Bosch CL400 User manual

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CL400
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Automationstechnik
Antriebs- und Steuerungstechnik
CL400
Manual
CL400
101
Version

CL400
CL400
Manual
1070 072 143-101 (95.04) GB
E1995
by Robert Bosch GmbH,
All rights reserved, including applications for protective rights.
Reproduction or handing over to third parties are subject to our written permission.
Discretionary charge 20.– DM

Safety instructions and reading help
V
1070 072 143-101
Safety instructions and reading help
ReadthisinstructionmanualbeforeyouusetheCL400.Keepthismanualin
a place where it is always accessible to all users.
Standard operation
This instruction manual contains all of the information required for standard
operation of the described products.
The products described were developed, manufactured, tested and do
cumented in accordance with the relevant safety standards. There should
be no risk of danger to personnel or property if the specifications and safety
instructions relating to the project phase and installation and correct oper
ation of the product are followed.
Qualified personnel
This instruction manual is designed for specially trained PLC personnel.
The relevant requirements are based on the job specifications as described
by the ZVEI, see:
Anforderungsprofile für SPSFachkräfte
I + K SPEKTRUM 19
Hrsg.: ZVEI
Stresemannallee 19
60596 Frankfurt
Federal Republic of Germany
ISSN 0932-5018
This instruction manual is designed for PLC engineer.
Interventions in the hardware and software of our products which are 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 prod
uct may result in serious personal injury or damage to property.

Safety instructions and reading help
VI 1070 072 143-101
Qualified personnel are persons who
Das planning personnel, are familiar with the safety guidelines used
in electrical engineering and automation technology.
Das operating personnel, are familiar with the equipment used in the
field of automation technology and are thus familiar with the operat
ing instructions in this manual.
Das commissioning personnel, are authorized to commission,
ground and classify electric circuits and devices/systems in accord
ance with the relevant safety standards.
Safety instructions on the control components
The following warnings and notices may be indicated on the control com
ponents themselves and have the following meaning:
Danger: High voltage!
Danger: Battery acid!
Electrostaticallysensitive components!
Disconnect at mains before opening!
Pin for connecting PE conductor only!
For screened conductor only!

Safety instructions and reading help
VII
1070 072 143-101
Safety instructions in this manual
! .
These symbols are used throughout this manual subject to the following
conditions.
DANGER
This symbol is used to warn of the presence of dangerous electrical cur
rent. Insufficient or lacking compliance with these instructions can result in
personal injury.
Safety instructions accompanied by this symbol are serially numbered, for
example 0.1. The appendix provides translations of the safety notes shown
here in all the official EC languages.
DANGER
This symbol is used wherever an insufficient or lacking compliance with in
structions can result in personal injury.
Safety instructions accompanied by this symbol are serially numbered, for
example 0.1. The appendix provides translations of the safety notes shown
here in all the official EC languages.
CAUTION
This symbol is used wherever an insufficient or lacking compliance with in
structions can result in damage to equipment or files.
Safety instructions accompanied by this symbol are serially numbered, for
example 0.1. The appendix provides translations of the safety notes shown
here in all the official EC languages.
.
This symbol is used to inform the user of special features.
!

Safety instructions and reading help
VIII 1070 072 143-101
Symbols used
L
This sign shows that the manual is describing an activity which you have to
perform, e.g.:
LInsert disk 1 into the floppy disk drive.
.We would greatly appreciate any contributions to improve this manual.
If you have any suggestions, please fill out the page provided at the
end of this manual.

Safety instructions and reading help
IX
1070 072 143-101
Safety instructions
DANGER 0.1
Danger to persons and equipment!
Test every new program before operating the system!
CAUTION 0.2
Danger to the module!
Do not insert or remove the module when the control is switched on!
This can destroy the module. Switch off or remove the power supply
module of the control, external power supply and signal voltage before
inserting or removing the module!
CAUTION 0.3
Danger to the module!
All ESD protection measures must be observed when using the mo
dule! Avoid electrostatic discharges!
Observe the following protective measures for electrostatically endan
gered modules! (EEM)!
DThe employees responsible for the storage, transport and handling
must be trained in ESD protection.
DEEMs must be stored and transported in the protective packaging
specified.
DEEMs may basically only be handled at special ESD work places set
up specifically for this purpose.
DEmployees, work surfaces and all devices and tools, which could
come into contact with EEMs must be same potential (e.g. earthed).
DWear an approved earthing strap around your wrist. The grounding
bracelet must be connected via a cable with integrated 1 M7resis
tance with the work surface.
DEEMs may on no account come into contact with chargeable ob
jects, these include most plastics.
DWhen inserting EEMs into devices and removing them, the power
source of the device must be switched off.
.These operating instructions apply to the following versions:
ZS400:
Firmware: 101
Hardware: Daughter board version: 0
Basic PCB version: 0
!

