Moeller PS416-INP-40 SERIES User manual

Hardware and Engineering
PS416-INP-40x
PS416-OUT-4xx
Digital I/O Card
01/00 AWB27-1239-GB
1st published 2000, edition 01/00,
See revision protocol page II
© Moeller GmbH, 53105 Bonn
Author: Werner Albrecht
Editor: Thomas Kracht
Translator: Terence Osborn, David Long
All 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 alteration without notice.

I
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 interfe-
rence do not impair the automation functions.
• Install automation devices and related opera-
ting 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!

II
01/00 AWB27-1239-GB
List of revisions for AWB27-1239-GB
Edition Page Description new Modification
01/00 1-3 Tables X
1-10 Section “PS416-OUT-400/-410” X
2-3, 2-9 Figure X
2-10, 2-18 Notes about this manual X
3-3, 3-4, 3-9 Figure
3-26 Notes about this manual X

III
01/00 AWB27-1239-GB
GeneralPS416-INP-400/-401PS416-OUT-400/-410AppendixIndex
Overview
About this Manual V
General 1-1
PS416-INP-400/-401 2-1
PS416-OUT-400/-410 3-1
Appendix 4-1
Index 5-1

IV
01/00 AWB27-1239-GB

V
01/00 AWB27-1239-GB
About this Manual
This manual describes the PS416-INP-400/-401
digital input cards and the PS416-OUT-400/-410
digital output cards for the Moeller modular control
PS416.
Descriptions dealing with all cards are presented in
the first section “General description”. The varying
characteristics are described separately in Parts 2
and 3 of the manual. The digital input cards and the
output cards are grouped together in the descrip-
tions.
For orientation, the chapter “General description,
Setup” presents the elements of the cards and the
commissioning procedure.
The manual is intended for project engineers,
programmers and commissioning engineers. The
reader is assumed to have general knowledge of
control technology.

VI
01/00 AWB27-1239-GB

1-1
01/00 AWB 27-1239-GB
General
Contents
1General
1 About the cards 1-3
Task 1-3
Hard-/Software requirements 1-3
Setup 1-4
2 Engineering 1-9
General engineering notes 1-9
Example 1-11
3 Installation 1-13
Inserting and removing cards 1-13
Screw terminal Inserting-/Removing 1-15
Inserting and removing the marking strip 1-16

1-2
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1-3
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General
1 About the cards
1
Task The digital input cards detect 24 V DC input signals
from external signal encoders via their 16 inputs and
make them available for further processing to the
central processor of the PLC.
Depending upon the requirements, the
PS416-INP-400 or the PS416-INP-401 can be used.
The basic difference has to do with the on/off delay
(see “Technical Data” on page 4-1).
The digital output cards supply the 24-V-DC for the
actuators. For this, the PS416-OUT-400 features
16 500 mA outputs; the PS416-OUT-410 has 8
2 A outputs.
Hard-/Software
requirements
The following hardware and software components
are required when using the digital input and output
cards in a PS416 system.
Table 1-1: Hardware and software requirements
1) For Hardware Configuration of PS416-CPU-223
see AWB27-1243GB.
Sucosoft
for PS416-CPU-2231):
for PS416-CPU-200/-300:
for PS416-CPU-400
Operating system version 1.32 or higher,
S30-S316-D/-GB/-F version 2.31 or higher
Operating system version 2.0 or higher,
S40-D/-GB/-F version 2.0 or higher
Operating system version 1.0 or higher,
S40-D/-GB/-F version 1.0 or higher
Rack PS416-BGT-400/-410/-420 or -421 with potential equalisation bar,
PS416-ZBX-401/-402/-403
Power supply cards PS416-POW-400/-410/-420
CPU PS416-CPU-200/-300/-400, PS416-CPU-2231)
Programming cable or
interface converter PS416-ZBK-210 (PRG/RS232) UM1.5 (PRG/RS485)

About the cards
1-4
01/00 AWB27-1239-GB
Setup The scope of delivery of all cards includes the plug
connector housing with a plug-in screw terminal and
the label strip with a plexiglass cover.
The plug connector is required for the card to
function in the PS416 automation system.
Figure 1-1: Setup of the digital input/output cards
j
a
i
c
a b
d
h
g
f
e

Setup
1-5
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General
Procedure
The following basic instructions ensure a correct
commissioning of the cards:
1. Setting the card address
The card is assigned a unique address with code
switch 햵and thus defines the addressing by the PLC
programm. The address to be set depends on the
card type and is explained for each card in the
chapter “Hardware Configuration”.
Pos. PS416-INP-400/401 PS416-OUT-400 PS416-OUT-410
햲Cable exit (bottom standard, top as an option)
햳Locking mechanism
햴– Operating mode
selector switch –
햵Code switch
햶Marking strip
햷– Short-circuit indication for central
disconnection module (ZAA)
햸– Reset button
햹Connector plug
햺– Connection terminal for “ZAA”
햻Plug-in screw terminal

