Parker PIO-400 User manual

PIO Electromechanical Automation
We reserve the right to make technical changes 27.04.04 16:00 PIO-343 Profibus ECO 192-120855 N2 May 2004
The data contained in this manual correspond to the current status at the time of printing.
Parker I/O-System
PROFIBUS DP ECO + I/O-Modules
Manual
Technical description,
installation and configuration

Important comments PIO Parker I/O-System
ii PIO-343 Profibus ECO 192-120855 N2 May 2004
Copyright © 2003 Parker Hannifin GmbH EME
All rights reserved.
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EME - Electromechanical Automation Europe
Parker Hannifin GmbH
Electromechanical Automation
Postfach: 77607-1720
Robert-Bosch-Str. 22
D-77656 Offenburg
Tel.: [phone]
Fax: [phone]
E-mail: mailto:[e-mail]
Internet: http://www.parker-eme.com
Parker Hannifin plc
Electromechanical Automation
21 Balena Close
Poole, Dorset England, BH17 /DX UK
Tel.: [phone]
Fax: [phone]
E-mail: mailto:[e-mail]
Internet: http://www.parker-eme.com
Parker Hannifin S. p. A
Electromechanical Automation
Via Gounod 1
I-20092 Cinisello Balsamo (MI), Italy
Tel.: [phone]
Fax: [phone]
E-mail: mailto:sales.sb[email protected]m
Internet: http://www.parker-eme.com
EMN - Electromechanical Automation North America
Parker Hannifin Corporation
Electromechanical Automation
5500 Business Park Drive
Rohnert Park, CA 94928
Phone #: [phone]
FAX #: [phone]
E-mail: mailto:[e-mail]
Internet: http://www.compumotor.com
Germany:
England:
Italy:
USA:

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PIO-343 Profibus ECO 192-120855 N2 May 2004 3
TABLE OF CONTENTS
1 Important comments.............................................................................................5
1.1 Legal principles.................................................................................................5
1.2 Symbols............................................................................................................6
1.3 Font Conventions .............................................................................................6
1.4 Number Notation ..............................................................................................6
1.5 Safety Notes .....................................................................................................7
1.6 Scope................................................................................................................7
1.7 Abbreviation......................................................................................................7
2 I/O-SYSTEM ...........................................................................................................8
2.1 I/O-System Description.....................................................................................8
2.2 Technical Data..................................................................................................9
2.3 Manufacturing Number...................................................................................13
2.4 Storage, Assembly and Transport..................................................................13
2.5 Mechanical Setup ...........................................................................................14
2.6 Power Supply .................................................................................................20
2.7 Grounding.......................................................................................................24
2.8 Shielding (Screening) .....................................................................................27
2.9 Assembly Guidelines / Standards ..................................................................27
3 Fieldbus Coupler.................................................................................................28
3.1 Description......................................................................................................29
3.2 Hardware ........................................................................................................30
3.3 Operating System...........................................................................................33
3.4 Process Image................................................................................................34
3.5 Configuration ..................................................................................................37
3.6 Configuring the Coupler..................................................................................41
3.7 Configuring the Process Data Channel..........................................................43
3.8 Configuration of I/O Modules..........................................................................44
3.9 Diagnostics .....................................................................................................52
3.10 LED Signaling.................................................................................................57
3.11 Fault Behavior ................................................................................................62
3.12 Technical Data................................................................................................63
4 I/O Modules..........................................................................................................64
4.1 PIO-400 [2 DI DC 24 V 3.0 ms, high-side switching] .....................................64
4.2 PIO-402 [4 DI DC 24 V 3.0 ms, high-side switching] .....................................67
4.3 PIO-430 [8 DI DC 24 V 3.0 ms, high-side switching] .....................................70
4.4 PIO-456 [2 AI DC ± 10 V, Differential Inputs].................................................73
4.5 PIO-468 [4 AI DC 0-10 V, Single-Ended] .......................................................77
4.6 PIO-480 [2 AI 0-20 mA Differential Measurement Input]................................80
4.7 PIO-501 [2 DO DC 24 V 0.5 A, high-side switching] ......................................85
4.8 PIO-504 [4 DO DC 24 V 0.5 A, high-side switching] ......................................88
4.9 PIO-530 [8 DO DC 24 V 0.5 A, high-side switching] ......................................91
4.10 PIO-550 [2 AO DC 0-10 V] .............................................................................94
4.11 PIO-552 [2 AO 0-20 mA] ................................................................................97
4.12 PIO-556 [2 AO DC ±10 V] ............................................................................101
4.13 PIO-600 [End Module]..................................................................................104
4.14 PIO-602 [24 V DC Power Supply] ................................................................106
5 PROFIBUS..........................................................................................................109
5.1 Description....................................................................................................109
5.2 Wiring ...........................................................................................................110
6 Use in Hazardous Environments.....................................................................112
6.1 Foreword ......................................................................................................112
6.2 Protective measures.....................................................................................112
6.3 Classification meeting CENELEC and IEC ..................................................112
6.4 Classifications meeting the NEC 500...........................................................116
6.5 Identification .................................................................................................118
6.6 Installation regulations..................................................................................120

