Moeller PS 416-CPU-x00 Series User manual

Hardware and Engineering
PS 416-CPU-x00
Central Unit
PS 416-POW-4x0
Power Supply Card
PS 416-BGT-4xx
Rack
02/98 AWB 27-1208 GB
3rd edition 02/98
© Moeller GmbH, Bonn
Author: Werner Albrecht
Editor: Thomas Kracht
Translator: Terence Osborn
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Caution!
Dangerous electrical voltage!
Before commencing the installation
●Disconnect the power supply of the
device.
●Ensure that the device cannot be
accidentally restarted.
●Verify isolation from the supply.
●Earth and short circuit.
●Cover or enclose neighbouring units that
are live.
●Follow the engineering instructions
(AWA) of the device concerned.
●Only suitably qualified personnel may
work on this device/system.
●Before installation and before touching
the device ensure that you are free of
electrostatic charge.
●Connecting cables and signal lines
should be installed so that inductive or
capacitive interference do not impair the
automation functions.
●Install automation devices and related
operating elements in such a way that
they are well protected against
unintentional operation.
●Suitable safety hardware and software
measures should be implemented for
the I/O interface so that a line or wire
breakage on the signal side does not
result in undefined states in the
automation devices.
●Ensure a reliable electrical isolation of
the low voltage for the 24 volt supply.
Only use power supply units complying
with IEC 60 364-4-41 or HD 384.4.41 S2.
●Deviations of the mains voltage from the
rated value must not exceed the
tolerance limits given in the
specifications, otherwise this may cause
malfunction and dangerous operation.
●Emergency stop devices complying with
IEC/EN 60 204-1 must be effective in all
operating modes of the automation
devices. Unlatching the emergency-stop
devices must not cause uncontrolled
operation or restart.
●Devices that are designed for mounting
in housings or control cabinets must only
be operated and controlled after they
have been installed with the housing
closed. Desktop or portable units must
only be operated and controlled in
enclosed housings.
●Measures should be taken to ensure the
proper restart of programs interrupted
after a voltage dip or failure. This should
not cause dangerous operating states
even for a short time. If necessary,
emergency-stop devices should be
implemented.
IBM is a registered trademark of International
Business Machines Corporation.
All other brand and product names are
trademarks or registered trademarks of the
owner concerned.
All rights reserved, including those of the
translation.
No part of this manual may be reproduced in
any form (printed, photocopy, microfilm or
any otherprocess) or processed, duplicated
or distributed by means of electronic
systems without written permission of
Moeller GmbH, Bonn.
Subject to alterations without notice.
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II
02/98 AWB 27-1208-GB
List of revisions to AWB 27-1208-GB
Edition Page Revision new Rev. n. a.
02/98 PS 416-CPU-200/-300 ҂
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02/98 AWB 27-1208-GB
PS 416 system PS 416-POW-4x0PS 416-BGT-4.. AppendixPS 416-CPU-200/-300/-400
Contents
About the manual 3
PS 416 system 5
PS 416-BGT-4.. racks 21
PS 416-POW-400/410/420
Power supply cards 35
PS 416-CPU-200/-300/-400 Central unit 57
Appendix 129
Index 141
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02/98 AWB 27-1208-GB
About This Manual
The rack, power supply card and the central
processing unit form the basis of the PS 416 system.
Their tasks and functions are described in this
manual.
There are various cards which you can integrate in
the modular system, depending on the requirements.
The functions of these cards are described in
separate manuals.
The communication between the stations in a
networked system is carried out via network cards.
These are the PS 416-CPU-300/-400 or the Suconet
K PS 416-NET-400 card if the stations are linked via
Suconet K. These cards manage the access to local
or remote input/output cards. This function is
explained in the “Suconet K Interface”manual
(AWB 27-1210-GB).
The Sucosoft S 40 programming software is used for
programming and configuration and is also
described in a separate documentation.
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PS 416 system
02/98 AWB 27-1208-GB
PS 416 System
Contents
1 System Description 7
Setup 7
Hardware/software requirements 7
Components 8
2 Configuration 11
Master 12
Slaves for remote I/O expansion 13
Intelligent slaves 15
3 Engineering 17
Electromagnetic compatibility (EMC) 17
Reaction times 17
Interference immunity 17
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02/98 AWB 27-1208-GB
PS 416 system
1 System Description
Setup The PS 416 is a modular programmable controller.
The rack with an internal bus system for signal
transfer and slots for the connections of cards form
the basic unit. Interference-free supply cards supply
the system with a stabilised voltage. A central
processing unit with universal functions manages the
access to local and/or remote input/output cards or
enables an application process to be run separately
in the same rack. Various cards can be used for
detecting digital, analog and counter signals.
Networking and communication are implemented via
standard interfaces or standard bus protocols. The
Moeller Suconet K bus protocol is used as a system
bus for connecting remote inputs/outputs or an
expander rack. The Sucosoft S 40 software package
forms the user interface for user-friendly
programming, testing and commissioning.