Safety instructions and reading help
X1070 072 143-101

Contents
XI1070 072 143-101
Contents
Page
1 System introduction CL400
1.1 General 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Configuration 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Programming 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 General specifications 1-6. . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Slots 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Subracks
2.1 Subracks GG2 and GG2/K 2-1. . . . . . . . . . . . . . . . . . . . . .
2.2 Basic unit 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Subracks EG2 and EG2/K 2-6. . . . . . . . . . . . . . . . . . . . . .
2.4 Expansion unit 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Expansion configuration 2-9. . . . . . . . . . . . . . . . . . . . . . . .
2.6 Fan unit 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 Installation into subracks and electrical connection 2-15.
2.6.2 Replacing the filter mats 2-19. . . . . . . . . . . . . . . . . . . . . . . .
2.7 Modules 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Power supply modules 3-1. . . . . . . . . . . .
3.1 Selecting the power supply module 3-2. . . . . . . . . . . . . .
3.2 Tasks and functions 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 NT1 and NT2 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 NT3 and NT24 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
XII 1070 072 143-101
Page
4 Central processing unit ZS400 4-1. . . . .
4.1 Display and control elements 4-5. . . . . . . . . . . . . . . . . . . .
4.1.1 Status and rolling 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Reset key, Fix LED 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Retention switch 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4 Lock output states switch 4-14. . . . . . . . . . . . . . . . . . . . . . .
4.2 Interface X31 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Memory card 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Operating states 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Stop 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Run 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Lock output states 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 Firmware update 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 Loading the PLC program from a memory card 4-22. . . .
4.4.6 Storing the PLC program on a memory card 4-24. . . . . .
4.5 Operating modes 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Operation with buffer battery 4-28. . . . . . . . . . . . . . . . . . . .
4.5.2 Operation without buffer battery, with memory card 4-29
4.6 ZS400 startup 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 ZS400 program execution 4-32. . . . . . . . . . . . . . . . . . . . . . .
4.8 ZS400 monitor functions 4-33. . . . . . . . . . . . . . . . . . . . . . . .
5 System modules 5-1. . . . . . . . . . . . . . . . . .
5.1 ZAT1/2, ZAT1/10, ZAT2/2 and ZAT2/10 5-3. . . . . . . . . . .
5.2 Computer interface module R500 5-4. . . . . . . . . . . . . . . .
5.3 Computer Interface Module R500P 5-5. . . . . . . . . . . . . . .
5.4 Diagnostic Module DB500 5-6. . . . . . . . . . . . . . . . . . . . . .

Contents
XIII1070 072 143-101
Page
6 Installation
6.1 Fan unit and assembly of the subracks 6-1. . . . . . . . . . .
6.2 Electrical installation 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 24 V load power supplies 6-5. . . . . . . . . . . . . . . . . . . . . . .
6.4 Power input from 24 V power supply 6-6. . . . . . . . . . . . .
A Appendix
A.1 Abbreviations A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Index A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Safety instructions A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.1 Dansk A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.2 Deutsch A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.3 %LLHNIK¼ A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.4 Español A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.5 Français A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.6 Italiano A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.7 Nederlands A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.8 Português A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.9 Suomi A-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.10 Svenska A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
XIV 1070 072 143-101

Illustrations
I1070 072 143-101
List of illustrations
Fig. Page
1-1 CL400 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 CL400, basic unit 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 CL400, expansion 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4 CL400, specifications 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5 Slots, system modules 1-9. . . . . . . . . . . . . . . . . . . . . . . . . .
1-6 Slots, peripheral modules 1-9. . . . . . . . . . . . . . . . . . . . . . .
2-1 GG2, dimensions 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 GG2/K, dimensions 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 CL400, basic unit 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 Basic unit, ordering information 2-5. . . . . . . . . . . . . . . . . .
2-5 AG/ZS, specifications 2-8. . . . . . . . . . . . . . . . . . . . . . . . . .
2-6 AG/ZS, slots 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7 Expansion unit, ordering information 2-8. . . . . . . . . . . . .
2-8 Expansion Module AG/PS, ordering information 2-9. . .
2-9 CL400, expansion 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10 Expansion configuration, example 2-11. . . . . . . . . . . . . . .
2-11 Fan units, specifications 2-13. . . . . . . . . . . . . . . . . . . . . . . .
2-12 Fan units, ordering information 2-14. . . . . . . . . . . . . . . . . .
2-13 Subracks, fan unit 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14 Fan unit with 3 fans 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15 Fan unit with 2 fans 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16 Fan unit with 1 fan 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-17 Fan unit, terminal 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-18 Fan unit, installation 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-19 Filter mats, ordering information 2-19. . . . . . . . . . . . . . . . .
2-20 Replacing filter mat 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-21 Components of fan unit with two fans 2-20. . . . . . . . . . . . .

