C-DIAS PROCESSOR MODULE
CCP 521
C-DIAS Processor Module
The CCP 521 processor module runs the control program and thereby represents an essential component of an automation system. The internal DC/DC converter powers all modules on a C-DIAS module carrier. The VAR
AN bus, the CAN bus, an Ethernet interface or the USB device (Mini USB) can be used as the online interface connection. A 7-segment display and 2 status LEDs provide information on the actual status of the CPU. For program updates, the integrated USB Host interface can be used (USB stick, keyboard). With help from the exchangeable SD card, the entire control program can be easily exchanged. The CCP 521 processor module is designed to be mounted in the control cabinet.
CCP 521
Compatibility Completely PC-compatible. The CCP 521 works with standard PC BIOS and therefore no SIGMATEK-specific BIOS is needed; the LASAL operating system in provided.
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CCP 521
C-DIAS PROCESSOR MODULE
Technical Data
Performance data
Processor Addressable I/O/P modules EDGE-Technology X86 compatible VARAN bus: 65,280 CAN bus: 32 C-DIAS bus: 8 No 32-kbyte L1 Cache 256-kbyte L2 Cache AMI 64 Mbytes 512 Kbytes 1-Gbyte micro SD card 1 x USB Host 2.0 (full speed 12 Mbit/s) 1 x USB Device 1.1 1 x Ethernet 1 x CAN 1 x VARAN 1 x C-DIAS Yes Yes Yes Yes (buffering approximately 10 days)
Internal I/O Internal cache BIOS Internal program and data memory (DDR2 RAM) Internal remnant data memory Internal storage device (IDE) Interface connections
Data buffer Status display Status LEDs Real-time clock
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C-DIAS PROCESSOR MODULE Electrical requirements
Supply voltage Current consumption of (+24 V) power supply Starting current Power supply on the C-DIAS bus Current load on C-DIAS bus (power supply for I/O/P modules). Typically 150 mA +18 –30 V DC
CCP 521
Maximum 500 mA
For a very short time (~20 ms) : 30 A Supplied by the CCP 521 Maximum 1.2 A
Standard configuration
Ethernet 1 CAN bus IP: 10.10.150.1 Station: 00 Subnet-Mask: 255.0.0.0 Baud rate: 01 = 500 kBaud
Problems can arise if a control is connected to an IP network, which contains modules that do not contain a SIGMATEK operating system. With such devices, Ethernet packets could be sent to the control with such a high frequency (i.e. broadcasts), that the high interrupt load could cause a real-time runtime error. By configuring the packet filter (Firewall or Router) accordingly however, it is possible to connect a network with SIGMATEK hardware to a third party network without triggering the error mentioned above.
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CCP 521 Miscellaneous
Article number Hardware version Project back-up Standard
C-DIAS PROCESSOR MODULE
12-104-521 1.x Internally on the micro SD card UL in preparation
Environmental conditions
Storage temperature Operating temperature Humidity EMV stability
Shock resistance Protection Type -10 –+85 °C 0 –+50 °C 10 - 90 %, uncondensed According to EN 61000-6-2 (industrial area) EN 60068-2-27 EN 60529 150 m/s? IP 20
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C-DIAS PROCESSOR MODULE
CCP 521
Mechanical Dimensions
104.10 (dimensioning incl. covers)
109.2
129
24.90
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CCP 521
C-DIAS PROCESSOR MODULE
Connector Layout
PC通讯
底层通讯
电源
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C-DIAS PROCESSOR MODULE X1: USB Device 1.1
CCP 521
Pin 1 2 3 4 5
Assignment +5 V DD+ GND
X2: USB Host 2.0
Pin 1 2 3 4 Assignment +5 V DD+ GND
It should be noted that many USB devices on the market do not comply with the relevant EMC standards for industrial environments. Connecting such a device can lead to malfunctions.
X3: Ethernet
Pin 1 2 3 4-5 6 7-8 Assignment TX+ TXRX+ RX-
X4: VARAN
Pin 1 2 3 4-5 6 7-8 Assignment TX+ / RX+ TX- / RXRX+ / TX+ RX- / TX-
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CCP 521 X5: CAN-Bus
C-DIAS PROCESSOR MODULE
12
Pin 1 2 3 4 5 6
Assignment CAN A (CAN LOW) CAN B (High) CAN A (CAN LOW) CAN B (High) GND -
56
X6: Power plug
1
Pin 1 2
Assignment +24 V supply GND
X7: micro SD card Sandisk SDSDQ-1024-K
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C-DIAS PROCESSOR MODULE Exchanging the micro SD card
CCP 521
The micro SD card is located under the LED cover.
