saia-burgess PCD3 Series User manual

Document-No. 26/789; Version E5; 31.01.2005
Hardware Manual for the PCD3 Series

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls AG Contents
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0 Content
0.1 Document history ............................................................................................ 0-4
0.2 Trademarks ..................................................................................................... 0-4
1 Graphical index
2 Orientation guide
2.1 Introduction ..................................................................................................... 2-1
2.2 Planning an application ................................................................................... 2-2
2.3 Cabling ............................................................................................................ 2-5
2.3.1 Cable layout .................................................................................................. 2-5
2.3.2 Cable routing ................................................................................................. 2-5
2.4 Addressing and cabling rows .......................................................................... 2-6
2.4.1 Labelling module holders and modules ........................................................ 2-7
3 PCD3.Mxxx0 Classic CPUs and expansion housings
3.1 System overview ............................................................................................. 3-1
3.2 General technical details ................................................................................ 3-2
3.3 System resources ........................................................................................... 3-3
3.3.1 Program blocks ............................................................................................. 3-3
3.3.2 Computation ranges for count types ............................................................. 3-4
3.3.3 Media ............................................................................................................ 3-4
3.4 PCD3 CPUs .................................................................................................... 3-5
3.4.1 Block diagram for PCD3.Mxx0 ...................................................................... 3-7
3.4.2 Hardware and firmware versions for the PCD3.Mxxx0 ................................. 3-8
3.5 Expansion with PCD3 components ................................................................. 3-9
3.6 Mounting CPUs and module holders .............................................................. 3-10
3.6.1 Mounting position and ambient temperature ................................................. 3-11
3.7 Dimensions ..................................................................................................... 3-11
3.8 Power supply and connection plan ................................................................. 3-13
3.8.1 External power supply ................................................................................... 3-13
3.8.2 Earthing and connection plan ....................................................................... 3-14
3.8.3 Internal power supply .................................................................................... 3-15
3.9 Operating states .............................................................................................. 3-15
3.10 Connections to the PCD3.Mxxx0 .................................................................... 3-17
3.11 Partitioning options for user memory .............................................................. 3-18
3.12 Data storage in case of power failure ............................................................. 3-19
3.13 Backup of the user program ............................................................................ 3-20
3.13.1 General ......................................................................................................... 3-20
3.13.2 Program backup and restore with onboard flash .......................................... 3-21
3.13.3 Program backup and restore with flash card (PCD3.M5xx0 only) ................ 3-22
3.13.4 Download backup option ............................................................................... 3-23
3.13.5 Backup/restore of RAM texts/DBs at run-time .............................................. 3-24
3.14 Hardware clock (Real Time Clock) .................................................................. 3-27
3.15 Hardware watchdog ........................................................................................ 3-27
3.16 Software watchdog ......................................................................................... 3-29
3.17 Interrupt inputs ................................................................................................ 3-30
3.17.1 Basics ........................................................................................................... 3-30

