Moeller easyControl EC4-200 Parts list manual

Programmable Logic Controller
easy Control
EC4-200
Bedienungshandbuch
Moeller GmbH
Industrieautomation
Hein-Moeller-Straße 7–11
D-53115 Bonn
E-Mail: [e-mail]
Internet: www.moeller.net
© 2002 by Moeller GmbH
Änderungen vorbehalten
AWB2724-1584D xx/xx/Ki 05/06
Printed in the Federal Republic of Germany (0x/02)
Article No.: xxxxxx
4*patpks#nycmyn*
Hardware, Engineering and
Function Description
05/06 AWB2724-1584GB
A
A A
Think future. Switch to green. Think future. Switch to green.
Rückenbreite bis 10 mm (1 Blatt = 0,106 mm, gilt nur für XBS)

All brand and product names are trademarks or registered
trademarks of the owner concerned.
1st edition 2006, edition date 05/06
© Moeller GmbH, 53105 Bonn
Author: Peter Roersch
Production: Thomas Kracht
Translation: Terence Osborn
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form
(printed, photocopy, microfilm or any other process) or processed,
duplicated or distributed by means of electronic systems without
written permission of Moeller GmbH, Bonn.
Subject to alteration without notice.
Rückenbreite festlegen! (1 Blatt = 0,106 mm, gilt nur für XBS)

1
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices 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 in accordance with
EN 50110-1/-2 (VDE 0105 Part 100) may work on
this device/system.
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• The functional earth (FE) must be connected to the protective
earth (PE) or to the potential equalisation. The system installer
is responsible for implementing this connection.
• Connecting cables and signal lines should be installed so
that inductive or capacitive interference does 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 60364-4-41 (VDE 0100 Part 410) 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 60204-1 must
be effective in all operating modes of the automation devices.
Unlatching the emergency-stop devices must not cause 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.
• Wherever faults in the automation system may cause
damage to persons or property, external measures must be
implemented to ensure a safe operating state in the event of
a fault or malfunction (for example, by means of separate limit
switches, mechanical interlocks etc.).
Moeller GmbH Safety instructions
Warning!
Dangerous electrical voltage!

2

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About This Manual 5
Additional documentation 5
Writing conventions 5
– Type overview 7
Inputs 9
– Inputs of the rocker and function buttons 10
– Diagnostics inputs 10
– Inputs for high-speed counters 10
Outputs 10
Memory card (MCC) 11
– Memory card data 11
– Data access on the memory card 11
LED status indication for RUN/STOP/SF and CAN/NET 11
Real-time clock 12
Programming interface for the PC 12
Universal interface 12
CAN(open) interfaces 13
Mounting on top-hat rail 15
Mounting on mounting plate 15
Connecting the power supply 17
Connecting digital inputs 18
Connecting analog inputs 18
– Setpoint potentiometer 18
– Temperature sensor 19
– 20 mA sensor 19
Connecting pulse transmitters/incremental encoders 20
– Pulse transmitter 20
– Connecting the incremental encoder 20
Connecting outputs 21
– Connecting relay outputs 21
Connecting transistor outputs 22
– EC4P-221/222-MT…, EASY6…-DC-TE 22
Memory card, CAN/easy-NET, PC connection 23
– Fitting or removing the memory card 23
– CAN/easy-NET, PC connection 23
Keypad 25
Selecting menus and entering values 25
Selecting or toggling between menu items 25
– Cursor display 25
– Set value 25
Choosing the main and system menu 26
– Status display 26
– Status display with time 26
Menu structure 27
– Main menu without password protection 27
– Main menu with password protection 28
– System menu 28
Password protection 29
– Password setup 29
– Selecting the scope of the password 29
– Activating the password 29
– Access with password protection 29
– Changing or deleting the password range 30
Changing the menu language 31
Setting date and time 31
Tables of contents

