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
0-1
0
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

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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

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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
1-1
1
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
2-1
2
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
2.2 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
2-3
2
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

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Planning an application
Orientation guide
2-4
2

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.

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Cabling
Orientation guide
2-5
2
2.3 Cabling
2.3.1 Cable layout
It is recommended to wire the I/O modules from a cable channel mounted above the
module holders.
Cables to connections on the lower part of the module holders (supply, earth) should
preferably be wired from a cable channel below the module holders.
Following these rules will ensure that the LEDs are visible and the bus connections
remain accessible.
2.3.2 Cable routing
● 230V supply lines and signal lines must be laid in separate cables at least 10 cm
apart. Even within the switching cabinet, it is advisable to leave space between
power and signal lines.
● Digital signal / bus lines and analogue signal / sensor lines should be laid in
separate cables
● It is advisable to use shielded cables for analogue signal lines.
● The shield should be earthed at the entry or exit to the switching cabinet. The
shields should be as short as possible and of the largest possible cross-section.
The central earthing point should be > 10 mm² and connected to the PE ground
wire by the shortest route
● The shield is generally connected to one side of the switching cabinet only, unless
there is a potential equalization with significantly lower resistance than the shield
resistance
● Inductivities installed in the same switching cabinet, e.g. contactor coils, should be
provided with suitable suppressors (RC elements)
● Switching cabinet components with high field intensity, e.g. transformers or
frequency inverters, should be shielded with separator plates with a good ground
connection.
Surge protection for long distances or external lines
● Where lines are laid outside the building, or over longer distances, suitable surge
protection measures should be applied. For bus lines in particular, these
measures are essential.
● With lines laid outside, the shield must have adequate current-carrying capacity
and be earthed at both ends.
● The surge conductors should be installed at the input to the switching cabinet.

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
Addressing and cabling rows
Orientation guide
2-6
2
2.4 Addressing and cabling rows
The address of a module is determined by its module position in the configuration.
PCD3 CPUs: Module addresses begin with base address 0 (zero) on socket 1
(addresses 0 to 15) and go up in increments of 16 to address 63 on
socket 4, regardless of the number of inputs/outputs (16, 8 or 4 )
PCD3 LIOs: Determined by the module position in the configuration; go up in
increments of 16
PCD3 RIOs: There is no direct access to the I/Os; the entries are defined by the
network configurator.
Extension cables connect the module holder at the right-hand end of a row with the
first module holder at the left of the next row. The address of the first module in a
second or third row equals the address of the last module in the previous row +16.
To simplify cabling, the module positions for the PCD3 module holders are labelled
0 to 3. For more precise addressing, each module holder and each module also has
an address field in the bottom right corner of the housing. The use of these address
fields is described in the next section.
Address 255 is reserved for the watchdog relay. Modules that use this address must
not be installed in module position 16. For more details, please refer to the section on
the “Hardware watchdog”.













 
next row up to
max. 1023
    

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
Addressing and cabling rows
Orientation guide
2-7
2
Each additional PCD3.C100/C200 module holder provides space for 4 further I/
O modules; at the end of the bus, a PCD3.C110 provides space for 2 further I/O
modules. The connection to the next row is via the PCD3.K106 26-core extension
cable.
Forces arising with too small cable radii (smaller than the natural radius) may damage
the plug connection.
The extension cables must not be plugged in or removed with the controller
connected to the power supply.
2.4.1 Labelling module holders and modules
The sockets for the PCD3 module holders are labelled 0 to 3.
Every module holder has an address field in the bottom right corner of the housing
Example:
All PCD3 module holders and the PCD3.K106 extension cable are provided with a
matching set of labels for additional markings.
Frontview
F rontview
Frontview
F rontview
01230
0 0
1
11
2
2 2
3
33
L3
0-L3 1-L3 2-L3 3-L3
L4
0-L4 1-L4 2-L4 3-L4
64 64 80 96 112 0
128 128 144 160 176 0
192 192 208 224 240 16
256 256 272 288 304 32
320 320 336 352 368 48
384 384 400 416 432
448 448 464 480 496
512 512 528 544 560
576 576 592 608 624
640 640 656 672 688
704 704 720 736 752
768 768 784 800 816
832 832 848 864 880
896 896 912 928 944
960 960 976 992 1008
4 310 8686 0

