Pleiger Elektronik

GmbH & Co. KG

Pleiger Control Loop

Modbus

PCL master A PCL master B

local
opterating
CAN

PCL
cabinet

Data bus

Power Bus 1 Power Bus 2

PCL-VCI PCL-VCI PCL-VCI PCL-VCI

M M M M
Valve 1 Valve 30 Valve 31 Valve 60

User’s Manual V1.30

PCL-Master
Operation
Technical data
PCL-Valve Control Interface
Technical data
PCL-IO
Technical data

by: H. Vögler
as of: 5/2007 subject to modification
Pleiger Elektronik GmbH & Co. KG
D-58456 Witten - Im Hammertal 51
D-58423 Witten - Postfach 32 63
Telephon (0 23 24) *3 98- 0
Telefax (0 23 24) 3 98- 3 89
Internet www.pleiger-elektronik.de
E-Mail info@pleiger-elektronik.de
 Pleiger Elektronik
GmbH & Co. KG

Contents

1 Overview 1
2 The Data Bus System 1
2.1 PCL Master Function............................................................................................................................ 1
2.2 Second Data Bus .................................................................................................................................. 1
2.3 PCL Slave Function .............................................................................................................................. 1
2.3.1 The physical layer............................................................................................................................. 1
2.3.2 Protocol............................................................................................................................................. 2
3 The power bus system 2
3.1 Handling power bus faults, interruption ............................................................................................ 2
3.2 Handling power bus faults, short circuit............................................................................................ 2
3.3 Power Management .............................................................................................................................. 2
3.4 Power Bus Cable .................................................................................................................................. 3
3.4.1 Length / Reduction factor table ........................................................................................................ 3
3.4.2 Distributed current sinks ................................................................................................................... 3
3.4.3 Reduced current ............................................................................................................................... 4
3.4.4 Additional supplies............................................................................................................................ 4
3.4.5 Installation rules................................................................................................................................ 4
3.5 Fusing .................................................................................................................................................... 4
4 Valve Control Interface (PCL-VCI) 5
4.1 Interface to actuator ............................................................................................................................. 5
4.1.1 Quick Closing Operation................................................................................................................... 5
4.2 Valve Control Function ........................................................................................................................ 6
4.3 Technical data....................................................................................................................................... 6
4.3.1 Connector for bus cable ................................................................................................................... 6
4.3.2 EHS connector ................................................................................................................................. 6
5 Bus IO Unit (PCL-IO) 8
5.1 Analog / digital inputs .......................................................................................................................... 8
5.2 Isolated digital inputs........................................................................................................................... 8
5.3 Digital relay outputs ............................................................................................................................. 8
5.4 Technical data....................................................................................................................................... 8
5.4.1 Connector for bus cable ................................................................................................................... 9
5.4.2 Connector for process IO ................................................................................................................. 9
6 Master Set-Up and local Operation 10
6.1 The Main Menu.................................................................................................................................... 10
6.1.1 Show Node Data ............................................................................................................................ 10
6.1.2 Set Node List .................................................................................................................................. 13
6.1.3 Set Modbus Parameter................................................................................................................... 15
6.1.4 PCL Parameter ............................................................................................................................... 16
6.1.5 Set IO Mapping............................................................................................................................... 17
6.1.6 Auxiliary Functions ......................................................................................................................... 18
6.1.7 Password ........................................................................................................................................ 19
6.1.8 Error Recording .............................................................................................................................. 19
7 Mimic diagram operation 21
8 Technical Data 22
8.1 PCL-Power Control............................................................................................................................. 22
9 The set-up Program PclService 23
9.1 Opening, Editing and Saving Parameter Files................................................................................. 23
9.2 Upload and Download of Parameters............................................................................................... 24
9.3 Disconnect serial interface................................................................................................................ 24

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 Pleiger Elektronik
GmbH & Co. KG

1 Overview
The PCL (Pleiger Control Loop) is a high reliable data and power bus system. It is primarily intended for use
with Pleiger EHS valves and similar devices. Major benefit of the system is the robustness against distur-
bances and damages to the bus cable and other parts of the system. Even in most cases of severe damage
not more than two drives of the system will fail.
This manual describes some basics of the system, the operation of the bus master as well as the technical
data of the bus master and the valve control interface.

2 The Data Bus System

The PCL data bus is a master slave system using a communication protocol similar to the Modbus protocol
but providing special function types and a very tight timing for increased performance. Hereby a fast data
transfer is achieved even at low baud rates.

2.1 PCL Master Function

In most applications two independent master controllers (A and B) handle the communication at both ends of
the data bus. The polling sequence is the major difference between both bus masters. While A is starting with
the first node counting upwards B starts with the last one and then counts downwards.
Note: The sequence used for polling the node is parameterised by the user. This sequence must be identical
to the physical sequence of the slave units (EHS) on the bus. Otherwise a proper fault localisation is not
guaranteed.
Both masters are connected via CAN bus. This connection is used to copy any information that one of the
masters receives to the other the foreign master immediately. Therefore both masters’ data are always identi-
cal.

2.2 Second Data Bus

To improve the speed and reliability of the data transfer each PCL-Master with software version V1.3 and
higher can handle two data busses. The busses are identical in all aspects. Additional parameters allow the
setting of the serial ports and the distribution of the nodes. Not more than 100 nodes may be connected to a
single data bus and not more than 127 nodes may be connected to both of them. If more than 60 nodes shall
be connected to a master the usage of two data busses is recommended.

2.3 PCL Slave Function

The PCL slave interface is the most important link in the PCL safety chain. It is not only acting as a communi-
cation slave but also takes over the following tasks:
Separating the bus loop sections electrically
Acting as a repeater
Selecting the valid bus master

2.3.1 The physical layer

Electrically the slaves perform a point-to-point communication on two RS485 ports A and B. Both ports are op-
tically insulated, overload protected and connected by a simple logic.
Because of the additional protection devices even a short circuit between the 230V AC supply and the data
bus will not cause a permanent damage of the slave but of course an interruption of the data link. For data
transmission a shielded twisted pair cable with at least 0,5 mm² cross-section is required. This twisted pair is
part of the bus cable delivered by Pleiger.