To exchange the micro SD card, carefully lift the LED cover.
The micro SD card is located on the left side and can be disengaged by lightly pressing on the card itself.
Remove the micro SD card.
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CCP 521
C-DIAS PROCESSOR MODULE
Applicable connectors USB Device: USB Host: Ethernet: VARAN: CAN-Bus: Supply: 5-pin, type mini B 4-pin, type A 8-pin, RJ45 8-pin, RJ45 6-pin Weidmüller plug, B2L3, 5/6 2-pin Phoenix plug with screw terminal technology MC1, 5/2-ST-3,5 2-pin Phoenix plug with spring terminal FK-MCP1, 5/2-ST-3
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C-DIAS PROCESSOR MODULE
CCP 521
Status Displays
Ethernet LED Active Link Color Yellow Green Description Lights when data is exchanged over Ethernet Lights when the connection between
the two PHYs is established VARAN LED Active Link Color Yellow Green Description Lights when data is exchanged over the VARAN bus Lights when the connection between the two PHYs is established Control LED ERROR DCOK Color Red Green Description Lights when an error occurs (defective USV) Lights when the power supply is OK
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CCP 521
C-DIAS PROCESSOR MODULE
Display
The CCP 521 processor module has a 2-digit decimal display (7 segment display) for the following functions:
- When configuring the processor module, the parameters are shown in the display. - If an error occurs while running the program or no valid user program is found, the display
shows an error message. Thereby, "Er" (error) and the error code are
displayed alternatingly. The same error code is also shown in the LASAL status line.
- While running the program, the display can be used to show digits using the system vari-
able _cpuDisplay. Valid values are 0 to 255; values over 99, however, are not shown and the display remains dark.
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C-DIAS PROCESSOR MODULE
CCP 521
CAN Bus Setup
This section explains how to configure a CAN bus correctly. The following parameters must first be set: Station number and data transfer rate. CAN bus station number Each CAN bus station is assigned its own station number. With this station number, data can be exchanged with other stations connected to the bus. Up to 31 stations can be installed in a CAN
bus system. However, each station number can only be assigned once. CAN bus data transfer rate The data transfer rate (baud rate) for the CAN bus can be set. However, the longer the length of the bus, the smaller the transfer rate that must be selected.
Value 00 01 02 03 04 05 06 07
Baud rate 615 kBit/s 500 kbit/s 250 kBit/s 125 kBit/s 100 kBit/s 50 kBit/s 20 kBit/s 1 Mbit / s
Maximum length 60 m 80 m 160 m 320 m 400 m 800 m 1200 m 30 m
These values are valid for the following cable: 120 ?, Twisted Pair. NOTE: the following is valid for the CAN bus protocol: 1 kBit/s = 1 kBaud.
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CCP 521
C-DIAS PROCESSOR MODULE
Configuration of the Process Module
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C-DIAS PROCESSOR MODULE
CCP 521
To enter the mode for setting changes, press and hold the SET button while the C-IPC is booting. When the following appears in the display:
the SET button can be released. After releasing the SET button, the first menu appears in the display.
With several short presses of the SET button, it is possible to switch through the various menu points. By pressing the SET button for approximately 1.5 s, the menu is accessed and the setting can be changed with short presses. Once the desired changes are made, press the SET button for about 5 seconds to end the process. If the changes are
to be discarded, press the RESET button to restart the C-IPC. The settings for the IP address, subnet mask and gateway are hexadecimal, whereas in the left and right digits, 0 - F must be entered separately. The switch occurs when the SET button is pressed for about 1.5 s. The values from AUTOEXEC.LSL are used as the standard settings; changes are written back to this file. Before this, the original content of the file is written to AUTOEXEC.BAK.
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CCP 521
C-DIAS PROCESSOR MODULE
C1 ... CAN PLC station 00 –30 ... Station number
C2 ... CAN PLC baud rate 00 ... 615.000 01 …500.000 02 …250.000 03 …125.000 04 …100.000 05 …50.000 06 …20.000 07 …1.000.000 I1, I2, I3, I4 IP address I1.I2.I3.I4, Hexadecimal 00 –FF respectively
S1,S2,S3,S4 Subnet Mask S1.S2.S3.S4, hexadecimal 00 –FF respectively
G1,G2,G3,G4 Gateway G1,G2.G3.G4, hexadecimal 00 –FF respectively
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C-DIAS PROCESSOR MODULE
CCP 521
CAN Bus Termination
In a CAN bus system, both end modules must be terminated. This is necessary to avoid transmission errors caused by reflections in the line.