Hardware/software
requirements
A P S416 system has the following minimum
requirements:
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System Description
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02/98 AWB 27-1208-GB
Table 1: Hardware and software requirements
1) Hardware and engineering of the
PS 416-CPU-223 see AWB 27-1243-GB
The central unit is supplied without an operating
system. Sucosoft S 40 is required for loading the
operating system or a bootable memory card with a
loaded operating system. The prrogramming, test
and commissioning of the P S416 are described in
the relevant Sucosoft S 40 manuals.
Components The PS 416 automation system consists of the
following components:
Basic elements
PS 416-BGT-4...rack
PS 416-POW-4x0 power supply card
PS 416-CPU-200/-300/-400/-223 central pro-
cessing unit
Sucosoft
for PS 416-CPU-2231):
for PS 416-CPU-200/-300:
for PS 416-CPU 400:
Operating system from version 1.32
S 30-S 316-D/-GB/-F from
version 2.31
Operating system from version 2.0
S 40-D/-GB/-F from version 2.0
Operating system from version 1.0
S 40-D/-GB/-F from version 1.0
Rack PS 416-BGT-400/410/420 or 421 with
potential equalisation bar
PS 416-ZBX-401/402/403
Power supply units PS 416-POW-400/410/420
Central processing unit PS 416-CPU-200/300/400
PS 416-CPU-2231
Programming cable or
interface converter PS 416-ZBK-210 (PRG/RS 232) UM 1.5 (PRG/RS 485)
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Components
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PS 416 system
Standard cards
Digital input/output cards
PS 416-INP-400/401
PS 416-OUT-400/410
Analogue input/output cards
PS 416-AIO-400/PS 416-AIN-400
PS 416-CNT-200 counter card
Networking/communications cards
PS 416-NET-210 Suconet K card
(only with PS 416-CPU-223 central unit)
PS 416-NET-400 Suconet K card
PS 416-NET-230 PROFIBUS card
PS 416-NET-220 Interbus S card
PS 416-COM-200 Communications card
PS 416-COM-200 Communications card
The basic elements, such as rack, power supply and
the central unit are described in this manual.
The hardware and programming of the
PS 416-CPU-223 are described in the
AWB 27-1243-GB.
Figure 1: PS 416 automation system
power supply
230 V AC
power
PS 416
POW-400
processing unit
run
CPU-400
ready
not ready
error
change
AIO-400
analog I/O
4xI, 4xQ, 12Bit
.0
.1
.2
.3
.4
.5
.6
.7
.0
.1
.2
.3
.4
.5
.6
.7
INP-400
digital in
16x0,3ms
I
I
OUT-400
digital out
16x0,5A
Reset
ZAA
.0
.1
.2
.3
.4
.5
.6
.7
.0
.1
.2
.3
.4
.5
.6
.7
Q
Q
NET-400
SUCOnet K
network
active
ready
error
CNT-200
COUNTER
PROFIBUS
Bus
ERR
NET-230
network
InterBus-S
NET-220
diag.-code
network
C
F
G
S
U
C
O
n
e
t
S
ready
out
run
bsa
con
rb
lb
mod
clear
COM
RxD/
TxD
ERR
COM-
200
1
CH0
2
CH0
3
CH1
4
CH1
5
CH2
6
CH2
7
CH3
8
CH3
9
CH4
10
CH4
11
CH5
12
CH5
13
14
GND
15
GND
16
GND
17
GND
18
GND
19
GND
20
5V
21
5V
22
5V
23
24V
24
24V
25
24V
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PS 416 system
2 Configuration
Networks for different applications can be created
with the Suconet K system bus. The network stations
are configured according to their functions. The
following functions are possible:
Master 햲
Slaves for the expansion of the remote inputs/
outputs:
Expander rack 햳
Expansion module 햴
Intelligent slaves 햵
Figure 2: Device configuration with Suconet K
*) This network line is not possible with the
PS 416-CPU-200.
EM 4-201-DX2
LE 4-
116-DX1
LE 4-
116-XD1
햴
햲햳
POW
NET 400 (E)
AIN AIO
INP
OUT
햵
POW
PS 416-CPU-x00
AIN AIO
INP
OUT
NET 400
AIN
PS 416-CPU-400
POW
AIO
INP
OUT
AIN
*
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Configuration
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Master The master manages the access to the remote input/
output cards. A master is any card that manages a
network line. In a PS 416 system the
PS 416-CPU-300/-400 and/or PS 416-NET-400 can
be implemented as master. Both cards have a
Suconet K interface. The configuration of the
operating mode and the stations is carried out in the
Sucosoft S 40 Topology Configurator.
A PS 416-CPU-300/-400 central unit can manage up
to nine bus lines. One line is integrated on the card,
whilst other lines can be formed using the
PS 416-NET-400 card.
A P S416-CPU-200 central unit can manage up to
eight bus lines, using the PS 416-NET-400 network
card to connect each line.
The current requirements must be calculated in all
cases for the number of bus lines to be used.