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2.3.2 Protocol
The protocol is quite similar to the Modbus protocol. Only the function types are different and the timing is
faster to achieve optimal performance. The most frequently used message exchange is based on the master’s
status request (4 bytes) and the slave’s status response (6 bytes). Using a baud rate of 19200 bits/s such a
message exchange is handled completely within 9,7ms (resp. 4,9 ms at 38400 baud). A 16 bit CRC is used for
error checking.
The node address in the range 1 to 127 is simply set by means of a 8 bit DIP switch (only the first 7 bits are
used). This is a very simple technique and does not require special skills or equipment during installation or
when defective parts are to be exchanged.

1 2 3 4 5 6 7 8
O
N
The position ON corresponds to a 1 whereas OFF corresponds to a 0. The first
switch 1 sets the least significant bit and the switch 7 sets the most significant bit
O
F of the address. Switch 8 determines the baudrate, OFF = 19200, ON = 38400.
F

3 The power bus system

Besides the data communication the bus cable also provides power supply with 230VAC. Similar to the data
bus the power bus is also configured as a loop. Both ends of the loop are protected by the same 16A fuse. Up
to five of such loops can be build up within a single data bus loop.

3.1 Handling power bus faults, interruption

If one or all conductors of the power bus break the current is still conducted by the both parts of the power
loop. Therefore any kind of interruption is not noticed by the system. To detect such faults the system is
equipped with a self-test function. Such a self-test has to be performed in regular intervals.

3.2 Handling power bus faults, short circuit

Naturally the effect of a short circuit is much more severe. Because the current is the same within the whole
loop the fuse of this loop will blow and all slaves connected to this loop will fail. Because the PCL masters su-
pervise the power loop voltage this event is going to be indicated via Modbus connection immediately.
The fuse may now be reset manually. Of course without any additional measures the fuse would just blow
again. Therefore the master cabinet as well as each slave is equipped with a power relay and a short circuit
snooping device. If a short circuit is detected the power relay stays open. This prevents that the fuse is blown
once again.
Note: If a short circuit is detected on either side of the slave the slave is not connected to the power bus and
therefore stays turned off.

3.3 Power Management

As each valve requires approximately 1,8A and the cable is fuse protected with 16A approximately 8 valves
can run simultaneously. If more than 8 valves shall be connected to a single bus section a power management
is required. This power management assures that not more than 8 valves connected to the same fuse will run
simultaneously. To avoid unacceptable delays it is recommended to limit the number or valves within one
power section to 25 .. 30.
For power management the master adds up all required current in each of those 5 sections. A command is
sent to the valve only if the required current for running this drive is still available within the power section. Be-
cause the start up current of the valves is significantly higher than the nominal current only one valve is started
within a checking cycle every 100ms.

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The maximum required current of each valve can be parameterised by the user whereas the idle current of all
drives are taken into consideration by using fixed values.

3.4 Power Bus Cable

Of course the length of the power bus cable is limited because of the voltage drop on the bus. Therefore it is
necessary to make a rough estimate of the allowed cable length. Please note that this max length does not
concern the data bus but only a single power bus loop.
The max allowed voltage drop on the power bus cable is 20% = 46V. By this and the max current of 8x1,8A =
14,4A this maximum cable length can be determined. Of course the worst case must be taken into considera-
tion. Therefore it is assumed that the power loop is supplied at one side only. Under normal conditions the bus
loop is supplied at both sides and therefore the max. voltage drop is reduced to approximately 10%. The max
allowed conductor resistance is:
Rmax = 46V/14,4A = 3,2Ohm
First it is assumed (worst case) that all 8 drives are mounted directly beneath each other at the end of the ca-
ble.

3.4.1 Length / Reduction factor table

The max cable length depends on the type of cable used. The EHS bus interface provides 4 terminals to con-
nect up to 4x2.5mm² power cable. If such a cable is used the max length between the power supply and the
last drive within the power loop is 441m.
Additional power bus loops should be connected via a 2x4mm² or a 2x6mm² cable.
Typ Conductors, power loop Resistance Length Reduction factor
1 1.5mm² + 3mm² (3x1.5) 9.08 mOhm/m 176 m 1
2 2x2.5mm² 7.26 mOhm/m 220 m 0.8
3 2x3mm² (4x1.5) 6.05 mOhm/m 264 m 0.666
4 2.5mm² + 5mm² (3x2.5) 5.45 mOhm/m 294 m 0.6
5 2x4mm² 4.54 mOhm/m 352 0.5
6 2x5mm² (4x2.5) 3.63 mOhm/m 441 m 0.4
7 2x6mm² 3.03 mOhm/m 528 m 0.333

The cable types 1-4 and 6 may be directly connected to the PCL-VCI board. Larger cross-sections may only
be used for additional supplies.
Note: In most cases the cable type 2 will be sufficient. To minimise cable cost and cabling efforts
cables with more than two conductors should only be used if this is absolutely necessary.
If different cable types are combined the following condition must be met:
L1*R1 + L2*R2 + .... <= 176m
In which L1, L2, … are the lengths of the cable sections and R1, R2, … are the reduction factors stated in the
table above

3.4.2 Distributed current sinks

Until now all considerations were made assuming a single current sink at the end of the cable. Of course usu-
ally the drives are distributed all over the cable. As a rule of thumb you may add half of the length of the bus
cable between the last 8 drives to the calculated allowed length.
Example: A power bus loop supplies 20 drives. The distance between each drive is 10 meters. Therefore the
distance between the last 8 drives is 7*10m = 70m. The max. allowed cable length is 70m / 2 =

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35m longer than stated in the above table. If cable typ 2 is used the max. length between the
switch cabinet and the last drive is 220m+35m = 255m. The drives are spread over 19*10m =
190m. The cable length between switch cabinet and the first drive must not exceed 255m-190m =
65m. The max. length of the whole loop may be 190m+65m+65m = 320.

