48-pole spring terminal strip. See next page for assign-
ment.

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Internal inputs and outputs

Connections

The connection of the integrated digital and analogue inputs and outputs is made via the terminal
module DKL 091.

20 19
1 16

20 pin connector

2 1

3 row terminalblock

48 pole 3 row spring terminal strip connections

Terminal Row a Row b Row c

1 digital output 1 digital output 2 digital output 3
2 GND GND GND
3 digital output 4 digital output 5 digital output 6
4 GND GND GND
5 digital input 1 24 V / 1 GND
6 digital input 2 24 V / 1 GND
7 digital input 3 24 V / 1 GND
8 digital input 4 24 V / 1 GND
9 digital input 5 24 V / 1 GND
10 digital input 6 24 V / 1 GND
11 digital input 7 24 V / 1 GND
12 digital input 8 24 V / 1 analogue output
13 analogue input analogue reference analogue GND
14 CAN A CAN B GND
15 CAN A CAN B GND
16 power supply + 24 V/ 1 power supply + 24 V/ 2 GND

Power supply + 24 V/ 1: power supply to CPU, analogue component and triggers (digital inputs)
Power supply + 24 V/ 2: power supply to the digital outputs

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Mechanical dimensions

80 mm 98 mm
45mm
93 mm

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Wiring instructions
Digital inputs and outputs

Please pay attention to the following guidelines:

- Avoid laying the input cables parallel to the load circuits

- Protective wiring of all contactor coils (RC network or recovery diodes)
- Correct earthing

Each terminal module is provided with a GND connection. These contacts and the GND contact of
the current supply module must be connected to a common earthing bus bar, and these connection
must be kept as short as possible.

Earthing bus bar

GND, terminal 16c

If possible, the earthing bus bar is to be connected to the earthing bus bar of the switch cabinet!
Each terminal module has GND contact springs on the module fastening (top hat rail) which must be
connected to the earth rail of the switch cabinet!

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Connection of the signal transmitters to the digital inputs

2-wire triggers and mechanical limit switches:

(switch, button)

trigger, limit switch

Input signal

+24 V

3-wire triggers:

trigger, limit switch

Input signal
+
+24 V
-
GND

Connection of inductive loads to the digital outputs

(relay, contactor)

Output

GND
recovery diode contactor coil

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Analogue inputs and outputs

The signals obtained from analogue inputs are small compared with the digital signals. In order to
guarantee trouble free functioning and to prevent malfunctioning and measuring errors it is essential
to stick to a meticulous wiring arrangement:

- The power supply GND connection must follow the shortest path to the common GND terminal
(earth rail).

- The connecting wires to the analogue signal source must be as short as possible and avoid lying in
parallel to the wires carrying digital signals.

- The signal carrying wires must be double-pole screened.

Connection of the analogue signal sources to the analogue input

Active voltage source:

(motor speedometer)

motor speedometer

+
Input signal

+10V ref.
-
GND

Passive transmitter:
(odometry)

Passive transmitter

+ Input signal
+
+10V ref.
- -

GND

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Connection to the analogue output

Direct current load:

(axis control via direct current servo, frequency converter)

DC-
servo

+ -
+
-

Output signal

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Function description
Digital inputs and outputs

The digital inputs and outputs are automatically read into the process map by the CPU DM 0 (M
0F00) and displayed.

Before execution of a program the digital inputs are read into the process map, after execution of a
program the digital outputs are set.

Digital input 3 can be set as an input with interrupt function using the system call SYS 079, function
40.

Digital inputs 1 and 2 can be set as counter inputs using the system call SYS 079, function 41.

Analogue inputs and outputs

The analogue inputs and the analogue outputs are not automatically read into the process map. The
operation is effected using the system call SYS 079 function 30 (read analogue input) or function 31
(set analogue output).

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Status displays

Status LEDs for the CPU

The status LEDs for the CPU signal the operating status of the processor module.