Up to 30 stations can be connected to each line. The
number depends on the memory requirements of
each station in the communication memory of the
master.
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Slaves for remote I/O
expansion
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PS 416 system
Figure 3: Maximum expansion
햲Lines with PS 416-CPU-300/-400
햳Lines with PS 416-CPU-200
햴Stations
Slaves for remote I/O
expansion
Slaves for remote I/O expansion have no individual
central unit. They provide the master their data if
requested but cannot communicate with the master.
The number of data bytes which the slaves occupy in
the communication memory of the master is
predefined. This therefore does not have to be
specified in the configuration.
The slaves are addressed in a 5-point notation based
on the spatial configuration of the stations. The
stations are configured in the Topology Configurator
of Sucosoft S 40. Expander racks or expansion
modules are used as slaves for the remote expansion
of the inputs/outputs.
1234
56789
1...30 1...30 1...30 1...30 1...30 1...30 1...30 1...30
햲
햴
1...30
PS 416-POW-4x0
PS 416-CPU-x00
NET 400 NET 400 NET 400 NET 400 NET 400 NET 400
NET 400 NET 400
12345678
햳
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Configuration
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Expander racks
The remote expansion of the inputs/outputs in a
PS 416 system is implemented with racks which do
not have a CPU (expander racks). The required
configuration parameters of the local inputs/outputs
of these racks are sent to the PS 416-NET-400 card
via the master.
The address set on the card must comply with the
address set in the Sucosoft Topology Configurator.
You will find detailed information on the
PS 416-NET-400 card in the Suconet K Interface
manual, AWB 27-1210-GB.
The PS 416 automation system can process up to
30 expander racks on one line. Up to nine/eight lines
(depending on the CPU) can be managed on each
basic unit. The total permissible number of cards
that can be used on the rack depends on the total
current consumption of the individual cards and the
power supply card used (current consumption
calculation). The standard cards can be used as
components of the expander rack. The
communication is carried out via Suconet K. The
following settings are possible depending on the
application at hand:
Table 2: Application criteria
1) These bus lengths can only be implemented with the
cable listed under Accessories in the appendix.
Baud rate
(Kbaud) CRC16 check max. bus length1) Data saving
187.5 no 600 m good
187.5 yes 600 m very good
375 no 300 m good
375 yes 300 m very good
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Intelligent slaves
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PS 416 system
784 bytes of memory are available for the
communication with all connected stations of a line
on the PS 416-CPU-300/-400. The following table
shows the memory assignment of the cards to be
used.
Table 3: Memory assignment of the cards of an expander
rack
Expansion modules
Expansion modules of the EM... compact series are
usually used for the expansion of remote inputs/
outputs. They do not have their own central unit.
Intelligent slaves Intelligent slaves have their own central unit and are
thus able to process their own user program. The
communication between the master and intelligent
slaves is carried out in both directions. The number
of send and receive data bytes for intelligent slaves
must be defined in the Sucosoft S 40 Topology
Configurator. The memory size depends on the type
of slave.
The following components can be used as intelligent
slaves:
Card Input byte Output byte
PS 416-INP-400/401 2 –
PS 416-OUT-400/410 – 2/1
PS 416-AIN-400 16 –
PS 416-AIO-400 8 8
PS 416-CNT-200 12 –
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Table 4: Data exchange memory of intelligent slaves
1) The available memory size depends on the number of
connected slaves on a line. The values stated in the
table apply with the maximum utilization of the line.
The station is addressed by the user program in bit,
byte, word or double word format depending on the
station. The operations with the possible operands
and function blocks are described in the
Sucosoft S 40 programming software.
Components Usable memory1)
PS 416-CPU-300/-400 784 bytes
PS 416-NET-400 1492 bytes
PS 4-101-DD1
PS 4-111-DR1/DR5 6 bytes Master 씮Slave 7 bytes Slave 씮Master
PS 4-201-MM1
PS 4-141-MM1
PS 4-151-MM1
Total I/O 78 bytes
PS 4-401-MM2 168 bytes
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PS 416 system
3 Engineering
Electromagnetic
compatibility (EMC)
Observe the engineering instructions in the manual
“EMC Engineering Guidelines for Automation
Systems” (AWB 27-1287-GB)
Reaction times The shortest reaction time can be implemented with
local cards that are addressed by the central unit via
the internal bus. Only the program cycle time and the
input/output delays of the cards determine the
reaction time.
If remote stations are connected via Suconet K, the
reaction time depends on the number of stations on
the line, the data volume and the data transfer rate.
Further information on the calculation of the reaction
time is given in the Appendix.
Interference immunity The PS 416 system is designed for industrial
applications.
Provide the supply cable of the power supply card
with a ferrite ring. Mounting should be carried out as
close to the card as possible. No further connections
to other devices may be implemented beyond this
point.
The following figure shows the use of the ferrite ring,
using the PS 416-POW-400 as an example:
The ferrite ring is not delivered with the cards.
Please order separately:
Type PS 416-ZBX-405
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