Important comments PIO Parker I/O-System
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7 Glossary ............................................................................................................ 121
8 Literature list..................................................................................................... 122
9 Index .................................................................................................................. 123

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1 Important comments
To ensure fast installation and start-up of the units described in this manual, we
strongly recommend that the following information and explanation is carefully read
and adhered to.
1.1 Legal principles
1.1.1 Copyright
This manual is copyrighted, together with all figures and illustrations contained
therein. Any use of this manual which infringes the copyright provisions stipulated
herein, is not permitted. Reproduction, translation and electronic and photo-technical
archiving and amendments require the written consent. Non-observance will entail
the right of claims for damages.
1.1.2 Personnel qualification
The use of the product detailed in this manual is exclusively geared to specialists
having qualifications in PLC programming, electrical specialists or persons instructed
by electrical specialists who are also familiar with the valid standards. The
manufacturer declines all liability resulting from improper action and damage to
products and third party products due to non-observance of the information contained
in this manual.
1.1.3 Intended use
For each individual application, the components supplied are to work with a dedicated
hardware and software configuration. Modifications are only admitted within the
framework of the possibilities documented in the manuals. All other changes to the
hardware and/or software and the non-conforming use of the components entail the
exclusion of liability.

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1.2 Symbols
Danger
Always abide by this information to protect persons from injury.
Warning
Always abide by this information to prevent damage to the device.
Attention
Marginal conditions must always be observed to ensure smooth operation.
ESD (Electrostatic Discharge)
Warning of damage to the components by electrostatic discharge. Observe the
precautionary measure for handling components at risk.
Note
Routines or advice for efficient use of the device and software optimization.
More information
References on additional literature, manuals, data sheets and INTERNET pages
1.3 Font Conventions
Italic Names of path and files are marked italic
i.e.: C:\programs\
Italic Menu items are marked as bold italic
i.e.: Save
\A backslash between two names marks a sequence of menu
items
i.e.: File\New
END Press buttons are marked as bold with small capitals
i.e.: ENTER
< > Keys are marked bold within angle brackets
i.e.: <F5>
Courier Program code is printed with the font Courier.
i.e.: END_VAR
1.4 Number Notation
Number Code Example Note
Decimal 100 normal notation
Hexadecimal 0x64 C notation
Binary '100'
'0110.0100'
Within ',
Nibble separated with dots

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1.5 Safety Notes
Attention
Switch off the I/O-System prior to working on bus modules!
In the event of deformed contacts, the module in question is to be replaced, as its
functionality can no longer be ensured on a long-term basis.
The components are not resistant against materials having seeping and insulating
properties. Belonging to this group of materials is: e.g. aerosols, silicones,
triglycerides (found in some hand creams).
If it cannot be ruled out that these materials appear in the component environment,
then additional measures are to be taken:
- installation of the components into an appropriate enclosure
- handling of the components only with clean tools and materials.
Attention
Cleaning of soiled contacts may only be done with ethyl alcohol and leather cloths.
Thereby, the ESD information is to be regarded.
Do not use any contact spray. The spray may impair the functioning of the contact
area.
The I/O-SYSTEM and its components are an open system. It must only be
assembled in housings, cabinets or in electrical operation rooms. Access must only
be given via a key or tool to authorized qualified personnel.
The relevant valid and applicable standards and guidelines concerning the
installation of switch boxes are to be observed.
ESD (Electrostatic Discharge)
The modules are equipped with electronic components that may be destroyed by
electrostatic discharge. When handling the modules, ensure that the environment
(persons, workplace and packing) is well grounded. Avoid touching conductive
components, e.g. gold contacts.
1.6 Scope
This manual describes the field bus independent I/O-SYSTEM with the Fieldbus
Coupler for PROFIBUS.
Components
ECO-coupler PROFIBUS 12 MBd
1.7 Abbreviation
AO Analog Output Module
AI Analog Input Module
DI Digital Input
DO Digital Output
I/O input/output
ID Identifier
PI Process Images
PLC Programmable Logic Control
RTS Running Time System
SM Special Module