Tables of contents 05/06 AWB2724-1584GB
2
Startup behaviour 31
– Setting the startup behaviour 31
Setting LCD contrast and backlight 31
Representation of the inputs/outputs in the configuration 33
Displaying the inputs/outputs 33
Changing the folder function 33
General technical data 35
– Overview of memory sizes 35
– Memory definition 35
Startup behaviour 35
– Startup behaviour with boot project on the
memory card 35
Setting the startup behaviour in the programming
software 37
Program START/STOP 37
– Program start (STOP lRUN) 37
– Behaviour after shutdown/interruption of the
power supply 37
–Programstop(RUNlSTOP) 37
– Starting/stopping the program via external switch 38
Program processing and system time 38
Cycle time monitoring 38
Reset 38
– Warm reset 38
– Cold reset 38
– Hard reset 38
– Restoring factory settings (factory set) 38
– Behaviour of variables after Reset 39
Test and commissioning 39
– Breakpoint/single-step mode 39
– Single cycle mode 39
– Forcing variables and inputs/outputs 39
– Status display in the programming software 39
High-speed counters 39
– 32-bit counter 39
– 16-bit counter 40
Incremental input 40
– Explanation of the input/output signals (I/Q) 41
– Overview of input/output signals (I/Q) 41
– Functions of the input/output signals 41
– Referencing: 42
System events 42
– START, COLD START, WARM START, STOP 42
– Interrupt inputs I1 to I4 43
– Counter interrupt 43
– Timer interrupt 43
Interrupt processing 45
– Steps for interrupt processing 45
– Example of interrupt processing 45
Generating and transferring a boot project 46
– Storing the boot project on a memory card 47
– Boot project and operating system (OS)
on memory card 47
– Deleting the boot project 47
Downloading/updating the operating system 47
– Transferring the operating system from the PC to PLC 47
– Transferring the OS from PC to the memory card 48
– Transferring the OS from the memory card

05/06 AWB2724-1584GB Tables of contents
3
to the controller 48
– canload 50
– setrtc 50
Using libraries 51
Installing other system libraries 51
EC4-200 specific functions 52
– EC_Util.lib library 52
– EC_Visu.lib library 52
Communication parameters of the PC 55
Communication parameters (baud rate) of the CPU 55
Overview 57
Structure of the INI file 57
Creating the Startup.INI file 57
Switching on the controller with the fitted memory
card containing the Startup.INI file 57
Changing parameters 58
Deleting the Startup.INI file 58
Requirements 59
Routing features of the controller 59
Routing through XC200 59
Notes on routing 60
Addressing 60
Procedure 61
PLC combinations for routing 62
Number of communication channels 62
Appendix 65
CAN/easy-NET network 65
– Accessories 65
Example program for PLC START/STOP using
external switch 66
Dimensions and weight 67
Technical data 68
– Transistor outputs 73
Index 75

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About This Manual
Additional documentation
At different points in this manual, references are made to more
detailed descriptions in other manuals. These are described with
their title and documentation number (e.g. AWB2700-1437GB).
All manuals are available in PDF format. If for some reason the
manual is not supplied on the product CD, it is available for
download as a PDF file. Go to http://www.moeller.net/support
and enter the document number in the Quick Search field.
Concrete information regarding communication with CAN stations
and their configuration can be found in the following listed
documentation:
• AN27K19GB: Communication between two PLCs using
network variables via CAN
• AN27K20GB: Coupling multiple stand-alone PLCs
(CAN-Device) via CANopen
• AN27K27GB: Engineering of CAN stations
• AWB2786-1554: Library description CANUser.lib,
CANUser_Master.lib.
Writing conventions
Select ‹File rNew› means: activate the instruction “New” in the
“File” menu.
For clarity of layout, we adhere to the following conventions in this
manual: at the top of left-hand pages you will find the Chapter
heading, at the top of right-hand pages the current Section
heading; exceptions are the first pages of Chapters and empty
pages at the end of Chapters.
hDraws your attention to interesting tips and
supplementary information.
hAttention!
Warns of the risk of material damage.
iCaution!
Warns of the possibility of serious damage and slight
injury.
jWarning!
Indicates the risk of major damage to property, or serious
or fatal injury.