Illustrations
II 1070 072 143-101
Fig. Page
3-1 Power supply modules NT1, NT2, NT3 and NT24 3-1. .
3-2 Current supply of the power supply modules 3-2. . . . . .
3-3 Power input internal 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 Buffer battery, power input of the modules 3-5. . . . . . . .
3-5 Power supply modules, specifications 3-7. . . . . . . . . . . .
3-6 Power supply modules, slots 3-8. . . . . . . . . . . . . . . . . . . .
3-7 Power supply modules, ordering information 3-8. . . . . .
3-8 NT1 and NT2, front panel 3-9. . . . . . . . . . . . . . . . . . . . . . .
3-9 NT1 and NT2, jumper setting 3-11. . . . . . . . . . . . . . . . . . . .
3-10 NT1 and NT2, buffer battery 3-12. . . . . . . . . . . . . . . . . . . . .
3-11 NT3 and NT24, front panel 3-14. . . . . . . . . . . . . . . . . . . . . .
3-12 NT3 and NT24, jumper setting 3-16. . . . . . . . . . . . . . . . . . .
3-13 NT3 and NT24, buffer battery 3-17. . . . . . . . . . . . . . . . . . . .
4-1 ZS400 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 ZS400, Specifications 4-3. . . . . . . . . . . . . . . . . . . . . . . . . .
4-3 ZS400, slots 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4 ZS400, ordering information 4-4. . . . . . . . . . . . . . . . . . . . .
4-5 ZS400, front panel 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6 Status and rolling 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7 2figure 7segment status display,
operational messages 4-10. . . . . . . . . . . . . . . . . . . . . . . . . .
4-8 Reset key, Fix LED 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9 Retention switch 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10 Lock output states switch 4-14. . . . . . . . . . . . . . . . . . . . . . .
4-11 Interface X31 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12 Connection cable K16, ordering information 4-15. . . . . . .
4-13 Dip switch S1 for X31 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14 X31, transmission format 4-17. . . . . . . . . . . . . . . . . . . . . . . .
4-15 X31, baud rate/lead length 4-17. . . . . . . . . . . . . . . . . . . . . .
4-16 X31, baud rate 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17 X31, control signals 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Illustrations
III1070 072 143-101
Fig. Page
4-18 Memory card 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19 Error messages when loading 4-23. . . . . . . . . . . . . . . . . . .
4-20 Error messages when storing 4-25. . . . . . . . . . . . . . . . . . .
4-21 Operating modes 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22 ZS400, Startup 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Version 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 System modules, slots 5-2. . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 ZAT, ordering information 5-3. . . . . . . . . . . . . . . . . . . . . . .
5-4 R500, ordering information 5-4. . . . . . . . . . . . . . . . . . . . . .
5-5 R500P, ordering information 5-5. . . . . . . . . . . . . . . . . . . . .
5-6 DB500, ordering information 5-6. . . . . . . . . . . . . . . . . . . . .
6-1 Basic unit 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2 Possible configuration of the subracks 6-2. . . . . . . . . . . .
6-3 Subracks and fan units, examples 6-3. . . . . . . . . . . . . . .
6-4 PE terminal 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5 24 V load power supplies, specifications 6-5. . . . . . . . . .
6-6 24 V load power supplies, ordering information 6-5. . . .
6-7 Power input from 24 V power supply 6-6. . . . . . . . . . . . .

Illustrations
IV 1070 072 143-101

Flexible Automation System introduction CL400
1-1
1070 072 143-101
1 System introduction CL400
1.1 General
Fig. 1-1 CL400
The Bosch CL400 Programmable Logic Controller is a PLC for all control
tasks in the mid to upper power range. The CL400 is a compact monopro
cessor control unit of modular construction. With regard to peripherals and
software, it is fully compatible with the reliable CL500 multiprocessor con
trol unit. The system modules of the CL500 can also be fitted in the CL400.
Similarly, the Bosch input, output, expansion and peripheral modules are
compatible with the CL400.

Flexible Automation
System introduction CL400
1-2 1070 072 143-101
Furthermore, the CL400 with COMNETDP represents an innovative sol
ution to the problem of decentralised installation.
COMNETDP combines the advantages of the DESI system with the bene
fits of networking via PROFIBUS. The Bosch COMNETDP is the realisation
of PROFIBUSDP and is based on DIN 19 245 part 3.
The CL400 operations set is compatible with CL500.
Memory card
The CL400 offers for the first time the possibly of operation with a memory
card in addition to operation with RAM memory and buffer battery.
Expansion capability
Possible expansions:
Dcentral and parallel expansion units
DCOMNETDP
Possible functional expansions:
DSystem modules
DPeripheral modules
Communication capability, interface capability
The standard interfaces
DR500
DR500P (PROFIBUSFMS)
make the CL400 capable of communicating and interfacing with
Dother control systems
Dcomputers
Dstandard peripheral devices
Additional functionalities
DPC modules ZAT1 and ZAT2
DDiagnostic module DB500
DProcess visualisation software PV2
Peripheral modules
DPower source module SQ16
DTemperature controller module RT6
DCounter module EZ50
DPeripheral Bus Interface Module PBK
DPositioning module CC10
DRobot control system rho3.0
DCycle time analysis module TZA