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
System overview
PCD3.Mxxx0 Classic CPUs and expansion housings
3-1
3
3 PCD3.Mxxx0 Classic CPUs and expansion housings
The CPUs in the xx7 Series are described in a separate manual.
3.1 System overview
Saia®S-Net networking concept
Saia®S-Net is the name of the new, flexible networking concept for innovative and
economical automation systems with Saia®PCDs.
● Based on the Ethernet-TCP/IP (Ether-S-Net) and Profibus (Profi S-Net) open
standards: use of existing network infrastructure → no duplicate cabling
required
● Supports multi-vendor and multi-protocol operation:
Reduced costs for project planning, programming, commissioning and
maintenance by general use of Ethernet TCP/IP and Profibus with S-Net, the
Private Control Network (PCN) for Saia®PCDs
● General use of web technologies via Ethernet TCP/IP and Profibus for
commissioning, operation, monitoring and diagnostics
● General programming and commissioning via Ethernet TCP/IP and Profibus
● Network connections integrated into the base unit; Profibus interface integrated
into the operating system of the new Saia®PCD3 controllers and Saia®PCD3
RIOs (included in the base unit, at no extra charge)
● Profi S-Net with optimized protocols and services for efficient operation of
Saia® PCD3 RIOs and Saia®PCD3 controllers on the Profibus
● Multi-protocol operation:
The new Saia®PCD3 controllers and Saia®PCD3 RIOs support Profibus-DP
and S-Net on the same socket
● Continuity and security of investment:
PCD3.RIO PCD3.LIO
PCD3.LIOPCD3.CPU
RIO for decentralized applications
CPU for centralized applications
S
a
i
a
-
S
-
N
e
t

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
General technical details
PCD3.Mxxx0 Classic CPUs and expansion housings
3-2
3
All Saia®PCD systems can be integrated into the design using existing Profibus
and Ethernet TCP/IP connections
Saia®PCD web server
All Saia®PCD3 controllers and Saia®PCD3 RIOs come with an integrated web server
as standard:
● Web browser as a tool for commissioning, support and visualization:
Access to the Saia® web server is via standard web browsers such as Internet
Explorer or Netscape Navigator. This makes the web browser, which can be
operated intuitively by anyone, the standard tool for commissioning, service,
support and visualization of machines, units and installations. The user can
retrieve pre-defined device and system-specific HTML pages, giving access to
all data on controllers and RIOs. Graphical elements (images, diagrams etc.) as
well as text documents (operating and repair manuals) can also be integrated
into the HTML pages, to provide a personalized user interface
● General access to any desired interfaces and networks:
Access to the web server is available not only via Ethernet TCP/IP, but also via
cost-effective standard serial interfaces (RS232, RS485, modem etc.) and via
Profibus networks, throughout the system and at different levels in the network.
This makes it economical to use web technology to operate and monitor even
the smallest applications.
● The Saia®PCD web server is integrated into all products:
Having a web server integrated as standard eliminates the cost of run-time
licenses or additional modules. In all new Saia®PCD3 controllers and the
Saia®PCD3 RIOs, the web server is already included in the base units, at no
extra cost.
3.2 General technical details
Supply (external and internal)
Supply voltage 24V DC ±20% smoothed or
19V AC ±15% full-wave rectified (18 VDC)
Power consumption1) PCD3: typically 15 W for 64 I/Os
Capacity of internal
5V bus2)
PCD3: 600 mA
Capacity of internal
+V bus (16..24V)2)
PCD3: 100 mA
1) The loads on the outputs are generally more significant for sizing the feed than the internal power leakage within
the controller
2) When planning PCD2 systems, it is essential to check that the two internal feeds are not overloaded. This check
is especially important where analogue, counter and motion control modules are used, as these may consume a
lot of power.
Atmospheric conditions
Ambient temperature Mounting on vertical surface with vertically aligned connection
terminals: 0..+55 °C
In all other mounting positions, a reduced temperature range of
0..+40 °C applies
Storage temperature -20...+85 °C (DIN 40040, class HS)
Relative humidity 30...95% without condensation (DIN 40040, class F)

