Bosch CL400 User manual

Antriebs- und Steuerungstechnik
COM-E
Module Description
CL400 / CL500
101
Edition

CL400 / CL500
COM-E
Module Description
1070 072 196-101 (00.06) GB
E2000
by Robert Bosch GmbH, Erbach / Germany
All rights reserved, including applications for protective rights.
Reproduction or distribution by any means subject to our prior written permission.
Discretionary charge 10.00 DM

Contents I
1070 072 196-101 (00.06) GB
Contents
Page
1 Safety Instructions 1--1............................
1.1 Intended Use 1--1...........................................
1.2 Qualified Personnel 1--2.....................................
1.3 Safety Markings on Components 1--3..........................
1.4 Safety Instructions in this Manual 1--4.........................
1.5 Safety Instructions for the Described Product 1--5...............
1.6 Documentation, Software Release and Trademarks 1--7.........
2 Hardware 2--1.....................................
2.1 Front Panel 2--2............................................
2.2 Slot 2--4...................................................
2.3 V.24/20 mA Interface 2--5....................................
2.4 Ethernet Interface 2--6.......................................
2.5 Settings on the COM-E 2--7..................................
2.5.1 Block Address of COM-E 2--8................................
2.5.2 Protocol-Specific Settings 2--9................................
2.5.3 Protocol-Specific Settings V.24/20 mA 2--9.....................
2.5.4 Ethernet-Specific Settings 2--13................................
2.6 Configuration File 2--14.......................................
2.6.1 Keywords 2--14..............................................
2.6.2 Example of a Configuration File 2--19...........................
2.7 Status Display 2--20..........................................
2.8 Technical Data 2--21.........................................
3 PLC Interface 3--1.................................
4R5INIT 4--1.......................................
4.1 Characteristics 4--1.........................................
4.2 Parameters 4--1............................................
4.2.1 Input Parameters 4--2.......................................
4.2.2 Output Parameters 4--3......................................
5R5REQ 5--1.......................................
5.1 Characteristics 5--1.........................................
5.2 Parameters 5--1............................................
5.2.1 Input Parameters 5--2.......................................
5.2.2 Output Parameters 5--4......................................
5.3 Meaning of the Parameters in the Data Storage Area 5--5........
5.3.1 Protocol-Independent Parameters 5--6.........................
5.3.2 Protocol-Dependent Parameters 5--7..........................
6R5CON 6--1.......................................
6.1 Characteristics 6--1.........................................
6.2 Parameters 6--1............................................
6.2.1 Input Parameters 6--2.......................................
6.2.2 Output Parameters 6--3......................................

Contents
II
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7 General Information Regarding BUEP-E
and BUEP19E 7--1................................
7.1 Parameter BUEP-E / BUEP19E 7--2...........................
7.1.1 Protocol-Independent Parameters 7--3.........................
7.1.2 Protocol-Specific Parameters 7--5.............................
7.2 Command Description for Central Units 7--10....................
7.2.1 Field Commands 7--10.......................................
7.2.2 Special Commands 7--11.....................................
7.3 Error Messages 7--13........................................
7.3.1 Parameter 3, Status / PLC Reaction R5CON 7--13...............
7.3.2 Parameter 4, Error Messages R5CON 7--14.....................
7.3.3 Catalogue of Errors 7--15.....................................
7.4 Password 7--17..............................................
8 TFTP Protocol 8--1................................
9 Ethernet Job Listing 9--1..........................
9.1 Client Command 9--5........................................
9.2 Server Command 9--6.......................................
9.3 Error Messages 9--7........................................
9.3.1 Client Error Messages 9--7...................................
9.3.2 Server Error Messages 9--7..................................
9.3.3 ICMP Error Messages 9--7...................................
10 Time Characteristics 10--1..........................
11 PLC Program Examples 11--1.......................
11.1 Function Module 11--1........................................
11.2 Job Parameters in the Data Module 11--6.......................
A Appendix A--1.....................................
A.1 Abbreviations A--1..........................................
A.2 Index A--2.................................................