About the cards
1-6
01/00 AWB27-1239-GB
2. Setting the mode
The setting of the operating mode selector switch 햴
determines how the card will react in the event of a
short-circuit. This function is only implemented with
the PS416-OUT-400 and is described in the chapter
“Hardware Configuration”.
3. Wiring the plug-in screw terminal
The 19-pole plug-in screw terminal 햻is wired
according to the connection diagram. For the
external 24-V-DC power supply, wire with a 1.5 mm2
diameter is recommended. Wire with a 0.75 mm2
diameter is recommended for the signal lines. The
wiring scheme is illustrated in the chapter
“Engineering” for each card.
The plug-in screw terminal is then locked into the
housing of the connection plug 햹and the cables are
pushed through the underside 햲of the housing
(see chapter “Installation” on page 1-13).
4. Filling out the marking strip
The marking strip 햶is used to document how you
address the card's inputs and outputs via the
software. The software addresses are related directly
to the card address setting (see step 1). The chapter
“Operation” of each card describes how the user
program addresses the card.

Setup
1-7
01/00 AWB27-1239-GB
General
Figure 1-2: Marking strip for PS416-INP-400/401
햲Status display
5. Inserting the card in the rack
The voltage-free card can now be inserted in the
rack. The card is fastened or removed via the locking
mechanism 햳. The cards are all inserted and
removed in the same way (see chapter “Installation”
on page 1-13).
a

About the cards
1-8
01/00 AWB27-1239-GB
6. Fitting the plug connector
The connection plug 햹is plugged in. This concludes
the installation of the card (see chapter “Installation”
on page 1-13).

1-9
01/00 AWB27-1239-GB
General
2 Engineering
General
engineering notes
The relevant regulations for safety and prevention of
accidents must be observed. Machines and systems
which are fetted with the PS416 are subject to the
relevant EN-, IEC-, VDE regulations.
Emergency OFF devices acc. EN 60204/IEC 204
(VDE 0113) must always be active in all operation
modes of the controller. A deactiviation of the
emergency OFF device must not cause an
uncontrolled or undefinded restart.
Power supply
When using 24 V power supplies, a safe electrical
isolation of the low voltage must be ensured. Only
power supply units designed acc. IEC 364-4-41 or
VDE 0100 Part 410 may be used.
An isolation monitoring device must be implemented
(IEC 364-4-41 or VDE 0100 Part 410) when using an
unearthed power supply.
With a potentially isolated operation the 24-V-DC
power supply must be a protective low voltage acc.
IEC 364-4-41 or VDE 0100 Part 410 or equivalent.
Suppression of interference sources
Connected inductive loads must always be
protected with suppressor circuits. When connecting
loads, the manufacturers specifications must be
adhered to.

Engineering
1-10
01/00 AWB27-1239-GB
Interference measures
왘Power, control and signal cables must be laid as
far away from each other as possible in order to
avoid capacitive and inductive coupling. If
separate cabling is not possible, then those
cables that are the interference sources must be
screened without fail.
왘Avoid long, parallel runs of cables with differing
power ratings.
You can find further information on this subject in the
Moeller Manual “Electromagnetic Compatibility of
Automation Systems (EMC)” (TB27-001-GB) and
“EMC-Engineering Guidelines for Automation
Systems PS4/PS416” (AWB27-1287GB).
PS416-OUT-400
PS416-OUT-410
The following engineering guideline must be observed
in order to conform to the EMC guidelines:
The voltage supply cables must be provided with a
ferrite ring. It should be installed in the closest
possible proximity of the card. One or more voltage
supply cables may be present. The cables may not
be connected to further devices.
HF-ferrite rings are not supplied with the card.
Place a separate order for type PS416-ZBX-405.

Example
1-11
01/00 AWB27-1239-GB
General
Example
Figure 1-3: Engineering guideline for voltage supply cables
of the output card
햲Ferrite ring
a
2
24 V
OUT-4xx

1-12
01/00 AWB27-1239-GB

1-13
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General
3 Installation
Inserting and
removing cards
Inserting cards
왘Insert the card into any slot of the rack to the right
of the power supply PS416-CPU-4x0 or the
SUCOnet K card PS416-NET-400.
The card requires one slot.
왘Press the lever and insert the card into the rack
until you hear a click.
왘Plug in the connection plug.
Removing
왘Remove the connection plug.
왘Press the lever to release the locking mechanism.
왘Pull the card forward.
Note
The PLC must be disconnected from the power
supply before you insert or remove cards.
Otherwise, voltage peaks at the bus plug can
damage the card.