3.4.3 Reduced current

If longer cables shall be used the max. current must be reduced by limiting the number of drives running con-
currently. This can easily be parameterised for each single power loop. The max. length may be enlarged by
the following factor.:
No of drives 8 7 6 5 4 3
Length multiplier 1 1.14 1.33 1.6 2 2.6

3.4.4 Additional supplies

If the max length of the power bus loop is exceeded or the number of drives is more than app. 25-30 a new
power bus loop must be inserted. Therefore an additional cable (4x4mm²) connects the end of the first power
bus loop with its supply within the switch cabinet and the supply of the next power bus loop with the bus cable
vice versa.

3.4.5 Installation rules

The bus cable may be laid parallel to other cables conduction a voltage of 230/400V with a maximum current
of 63A. If current or voltage is above this limit or if the cable is used to connect a drive to a frequency inverter
a minimum distance of 1 m must be kept.
Both ends of the bus loop or of a power loop should be laid in separate paths to avoid a damage of both ends
at the same time. If the outer hull of the cable is damaged the cable must be replaced. This holds true even if
the damage is diminutive.

3.5 Fusing
Each power bus loop must be fused separately with two 16A automatic fuses with B characteristic.
Attention: Fuses with different characteristic of different design current must not be used!

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4 Valve Control Interface (PCL-VCI)

The data interface, the short circuit detection as well as the valve control unit are implemented on a single
PCB the PCL-VCI (Valve Control Interface). This board may either be integrated in the drive’s case or may be
installed in a separate bus box.

4.1 Interface to actuator

Two relays, two binary inputs and one analogue 4..20mA input form the interface to the valve drive. Addition-
ally the board also supplies the limit switches and eventually the analogue feedback unit of the drive. The sup-
ply voltage is 15..27V at 50mA maximum.
One of the two relays is always used as a make contact whereas the second one can be switched to two dif-
ferent operational modes by means of an additional switch.
1. Make contact switching the 230VAC of the power bus
2. Break contact switching an external supply voltage of 24VDC or 230VAC
Operation mode 1 is the standard one. Mode 2 is used for single acting valves that must stay open in case of
a power fail or such valves that belong to a quick close system. If the external supply voltage is turned off the
valve will close in any case.

4.1.1 Quick Closing Operation

The PCL system uses two different ways to connect the drives to a quick closing system:
1. Software Control:
The quick close signal is collected by the bus masters by means of a digital input (24V = normal op-
eration, 0V = quick close). The quick close signal is transformed into a close command and sent to the
valves. This of course means that the data transfer function of the system must work properly.
2. Hardware Control:
The quick close signal is hard wired to each drive of the quick close system. This wiring is used to
supply the magnetic valve within each single acting drive. If this supply voltage is turned off, the drive
will close whatever happens to the data communication system.

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4.2 Valve Control Function

The kind of control algorithm is selected by the PCL master on slave start-up. A present 12 different drives
are supported.
Abbreviation Description
EHS_D standard double acting valve
EHS_DK double acting valve operating in continuous mode
EHS_SO single acting valve, spring open
EHS_SC single acting valve, spring close
EHS_SOK single acting valve, spring open, operating in continuous mode
EHS_SCK single acting valve, spring close, operating in continuous mode
EHS_SCO single acting valve, spring close with mechanical override
EHS_SOO single acting valve, spring open with mechanical override
MOV standard motor valve
QC_SC single acting valve, spring close, with external quick close circuit
QC_SCK single acting valve, spring open, with external quick close circuit
EHS_SCH single acting valve, spring close with electro-hydraulic override
Type QC_SC and QC_SCK are especially intended for valves within a quick close system. Master Set-Up and
local Operation

4.3 Technical data

This board provides two screw plug connectors to connect the bus cable and the EHS itself. This board may
either be integrated in the actuator casing or encased separately in a so called bus box.
Power supply AC 230V 20%, 50-60Hz 10%,
max. current on power bus 16Arms
current to detect a short circuit 10mA
Power consumption (without drive) max. 6W
Power supply for ext. sensors 15-27VDC, max. 50mA
Nominal current of drive max. 2A
Ambient temperature (casing) -25°C – 55°C

4.3.1 Connector for bus cable

predecessor Pin Meaning successor
5+6 1+2 Power bus L1, A side
7+8 3+4 Power bus L2, A side
5+6 Power bus L2, B side 1+2
7+8 Power bus L1, B side 3+4
11 9 Data bus -, A side
12 10 Data bus +, A side
11 Data bus -, B side 9
12 Data bus +, B side 10
Please note that each node will turn the phase of the power bus by 180°.

4.3.2 EHS connector

Pin I/O Meaning
1 in Feedback open, make contact to 0V
2 in Feedback closed, make contact to 0V
3 in Analogue position feedback, +4..20mA
4 out Supply sensor, 24V

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5 out Supply sensor, 0V

6 out Power bus L1
7 out Function close L2
8 out Power bus L1
9 out Function open L2
10 in External magnetic valve supply (quick close)
11 in External magnetic valve supply (quick close)

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5 Bus IO Unit (PCL-IO)

The PCL-IO is used to acquire digital and analog data via the PCL system. Addi-
tionally control commands can be sent to the process by means of two relays.
The PCL-IO provides the same bus interface like the PCL-VCI. All safety fea-
tures of the PCL are also implemented. The PCL-IO is encased into a waterproof
(up to IP68) casing. Water tight cable fittings are used for the complete cabling.

