Bosch CL550 User manual

Antriebs- und Steuerungstechnik
Controller Manual
CL550
Edition 101

CL550
Controller Manual
1070 072 263-101 (01.08) GB
E2001
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 V
1070 072 263-101 (01.08) 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 System Overview CL550 2–1. . . . . . . . . . . . . . . . . . . . . .
2.1 Controller Structure 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Communication via Ethernet 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Communication via LAN 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Decentralized In-/Outputs 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Configuration 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Programming 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Central Programming 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Program Display 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 WinSPS 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4 WinDP 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.5 CMD Software (used only with operation of the ZS550-DP-IBS) 2–6
2.5 Installation 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Compliance with Statutes and Standards 2–8. . . . . . . . . . . . . . . . . . .
3 Mounting Rack GG4-9 3–1. . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Dimensions and Assembly 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Fan 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Installation and Electric Connection 3–3. . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Changing the Filter Matt 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Power Supply Module 4–1. . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Selection 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Power Supply NT4 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 NT1 / NT2 / NT3 / NT24 4–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Backup battery 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Data Backup prior to Power Supply Module Exchange 4–11. . . . . . .

Contents
VI
1070 072 263-101 (01.08) GB
Page
5 ZS550 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Structure and Function 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Elements for Display and Operation 5–3. . . . . . . . . . . . . . . . . . . . . . .
5.2.1 PLC Functionality 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Busmaster Functionality 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 TCP/IP-COM Functionality 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 DP/V1-COM Functionality 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5 Power Supply Functionality 5–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6 InterBus-S Functionality (ZS550-DP-IBS only) 5–11. . . . . . . . . . . . . .
5.2.7 Functional and Configuration Mode 5–12. . . . . . . . . . . . . . . . . . . . . . . .
5.3 Serial Interface X31 (ZS550-DP-IBS only) 5–14. . . . . . . . . . . . . . . . . .
5.4 Serial Interface X32 5–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Serial Interface X33 (ZS550-DP-IBS only) 5–16. . . . . . . . . . . . . . . . . .
5.6 Ethernet Interface X71 5–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 PROFIBUS-DP Interface X72 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 InterBus-S Interface X73 (ZS550-DP-IBS only) 5–20. . . . . . . . . . . . . .
5.9 Technical Data 5–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 CON550 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Structure and Function 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Address Settings 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Display Elements 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Ethernet Interfaces X71 and X72 6–3. . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Technical Data 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Commissioning and Configuration 7–1. . . . . . . . . . . . .
7.1 Project Configurator 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Address Assignment 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Accessories and Ordering Information 8–1. . . . . . . . .
A Appendix A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Glossary A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Subject Index A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions 1–1
1070 072 263-101 (01.08) GB
1 Safety Instructions
Before you start working with the CL550 controller, 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 manual contains a comprehensive set of instructions and information
required for the standard operation of the described products. The described
products are used for installation and operation of a CL550 controller.
The described products
Dwere developed, manufactured, tested and documented in accordance
with the relevant safety standards. Normally, the product does not pres-
ent any danger for people or equipment provided that the specifications
and safety instructions relating to project planning, installation, and nor-
mal operation of the product are observed.
Dfully comply with the requirements of
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), i.e.
Ddirect connection to the public low-voltage power supply is not per-
mitted;
DConnection to the medium and/or high-voltage system must be pro-
vided via transformer.
The following applies to the usage in residential settings, in business and
commercial areas and in small-industry settings:
DInstallation in an enclosure with high shield attenuation.
DCables that exit the screened area must be provided with filtering or
screening measures.
DThe user will be required to obtain an individual operating license is-
sued by the appropriate national authority or approval body. In Ger-
many, this is the Regulierungsbehörde für Post und
Telekommunikation(RegTP) (Regulatory Body for Post and Telecom-
munication), and/or its local offices.
.This is a Class A device. In a residential setting, this device may cause
radio interferences. In such a case, the user may be required to
introduce suitable countermeasures at his own costs.
Proper transport, handling and storage, placement and installation of the
product are indispensable prerequisites for its correct and safe operation.