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls AG Contents
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3.17.2 PCD3.Mxxx0 interrupt inputs ........................................................................ 3-30
3.18 Hardware options ............................................................................................ 3-31
3.19 Expansion housings ........................................................................................ 3-32
3.19.1 Internal supply to PCD3.C200/T76x expansion housings ............................. 3-32
3.19.2 LIO module holders ....................................................................................... 3-32
3.19.3 Connections to PCD3.Cxxx LIO module holders .......................................... 3-34
3.19.4 RIO head stations ......................................................................................... 3-35
3.19.5 Connections to PCD3.T76x RIO head station for 4 modules ........................ 3-36
3.19.6 Diagnostic information on RIOS .................................................................... 3-39
4 Communication interfaces
4.1 Summary of onboard interfaces and plug-in interface modules ...................... 4-1
4.2 Protocols on serial ports ................................................................................. 4-3
4.2.1 Protocols supported by the firmware ............................................................ 4-3
4.2.2 Serial S-Net ................................................................................................... 4-4
4.2.3 Profi S-Net .................................................................................................... 4-4
4.2.4 Ether S-Net ................................................................................................... 4-4
4.2.5 Protocols implemented in the user program ................................................. 4-4
4.4 RS232 connector (Port 0) as communication interface and as connection
for programming unit (PCD3.M5xx0 only) ....................................................... 4-6
4.5 Serial interfaces on I/O module Slot 0 (Port 1) ............................................... 4-8
4.5.1 RS 485/422 with PCD3.F110 ........................................................................ 4-8
4.5.2 RS 485 with PCD3.F150 ............................................................................... 4-10
4.5.3 RS 232 with PCD3.F121 (suitable for modem) ............................................. 4-12
4.6 LIOs and RIOs ................................................................................................ 4-16
5 Input/output (I/O) modules
5.1 Introduction to I/O modules ............................................................................. 5-1
5.1.1 Types of connectors and Accessories ........................................................... 5-3
5.1.2 Power requirements of the PCD3....-cassettes ............................................. 5-4
5.1.3 Power supply, external input voltage ............................................................. 5-5
5.1.4 Examples of I/O modules .............................................................................. 5-6
5.1.5 Opening the module housing ........................................................................ 5-6
5.2 Digital I/O modules, 24 VDC ........................................................................... 5-7
5.2.1 PCD3.E110/111, 8 digital inputs .................................................................... 5-8
5.2.2 PCD3.E160, 16 digital inputs, ribbon cable connector .................................. 5-10
5.2.3 PCD3.E165, 16 digital inputs, screwless terminals ....................................... 5-12
5.2.4 PCD3.E610, 8 digital inputs, galvanically isolated ........................................ 5-14
5.2.5 PCD3.B100, 2 + 4 digital inputs /outputs ...................................................... 5-16
5.2.6 PCD3.A400, 8 digital outputs for 0.5 A each ................................................. 5-19
5.2.7 PCD3.A410, 8 digital outputs for 0.5 A each, galvanically isolated ............... 5-21
5.2.8 PCD3.A460, 16 digital outputs for 0.5A each, ribbon cable connector ......... 5-23
5.2.9 PCD3.A465, 16 digital outputs, for 0.5A each ............................................... 5-25
5.2.10 PCD3.A300, 6 digital outputs for 2A each ..................................................... 5-27
5.3 Digital I/O modules, 230 VAC ......................................................................... 5-29
5.3.1 PCD3.A200, 4 relay contacts, type “NO”, with contact protection ................ 5-30
5.3.2 PCD3.A210, 4 relays with “normally closed” contacts, with contact
protection ...................................................................................................... 5-32
5.3.3 PCD3.A220, 6 relay contacts, type “NO”, w/o contact protection ................. 5-34