5.1 Analog / digital inputs

The PCL-IO provides 8 analog inputs with an input range of 0..20,4mA. The in-
ternal resistance of each input is 100Ohm. The inputs are not isolated from one
another and therefore only suited for floating current sources like pressure or
temperature sensors. The PCL-IO also provides 24VDC to supply the sensors.
Self-resetting fuses protect the inputs against overload due to short circuit in the
sensor cabling.
An 8-fold switch on the board is used to configure the input either as analog or
digital. If an input is used as digital input a 24V input signal is converted to a 4mA
current. Please note that these input must only be used for floating signal
sources like liquid level switches, relays etc.
current input = switch position ON
digital input = switch position OFF

5.2 Isolated digital inputs

Additionally each PCL-IO provides two opto-isolated inputs. Both inputs have
common 0V.

5.3 Digital relay outputs

For control purposes each PCL-IO is equipped with two relay outputs. Both contacts of a normally open relay
are connected to separate terminals.

5.4 Technical data

Power supply AC 230V 20%, 50-60Hz 10%,
max. curren ton power loop 16Arms
min. current to detect a short circuit 8mA
Power consumption (without drive) max. 6W
Power supply for ext. sensors 24VDC, max. 200mA
Max error of analog inputs max. ±0,4% of full range
Trigger level of digital inputs 12V ±2V
Ambient temperature (casing) -25°C ... 55°C

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5.4.1 Connector for bus cable

predecessor Pin Meaning successor
5+6 1+2 Power bus L1, A side
7+8 3+4 Power bus L2, A side
5+6 Power bus L2, B side 1+2
7+8 Power bus L1, B side 3+4
11 9 Data bus -, A side
12 10 Data bus +, A side
11 Data bus -, B side 9
12 Data bus +, B side 10
Please note that each node will turn the phase of the power bus by 180°.

5.4.2 Connector for process IO

Pin I/O Meaning
1 in analog / digital input 1
2 +24V
3 in analog / digital input 2
4 +24V
5 in analog / digital input 3
6 +24V
7 in analog / digital input 4
8 +24V
9 out relay output 1, make
10 out relay output 1, make
11 out relay output 2, make
12 out relay output 2, make
13 in analog / digital input 5
14 +24V
15 in analog / digital input 6
16 +24V
17 in analog / digital input 7
18 +24V
19 in analog / digital input 8
20 +24V
21 0V
22 in - common, isolated digital inputs
23 in + isolated digital input 9
24 in + isolated digital input 10

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6 Master Set-Up and local Operation

For local operation and parameter set-up a small LCD terminal is used. This terminal is connected to the serial
interface “si-service” of one of the bus masters. As there is only one terminal for both bus masters the desired
bus master may be selected by a switch. This is necessary for parameter set-up only.
Local operation can be done on both masters in the same way.

Note: Most operating functions are not available as long as the local operation mode is not turned on. If local
operation is disabled only the “show node data” window is displayed.

6.1 The Main Menu

PCL Master A Vx.xx

1: Show Node Data
2: Set Node List
3: Set Mobus Param.
4: Set PCL Param.
5: Set IO mapping
6: Aux Functions
7: Password

This menu shows the type of selected master and the version number Vx.xx of the software. Seven sub
menus may be called by typing the digits 1..7. Please note that as only 4 lines can be displayed on the LCD
screen you have to scroll the screen using the UP / DOWN arrow keys to make the complete screen visible.

6.1.1 Show Node Data

Node 1 NE Pos Cmd Ms Node 1 ErrPosCmd
Name01-ok CL CL 0A Long-Name01-ok-CL-CL
Name02 ok OP OP 0A Long-Name02 ok OP OP
1:Open 2:Close 3:Pos 1:Open 2:Close 3:Pos

Display for short names Display for long names

This menu is used to show the state of all nodes and if local operation is enabled to enter commands locally. If
local operation is turned off the fourth line is not displayed. The up / down keys may be used to scroll the node
list in line 2 and 3. Press the SFT key additionally to increase the scrolling increment to 10 instead of 1. The

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selected line is marked with – sign instead of blanks. Because each line covers 20 characters only the data is
displayed abbreviated and need some explanation.
th
If local operation is enabled the 4 line changes to command input mode. The digits ‘1’ and ‘2’ are used to
send the commands “open” or “close” to the selected node. To enter the nominal position for a continuous
mode valve type the digit ‘3’ to start the edit mode and than type in the desired value 0..100%.
Node:
This is a 6 or 11 character name set by the user. Usually the name is build up from the system name and the
valve number, like Ba1017 that means ballast system valve no 1017, or Bi1432 for a bilge system valve.
Hint: A hyphen following the node name (Bi1432 ) indicates that this valve is selected and consequently
the commands are sent to this valve!
NE or Err:
The two characters are used to display the node’s error status.
Node error Display
no error ok
timeout while opening TO (Time Opening)
timeout while closing TC (Time Closing)
illegal feedback FB (Feedback)
illegal command CM (Command)
illegal parameter PA (Parameter)
new, after reset without parameter NW (New)
waiting for parameter (temporary) ii (Init)
unknown, after master reset ??
self test error (if slave still works) DI (Diagnosis)
According to this table a node without any error is displayed as “OK”. The error TC or TO may occur if the pa-
rameter “run time” is set to small. The errors CM to DI should never occur after putting into operation.
Pos:
The position of the valve is displayed abbreviated using 2 to 4 characters. If the drive is running in continuous
mode the position is displayed in 0..100% in which 0 means closed and 100 means open. As long as the drive
is running a tilde is shown preceding the position.
Position Display or short
position of continuous mode valves in a standstill 0 .. 100 CL, 1..99, OP
position of continuous mode valves while running ~0 ..~100 ~CL, ~1..~99, ~OP
closed, valve stopped CL CL
open, valve stopped OP OP
open but got command to close OP> O>
closed but got command to open CL> C>
neither open nor close while closing CLr Cr
neither open nor close while opening OPr Or
in closed position but still running CLp Cp
in open position but still running OPp Op
position unknown -?- ??
Example: The drive is closed CL, gets the command to open CL>, the closed position is left OPr, the open po-
sition is reached OPp and finally the run is finished OP.