Device 1
e.g. CPU DCP 080 CAN-Bustermination on terminal module
Device 2
e.g. Terminal ET 081
Device 3
Device n
e.g. Terminal ET 805 D-SUB-plug with terminating resistors
CAN-Bus-Connections
If the CCP 521 processor module is an end module, it can be terminated by placing a 150Ohm resistor between CAN-A (Low) and CAN-B (High).
1 x 150-Ohm resistor
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CCP 521
C-DIAS PROCESSOR MODULE
Wiring and Mounting Instructions
Earth Connection
The CCP 521 must be connected to earth over the mounting on the back wall of the control cabinet or over the earth terminal provided (C-DIAS module carrier). It is important to create a low-ohm earth connection, only then can error-free operation be guaranteed. The earth connection should have the maximum cross section and the largest electrical surface possible. Any noise signals that reach the CCP 521 over external cables must be filtered out over the earth connection. With a large (electrical) surface, high frequency noise can also be well dissipated.
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C-DIAS PROCESSOR MODULE
CCP 521
Shielding
The wiring for the CAN bus, Ethernet and VARAN bus must be shielded. The low-ohm shielding is either connected at the entry to the control cabinet or directly before the CCP 521 processor module over a large surface (cable grommets, grounding clamps)! Noise signals can therefore
be prohibited from reaching the electronics and affecting the function.
ESD Protection
Before any device is connected to or disconnected from the CCP 521, the potential with ground should be equalized (by touching the control cabinet or earth terminal). Static electricity (from clothing, footwear) can therefore be reduced.
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CCP 521
C-DIAS PROCESSOR MODULE
Process Diagram
Main voltage on
Online with Lasal Software?
no
yes Output of a reset of the peripheral modules Output of a reset of the peripheral modules
Deletion of specific data areas
Deletion of specific data areas
Status RESET
Program in external memory module functional?
no
yes Copy program into application program memory Program in internal memory module functional? no
yes Status RUN ROM Copy program into application program memory Status CHKSUM or POINTER
Call of application program
Status RUN ROM
Call of application program
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C-DIAS PROCESSOR MODULE
CCP 521
Status and Error Messages
Status and error messages are shown in the status test of the Lasal Class software. If the CPU has a status display, the status or error number is also show here as well. POINTER or CHKSUM messages can also be shown on the terminal screen.
Number 00 Message RUN RAM Definition The user program is currently running in RAM. The display is not affected. 01 RUN ROM The user program in the program memory module was loaded into the RAM and is currently being run. The display is not affected. 02 RUNTIME The total duration of all cyclic objects exceeds the maximum time; the time can be
configured using 2 system variables: -Runtime: time remaining -SWRuntime: pre-selected value for the runtime counter 03 POINTER Incorrect program pointers were detected before running the user program Possible Causes: Cause/solution
- The program memory module is
missing, not programmed or defect.
- The program in the user program
memory (RAM) is not executable.
- The user program is overwriting a
software error Solution:
- Reprogram the memory module, if the
error reoccurs exchange the module.
- Correct programming error
04 CHKSUM An invalid checksum was detected before running the user program. Cause/solution: s. POINTER
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CCP 521
05
C-DIAS PROCESSOR MODULE
Watchdog The program was interrupted through the watchdog logic. Possible Causes:
- User program interrupts blocked
over a longer period of time (STI command forgotten)
- Programming error in a hardware
interrupt.
- INB, OUTB, INW, OUTW instructions used incorrectly.
- The processor is defect.
Solution:
- Correct programming error.
- Exchange CPU. 06 07 GENERAL ERROR PROM DEFECT General error An error has occurred while programming the memory module. Cause:
- The program memory module is
defect.
- The user program is too large. - The program memory module is missing. Solution:
- Exchange the program memory
module 08 Reset The CPU has received the reset signal and is waiting for further instructions. The user program is not processed. 09 WD DEFEKT The hardware monitoring circuit (watchdog logic) is defect. After power-up, the CPU checks the watchdog logic function. If an error occurs during this test, the CPU deliberately enters an infinite loop from which no further instructions are accepted. 10 11 12 13 14 STOP PROG BUSYS PROGRAM LENGTH PROG END PROG MEMO The memory module was successfully completed. The CPU is currently programming the memory module. Solution: Exchange CPU.