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1 Device application
The controllers of the EC4-200 series are programmable switching
and control devices. They can be used in domestic applications,
machine building and plant construction. An EC4-200 controller
can be used as a stand-alone PLC or connected to remote input/
output devices via the CANopen interface. This interface also
allows you to communicate with other PLCs (with a CANopen
interface). The controller is programmed with the easy Soft
CoDeSys programming software. This software should be installed
on a standard PC with the Windows NT, 2000 or XP operating
system. Further information on the software is provided in the
manual AWB2700-1437GB.
This software provides you with a simple entry in the IEC
programming languages such as:
• Instruction List (IL)
• Function Block Diagram (FBD)
• Ladder Diagram (LD)
• Structured Text (ST)
• Sequential Function Chart (SFC).
This provides a large number of operators such as:
• Logic operators such as AND, OR, …
• Arithmetic operators such as ADD, MUL, …
• Comparison operators such as <,=, >
You use the programming software to create, test and document
a project. Functions for analog processing, closed-loop control and
function blocks such as timers, counters simplify programming.
Type overview
The EC4-200 series consists of a range of controllers that come
with different displays and types of inputs/outputs.
Type Features
Keys/
display
Transistor
outputs
Relay
outputs
EC4P-221-MTXD1 x 8 –
EC4P-221-MTXX1 – 8 –
EC4P-221-MRXD1 x – 6
EC4P-221-MRXX1 – – 6

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9
2Setup
Inputs
Table 1: Type and number of inputs
Inputs I7, I8, I11, I12 can also be used as analog inputs. They are
selected in the user program by means of the appropriate syntax
used in the PLC configurator.
When programming the inputs as digital inputs in the user
program, the input voltage of 8°V forms the limit value for the
TRUE/FALSE signals.
Technical data: aAppendix
Inputs I1, I2, I3, I4 can be used for:
• generating interrupts (inputs I1, I2, I3, I4)
• controlling high-speed counters such as:
– 16 or 32-bit counters, for counting pulses (I1, I2), up/down
counting
– Incremental counters, 32-bit, for processing the signals of an
incremental encoder (I1, I2, I3, I4).
The function is selected in the PLC configuration. However, several
functions cannot be used at the same time.
Figure 1: Front of the EC4P-221-MRAD1,
Legend afigure 2
Figure 2: Front of the EC4P-221-MTAD1
a24 V DC power supply
bInputs
cInterface for connecting the CAN network
dAnalog output, 0 – 10 V (not active)
eDEL button
fALT button
gRUN/STOP/SF LED
hCAN/NET LED
iField for device labelling
jInterface for expansion (not active)
kProgramming interface for connection to a PC
lUniversal interface for adapter with memory card
mRelay outputs
nTransistor outputs
oOK button
pESC button
qLCD display (EC4P-22x-M…D1)
rFour-way rocker switch with function buttons P1-P4
Q1 Q2 Q3Q4 Q5 Q6
RUN
STOP
SF
CAN/
NET
e
abd
c
f
g
h
i
j
k
l
p
r
o
m
q
Q7 Q8Q5 Q6Q3Q4Q1 Q2+24V 0V
RUN
STOP
SF
CAN/
NET
e
abd
f
g
h
i
j
k
l
p
r
o
n
q
c
Digital 12 (I1…I12) 24 V DC
Of which can be used
as analog
4 (I7, I8, I11, I12) 24 V DC/0…10 V
Figure 3: Selection between digital and analog input, e.g. I7
Voltage [V] State
F8 FALSE
>8 TRUE