Safety Instructions 1--1
1070 072 196-101 (00.06) GB
1 Safety Instructions
Before you start working with COM-E, we recommend that you thoroughly
familiarize yourself with the contents of this manual. Keep this manual in a
place where it is always accessible to all users.
1.1 Intended Use
This instruction manual presents a comprehensive set of instructions and in-
formation required for the standard operation of the described products.
The products described hereunder
Dwere developed, manufactured, tested and documented in accordance
with the relevant safety standards. In standard operation, and provided
that the specifications and safety instructions relating to the project
phase, installation and correct operation of the product are followed,
there should arise no risk of danger to personnel or property.
Dare certified to be in full compliance with the requirements of the
DEMC Directives (89/336/EEC 93/68/EEC, and 93/44/EEC)
DLow-Voltage Directive (73/23/EEC)
DHarmonized standards EN 50081-2 and EN 50082-2
Dare designed for operation in an industrial environment (Class A emis-
sions). The following restrictions apply:
DNo direct connection to the public low-voltage power supply is per-
mitted.
DConnection to the medium and/or high-voltage system must be pro-
vided via transformer.
The following applies for application within a personal residence, in busi-
ness areas, on retail premises or in a small-industry setting:
DInstallation in a control cabinet or housing with high shield attenua-
tion.
DCables that exit the screened area must be provided with filtering or
screening measures.
DThe user will be required to obtain a single operating license issued by
the appropriate national authority or approval body. In Germany, this
is the Federal Institute for Posts and Telecommunications, and/or its
local branch offices.
.This is a Class A device. In a residential area, this device may cause
radio interference. In such case, the user may berequired to introduce
suitable countermeasures, and to bear the cost of the same.
Proper transport, handling and storage, placement and installation of the
product are indispensable prerequisites for its subsequent flawless service
and safe operation.

Safety Instructions
1--2
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1.2 Qualified Personnel
This instruction manual is designed for specially trained personnel. The rele-
vant requirements are based on the job specifications as outlined by the
ZVEI and VDMA professional associations in Germany. Please refer to the
following German-Language publication:
Weiterbildung in der Automatisierungstechnik
Publishers: ZVEI and VDMA Maschinenbau Verlag
Postfach 71 08 64
60498 Frankfurt/Germany
This instruction manual is specifically designed for specially trained PLC
technicians. They are required to have special skills and knowledge regard-
ing programmable logic controllers.
Programming, start and operation as well as the modification of program pa-
rameters may only be executed by specially trained personnel! This person-
nel must be able to recognize possible hazards that might be caused by
programming and program modification, and in general by mechanical,
electrical or electronical equipment.
Interventions in the hardware and software of our products not described in
this instruction manual may only be performed by our skilled personnel.
Unqualified interventions in the hardware or software or non-compliance
with the warnings listed in this instruction manual or indicated on the product
may result in serious personal injury or damage to property.
Installation and maintenance of the products described hereunder is the ex-
clusive domain of trained electricians as per IEV 826-09-01 (modified) who
are familiar with the contents of this manual.
Trained electricians are persons of whom the following is true:
DThey are capable, due to their professional training, skills and expertise,
and based upon their knowledge of and familiarity with applicable techni-
cal standards, of assessing the work to be carried out, and of recognizing
possible dangers.
DThey possess, subsequent to several years’ experience in a comparable
field of endeavor, a level of knowledge and skills that may be deemed
commensurate with that attainable in the course of a formal professional
education.
With regard to the foregoing, please read the information about our compre-
hensive training program. The professional staff at our training center will be
pleased to provide detailed information. You may contact the center by tele-
phone at ([phone].

Safety Instructions 1--3
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1.3 Safety Markings on Components
DANGER! High voltage!
DANGER! Corrosive battery acid!
CAUTION! Electrostatically sensitive components!
Disconnect mains power before opening!
Lug for connecting PE conductor only!
Functional earthing or low-noise earth only!
Screened conductor only!

Safety Instructions
1--4
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1.4 Safety Instructions in this Manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol warns of the presence of a dangerouselectrical voltage.In-
sufficient of lacking compliance with this warning can result in personal
injury.
DANGER
This symbol is used wherever insufficient or lacking observance of this in-
struction can result in personal injury.
CAUTION
This symbol is used wherever insufficient or lacking observance of instruc-
tions can result in damage to equipment or data files.
.This symbol is used to alert the user to an item of special interest.