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C-DIAS PROCESSOR MODULE
15 16 17 STOP BRKPT CPU STOP INT ERROR The CPU was stopped by a breakpoint in the program. The CPU was stopped by the PG software (F6 HALT in status test). The CPU has triggered a false interrupt and stopped the user program or has encountered an unknown instruction while running the program. Cause:
CCP 521
- A nonexistent operating system was
used.
- Stack error (uneven number of PUSH
and POP instructions).
- The user program was interrupted by
a software error. Solution: - Correct programming error. 18 19 20 21 22 SINGLE STEP Ready LOAD UNZUL. Modul MEMORY FULL The CPU is in single step mode and is waiting for further instructions. A module or project has been sent to the CPU and it is ready to run the program. The
program has stopped and is receiving a module or project. The CPU has received a module, which does not belong to the project. The operating system memory /Heap) is too small. No more memory could be reserved, when an internal or interface function was called from the application. When starting the CPU, a missing module or a module that does not belong to the project was detected. A division error has occurred. Possible Causes:
23
NOT LINKED
24
DIV BY 0
- Division by 0. - The result of a division does not fit in
the result register. Solution: - Correct programming error.
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CCP 521
25
C-DIAS PROCESSOR MODULE
DIAS ERROR An error has occurred accessing a DIAS module. while Possible Causes:
- An attempt is made to access
a nonexistent DIAS module.
- DIAS bus error.
Solution:
- Check the DIAS bus - Check the termination resistors. 26 27 28 29 30 WAIT OP PROG OP INSTALLED OS TOO LONG NO OPERATING SYSTEM The CPU is busy. The operating system is currently being reprogrammed. The operating system has been reinstalled. The operating system cannot be loaded; too little memory. Boot loader message. No operating system found in RAM. 31 32 33 34 SEARCH FOR OS NO DEVICE UNUSED CODE MEM ERROR The operating system loaded does not match the hardware configuration. The boot loader is searching for the operating system in
RAM.
35 36 37
MAX IO MODULE LOAD ERROR GENERELLER BS-FEHLER The LASAL Module or project cannot be loaded. A general error has occurred while loading the operating system. An error has occurred in the application memory (user heap).
38 39 40 41
APPLMEM ERROR OFFLINE APPL LOAD APPL SAVE
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C-DIAS PROCESSOR MODULE
46 47 50 APPL-LOAD-ERROR APPL-SAVE-ERROR ACCESS-EXCEPTIONERROR BOUND EXCEEDED PRIVILEDGED INSTRUCTION An error has occurred loading the application. while
CCP 521
An error has occurred while attempting to save the application. Read or write access of a restricted memory area. (I.e. writing to the NULL pointer). An exception error caused by exceeding the memory limits An unauthorized instruction for the current CPU level was given. For example, setting the segment register. An error has occurred during a floating-point operation. Error from ASMaster. the Intelligent DIRestart; report error to Sigmatek.
51 52
53 60 64 65 66 67
FLOATING POINT ERROR DIAS-RISC-ERROR INTERNAL ERROR FILE ERROR DEBUG ASSERTION FAILED REALTIME RUNTIME
An internal error has occurred, all applications are stopped. An error has occurred during a file operation. Internal error. The total duration of all real-time objects exceeds the maximum time; the time cannot be configured. 2 ms for 386 CPUs 1 ms for all other CPUs
Restart; report error to Sigmatek. Starting from Version 1.1.7
68
BACKGROUND RUNTIME
The total time for all background objects exceed the maximum time; the time can be configured using two system variables: -BTRuntime: time remaining -SWBTRuntime: pre-selected value for the runtime counter
95 96 97 98
USER DEFINED 0 USER DEFINED 1 USER DEFINED 2 USER DEFINED 3
User-definable code. User-definable code. User-definable code. User-definable code.
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CCP 521
99 100 101 102 103 104 105 106
C-DIAS PROCESSOR MODULE
USER DEFINED 4 C_INIT C_RUNRAM C_RUNROM C_RUNTIME C_READY C_OK C_UNKNOWN_CID The CPU is ready for operation. The CPU is ready for operation. An unknown class from a standalong or embedded object: unknown base class. The operating system class cannot be created; the operating system is probably wrong. Reference to an unknown object in an interpreter program, creation of more than one DCC080 object. The hardware module number is greater than 60. No connection to the required channels. Wrong server attribute. No specific error, recompile all and reload project components. An attempt was made to open an unknown table. Memory allocation error Memory allocation error User-definable code. Initialization start; the configuration is run. The LASAL project was successfully started from RAM. The LASAL project was successfully started from ROM.