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Cmd:
The column Cmd shows the last command given:
Command Display
Open OP
Close CL
Stop ><
unknown ??
Position set point 0..100
The position set point can only be used if the drive provides an analogue position indication. To enter the set
point type a “3”. The input moves to the column Cmd. Now the new position set point can be typed in and ac-
knowledged with . A * following the command shows that this command has not yet been sent to the valve
control interface. This may happen because:
There is no connection to the node
The power management causes a delay
Running of the drives is prohibited, because the system is supplied by a UPS
Ms:
The first character shows the current master A or B and the succeeding digit shows the timeout counter (in s)
of the node. The timeout counter should stay 0 that means less than one second.
A, a Master A first data bus
C, c Master A second data bus
B, b Master B first data bus
D, d Master B second data bus
If a non capital letter is displayed it indicates that the node is not communicating with its default master. If “OL”
= offline is displayed for more than 5s an error message is sent to the Modbus master. In this case the com-
munication to the slave is interrupted completely.
Note: During normal operation the timeout should never exceed 1.

6.1.1.1 Selection of display format

The data display may be formatted in two different ways. The format depends on the max. length of the node
names. The default format may be used for name length of up to 6 characters. The extended format may show
names with 11 characters.
If one of the node names requires more than 6 letters the extended format is used automatically. To switch
over to the other format the key combination STF / Setup must be used.

6.1.1.2 setting display order

By default the drives are listed by their name in ascending order. That means the valve named Ba0815 is dis-
played above the valve Bi4711. Of course this sequence does not describe the physical order of the drives.
The physical placing of the valves is described by the node number. This node is shown in the top line on the
right hand of the header “Node”.
For diagnosis purpose it is useful to change the display order. This can be done by the “mode” button (shift +
ESC). If you press it once the display order will change to physical placing. If you press it a second time the
order returns to default.

6.1.1.3 Displaying PCL-IO nodes

If a node of PCL-IO Type is selected a different presentation of the data is used. The column “Pos” is now
used to show the state of the 8 analog / digital inputs as a hexadecimal figure. The column “Cmd” is used to
show the state of the two digital outputs of the PCL-IO. If local operation is enabled the digital outputs can be

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set by means of the „set output“ function. Use 1 to set the first output, 2 to set the second one and 3 to set
both.

Node 1 NE Pos Cmd Ms Node 1 ErrPosCmd

IO 01 -ok 03 00 A0 LongNameIO1-ok-03-CL
IO 02 ok 00 01 A0 LongNameIO2 ok 45 46
1: Set Output 2:Data 1:Open 2:Close 3:Pos

Display for short names Display for long names

Showing all data of a PCL-IO node

The function „2. data“ switches to a screen that shows all 8 analog / digital inputs and also the two additional
opto-isolated inputs.

1: 0 2:1850 3:1500
4: 800 5: 400 6:1524
7:2048 8:1200
Dig1-8:FE Dig9-10:2

The analog values are displayed as 0..2048 corresponding to 0.00 .. 20,48 mA. Dig1-8: shows the state of the
analog / digital inputs and “Dig9-10:” shows the state of the two additional opto-isolated inputs.

6.1.2 Set Node List

Node 1:ID 2:Type
> 1 1 EHS-D
2 2 EHS-SC
3:Ins 4:Del 5:Par

This menu is similar to the one described before. Again a certain node can be selected by scrolling the node
list by means of the arrow keys. Furthermore you can select 5 options.
Note: As long as both masters are connected via CAN-Bus each change in the node set-up menu is imme-
diately copied to the foreign master. This function assures that the node set-up keeps the same in
both masters. Only the parameter “Mimic IO-No” is not copied because it may be different for both
masters.
Hint: This menu is intended for minor changes only. Setting up the whole system should always be done by
means of the PCL Service program (see 9. The set-up Program PclService).
1:ID
Type 1 to change the ID that means the address of this node within the PCL. The range is 1..127. This ad-
dress must be identical to the node’s physical address selected by the DIP switch. Acknowledge with or
leave with ESC.
2:Type
Type 2 and use the arrow keys to select the appropriate node type. Acknowledge with or leave with ESC.
At present the following valve types are supported:
Abbreviation Description
EHS_D double acting valve

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EHS_DK double acting valve operating in continuous mode

EHS_SO single acting valve, spring open
EHS_SC single acting valve, spring close
EHS_SOK single acting valve, spring open, operating in continuous mode
EHS_SCK single acting valve, spring close, operating in continuous mode
EHS_SCO single acting valve, spring close with mechanical override
EHS_SOO single acting valve, spring open with mechanical override
MOV standard motor valve
QS_SC single acting valve, spring close, with external quick close circuit
QS_SO single acting valve, spring open, with external quick close circuit
EHS_SCH single acting valve, spring close with electro-hydraulic override

3:Insert
Type 3 to insert a new node succeeding the selected one. The node numbers of all succeeding nodes are
automatically incremented by one.
4:Delete
Type 4 to delete the selected node. The node numbers of all succeeding nodes are automatically decre-
mented by one. There is no undo function.
5:Parameter
Type 5 to select another sub menu.