Safety Instructions 1--5
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1.5 Safety Instructions for the Described Product
DANGER
Fatal injury hazard through ineffective Emergency-OFF devices!
Emergency-OFF safety devices must remain effective and accessi-
ble during all operating modes of the system. The release of func-
tional locks imposed by Emergency-OFF devices must never be al-
lowed to cause an uncontrolled system restart!
Before restoring power to the system, test the Emergency-OFF se-
quence!
DANGER
Danger to persons and equipment!
Test every new program before operating the system!
DANGER
Retrofits or modifications may interfere with the safety of the prod-
ucts described hereunder!
The consequences may be severe personal injury or damage to
equipment or the environment. Therefore, any system retrofitting or
modification utilizing equipment components from other manufac-
turers will require express approval by Bosch.
DANGEROUS ELECTRICAL VOLTAGE
Unless described otherwise, maintenance procedures must always
be carried out only while the system is isolated from the power sup-
ply. During this process, the system must be blocked to prevent an
unauthorized or inadvertent restart.
If measuring or testing procedures must be carried out on the active
system, these must be carried out by trained electricians.
CAUTION
Danger to the module!
Do not insert or remove the module while the controller is switched
ON! This may destroy the module. Prior to inserting or removing the
module, switch OFF or remove the power supply module of the con-
troller, external power supply and signal voltage!
CAUTION
Only Bosch-approved spare parts may be used!

Safety Instructions
1--6
1070 072 196-101 (00.06) GB
CAUTION
Danger to the module!
AllESDprotection measuresmust beobservedwhen usingthemod-
ule! Prevent electrostatic discharges!
Observe the following protective measures for electrostatically endangered
modules (EEM)!
DThe Employees responsible for storage, transport and handling must be
trained in ESD protection.
DEEMs must be stored and transported in the protective packaging speci-
fied.
DOut of principle, EEMs may be handled only at special ESD work stations
equipped for this particular purpose.
DEmployees, work surfaces and all devices and tools that could come into
contact with EEMs must be on the same potential (e.g. earthed).
DAn approved earthing wrist strap must be worn. It must be connected to
the work surface via a cable with integrated 1 MΩresistor.
DEEMs may under no circumstances come into contact with objects sus-
ceptible to accumulating an electrostatic charge. Most items made of
plastic belong to this category.
DWhen installing EEMs in or removing them from an electronic device, the
power supply of the device must be switched OFF.

Safety Instructions 1--7
1070 072 196-101 (00.06) GB
1.6 Documentation, Software Release and Trademarks
Documentation
The present manual provides the user with comprehensive information
about the COM-E module.
Overview of available manuals:
Manuals Language Order no.
COM-E Module Description English 1070 072 196
R500 Computer Interface Module English 1070 072 131
Hexadecimal numbers are represented by a sub H (FFH) or they are written
the same way as they must be entered (16#FFFF).
Release
.This manual applies to the following versions:
Hardware version: 1.1
Firmware version: starting at 1.2
See also chapter 2.5.4.
Trademarks
All trademarks referring to software that is installed on Bosch products when
shipped from the factory represent the property of their respective owners.
At the time of shipment from the factory, all installed software is protected by
copyright. Software may therefore be duplicated only with the prior permis-
sion of the respective manufacturer or copyright owner.
MS-DOSrand Windowstare registered trademarks of Microsoft Corpo-
ration.

Safety Instructions
1--8
1070 072 196-101 (00.06) GB

Hardware 2--1
1070 072 196-101 (00.06) GB
2 Hardware
The COM-E module is provided with a serial V.24/20 mA interface and an
Ethernet interface (10Base-T) which make it possible to couple the CL400 /
CL500 controllers with other Bosch controllers or other communication-ca-
pable devices.
Power Supply The COM-E does not require an external power supply. All supply voltages
are provided by the CL400 / CL500’s power supply unit.
Compatibility with R500P, R500MAP, R500M-EN and COM-P
The COM-E’s hard- and software concept makes it possible to operate the
COM-E in combination with the COM-P, R500P, R500, R500MAP, and
R500M-EN modules in the CL400 / CL500 basic device.
To address the COM-E from the PLC program, the function modules for com-
puter interfaces are to be linked to the PLC program.

Hardware
2--2
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2.1 Front Panel
Link
Transmit
Receive
Status display
Channel 0
25-pin socket
Reset button
Link-LED
Receive-LED
Transmit-LED
10Base-T
Labeling field
Version identification
Status display
Channel 1
V.24/20 mA
Channel 0
Ethernet socket
Channel 1
Status Display
Each of the two channels on the COM-E is provided with a status display.
DFor channel 0, the upper 7-segment display is responsible.
DFor channel 1, the lower 7-segment display is responsible.
Interfaces
DThe X31 interface is a V.24/20 mA interface. It is used for point to point
coupling to an external device or as a diagnosis/protocol monitor for the
Ethernet interface, compare with Tracer for PROFIBUS-FMS.
DThe 10Base-T connector is used for the connection to the Ethernet net-
work.

