Moeller PS 4-271-MM1 User manual

Hardware and Engineering
PS 4-271-MM1
06/99 AWB 2700-1364 GB
1st published 1999, edition 06/99
© Moeller GmbH, Bonn
Author: Peter Roersch
Editor: Thomas Kracht
Translators: B & H, 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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06/99 AWB 2700-1364 GB
Contents
Contents 1
About This Manual 3
Documentation for PS 4-271 3
Symbols used 4
1 About the PS 4-271 Compact PLC 5
Hardware and software requirements 5
Features 5
Setup 6
Elements of the PS 4-271 8
2 Engineering 15
Overview of terminals 15
Programming device interface 16
Suconet K interface 17
Setting of bus terminating resistors 18
Local expansion 18
Electromagnetic compatibility (EMC) 19
Layout of control cabinet 22
Power supply 26
Lightning protection measures 28
3Mounting 29
Mounting on top-hat rail 29
Mounting with mounting feet 30
4 Software Configuration 31
General 31
Creating configurations 31
Setting the parameters of the PS 4-271 35
Configuration example 47
5SlaveAddressing 51
Slaves without CPU 51
Slaves with CPU 53
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Contents
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6Operation 55
Power-up behaviour 55
Shutdown behaviour 55
Operating states of the PLC 56
Start-up behaviour 59
Transferring programs 61
Starting the PLC with a memory module
plugged in 63
Programming via Suconet K 63
7 Test/Commissioning/Diagnostics 65
LEDs 65
Diagnostic status word 66
Diagnostic bytes 69
Message byte 75
8 Representation of Analog Values 77
Analog-digital conversion 77
Appendix 83
Slave addressing 84
Technical data 88
Index 95
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06/99 AWB 2700-1364 GB
About This Manual
Documentation
for PS 4-271
The documentation for the PS 4-271-MM1 compact
PLC (referred to below as the PS 4-271) is
subdivided into four manuals with the following
topics:
Hardware and engineering
User interface for the programming software
Programming
Training guide
Hardware and engineering manual
This “Hardware and engineering” manual explains
how to install and configure the PLC and how to alter
the settings on the PLC.
How to configure and set parameters for the PLC in
the topology configurator of the Sucosoft S 40
programming software is described in the chapter
entitled “Software configuration”.
The “Slave addressing” chapter defines the general
syntax rules for addressing the stations in a
Suconet K network.
The chapter “Test/Commissioning/Diagnostics”
provides an overview of the possible error and
diagnostic signals and their meanings.
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About This Manual
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06/99 AWB 2700-1364 GB
User interface for the programming software
The PS 4-271 is programmed with version 3.0 or
higher of the Sucosoft S 40 programming software
(Windows, IEC 1131).
The user interface of this software is described in
manual AWB 2700-1305 GB.
Programming
Information on how to program the PS 4-271 can be
found in the “Language elements of the
PS 4-150/-200/-300 and PS 416”manual
(AWB 2700-1306 GB).
Training guide
The AWB 27-1307 GB training guide illustrates the
most important functions of Sucosoft S 40 with the
help of practical examples.
Symbols used Symbols with the following meaning are used in this
manual:
왘Indicates instructions on what to do.
Draws your attention to useful tips and additional
information.
Warning!
Warns of the possibility of damage. The product
itself or anything in the immediate vicinity of the
product or data could be damaged.
Caution!
Warns of the possibility of serious damage. The
product itself, anything in the immediate vicinity
of the product or data could be seriously
damaged or destroyed; there is also a risk of
serious or fatal injury.
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06/99 AWB 2700-1364 GB
1 About the PS 4-271 Compact PLC
Hardware and software
requirements
To program the PS 4-271, you need a PC (IBM or
IBM-compatible) equipped with
Pentium microprocessor
Operating system Windows 95, Windows 98 or
Windows NT 4.01)
16 MByte RAM
(32 MByte recommended)
3.5”/1.44 MByte diskette drive and CD-ROM
Hard disk with at least 50 MByte free memory;
during installation, the directory C:\{_PS 4_}.TMP
will be created and then deleted again. To do this,
there must be at least 250 kBytes available on
drive “C”.
Serial COM interface
Parallel printer interface (LPT)
VGA graphics card
ZB 4-303-KB1 programming cable (connecting
cable between PC and PS 4-271)
1) (version 3.x of Sucosoft is the last version supported by
Windows 3.1x).
Features The PS 4-271 has the following distinguishing
features:
120/240 V AC power supply
12 digital inputs 120/240 V AC
8 relay outputs
4 analog inputs
0 to 10 V, 0(4) to 20 mA
0 to 1500 , e.g.: Pt1000, Ni1000
4 analog outputs (0 to 10 V, 0(4) to 20 mA)
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About the PS 4-271
Compact PLC
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Setup Figure 1 provides an overview of the controls,
indicators and connecting terminals of the PLC.
Warning!
Always ground yourself before touching the PLC
to protect the components against electrostatic
discharge.
Key to figure 1: 120/240 V AC power supply Digital inputs 120/240 V AC Status LEDs for digital inputs 0.0 to 0.7 Plug-in screw terminal Analog inputs AI0, AI1: 0 to 10 V/0(4) to 20 mA Analog inputs AI2, AI3: Pt1000, Ni1000 Analog outputs AQ0, AQ1: 0 to 10 V Analog outputs AQ2, AQ3: 0 to 20 mA Status LEDs for digital inputs 1.0 to 1.3 Relay outputs (make contacts) 24 V DC or 250 V AC Status LEDs for digital outputs C0 to C7 Suconet K interface Setpoint potentiometers P1, P2 Switch S1 for bus terminating resistors Programming device interface (PRG) Memory module Status LEDs for PLC
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Setup
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   