6.1.2.1 Parameter Sub Menu

Node 1 of 50
1: Run Time [s] 35
2: Current [mA] 1000
3: Fuse No 1
4: Quick Close 0
5: Aux 1 0
6: Aux 2 0
7: Mimic IO-No 0
8: Valve Name Bi4711

This menu is used to enter some more parameters of the node. Just to assist the user the node number is
stated in the header line.
1:Run Time [4..255s]
Enter the nominal run time from open to close or close to open whatever is the longest. It is used to supervise
the valves function. Default 60s. In case of analogue feedback the run time should be set as exact as possible
but never to short.
2:Current [0..16000mA]
Enter the maximum permanent current (not the start up current) required by the valve while running. Default
1800mA.
3:Fuse No [1..5]
Enter the number of the fuse (power section) the valve is connected to. Default 1.
4:Quick Close [0..7]
Enter the number of the quick close circuit the valve belongs to or 0 if quick closing is not used. Default 0.

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0 = no quick closing 4 = quick close system 3

1 = quick close system 1 5 = quick close system 3+1
2 = quick close system 2 6 = quick close system 3+2
3 = quick close systems 1+2 7 = quick close system 3+2+1
5:Aux 1, 6:Aux 2 [0..255]
The meaning of these parameters depends on the kind of valve. At present only a few valves use these pa-
rameters. Default 0.In case of an EHS-DK Aux1 is used as stop offset in %. If the drive is approaching the
nominal position it is stopped Aux1 % before reaching this position. If Aux1 is set to 0 the stop offset is de-
rived from the nominal runtime:
stop offset = 60s/ nominal run time +2
This will be OK for most drives.
If a single acting valve is used Aux2 can be used to supervise the presence of a data connection. If there
is no data exchange for more than Aux2 seconds the drive moves to its default position. This option may
be used for drives within the quick closing system to assure that the drives are closed even if the bus sys-
tem fails completely.
7:Mimic IO-No [0..255]
If this does not equal 0 the valve may be operated via a mimic diagram. Digital inputs provide a command in-
put whereas digital outputs indicate the state. All data is mapped to modbus registers “Mimic Base Register”
and successors. If mimic IO-No is 1 the first two bits of Mimic Base Register are used as command input und
the first two bits of Mimic Base Register + 1 as state output. Default 0.
8:Valve Name
By default the valve’s name is set “node number / node address” (e.g. 5/ 5). You may now set the desired
node name. Select the first character by means of the up / down arrow keys and press return to confirm the
selection. Do so for all 6 / 11 characters of the node name. Please note: This menu is intended for minor
changes, setting up the whole system should always be done by the PCL Service program.

6.1.3 Set Modbus Parameter

A Modbus slave interface is used to connect one or both masters to a superior control system. An rs485 inter-
face is used as physical layer. For safety reasons it is strongly recommended to use the Modbus interface of
both masters. In this case one of the connections may fail without any effect, because both masters have iden-
tical data and function.

1: Slave Address 1
2: Port No 2
3: Baudrate 9600
4: Parity None
5: Base Register 1
6: Select Reg 1
7: Set Reg 0/ 0

Slave Address [1..127]

Select the modbus slave address of the master (1..127 ). Default 1.
PortNo [1..10]
Select the number of the port used for modbus connection. The port numbers of the PMC are selected as:

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Slot No CPU I/O1..5 I/O1..5

st nd
Device dc1 mc1 1 si2 2 si2
Upper port No service 2 4
Lower Port No 0 1 3
If for example only one si2 board is installed the lower port is always 1 and the upper port is always 2 regard-
less of the slot used. Default 1, that means the lower port of he first si2 in the system.
Baudrate [2400..38400]
Enter any baud rate between 2400 and 19200 Bit/s. Please note that any baud rate can be set even those that
are not common. Default 19200.
Parity [none, odd, even]
Usually Modbus RTU does not use parity checking because it is not necessary. If required you may select
even or odd parity by means of the arrow keys. Default “none”.
Base Register [0..32767]
The bus master only provides 250 registers. This would limit the modbus address range to 0x40000 ..
0x400FA. The parameter base register is used as an address offset, that means the modbus address 0x40000
+ Base Register points to the first register of the master. Default 0.
Select Reg / Set Reg
This function is used to display and set a Modbus register for test purpose. First selcted the desired register.
The register dat ais known displayed in the next line “upper byte of register / lower byte of register”. Both bytes
are displayed as a decimal figure. To change the register use the “Set Reg” function. Set the upper byte if de-
sired, press the enter key, set the lower by byte and press the enter key once more. It is not possible to chan-
ge registers written by the PCl-Master.

6.1.4 PCL Parameter

Usually these parameters must not be changed during commissioning or operation.

1: Master Typ A
2: PortNo 1
3: First Port2 100
4: Resp Timeout 50
5: Request Delay 0
6: Extnd Bas Adr 71
7: IO Bas Adr 81
8: Ctrl Bas Reg 151
9: Mimic Bas Reg 121
0: Set Max Current

Master Typ [A, B]

Select master A or B type. A must be the master directly connected to the first node. B must be the master
next to the last node. Default A.
Note: Never use 2 masters of the same type within a single bus loop.
PortNo
The ones column of the number defines the number of the first serial data port and the tens column defines
the second serial data port (if any).

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Slot No CPU I/O1..5 I/O1..5

st nd
Device dc1 mc1 1 si2 2 si2
Upper port No service 2 4
Lower Port No 0 1 3

First Port2
This number defines the first node that is connected to the second bus. Make sure that a second bus is de-
fined and the stated node is connected to this bus.
Response Timeout [10..180]
The first character or the nodes response must be received within this period of time. The time unit is 0,1 ms.
Default 50 = 5ms.
Request Delay [0..180]
Programmable delay between the reception of a response and the start of the next request in 0,1ms. Default
0.
Extnd Base Address
This is the node address of the first PCL-VCI that uses both bytes of Modbus register. This is necessary if the
actuator is equipped with an analog position feedback. Nodes with smaller addresses only use one byte to
transmit their status. Usually the extended format is always used and therefore the default value is 1.
IO Base Address
This is the node address of the first PCL-IO. Starting with this address 7 registers are allocated for each node.
Control Base Register
This is the register number of the first register used for control purpose.
Mimic Base Register
The mimic registers are use to connect an actuator to a mimic diagram. The mimic diagram is connected to
the PCL master by means of digital IO boards like the dea8. These boards are than mapped to the mimic reg-
isters by means of the IO mapping utility.