Hardware 2--3
1070 072 196-101 (00.06) GB
Reset Button
Pressing the reset button starts reinitialization of COM-E’s operating soft-
ware.
DAll active jobs are aborted undefined.
DAll jobs are deleted from the job queue.
DSTOP and CLAB requests of the module are deleted.
Link-LED
This LED indicates that the link integrity signals can be exchanged between
COM-E and the coupled partner device. This way it is possible to enable a
communication between both stations.
Receive/Transmit-LED
These LEDs indicate the data traffic. They are lit when messages are going
out or coming in.
Identification of Version
This label identifies the revision level of the module. Changes are marked by
a black point.
Labeling Field The labeling field is for you, the user, to identify the module according to your
plant’s identification system. This e.g. might be the module’s block address
or the IP address.

Hardware
2--4
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2.2 Slot
A maximum of 5 COM-Es can be operated in a PLC. In server operation,
even more modules can be implemented.
CL400 For the CL400, the slots 4 to 14 in the GG2 are at your free disposal.
12345678910 12 12 13 14
In GG2/K, the slots 4 to 8 are freely available.
12345678
CL500
For the CL500, the slots 5 to 14 in the GG2 are at your free disposal.
12345678910 12 12 13 14
In GG2/K, the slots 5 to 8 are freely available.
12345678

Hardware 2--5
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2.3 V.24/20 mA Interface
The V.24/20 mA interface is available at channel 0. Via this interface, devices
that are equipped with a V.24/20 mA interface themselves can be connec-
ted.
The following protocols can be used:
DBUEP03E Transmission protocol for free configuration
DBUEP19E Protocol for secure data transmission
DBUEP64 Transmission protocol 3964R
DTracer/Monitor

Hardware
2--6
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2.4 Ethernet Interface
The Ethernet is connected via a twisted pair cable with RJ45 connector. The
in IEEE 802.3 defined terminal conditions for 10Base-T are applicable:
DNetwork topology star
DMax. transmission rate: 10 Mbit/s
DMax. segment length: 100 m
D100 Ωtwisted pair cable
DLink monitoring
DManchester-coded data transmission
DConnector style: eight-pin RJ-45
The line should have a cross section of 0.08 mm2to 0.34 mm2, 100 Ωimped-
ance, and 12 to 45 transpositions per meter. For this use, special cables,
called Shielded Twisted Pair (STP), are available:
DSTP cable category 3
DSTP cable category 4
DSTP cable category 5
DSTP cable category 6
Increasing category numbers correspond to better cable characteristics.
We recommend the use of STP cables category 5.
Pin Assignment
Pin No. Explanation
1Tx+
2Tx--
3Rx+
4free
5free
6Rx--
7free
8free

Hardware 2--7
1070 072 196-101 (00.06) GB
2.5 Settings on the COM-E
The settings must be made prior to the COM-E’s commissioning.
CAUTION
Danger to the module!
AllESDprotection measuresmust beobservedwhen usingthemod-
ule! Prevent electrostatic discharges!
DIP Switch Explanation
S2 Setting the block address
S3 Protocol-specific setting channel 0
S4 Reserved
S5 Reserved
S6 Multiswitch
S2 S3 S4 S5 S6

Hardware
2--8
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2.5.1 Block Address of COM-E
At the CL400 / CL500’s system bus, the COM-E occupies a block of 256 kB
or four blocks.
The block address of the COM-E is set at DIP switch S2.
The settings are made in the same way as for all other modules of the CL400
/ CL500 controller series.
S2
12345678System Bus Address [hex]
off off off off off off off off 00
off off on off off off off off 04
off off off on off off off off 08
off off ... ... ... ... ... ... ...
off off off off off on off off 20 (32)
off off on off off on off off 24 (36)
off off off on off on off off 28 (40)
off off on on off on off off 2C (44)
off off off off on on off off 30 (48)
off off on off on on off off 34 (52)
.. .. .. .. .. .. .. .. ..
off off off on off on on on E8 (232)
off off on on off on on on EC (236)
off off off off on on on on reserved at CL400 f0 (240)
off off on off on on on on F4 (244)
off off off on on on on on F8 (248)
off off on on on on on on FC (252)
The block address for the COM-E module must be given in quadruple steps
because the module always occupies 4 blocks.
We recommend to set block addresses starting at 20H,e.g.20
H,24 H,28 H,
2CH,30
H.