Safety Instructions
1–2
1070 072 263-101 (01.08) GB
1.2 Qualified Personnel
The relevant requirements are based on the job specifications as outlined by
the ZVEI and VDMA in Germany. Please refer to the following German-Lan-
guage publication:
Weiterbildung in der Automatisierungstechnik
Editor: ZVEI and VDMA
Maschinenbau Verlag
Postfach 71 08 64
60498 Frankfurt/Germany
This manual is intended for especially qualified PLC experts.
Interventions in the hardware and software of our products that are not de-
scribed in this manual may only be performed by Bosch’s own specifically
trained 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 of the equipment.
Only trained electricians as per IEV 826-09-01 (modified) who are familiar
with the contents of this manual may undertake installation and mainte-
nance tasks regarding the described products.
These electricians
Dare, due to their professional training, skills and experience and based
upon their knowledge of and familiarity with applicable technical stan-
dards, capable of evaluating the work to be carried out, and of recogniz-
ing possible dangers.
Dpossess, based upon several years of working in a comparable field, a
level of knowledge and skills that may be deemed equal to that after for-
mal professional education.
With regard to the foregoing, please note our comprehensive training pro-
gram. For up-to-date information, web shop for teachware and online sem-
inar booking, please refer to http://www.bosch.de/at/didactic or call our
training center at (+49) (0) 60 62 78-258.

Safety Instructions 1–3
1070 072 263-101 (01.08) GB
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
1070 072 263-101 (01.08) GB
1.4 Safety Instructions in this Manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol warns of the presence of dangerous electrical voltage. In-
sufficient or non-compliance with this warning can result in personal in-
jury.
DANGER
This symbol is used whenever insufficient or non-compliance with instruc-
tions can result in personal injury.
CAUTION
This symbol is used whenever insufficient or non-compliance with instruc-
tions can result in damage of equipment or data files.
.This symbol is used to alert the user to an item of special interest.
LThis symbol indicates an activity to be performed by the user.

Safety Instructions 1–5
1070 072 263-101 (01.08) GB
1.5 Safety Instructions for the Described Product
DANGER
Life endangered by ineffective EMERGENCY-STOP devices!
EMERGENCY-STOP safety devices must remain effective and acces-
sible during all operating modes of the system. Unlocking the EMER-
GENCY-STOP device must not cause an uncontrolled system restart!
First, test the EMERGENCY-STOP sequence, then restore power!
DANGER
Danger for persons and equipment!
Before operating the system, test every new program!
DANGER
Retrofits or modifications may interfere with the safety of the de-
scribed products!
The consequences may be severe personal injury or damage to the
equipment or the environment. Therefore, any retrofitting or modifi-
cation of the system utilizing components from other manufacturers
does require approval by Bosch.
DANGEROUS ELECTRICAL VOLTAGE
Unless described otherwise, maintenance procedures must only be
carried out when the system is turned off! During this process, the
system must be safe from unauthorized or inadvertent restart.
If measuring or testing procedures must be carried out when the sys-
tem is active, it must be done by trained electricians only.
CAUTION
Do not plug or unplug the module as long as the controller is
switched on! The module could be destroyed. Turn off or unplug the
controller’s power supply module, the external power supply and the
signal voltage first. Only then plug or unplug the module!
CAUTION
Please use only spare parts that are approved by Bosch!

Safety Instructions
1–6
1070 072 263-101 (01.08) GB
CAUTION
Please comply with all ESD protection measures when using the
module! Avoid electrostatic discharges!
Please comply with the following protection measures for electrostatically
endangered modules and components (EEM)!
DThe employees responsible for storage, transport and handling must be
trained in ESD protection.
DStore and transport EEMs in the specified protective packaging.
DWork with EEMs only at special ESD work stations equipped for this par-
ticular 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 an integrated 1 MWresistor.
DEEMs must, 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.