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls AG Contents
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5.3.4 PCD3.A251, 6 change-over and 2 make relay contacts 2A/48VAC .............. 5-36
5.4 Analogue I/O modules .................................................................................... 5-38
5.4.1 PCD3.W2x0, analogue inputs, 8 channels, 10 bit resolution ........................ 5-39
5.4.2 PCD3.W3x0, analogue inputs, 8 channels, 12 bit resolution ........................ 5-43
5.4.3 PCD3.W3x5, analogue inputs, galvanically separated, 7 channels,
12 bit resolution ............................................................................................. 5-50
5.4.4 PCD3.W500, analogue inputs/outputs, 2 + 2 channels, 12 bit resolution ..... 5-54
5.4.7 PCD3.W6x5, analogue outputs, galvanically isolated, 6 resp. 4 channels,
10 bit resolution ............................................................................................. 5-67
5.5 Weighingsystems and Thermocouple module ................................................ 5-71
5.6 Counting and motion control I/O modules ....................................................... 5-73
5.6.1 PCD3.H100, Simple counting module .......................................................... 5-74
5.6.2 PCD3.H110, Universal counting and measuring module .............................. 5-79
5.6.3 PCD3.H150, SSI interface for absolute encoder .......................................... 5-81
5.6.4 PCD3.H210, Motion control module for stepper motors ............................... 5-84
5.6.5 PCD3.H31x, Motion control modules for servo drives .................................. 5-87
6 Configuration
6.1 CPUs ............................................................................................................... 6-1
6.2 RIOs ................................................................................................................ 6-6
6.2.1 Example project with PG5 and Profibus-DP ................................................. 6-6
6.2.2 Web server .................................................................................................... 6-16
6.2.3 Device-specific web pages ........................................................................... 6-17
6.2.4 Application-specific web pages ..................................................................... 6-29
7 Maintenance
7.1 Changing the battery on the PCD3.M5xx0 ..................................................... 7-1
7.2 Other PCD3 components (in preparation) ...................................................... 7-2
8 Troubleshooting
8.1 CPUs (in preparation) ..................................................................................... 8-1
8.2 RIOs ................................................................................................................ 8-2
9 Appendix
9.1 Icons ............................................................................................................... 9-1
9.2 Definitions of serial interfaces ......................................................................... 9-2
9.2.1 RS 232 .......................................................................................................... 9-2
9.2.3 TTY/current loop ........................................................................................... 9-4
9.3 Order details ................................................................................................... 9-5
Address of SAIA-Burgess Controls AG ........................................................... 9-8

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls AG Contents
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0.1 Document history
Document-no. Version Changed Published Remarks
26/789 E4 08.01.2005 ??.??.2005 Translation
E5 31.01.2005 31.01.2005 Changes
0.2 Trademarks
Saia® and Saia®PCD are registered trademarks of Saia-Burgess Controls AG.
STEP7® ,SIMATIC®, S7-300®, S7-400®, and Siemens® are registered trademarks of
Siemens AG.
Technical changes are subject to the state of technology.
Saia-Burgess Controls AG, 2004. © All rights reserved.
Published in Switzerland

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls AG Graphical index
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1 Graphical index
The graphical index singles out some highlights from the Hardware manual for the
PCD3 Series, and allows you to click on the text frames or directly on a component/
connector to jump straight to the corresponding section. The facility to jump to any
section from the table of contents is still to be completed.
Plug-in serial interfaces
in Slot 0 (Port 1), 4.8
LEDs for operating status,
3.9
LEDs for operating status,
3.9
Battery
changing, 7.1
Flash card,
3.13
Run/Stop
switch,
3.18
RS232/
PGU
(Port 0),
3.10
S-Net/
RS485
(Port 10),
3.10
Communication, 4. Terminal block for supply,
watchdog, interrupt inputs and
Port 2, 3.10
Communication, 4.
USB port,
4.
Ethernet, 4. Earthing, 3.8.2

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
Introduction
Orientation guide
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2 Orientation guide
2.1 Introduction
This manual covers the technical aspects of the PCD3 components. The following
terms are used frequently:
● CPU Central processing unit: the heart of the PCD
● RIOs Remote I/Os: inputs and outputs connected to the CPU via a field bus
such as Profibus
● LIOs Local I/Os: these are connected to the CPU via the I/O bus or a RIO
(i.e. with the shortest possible cables)
● Modules Input/output elements, mounted in a housing, matched to the PCD3
system
● Module
holder CPU, RIO or LIO, to which modules may be attached
The aim of this section is to present the essentials of planning and installing control
systems with PCD3 components. It covers the following topics:
● Planning an application
● Cabling
● Addressing and cabling of rows of controllers
Details of hardware, software, configuration, maintenance and troubleshooting are
described in separate sections. The Appendix contains an explanation of the icons
used, and the company address.