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2 I/O-SYSTEM
2.1 I/O-System Description
The I/O-SYSTEM is a modular, fieldbus independent I/O system. The structure
described here consists of an ECO fieldbus coupler (1) and up to 64 connected
fieldbus modules (2) for any kind of signal. Together, these make up the fieldbus
node. The end module (3) completes the node.
PIO-400
++
E1 E2
DE DE
PIO-400
++
E3 E4
DE DE
++
PIO-XXX
E5 E6
AE AE
PIO-501
++
A1 A2
DA DA
PIO-501
++
A3 A4
DA DA
PIO-501
++
A5 A6
DA DA
PIO-501
++
A7 A8
DA DA
++
PIO-XXX
A9 A10
AA AA
PIO-602
++
PIO-602
++
PIO-602
++ ++
PIO-XXX
E7 E8
AE AE
++
PIO-XXX
A11 A12
AA AA
++
PIO-XXX
E9 E10
AE AE
PIO-602
++
PIO-501
++
A13 A14
DA DA
PIO-600
123
Fig. 2-1: Fieldbus node
ECO couplers for fieldbus systems such as PROFIBUS DP, CANopen and DeviceNet
are available.
The ECO coupler contains the fieldbus interface, electronics and a power supply
terminal. The fieldbus interface forms the physical interface to the relevant fieldbus.
The electronics process the data of the bus modules and make it available for the
fieldbus communication. The 24 V system supply are fed in via the integrated power
supply terminal.
The fieldbus coupler communicates via the relevant fieldbus.
At first the ECO coupler is concepted for applications with digital I/O functions. Bus
modules for diverse digital and analog I/O functions and special functions can be
connected as well. The communication between the ECO coupler and the bus
modules is carried out via an internal bus.
The I/O-SYSTEM has a clear port level with LEDs the status indication, insertable
mini WSB markers and pullout group marker carriers. The 3-wire technology
supplemented by a ground wire connection allows for direct sensor/actuator wiring.

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2.2 Technical Data
Mechanic
Material Polycarbonate, Polyamide 6.6
Dimensions Coupler 50 mm x 65* mm x 97 mm
Dimensions I/O module, single 12 mm x 64* mm x 100 mm
Dimensions I/O module, double 24 mm x 64* mm x 100 mm
Installation on DIN 35 with interlock
modular by double featherkey-dovetail
Mounting position any position
Length of entire node ≤831 mm
Marking marking label type 247 and 248
paper marking label 8 x 47 mm
Wire range
Wire range CAGE CLAMP®Connection
0,08 mm² ... 2,5 mm²
AWG 28-14
8 – 9 mm Stripped length
Contacts
Power jumpers contacts blade/spring contact
self-cleaning
Current via power contacts max 10 A
Voltage drop at Imax < 1 V/64 modules
Data contacts slide contact, hard gold plated
1,5µ, self-cleaning
Climatic environmental conditions
Operating temperature 0 °C ... 55 °C
Storage temperature -20 °C ... +85 °C
Relative humidity 95 % without condensation
Resistance to harmful
substances
acc. to IEC 60068-2-42 and IEC 60068-2-43
Special conditions Ensure that additional measures for
components are taken, which are used in an
environment involving:
– dust, caustic vapors or gasses
– ionization radiation.
Mechanical strength
Vibration resistance acc. to IEC 60068-2-6
Shock resistance acc. to IEC 60068-2-27
Free fall acc. to IEC 60068-2-32
≤1m (module in original packing)
* from upper edge of DIN 35 rail

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Safe electrical isolation
Air and creepage distance acc. to IEC 60664-1
Degree of protection
Degree of protection IP 20
Electromagnetic compatibility*
Directive Test values Strength
class
Evaluation
criteria
Immunity to interference acc. to EN 50082-2 (96)
EN 61000-4-2 4kV/8kV (2/4) B
EN 61000-4-3 10V/m 80% AM (3) A
EN 61000-4-4 2kV (3/4) B
EN 61000-4-6 10V/m 80% AM (3) A
Emission of interference acc. to EN 50081-2 (94) Measuring
distance
Class
EN 55011 30 dBµV/m (30m) A
37 dBµV/m
Emission of interference acc. to EN 50081-1 (93) Measuring
distance
Class
EN 55022 30 dBµV/m (10m) B
37 dBµV/m
Range of
application
Required specification
emission of interference
Required specification
immunity to interference
Industrial areas EN 50081-2 : 1993 EN 50082-2 : 1996
Residential areas EN 50081-1 : 1993*) EN 50082-1 : 1992
*) The I/O-System meets the requirements on emission of interference in residential
areas with the fieldbus coupler for:
CANopen
DeviceNet
PIO-337
PIO-306
With a special permit, the I/O-System can also be implemented with other
fieldbus couplers in residential areas (housing, commercial and business areas,
small-scale enterprises). The special permit can be obtained from an authority or
inspection office. In Germany, the Federal Office for Post and
Telecommunications and its branch offices issues the permit.
It is possible to use other field bus couplers under certain boundary conditions.
Please contact the manufacturer.