6.1.5 Set IO Mapping

1: Slot No 1
2: Device none
3: PortAdr low 0
4: PortAdr High 0

IO mapping offers a simple procedure to map local IO devices that are integrated into the PCL master to the
modbus registers. This is used for valve operation via mimic diagrams, output of analogue values like tank
levels etc.
Slot No [1..5]
Select the slot number of the desired IO device [1..5].
Device [----, de16, dea8, da16, ae8, aa4, aa44]
Select the desired IO device by means of the cursor keys. Currently supported devices are:
- de16 2 x 8 inputs with common ground
- da16 2 x 8 relay outputs
- dea8 8 inputs with common ground, 8 relay outputs
- ae8 8 differential analogue inputs, 10V or 20mA, -100% = -32000, 100% = 32000

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- aa4 4 analogue outputs, 10V or 20mA, -100% = -32768, 100% = 32767

- aa44 4 analogue outputs, 4..20mA, 4mA = 0, 20mA = 32767
Devices aa4 and aa44 are using the same hardware (aa4) but different scaling. Default “----”.
Port Address [0..499]
Use this parameters to select to which byte within the register range the device shall be mapped. Keep in mind
that each register consists of two bytes. The meaning of these parameters depends on the selected device.
Port address of Register x, lower byte = 2*(x-1)
Port address of Register x, upper byte = 2*(x-1)+1
Device PortAdr Low PortAdr High
de16 lower input group upper input group
da16 lower output group upper output group
dea8 input group output group
ae8 first of channel 1..4 first of channel 5..8
aa4 first of channel 1..2 first of channel 3..4
Please note that analogue IO always use complete registers and therefore start with an even byte number.
The IO data is updated every 250ms. Default 0.
Example:
The lower byte of the modbus register 12 shall be mapped to 8 digital outputs and the higher byte of register 7
shall be mapped to 8 digital inputs. You may select a ‘dea8’ board for this purpose.
input group -> PortAdr low = 7*2+1 = 15
output group -> PortAdr high = 12*2 = 24
In each application two registers are always mapped to an IO device usually a dea8 board.

6.1.6 Auxiliary Functions

F1: Del Node List
F2: Copy Node List
3: Self Test, Status:
4: Pos Check, State:

This menu provides two functions that can be used to achieve identical node lists in both masters. These func-
tions are very useful when one of the masters has to be exchanged.

6.1.6.1 Del node list

The function “DelNode List” simply erases the whole node list of the local master (of course not the foreign
one).

6.1.6.2 Copy node list

The function “Copy Node List” copies all nodes including all parameters to the foreign master. Please note that
the parameter “Mimic IO-No” is not copied because this parameter may be and usually is different for both
masters. The type in the function keys you must keep the shift key pressed while pressing 1 or 2.

6.1.6.3 Self Test

Due to the highly redundant system architecture several faults will not cause any disturbance and will not be
noticed during normal operation like for example the interruption of the power loop. The self-test helps to de-
tect errors that are covered by this redundancy. The function “Self Test” starts the same self test procedure
that may also be started via Modbus. While running the current state of the self-test is shown.

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Note: The self test is the only way to detect hidden faults. It must be performed regularly at least once
a week. If any error is detected when the self test procedure is performed the system must be
repaired even if it works properly when the test is finished.

State Step
1 Check if system has no error
2 Break power loop on one side and start timer
3 Wait for 30s
4 Close power loop again, stop polling data bus at one side and start timer
5 Wait for 30s
6 Start polling again and reset all timeout counters to initial values
7 Self test finished
On any error the self-test finished and the PCL master returns to the normal operation.
Note: During such a self-test hidden errors are detected. If there is such a fault one or more drives cannot be
controlled or monitored any longer until the self-test is finished. Spring closed drives may close uninten-
tionally. This must be taken into consideration before a self-test is performed.

6.1.6.4 Pos Check

This function is for set-up purpose by Pleiger staff only.

6.1.7 Password
1: Set Password
2: Protection is off

This menu provides two functions to set the password and to turn password protection on and off. If the pass-
word protection is enabled only the menus 1 and 7 can be selected.
1: Set Password
new password: enter a 4 digit number as new valid password
2: Protection is off (on)
enter passw: enter valid password to turn protection on or off
Note: After set-up is finish the password protection must be turned on. An erroneous or unintentional change
of parameters may cause severe problem and even a complete system failure.
Note: Make sure that the password is known to everyone who is responsible for the system.

6.1.8 Error Recording

Each time an error state occurs (or disappears) an error record is added to the error list. The red LED of the
ERR-key indicates that the error list is not empty. Pressing the ERR-key displays the error list. Each error re-
cord covers one line of the display. Each error record is subdivided into three or four sections:
error no | error text | optional error data | relative time [s]
Example:

1 Node offl. 3 3247

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Error no error text Description optional error data

1 Node offl.", at least one node got offline node number
2 Modbus offl.", no mobus request for more than 10 s ---
3 CAN bus offl.", no CAN bus message for more than 10 s ---
4 PCL stop cmd PCL has been stopped for any reason ---
5 open UART initialisation of an UART failed no of the serial port
6 Flash write error when writing a page of the parameter flash page no
7 CRC par page wrong CRC in parameter flash page page no
8 CRC par sect wrong CRC in parameter flash section section no
9 RAM check error while testing RAM area ---
10 ROM check wrong CRC in program flash ---
11 Node fail any node returns an error code node number
12 Watchdog Reset program starts after a watchdog reset ---
13 Software Reset program starts after a software reset ---
14 Power Fail power fail input changes state 0=fall, 1= raise
15 QuickClose quick close inputs change state 00, 01, 10, 11
16 Fuse Blown power control input changes state 0= fall, 1= raise
17 CanMsgLost CAN message lost ---
18 CanntFetch node can not be connected with default master node number

The relative time is a simple time counter repetitively counting from 0 to 9s (app. 2,5 h) and starting with 0 af-
st
ter reset. The max number of records in the error list is limited to 100. The 101 error record will overwrite the
st
1 one and so on. Use the arrow keys to scroll through the error list. Press the Shift- and the Err- key simulta-
neously to erase the error list.