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
Planning an application
Orientation guide
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2.2 Planning an application
The following aspects should be considered when planning PCD3 applications:
● The internal load current taken by the I/O modules from the +5V and V+ supply
must not exceed the maximum supply current specified for the CPUs, RIOs or
LIOs (PCD3.C200)
● The CPU or the RIO type determines the maximum number of module holders
● The total length of the I/O bus is limited by technical factors; the shorter, the
better
The PCD3.C200 is used to extend the I/O bus or for the internal power supply (+5V
and V+) to a module segment. Please note the following rules:
● Use no more than six PCD3.C200s in one configuration, or the time delay will
exceed the I/O access time
● Use a maximum of five PCD3.K106 cables
● After each cable (at the start of a row), insert a PCD3.C200
Exception: In a small configuration with no more than 3 LIOs, these can be
supplied from the PCD2.Mxxx. A PCD3.C200 is not needed
● Where an application is mounted in a single row (max. 15 LIOs), after every
five PCD3.C100s a PD3.C200 must be inserted to amplify the bus signal
(unless the configuration ends with the fifth PCD3.C100)
● If the application is mounted in multiple rows, the restricted length of cable
means that only three LIOs (1x PCD3.C200 + 2x PCD3.C100) may be
mounted in one row

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
Planning an application
Orientation guide
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When planning an application, we recommend the following procedure:
 Select the I/O modules according to your requirements. Where possible, use
PCD3 I/O modules with 16 connections; these have 16 red LEDs.
 From the number of I/O modules, calculate the required number of module
holders. Check that the number of module holders is allowed:
PCD3 M3020 M3230 M3330 M5440 M5540
I/O bus connection for expansion
units no Yes
Number of inputs/outputs or I/O
module sockets 641)
4
10231) 2)
64
1) Using digital I/O modules PCD3.E16x or A46x with 16 I/Os each
2) On all PCD3 units, address 255 is reserved for the watchdog. The I/Os reserved for the watchdog cannot be used,
and no analogue and H modules can be used on the sockets with base address 240
 Arrange module holders in row(s) according to the mounting area avaliable
Connecting material required
Arrangement with one PCD3.Mxx0; LIOs in one row
Max. 15 x PCD3.LIO’s in a row, no extension cable, with PCD3.K010 connector
only
Connecting material for this arrangement:
n x PCD3.K010 connectors between PCD3 module holders
Arrangement with one PCD3.Mxx0; LIOs in multiple rows
Max. 3 PCD3.LIOs side-by-side and one row beneath the other, with extension
cables for the rows beneath (max. 15 PCD3.LIOs)
Connecting material for this arrangement:
n x PCD3.K106 extension cables to connect the last PCD3 module holder in
one row with the first PCD3 module holder in the next row
n x PCD3.K010 connectors between PCD3 module holders
Arrangement of a RIO node with the LIOs side-by-side
Max. 3 x PCD3.LIOs total
Connecting material for this arrangement:
n x PCD3.K010 connectors between PCD3 module holders
For all arrangements: After every five PCD3.C100 module holders, insert a PCD3.
C200 base unit as an I/O bus amplifier

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
Planning an application
Orientation guide
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
Use the table in the section on “Current consumption of the modules” to
calculate the load current on the internal +5V supply (use the worst-case /
highest values)
 Check that the max. supply current is sufficient for the CPU, RIO or PCD3.
C200. To supply a module segment separately, use a PCD3.C200 instead of a
PCD3.C1xx. Check that the load current for all segments does not exceed the
max supply current for the CPU/RIO/PCD3.C200. The max. supply current can
be found in the section on “Internal supply”
 Calculate consumption from the 24V supply. The current consumption for the
PCD3 configuration can be determined from the section on “Current
consumption of the modules” (use the worst-case / highest values)
Note that in most applications the outputs place the heaviest load on the 24V supply.
For 16 outputs with a load current of 0.5A each, the loading will be 8A with all outputs
connected.
 Do not forget the appropriate connecting cables for the module holders
 Calculate the number of terminal blocks required for the I/Os, and order
separately. Screw or spring clamp terminal blocks can be ordered as required.
Not all modules require the same type of socket connection.