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Maximum power dissipation of the components
Bus modules 0,8 W / bus terminal (total power dissipation, system/field)
ECO Fieldbus coupler 2,0 W / coupler
Warning
The power dissipation of all installed components must not exceed the maximum
conductible power of the housing (cabinet).
When dimensioning the housing, care is to be taken that even under high external
temperatures, the temperature inside the housing does not exceed the permissible
ambient temperature of 55 °C.

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Dimensions
Side view Dimensions in mm
Fig. 2-2: Dimensions

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2.3 Manufacturing Number
The manufacturing number is part of the lateral marking on the component.
PIO
Manufacturing Number
Calenda
r
week Year Software version Hardware version
Fig. 2-3: Manufacturing Number
The manufacturing number consists of the production week and year, the software
version (if available), the hardware version of the component, the firmware loader (if
available) and further internal information for the
manufacturer.
The production number is also printed on the cover of the configuration and
programming interface of the fieldbus coupler.
2.4 Storage, Assembly and Transport
Wherever possible, the components are to be stored in their original packaging.
Likewise, the original packaging provides optimal protection during transport.
When assembling or repacking the components, the contacts must not be soiled or
damaged. The components must be stored and transported in appropriate
containers/packaging. Thereby, the ESD information is to be regarded.
Statically shielded transport bags with metal coatings are to be used for the transport
of open components for which soiling with amine, amide and silicone has been ruled
out, e.g. 3M 1900E.

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2.5 Mechanical Setup
2.5.1 Installation Position
Along with horizontal and vertical installation, all other installation positions are
allowed.
Attention
In the case of vertical assembly, an end stop has to be mounted as an additional
safeguard against slipping.
2.5.2 Total Expansion
The maximum total expansion of a node is calculated as follows:
Quantity Width Components
1 50 mm ECO coupler
64 12 mm bus modules
- inputs / outputs
– power supply modules
- etc.
1 12 mm end module
sum 830 mm
Warning
The maximal total expansion of a node must not exceed 830 mm.
2.5.3 Assembly onto Carrier Rail
Carrier Rail Properties
All I/O-System components can be snapped directly onto a carrier rail in accordance
with the European standard EN 50022 (DIN 35).
Carrier rails have different mechanical and electrical properties. For the optimal I/O-
System setup on a carrier rail, certain guidelines must be observed:
•The material must be non-corrosive.
•Most components have a contact to the carrier rail to ground electro-magnetic
disturbances. In order to avoid corrosion, this tin-plated carrier rail contact must
not form a galvanic cell with the material of the carrier rail which generates a
differential voltage above 0.5 V (saline solution of 0.3% at 20°C) .
•The carrier rail must optimally support the EMC measures integrated into the I/O-
System and the shielding of the bus module connections.
•A sufficiently stable carrier rail should be selected and, if necessary, several
mounting points (every 20 cm) should be used in order to prevent bending and
twisting (torsion).
•The geometry of the carrier rail must not be altered in order to secure the safe
hold of the components. In particular, when shortening or mounting the carrier
rail, it must not be crushed or bent..
•The base of the I/O components extends into the profile of the carrier rail. For
carrier rails with a height of 7.5 mm, mounting points are to be riveted under the
node in the carrier rail (slotted head captive screws or blind rivets).