 
 
  


1234
NL1 Power Supply
ttery
4 Ba yRead3 Not
n2 Ruady1 Re
Suconet K
PRG
12
S1 P2P1
Output Relais Input Digital
.0 .1 .2 .3 .4 .5 .6 .7
Output Relais
Input Digital
Input Analog
Output Analog
PS 4-271-MM1



.5
C5
AI
0
.6
C6 .7
N2
C7
1.1 1.2 1.3
.0
C0
0.0
.1
C1 .2
C2 .3
C3 .4
C4
AI
1
AI
2
AI
3
0V
A
0V
A
AQ
0
AQ
1
AQ
2
AQ
3
0.1 0.2 0.3 0.4N10.5 0.6 0.7 1.0
Figure 1: Setup of PS 4-271
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About the PS 4-271
Compact PLC
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06/99 AWB 2700-1364 GB
Elements of the
PS 4-271
Power supply unit
The PS 4-271 requires a power supply rated at
120/240 V AC.
Digital inputs
The PLC has 12 digital inputs. These are electrically
isolated from the CPU and designed for a rated
voltage of 120/240 V AC. The inputs I0.0 to I0.7 and
I1.0 to I1.3 can be addressed in bits, bytes or words.
Three different external cables can be connected to
the groups of input. Only one external cable should
be used for each group..
The two neutral conductor terminals N1/N2 are
isolated.
, Status LEDs for analog outputs
LEDs for inputs I0.0 to I0.7 indicate the physical,
logical states of the signal inputs, as well as the
diagnostic status word of the PLC (see the section
entitled "Description of the diagnostic status word"
on Page 67).
Plug-in screw terminal
Please refer to the chapter “Engineering”for a
summary of terminals for the digital and analog
inputs/outputs.
, Analog inputs
The PLC has 4 analog inputs. You can configure
inputs AI0and AI1as voltage inputs (0 to 10 V) or
current inputs (0(4) to 20 mA). The inputs AI2and AI3
are provided for connecting temperature sensors
such as Pt1000 or Ni1000. All inputs have a
resolution of 10 bits (1024 increments).
Group External cable
I0.0 to 0.3 1
I0.4 to I0.7 and I1.0 2
I1.1 to I1.3 3
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Elements of the PS 4-271
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06/99 AWB 2700-1364 GB
The addresses of the analog inputs are as follows:
AI0IAW0.0.0.4
AI1IAW0.0.0.6
AI3IAW0.0.0.8
AI4IAW0.0.0.10
See also the chapter "Representation of Analog
Values".
, Analog outputs
The PLC has 4 analog outputs. Outputs AQ0and AQ1
generate signals of 0 to 10 V. Outputs AQ2and AQ3
can be configured for 0(4) to 20 mA signals. You
adjust the output range from 4 to 20 mA in the
Sucosoft S 40 programming software.
All outputs have a resolution of 12 bits
(4096 increments).
The addresses of the analog outputs are as follows:
AQ0QAW0.0.0.0
AQ1QAW0.0.0.2
AQ3QAW0.0.0.4
AQ4QAW0.0.0.6
See also the chapter "Representation of Analog
Values".
Relay outputs
The PLC has 8 relay outputs, which are electrically
isolated from the CPU. The terminals of all contacts
are accessible. The contacts can take a load of up to
12 A and thus allow you to switch large loads.
The outputs can be addressed in bits or bytes.
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About the PS 4-271
Compact PLC
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06/99 AWB 2700-1364 GB
Status LEDs for the relay outputs
LEDs (LEDs) indicate the logical states of the relay
outputs.
Suconet K interface
The interface has the following functions:
Networking:
Network interface for Suconet K stations (e.g. for
connecting Suconet K master or slave PLCs,
EM 4-... expansion modules).
The programming of networks via Suconet K is
described in the section entitled "Programming
via Suconet K" on Page 63. The Suconet K
interface (RS 485) is electrically isolated from the
CPU.
Transparent communication:
Transparent communication for the exchange of
data with partner devices which have a serial
interface (e.g. printers, terminals, etc.). Data for