Setup 05/06 AWB2724-1584GB
10
Example: If you are using input I1 for a high-speed counter (16-
bit), I2 can be used for another high-speed counter (16-bit) but not
for generating an interrupt. Inputs I3 and I4 likewise cannot be
used for generating an interrupt.
Connection description afigure 19 on page 20.
Inputs of the rocker and function buttons
The front plate of the device is provided with the function buttons
DEL, ALT, ESC, OK which are arranged around the rocker switch.
The rocker switch is divided into 4 sections with the designations
P1 to P4. The function buttons and the rocker buttons P1 to P4 are
represented in the PLC configuration as inputs. Their symbolic
names correspond to the name of the button or rocker section, e.g.
P1. These inputs are scanned in the program according to general
syntax rules. Only one button can be actuated at a time, otherwise
uncontrolled states may occur when the P buttons are scanned.
The “GetDisplayInfo” function block from the “EC_Visu.lib
library” enables you to control the scanning of the buttons
according to the active menu on the controller, asection
“EC_Visu.lib library”, page 52.
Diagnostics inputs
The inputs I13, I14, I15, I16 provide you with additional
information:
The inputs can be scanned in the program with symbolic operands.
Inputs for high-speed counters
You can choose between several different functions:
• 1 x 32-bit counters, for counting pulses (up/down)
• 2 x 16-bit counters, for counting pulses (up/down); the count
direction (up/down) can be set via the DIRECTION operand in
the program.
• 1 x incremental value counter, 32-bit, for processing the signals
of an incremental encoder; the count direction is set by the edge
sequence of the encoder.
You can select the counter type in the PLC configuration.
The function of the high-speed counter requires the setting of
inputs and the scanning of outputs in a POU, e.g. PLC_PRG.
This POU must not be called by an interrupt generated by a
counter.
For further information see section “High-speed counters”,
page 39.
Outputs
Table 2: Type and number of outputs
The transistor outputs are provided with a short-circuit monitoring
function . In the event that a short-circuit occurs at one of the
outputs, this is indicated via the diagnostics inputs I15/I16. I15 is
set to 1 if a short-circuit occurs at the outputs Q1 to Q4. Input I16
is toggled if a short-circuit occurs on Q5 to Q6.
Figure 4: Rocker switch with rocking ranges P1, P2, P3, P4
Figure 5: Inputs of the rocker and function buttons
P2
OK
P3
ALT
P4
ESC
P1
DEL
Input Function
I13 No function
I14 Connection to the expansion device via easy-Link (not yet
active in the operating system version 1.x):
0: ok, 1: not ok
I15 Outputs Q1, Q2, Q3, Q4:
0: No short-circuit, 1: Short-circuit
I16 Outputs Q5, Q6, Q7, Q8:
0: No short-circuit, toggle: Short-circuit
EC4P-221/222-MT…
transistor outputs
8 (Q1…Q8) 24 V DC/0.5 A
EC4P-221/222-MR…
relay outputs
6 (Q1…Q6) 250 V AC/8 A

05/06 AWB2724-1584GB Memory card (MCC)
11
Memory card (MCC)
The memory card is used for data storage and supports the FAT16
file system.
Memory card data
On the memory card you can save the following data:
A brief description of the browser commands is provided from
page 49.
Data access on the memory card
Functions such as “FileOpen” or “FileRead” allow you to access
the files of the memory card from the user program. These
functions are provided in the library “EC_File.lib” and are
described in the “Function Blocks” manual (AWB2786-1456GB).
LED status indication for RUN/STOP/SF and CAN/NET
After power up, the CPU can switch to the following states, as
indicated by the LEDs:
Table 3: LED status indication
If the CPU is in RUN status, the CAN/NET LED indicates the
following states:
Table 4: LED status indication for CAN/easy NET
iCaution! Scan I15/I16 in the program. In the event of a
short-circuit set the outputs to 0 in order to prevent the
thermal overload of the output circuit.
Data Transfer method
Boot project Browser command: copyprojtommc
Startup.INI file Browser command: createstartupini
Operating system (OS) Updating the OS, apage 47
Source code of the
project
Online mode/Online menu: load source
code
General data Online mode/Online menu:
Write file to PLC
Load file from PLC
hAttention! In order to avoid any loss of data, ensure that
you have closed all files of the program before removing /
inserting the memory card or switchingoff the power
supply.
LED Meaning/CPU status
RUN/STP/SF CAN/NET
Red Red1) System test being run (up to 6 seconds after
start; after 6 seconds if no user program is
present).
CPU in NOT READY!
Orange Orange1) System update in progress
Red OFF1) System test finished without error
Red
Flashing
Red
Flashing1)
System test found a fault
Orange OFF No user program present
CPU in NOT READY
Green
Flashing
–User program loaded
CPU in STOP
Green – User program loaded
CPU in RUN
Red – Cycle time exceeded
CPU in STOP
Orange
Flashing
–Continuous loop detected in program
CPU in STOP
Red
Flashing
Red
Flashing
Fatal error
1) LED is only relevant during startup/system test
LED Meaning
RUN/STP/SF CAN/NET
Green OFF Communication not active
Green Red Bus status STOP
Green Orange Bus status PREOPERATIONAL
Station can be initialised
No process data transferred
Green Green Bus status “OPERATIONAL”
Process data transferred