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7 Mimic diagram operation

Some or all valves may be operated from a mimic diagram. The command is set by push buttons one for open
and one for close whereas the position is indicated by lights. Therefore two digital inputs and two digital out-
puts are required for each valve. These local IO are mapped to several Modbus registers. These registers may
be read by the modbus master but usually they are not.
The mapping starts with register “Mimic Base Register”. The lower byte of this register is used to read the
commands of the first 4 valves to be controlled by external push buttons. The upper bytes of this register are
used to write the status of these valves. If more valves have to be controlled the next registers are used in the
same way.
A “dea8” board is mapped to each of these registers. The 8 inputs are mapped to the lower byte and serve as
command inputs (push buttons). The 8 outputs are mapped to the upper byte and serve as feedback outputs
(lamps).
The IO-bit used is determined by the parameter Mimic IO-Number.
Mimic IO-No Register Command Open Command Close Feedback Open Feedback Closed
1 Mimic Base Reg. Bit0 Bit1 Bit8 Bit9
2 Mimic Base Reg. Bit2 Bit3 Bit10 Bit11
3 Mimic Base Reg. Bit4 Bit5 Bit12 Bit13
4 Mimic Base Reg. Bit6 Bit7 Bit14 Bit15
…
22 Mimic Base Reg.+5 Bit2 Bit3 Bit10 Bit11

The drive status is displayed via the feedback outputs corresponding to the following scheme.
State Output open Output closed
closed, command open sent blinking 1/s on
during opening blinking 1/s off
open, drive is still running on off
open completely on off
open, command close sent on blinking 1/s
during closing off blinking 1/s
closed, drive is still running off on
closed completely off on
position unknown blinking 1/s blinking 1/s
error while closing off blinking 2/s
error while opening blinking 2/s off
error else alternating 2/s alternating 2/s

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8 Technical Data
8.1 PCL-Power Control
PCL-PC is a short circuit snooping device in a separate casing. This device is used inside the bus master
cabinet to feed the power bus. One device is required at each end of each power loop. The function is the
same like the circuitry used on the PCL-VCI. A separate input is used to turn off the power bus. The correct
supply of the power loop is indicated by a green LED.
Note: Each PCL-VCI and each PCL-Power Control turns the phases 180°. In order to connect both ends of
the power loop the same phases must be connected to the same terminal.
even no of drives supply inputs L1 and L2 or PCL-PC are parallel
odd no of drives supply inputs L1 and L2 or PCL-PC are anti-parallel

Pin layout (Version 9321209840, new)

Pin I/O Meaning
1 in Power supply L1, A side
2 in
3 in Power supply L2, A side
4 out
5 out Power bus L2, B side
6 out
7 out Power bus L1, B side
8 out
9 out Make contact, supply OK
10 in Make contact, supply OK
11 in 0V, turn off power supply
12 24V, turn off power supply

Pin layout (Version 9321209820, old)

Pin I/O Meaning
1 in Power supply L1
2 in Power supply L2
3 in Nc
4 out Power bus L2
5 out Power bus L1
6 out Nc
7 out Make contact, supply OK
8 out Make contact, supply OK
9 out 0V, turn off power supply
10 in 24V, turn off power supply
11 in Same as 8
12 Same as 9

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9 The set-up Program PclService

The program PclService is used to edit and transfer parameters between a PC and the PCL masters. The
program works under Windows 98/NT/2000/XP. One serial port of the PC must be connected with the si-
Service interface of the PCL master by means of a standard interface cable 2xSub-D 9-pol female (2x3).
The program provides two display windows. The upper one replaces the LCD terminal of the bus master cabi-
net. The large one is used to display and edit the parameters. Each of the windows may be activated by click-
ing at it. The activated window is indicated by a 3D frame and receives all keyboard input.
After connecting the PC to the PCL master and selecting the right Com port the master output is displayed in
the small terminal window. Please note that the status panel must show the message “port opened”.

9.1 Opening, Editing and Saving Parameter Files

The “Open” Button is used to select and load a parameter file with the extension “pcl”. These file are struc-
tured like ”ini” files. The different sections are separated by section names in [ ]. Each parameter within such a
section begins with a parameter name and a “=” sign followed by the parameter value. The parameter names
are equal to the names in the PCL master menu.
The sections are:
[PclMaster] similar to “Set PCL Param.” menu
Please note that the Parameter CodeCRC is ignored in this application. The parameter “Baudrate” in inserted
for future use and must not be changed.
[MbSlave] like the “Set Modbus Param.” menu
[Slot i] with i = 1..5 used for IO mapping like “Set IO mapping” menu

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[Node i] with i = 1 .. number of nodes, in which i is equal to the position of the node
This parameter file may be edited within the editor window. Please keep in mind that parameters with invalid
or misspelled names are ignored and replaced by their default values. Use the “save” button to store the pa-
rameters in a file.

9.2 Upload and Download of Parameters

Pressing the “Download” button starts the transferring of the parameters to the PCL master. The parameters
on the PCL master are overwritten.
Pressing the “Upload” button starts the transferring of the parameters from the PCL master. The parameters in
the terminal window are overwritten.

9.3 Disconnect serial interface

The “Disconnect” button simply releases the Com port and interrupts the data transfer.

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