process control must not be exchanged.
Transparent communication via the Suconet K
interface is enabled by the “SCO”function block
of Sucosoft S 40. A description of the function
block can be found in the manual “Language
elements of PS 4-150/-200/-300 and PS 416"
(AWB 2700-1306 GB). The interface is electrically
isolated from the CPU.
The parameters of the interface such as “baud
rate“, “parity“, “stop bit”can be set in the
topology configurator of Sucosoft S 40 via
‹Edit ➞Set Parameters ➞Transparent mode›.
A maximum of 127 bytes of data can be
transferred.
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Elements of the PS 4-271
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06/99 AWB 2700-1364 GB
Setpoint potentiometers
The two setpoint potentiometers P1and P2can be
set externally with a screwdriver. This allows you to
change setpoint values without a programming
device. The resolution is 10 bits. In the programming
software, you can address the setpoint
potentiometers with the operands “IAW0.0.0.0”and
“IAW0.0.0.2“.
Switch S1 for setting the bus terminating
resistors
The bus terminating resistors of the stations which
are physically first and last on the bus must be turned
on. The bus terminating resistors of stations between
these two must be turned off (see section "Setting of
bus terminating resistors" on Page 18).
Programming device interface (PRG)
The interface has the following functions:
Programming of the PLC with a PC
Data exchange with partner devices which have a
serial interface (e.g. printers, terminals, etc.). Data
for process control must not be exchanged.
Communication via the interface is controlled by
the “SCO”function block of Sucosoft S 40. A
description of the block can be found in the
manual “Language elements of
PS 4-150/-200/-300 and PS 416"
(AWB 2700-1306 GB). The interface is electrically
isolated from the CPU.
The parameters of the interface are fixed:
Baud rate: 9600 Baud
Data bits: 8
Stop bits: 1
Parity bits: 0
Max. transferrable data: 63 Byte
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About the PS 4-271
Compact PLC
12
06/99 AWB 2700-1364 GB
Memory modules
The PS 4-271 has an internal 32 kByte RAM memory
with battery backup. The memory is subdivided into
data and user program memory areas.
Up to 24 kByte are available for the user program.
The storage space for data and user program is
allocated dynamically: if the data memory requires
more than 8 kByte, the size of the user program
memory is reduced accordingly.
Figure 2: Dynamic memory allocation
The memory capacity of the internal RAM can be
expanded with plug-in memory modules. The
following modules are available:
The 32 kByte RAM module increases the size of
the user program memory. There is then a
maximum of 56 kByte of user program memory
available.
The 128 kByte flash module is divided into a
64 kByte backup memory (the user program is
stored instead of being reset in the event of
voltage failure) and a 64 kByte memory - for
recipe data, for example.
8 Kbyte data memory
24 Kbyte program memory
32 Kbyte program memory
RAM memory
PS 4-201-MM
1
Memory modu
l
(external)
Program memory
Data memory
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Elements of the PS 4-271
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06/99 AWB 2700-1364 GB
The 160 kByte combination module combines all
the features of the above two memory modules.
Status LEDs for the PLC
The PLC states are indicated with the LEDs “Ready“,
“Run“, “Not Ready”and “Battery“. The meaning of
the indicators is described in the section "LEDs" on
Page 65.
Figure 3: Controls and LEDs of the PS 4-271 (with cover
open)
Backup battery
Reset button
Plug connector for local expansion module
Mode selector