107
C_UNKNOWN_CONSTR
108
C_UNKNOWN_OBJECT
109 110 111 112 113 114 115
C_UNKNOWN_CHNL C_WRONG_CONNECT C_WRONG_ATTR C_SYNTAX_ERROR C_NO_FILE_OPEN C_OUTOF_NEAR C_OUT OF_FAR
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C-DIAS PROCESSOR MODULE
116 117 224 225 C_INCOMAPTIBLE C_COMPATIBLE LINKING LINKING ERROR An object with the same name exists but has another class. An object with the same name and class exists but must be updated. The application is currently linking. An error has occurred while linking. An error messaged is generated in the LASAL status window. Linking is complete. The operating system is currently being burned into the Flash memory. An error has occurred while burning the operating system. The operating system is currently being installed. The power supply was disconnected; the UPS is active. The operating system is restarted.
CCP 521
226 230 231 232 240 241 242 243 252 253 254 255
LINKING DONE OP BURN OP BURN FAIL OP INSTALL USV-WAIT Reboot LSL SAVE LSL LOAD CONTINUE PRERUN PRERESET CONNECTION BREAK
The application is started. The application is ended.
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CCP 521
C-DIAS PROCESSOR MODULE
Application exceptions
SRAM and IRQ routines Writing remnant data during interrupt routines is not allowed and leads to a system crash. SRAM and consistency of changed data If more than 32 different sectors are changed (512 bytes
each) shortly before shutting down the voltage supply while the user program is writing to the micro SD card, this can sometimes lead to partial loss of remnant data. The file system does not support safe writing through SRAM If files are stored, modified or written on the micro SD card from the user program, these files must always be stored with a fixed maximum size. Since changes in size and the simultaneous shutdown of the voltage supply can corrupt the file system, a later change in the file size is not allowed. Data Breakpoint This CPU does not support the data breakpoint is a feature.
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C-DIAS PROCESSOR MODULE
CCP 521
Recommended Shielding for VARAN
The real-time VARAN Ethernet bus system exhibits very robust characteristics in industrial environments. Through the use of IEEE 802.3 standard Ethernet physics, the potentials between an Ethernet line and
sending/receiving components are separated. Messages to a bus participant are immediately repeated by the VARAN Manager in the event of an error. The shielding described below is principally recommended. For applications in which the bus is run outside the control cabinet, the correct shielding is required. Especially when for structural reasons, the bus line must be placed next to strong electromagnetic interference. It is recommended to avoid placing Varan bus lines parallel to power cables whenever possible. SIGMATEK recommends the use of CAT5e industrial Ethernet bus cables. For the shielding, an S-FTP cable should be used. An S-FTP bus is a symmetric, multi-wire cable with unshielded pairs. For the total shielding, a combination of foil and braiding is used. A non-laminated variant is recommended.
The VARAN cable must be secured at a distance of 20 cm from the connector for protection against vibration!
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CCP 521
C-DIAS PROCESSOR MODULE
1. Wiring from the Control Cabinet to an External VARAN Component
If the Ethernet lines are connected from a VARAN component to a VARAN node located outside the control cabinet, the shielding should be placed at the entry point to the control cabinet housing. All noise can then be dissipated before reaching the electronic components.
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C-DIAS PROCESSOR MODULE
CCP 521
2. Wiring Outside of the Control Cabinet
If a VARAN bus cable must be placed outside of the control cabinet, additional shielding is not required. Outside of the control cabinet, IP67 modules and connectors are used exclusively. These components are very robust and noise resistant. The shielding for all sockets in IP67
modules is electrically connected internally or over the housing, whereby voltage spikes are not deflected through the electronics.
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CCP 521
C-DIAS PROCESSOR MODULE
3. Shielding for Wiring Within the Control Cabinet
Sources of strong electromagnetic noise located within the control cabinet (drives, Transformers, etc.) can induce interference in a VARAN bus line. Voltage spikes are dissipated over the metallic housing of a RJ45 connector. Noise is conducted over the control cabinet without additional measures needed on the circuit board of electronic components. To avoid error sources with data exchange, it is recommended that shielding be placed before any electronic components in the control cabinet.
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C-DIAS PROCESSOR MODULE
CCP 521
4. Connecting Noise-Generating Components.
When connecting power lines to the bus that generate strong electromagnetic noise, the correct shielding is also important. The shielding should be placed before a power element (or group of power elements).
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CCP 521
C-DIAS PROCESSOR MODULE
5. Shielding Between Two Control Cabinets
If two control cabinets must be connected over a VARAN bus, it is recommended that the shielding be located at the entry points of each cabinet. Noise is therefore prevented from reaching the electronic components in both cabinets.
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