RO yellow Run ROM Illuminates when the program from the external memory module is executing.
Flashes when the program from the internal memory module (Flash-PROM)
is executing.
RA yellow Run RAM Illuminates when the program from the internal applications program storage
(SRAM) is executing.
ER red Error Flashes when an error has occurred. The error code is displayed in the status
line of the PG-Software.
DC green DC OK Illuminates when the supply voltage to the CPU is connected correctly.

Status LEDs for the digital inputs and outputs

The status LEDs indicate the signal statuses of the digital inputs and outputs.

Channel 1 – 6 yellow digital outputs Illuminates when the digital output is switched on.
Channel 7 – yellow digital inputs Illuminates when the input signal exceeds the high level
14 and the input status is therefore 'High''.

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CAN BUS setup

In this section it is explained how the CAN bus is correctly configured. For this purpose the follow-
ing parameters must be set: station number and transmission rate.

CAN Bus station number

Each CAN bus station has its own station number. Under this station number the other bus elements
can fetch data from the station and send data to it. It is possible to install up to 31 elements on one
CAN bus system. Please note that each station number in the CAN bus system may be allocated
only once!

CAN Bus transmission rate

It is possible to set different transmission rates (baud rates) on the CAN bus. The greater the length
of the bus line, the smaller the transmission rate must be.

Value Baud rate Maximum length

0 615 kBit / s 60 m
1 500 kBit / s 90 m
2 250 kBit / s 200 m
3 125 kBit / s 450 m
4 100 kBit / s 600 m
5 50 kBit / s 1000 m
6 20 kBit / s 1000 m
7 1 Mbit / s 5m

These values apply to the following cable: 120 Ω, Twisted Pair.

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With the DCC 080 the CAN bus station number is set via DIP switches. They are found on the top of
the module underneath the slide-in sheet.

DIP switch CAN station DIP switch Baud rate

0 615 kBit/ s
1 2 3 4

1 500 kBit/ s
1 2 3 4

2 250 kBit/ s
1 2 3 4

3 125 kBit/ s
1 2 3 4

The setting of the CAN bus transmission rate can be changed via software with the help of the sys-
tem call SYS 164, function 6.

Note: For the CAN bus protocol: 1 kBit/s = 1 kBaud.

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PROCESSOR MODULE DCC 080

CAN bus termination

On both terminal devices in a CAN bus system the line must be terminated. This is necessary for
preventing transmission errors occurring through reflections in the circuit.

Device 1 Device 2 Device 3 Device n

e.g. CPU e.g. Terminal e.g. Terminal
DCC 080 ET 081 ET 805

CAN-Bus- D-SUB-plug
termination on with terminating
terminal module resistors
CAN-Bus-Connections

If the DCP 080 processor module is one of these terminal devices, the termination can be done by
setting a jumper on the terminal module.

Jumper for CAN bus termination DKL 091

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 PROCESSOR MODULE DCC 080

Buffer battery
The buffer battery takes care of preserving programs and data in the applications program storage
(RAM) when the supply voltage is switched off. The lithium battery is fitted in the factory.

The capacity of this battery is sufficient for securing data for a period of 3 years while the supply
voltage is turned off.
However, for your own security we recommend exchanging the battery yearly.

DCC 080 (05-700-080)

Order number for the battery: 01-690-027

FIRMA DATA

Lithium battery RENATA 3,0 V / 500 mAh

Caution:
A change of battery may only take place, of course, when the control terminal is switched on –
otherwise a loss of data occurs!

DCC 080 V2 (05-700-080-2)

From version V2 (Article number 05-700-080-2) a battery with a small adhesive strip is required.

Order number for the battery: 01-690-051

FIRM DATA

Lithium battery RENATA 3,0 V / 500 mAh

Caution:
Pay special attention to the polarity at re-insertion of the battery, otherwise the battery is
short-circuited and discharged!
See illustration below and backside of labeling strip.