Setup 05/06 AWB2724-1584GB
12
Real-time clock
The PLC is provided with a real-time clock that can be accessed in
the user program via functions from the “SysLibRTC library”. The
functions are described in the PDF file “SysLibRTC”. After the
software is installed, this file can be opened via <Programs l
Moeller Software leasy Soft CoDeSys lDocumentation l
Automation Manuals>.
The clock can be read or set using the browser command “getrtc”
and “setrtc”. More information is provided in section “setrtc” on
page 50.
The clock is backed up for at least 72 hours in the event of a power
failure.
Programming interface for the PC
To connect the controller with a PC, use the cable EU4A-RJ45-
CAB1. The cable should be plugged into the programming
interface (RS232) of the controller. The interface is not electrically
isolated.
The interface is initialised with the following default parameters
when the PLC is started.
Table 5: Default parameters of the RS232 interface
Table 3: Pin assignment of the RS232 programming interface
Transparent mode
The programming interface is addressed as COM1. It can be
switched to Transparent mode using the functions of the library
EC_SysLibCom.lib.
achapter “RS 232 interface in Transparent mode”, page 63.
Universal interface
This interface is used for communication between the PLC and a
memory card. The memory card should be fitted in an adapter
which is then fitted on this slot.
aProgramming interface for connection to a PC
bUniversal interface
cEU4A-RJ45-CAB1 cable
dAdapter with memory card
Data length 8 Bit
Parity None
Stop bits 1
Baud rate 38400 Baud
Signal
1–
2–
3 –
4GND
5TxD
6–
7GND
8RxD
12345678
Figure 6: Universal interface/Memory card socket
RUN
STOP
SF
CAN/
NET
a
b
PC
(RS 232)
c
d

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13
CAN(open) interfaces
The PLC is provided with a CAN interface with two slots that are
internally connected via terminals.
CANopen
The CAN interface is designed as a CANopen interface in
compliance with the CIA specification DS301V4.0. The PLC can be
operated both as an NMT master as well as a CAN device on CAN
networks. When used as a CAN device the PLC requires an address
(= Node ID) for identification on the bus. The configuration of the
master and the device are carried out in the PLC configuration.
asection “CAN/easy-NET network”, page 65.
Figure 7: CAN interfaces
8
1
18 1
2
NET
1
SELECT_IN GND(GROUND) (E)CAN_L (E)CAN_H SELECT_OUT
2341234

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3 Mounting
Install the PLC in a control cabinet, a service distribution board or
in an enclosure so that the power supply terminals and other
terminals are protected against direct contact during operation.
The PLC can be installed vertically or horizontally on a top-hat rail
in compliance with IEC/EN 60715 or on a mounting plate using
fixing brackets.
Ensure that the terminal side has a clearance of at least 3 cm from
the wall and from neighbouring devices in order to simplify wiring.
Mounting on top-hat rail
XPlace the device diagonally on the upper lip of the top-hat rail.
Press down lightly on both the device and the top-hat rail until
the unit snaps over the lower edge of the top-hat rail. The
spring mechanism should ensure that the device snaps into
position automatically.
XCheck that the device is seated firmly.
.
The device is mounted vertically on a top-hat rail in the same way.
Mounting on mounting plate
Fixing brackets that can be inserted on the rear of the device are
required for screw mounting. The fixing brackets are available as
an accessory.
Figure 8: Observing the clearances for wiring
30
30
30
30
Figure 9:
hThree fixing brackets are sufficient for a device with four
fixing points.
Figure 10: Inserting a fixing bracket
1
2
CLICK !

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Figure 11: Screw fixing the EC4-200