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2.5.4 Spacing
The spacing between adjacent components, cable conduits, casing and frame sides
must be maintained for the complete field bus node.
Fig. 2-4: Spacing
The spacing creates room for heat transfer, installation or wiring. The spacing to
cable conduits also prevents conducted electromagnetic interferences from
influencing the operation.
2.5.5 Plugging and Removal of the Components
Warning
Before work is done on the components, the voltage supply must be turned off.
In order to safeguard the ECO coupler from jamming, it should be fixed onto the
carrier rail with the locking disc To do so, push on the upper groove of the locking
disc using a screwdriver.
To pull out the fieldbus coupler, release the locking disc by pressing on the bottom
groove with a screwdriver and then pulling the orange colored unlocking lug.
fix
loosen
Release lug
locking disc
Fig. 2-5: Coupler and unlocking lug

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It is also possible to release an individual I/O module from the unit by pulling an
unlocking lug.
Fig. 2-6: removing bus terminal
Danger
Ensure that an interruption of the PE will not result in a condition which could
endanger a person or equipment!
For planning the ring feeding of the ground wire, please see chapter "Grounding
Protection“
2.5.6 Assembly Sequence
All I/O-System components can be snapped directly on a carrier rail in accordance
with the European standard EN 50022 (DIN 35).
The reliable positioning and connection is made using a tongue and groove system.
Due to the automatic locking, the individual components are securely seated on the
rail after installing.
Starting with the ECO coupler, the bus modules are assembled adjacent to each
other according to the project planning. Errors in the planning of the node in terms of
the potential groups (connection via the power contacts) are recognized, as the bus
modules with power contacts (male contacts) cannot be linked to bus modules with
fewer power contacts.
Attention
Always link the bus modules with the ECO coupler, and always plug from above.
Warning
Never plug bus modules from the direction of the end terminal. A ground wire power
contact, which is inserted into a terminal without contacts, e.g. a 4-channel digital
input module, has a decreased air and creepage distance to the neighboring
contact.
Always terminate the fieldbus node with an end module.

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2.5.7 Internal Bus / Data Contacts
Communication between the ECO coupler and the bus modules as well as the I/O-
System supply of the bus modules is carried out via the internal bus. It is comprised
of 6 data contacts, which are available as self-cleaning gold spring contacts.
Fig. 2-7: Data contacts
Warning
Do not touch the gold spring contacts on the I/O Modules in order to avoid soiling or
scratching!
ESD (Electrostatic Discharge)
The modules are equipped with electronic components that may be destroyed by
electrostatic discharge. When handling the modules, ensure that the environment
(persons, workplace and packing) is well grounded. Avoid touching conductive
components, e.g. gold contacts.

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2.5.8 Power Contacts
Self-cleaning power contacts , are situated on the side of the components which
further conduct the supply voltage for the field side. These contacts come as
touchproof spring contacts on the right side of the coupler and the bus module. As
fitting counterparts the module has male contacts on the left side.
Danger
The power contacts are sharp-edged. Handle the module carefully to prevent injury.
Attention
Please take into consideration that some bus modules have no or only a few power
jumper contacts. The design of some modules does not allow them to be physically
assembled in rows, as the grooves for the male contacts are closed at the top.
Fig. 2-8: Example for the arrangement of power contacts

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2.5.9 Wire Connection
All components have CAGE CLAMP®connections.
The CAGE CLAMP®connection is appropriate for solid, stranded and fine–stranded
conductors. Each clamping unit accommodates one conductor.
Fig. 2-9: CAGE CLAMP®Connection
The operating tool is inserted into the opening above the connection. This opens the
CAGE CLAMP®. Subsequently the conductor can be inserted into the opening. After
removing the operating tool, the conductor is safely clamped.
More than one conductor per connection is not permissible. If several conductors
have to be made at one connection point, then they should be made away from the
connection point using Terminal Blocks. The terminal blocks may be jumpered
together and a single wire brought back to the I/Omodule connection point.
Attention
If it is unavoidable to jointly connect 2 conductors, then a ferrule must be used to join
the wires together.
Ferrule:
Length 8 mm
Nominal cross sectionmax. 1 mm2for 2 conductors with 0.5 mm2each

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2.6 Power Supply
2.6.1 Isolation
Within the fieldbus node, there are three electrically isolated potentials.
•Operational voltage for the fieldbus interface.
•Electronics of the couplers and the bus modules (internal bus).
•All bus modules have an electrical isolation between the electronics (internal bus,
logic) and the field electronics. Some analog input modules have each channel
electrically isolated, please see catalog.
per module
per channel
Potential of the system supply Electrical isolation
to the field level
Potentials
in the field level
Potential
Fieldbus interface
Fig. 2-10: Isolation
Attention
The ground wire connection must be present in each group. In order that all
protective conductor functions are maintained under all circumstances, it is
recommended that a ground wire be connected at the beginning and end of a
potential group. (ring format, please see chapter Grounding Protection"). Thus, if a
bus module comes loose from the node during servicing, then the protective
conductor connection is still guaranteed for all connected field devices.
When using a joint power supply unit for the 24 V system supply and the 24 V field
supply, the electrical isolation between the internal bus and the field level is
eliminated for the potential group.