+
Battery
Reset3 Run M-
2 Run
1 Halt
Reset
S2
32
1



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About the PS 4-271
Compact PLC
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06/99 AWB 2700-1364 GB
Backup battery
The battery backs up the internal RAM memory and
the real-time clock.
,  Mode selector/
Reset button
With the mode selector, you can select between the
modes “Halt“, “Run”and “Run M reset“. The modes
are explained in the section entitled "Operating
states of the PLC" starting on Page 56.
Plug connector for local expansion modules
The plug connector represents the interface to the
terminals of LE 4-... local expansion modules.
Real-time clock
The PLC has a real-time clock with battery backup. It
allows time-controlled switching of machines and
plants. You can set or scan the real-time clock with a
function block in the user program. The function
block also enables switching between summer and
winter time (DST).
Warning!
Only change the backup battery when the power
supply is switched on or you will lose programs
and data.
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06/99 AWB 2700-1364 GB
2 Engineering
Overview of terminals
Figure 4: Overview of terminals
Screw terminals, terminal capacities:
Flexible with ferrule - 0.22 to 2.5 mm2 (AWG 24 to 13)
Solid - 0.22 to 2.5 mm2 (AWG 24 to 13)
Plug-in screw terminal
Terminal capacities:
Flexible with ferrule - 0.22 to 1.5 mm2 (AWG 24 to 16)
Solid - 0.22 to 2.5 mm2 (AWG 24 to 13)
Plug connector for local expansion module (LE 4)
Suconet K interface (RS 485)
Programming device interface (RS 232)
Suconet K
12
Power Supply
PRG











+

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Engineering
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06/99 AWB 2700-1364 GB
Programming device
interface
Pin assignment of connector
Figure 5: Pin assignment of programming device (PRG)
interface (left-hand socket, top view)
PIN 1 Unused
PIN 2 RxD
PIN 3 0 V for interface
PIN 4 Unused
PIN 5 TxD
PIN 6 –8 Unused
Connecting the programming device (PC)
왘Connect the PC to the PRG interface by means of
the ZB 4-303-KB1 programming cable (left-hand
socket) of the PS 4-271:
Figure 6: Pin assignment of ZB 4-303-KB1 programming
cable
Jumpers
PS 4-271-MM1:
PRG interface
(8-pin DIN connector)
PC:
COM interface
(9-pin socket)
3
5
2
4
16
78
5
2
3
1
2
3
4
5
6
7
8
9

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Suconet K interface
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06/99 AWB 2700-1364 GB
If it is not possible to achieve equal ground
potentials, connect the PC to the mains supply via an
isolating transformer or use a laptop powered by an
internal battery.
Suconet K interface Connector pin assignment
Figure 7: Pin assignment of Suconet K interface (right-hand
socket, top view)
Connecting to the Suconet K field bus
왘Use the KPG 1-PS3 bus cable to connect
additional Suconet K stations (PS 4, EM 4) to the
PS 4-271 compact PLC.
5-pin DIN connector (pin) 5-pin DIN connector (pin)
1--------------------------------1
4--------------------------------4
Warning!
To prevent potential equalisation currents arising
between the PLC and PC, devices attached to
the PRG and Suconet K interfaces must have the
same ground potential. If the ground potentials
differ, the interfaces can be destroyed.
PIN 1 Data cable RS 485, Suconet K (TB/RB)
PIN 2, 3, 5 Assigned internally
PIN 4 Data cable RS 485, Suconet K (TA/RA)
3
5
2
4
1
The interface is also used for connecting the
ZB 4-501-TC1 telecontrol module and the ZB 4-
501-UM3 interface converter.
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Engineering
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06/99 AWB 2700-1364 GB
왘Connect the screen of the Suconet K data cable
to the potential equalisation strip ensuring a large
contact area and low impedance joint (e.g. with a
metal cable clip) (see also Page 19).
Setting of bus
terminating resistors
왘Set the bus terminating resistors on the PLC for
the first and last physical stations on the line. To
do this, set both S1 switches to the “ON”
position. The S1 switches must be set to “OFF”
for all other stations on the bus.
Figure 8: Bus terminating resistors active
Local expansion The PS 4-271 is locally expandable. The local
expansion modules (LE 4) are connected to the local
bus connector of the PS 4-271 using a bus
connecting cable. All of the available types of LE 4
can be used. However, note the following limitations:
A maximum of five LE 4 can be connected to the
bus.
The local expansion modules with digital inputs/
outputs can be used at positions 1 to 5 (1st to 5th
module).
No more than two of the LE 4 modules below can
be used per local bus; they can only be arranged
immediately after the master (1st and 2nd
module):
21
OFF
Both S1 switches must be set to the same
position for the PLC to work correctly.
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