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Switching-on procedure

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Status and Error Messages PG50

Number Message Meaning Cause/Solution

RUN RAM The application program is running. The
00
display is not influenced.
RUN ROM The application program, which is in the
01 application memory modules being run.
The display is not influenced.
RUNTIME The application program was interrupted Possible Causes:
by an cycle time of an incorrect length - Too many program loops
( > 100 msec).
- Endless loop
02
- Time intensive subroutine
Solution:
- Correct program error
POINTER Before the application program was run, Possible Causes:
erroneous program pointers were found. - Program memory module missing, is
not programmed or is defect
- Program in application program mem-
ory (RAM) will not run
- No longer battery buffered
03 - Software error - application program
partially overwritten
Solution:
- Reprogram program memory module.
If error occurs again, replace
- Replace battery
- Correct program error
CHKSUM Before running the application program, Cause/Solution: see POINTER
04
an incorrect checksum was found.
WATCHDOG The program was interrupted by the Possible Causes:
watchdog. - Interrupts blocked by application pro-
gram (Forgotten STI instruction)
- Erroneous hardware interrupt pro-
grammed.
05 - INB, OUTB, INW or OUTW instruc-
tion used incorrectly
- Defect processor
Solution:
- Correct program error
- Exchange CPU

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06 ERROR
PROM DEFECT Error occurred programming program Causes:
memory module. - Defect program memory module
- Application program too long
07
- Missing program memory module
Solution:
- Replace program memory module
RESET The CPU has been RESET and is waiting
08 for further instructions.
The application program is not processed.
WD DEFECT The hardware watchdog is defect. Solution:
The CPU checks the watchdog functions - Replace CPU
09 after booting. If an error occurs during this
test, the CPU intentionally goes into an
endless loop and no longer accepts any
instructions.
10 STOP
BUSY PROG The CPU is currently programming a
11 program memory module with the operat-
ing system and application program.
PGM TOO The program is too long for the type of Solution:
12 LONG memory being used. - Use a larger program memory mo-
dule.
PROG END Programming the program memory
13
module has been ended successfully.
PROG EEPROM The CPU is programming the program
14
memory module now.
STOP BRKPT The CPU has been stopped by a break-
15
point.
CPU HALT The CPU has been stopped by the PG
16
software (F6 HALT in debugger).
INT ERROR The CPU has incorrectly generated an Causes:
interrupt and the application program - A non-existent operating system
ended. instruction has been used
- Stack error (unequal amount of
17 PUSH and POP instructions)
- The application program was s-
topped by a software error
Solution:
- Correct program error
18 SINGLE STEP The CPU is in single step mode.

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READY A module or project has been sent to the

19
CPU and it is now ready to be run.
LOAD Program processing has stopped and the
20
CPU is receiving a module or project.
BAD MODULE The CPU has received a module that
21
doesn't belong to the project.
MEMORY FULL During the transfer of a module or
22 project to the CPU, not enough program
memory was found.
NOT LINKED During the CPU start, a module was
23 found to be missing in the program or a
module does not belong to the project.
DIV. ERROR An error has occurred during a division. Possible Causes:
- Division by 0
24
- Result of a division doesn't fit in the
result register
Solution:
- Correct program error
DIAS ERROR An error has occurred while accessing a Possible Causes:
DIAS module - Module doesn't exist
- DIAS Bus error
25
Solution:
- Check DIAS Bus
- Check termination resistor
26 WAIT CPU is busy
27 OP PROG Reprogramming operating system
28 OP INSTALLED Reinstalling operating system

29 OP TO LONG Operating system is too long

NO OP-SYSTEM No operating system Possible Causes:
- The CPU cannot find a valid operat-
ing system in memory
- The checksum of the operating sys-
30 tem has been destroyed
Solution:
- Reload the operating system with
the PG Software

SEARCH OP SYS The Base operating system is looking

31
for a valid operating system

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PROCESSOR MODULE DCC 080

NO MEMORY External program memory module doesn't Possible Causes:

exist. - An attempt is being made to program
32
an external program memory module
although none is installed in the CPU
UNUSED CODE The CPU has received an invalid instruc-
33
tion from the programming software.
MEM ERROR The operating system does not correspond
34
with the hardware configuration.
MAX. IO´s The maximum number of addressable
35
DIAS modules has been exceeded.

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