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
System resources
PCD3.Mxxx0 Classic CPUs and expansion housings
3-3
3
Vibration resistance
Vibration according to EN/IEC 61131-2
5...13.2 Hz, constant amplitude 1.42 mm
13.2...150 Hz, constant acceleration (1 g)
Electrical safety
Protection type IP 20 according to EN 60529
Air/leakage paths according to DIN EN 61131-2 and DIN EN 50178: between
circuits and bodies and between electrically isolated circuits:
surge category II, fouling level 2
Test voltage 350V / 50Hz AC for nominal unit voltage 24 VDC
Electromagnetic compatibility
Electrostatic discharge According to EN 61000-4-2: 8 KV: contact discharge
Electromagnetic fields According to EN 61000-4-3: field intensity 10 V/m, 80...1000
MHz
Bursts According to EN 61000-4-4: 4 KV on DC supply lines, 4 kV on
I/O signal lines, 1 kV on interface lines
Noise emission According to EN 50 081-2: Class A (for industrial areas)
Guidance on the correct use of these controls in residential
areas can be found at www.sbc-support.ch (additional
measures).
Noise immunity according to EN 50 082-2
Mechanism and mounting
Housing material Module holder: PC/ABS, light grey, RAL 7035
I/O modules: PC, transparent blue
Clips: PAM, orange, RAL 2003
Fibre optics: PC, crystal-clear
Mounting rail Top-hat rail according to EN 50022-35 (35 mm)
Connections
Terminal
blocks
Spring
terminals
10-pole
Screw
terminals
10-pole
Spring
terminals
14-pole
Spring
terminals
24-pole
Earth
terminal Terminal 2-pole
supply
X-section
stranded
single wire
0.5...2.5 mm²
0.5...2.5 mm²
0.5...2.5 mm²
0.5...2.5 mm²
0.5...1.5 mm²
0.5...1.5 mm²
0.5...1.0 mm²
0.5...1.0 mm²
0.08...
2.5 mm²
0.5...
1.5 mm²
The terminal blocks may only be plugged into 20 times. They must then be replaced, to guar-
antee a reliable contact
Length of
insulation 7 mm 7 mm 7 mm 7 mm 5...6 mm 7 mm
3.3 System resources
3.3.1 Program blocks
Type Number Addresses Remarks
Cyclic organization blocks
(COB) 16 0...15 Main program elements
Exception/system-dependent
organization blocks (XOB) 32 0...31 Called from the system
Program blocks (PB) 300 0...299 Sub-programs
Function blocks (FB) 1000 0...999 Sub-programs with parameters

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
System resources
PCD3.Mxxx0 Classic CPUs and expansion housings
3-4
3
Sequential blocks (SB)
total 6000 steps and transi-
tions each (with PG5 ≥ 1.3 and
firmware version ≥ xxx)
96 0...95
for Graftec programming of se-
quential processes
3.3.2 Computation ranges for count types
Type Remarks
Integers – 2,147,483,648 to
+ 2,147,483,647 Format: decimal, binary, BCD or hexadecimal
Floating point numbers – 9.22337 x 1018 to
– 5.42101 x 10-20
+ 9.22337 x 1018 to
+ 5.42101 x 10-20
Instructions are provided to
convert values held in Saia
format (Motorola Fast Floating
Point, FFP) to IEEE 754 format
and vice versa.
3.3.3 Media
Type Number Addresses Remarks
Flags (1 bit) 8192 F 0...8191 By default, flags are not volatile,
but a volatile range can be
configured, beginning with
address 0
Registers (32 bit) 16384 R 0...16383 For integer or floating point
values
Text/data blocks
8192
X or DB
0...8191
The texts 0..3999 are always
written to the same memory area
as the user program.
Where the user memory has
been extended, the base
memory can be configured to
hold RAM texts and DBs.
The texts and DBs held in this
way have addresses ≥ 4000
Timers/counters (31 bit) 16001) T/C 0...1599 The breakdown of timers and
counters is configurable. Timers
are periodically decremented by
the operating system; the basic
time unit can be set between 10
ms and 10 s
Constants with media code K any num-
ber Values 0..16383; may be used in instructions instead of registers
Constants with no media
code any num- ber Values - 2,147,483,648 to +2,147,483,647. Can only be
loaded into a register with an LD
command, and cannot be used in
instructions instead of registers
1) The number of timers configured should be only as many as required, to prevent unnecessary CPU loading

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
PCD3 CPUs
PCD3.Mxxx0 Classic CPUs and expansion housings
3-5
3
3.4 PCD3 CPUs
Differentiation of PCD3 base
units
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
Processor (Motorola) CF 5272
Processing time
Bit instruction
Word instruction
0.3...1.5 µs3)
0.9 µs3)
Firmware, firmware update
(firmware memory soldered on) Downloadable from the PG5 environment
Minimum PG5 version 1.3.100
Working memory 128 kB 256 kB 512 kB
Backup memory 128 kB
onboard
flash
256 kB
onboard flash 256 kB onboard flash
1 MByte flash card
(optional)
Clock (RTC) yes, deviation < 1 min./month
Data protection 8 hours with Super Cap
(after 5 min. loading) CR 2032 lithium battery
1-3 years4)
Interrupt inputs
Maximum input frequency 2 1 kHz 5)
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
3) Typical values; the processing time is dependent on the load on the communication ports
4) The period given is a buffer time; it is dependent on the ambient temperature (a higher temperature means a
shorter buffer time)
5) The 1kHz applies with a pulse/pause ratio of 1:1 and refers to the total frequencies of the two inputs

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
PCD3 CPUs
PCD3.Mxxx0 Classic CPUs and expansion housings
3-6
3
Differentiation of PCD3 base
units (ports)
M3020 M3230 M3330 M5440 M5540
Programming interface USB1)
Optional serial port
Port 1 1 x RS 232, RS422/485 or TTY current loop 20mA,
pluggable (PCD3.F1xx modules)
Port 0 (PGU) also available as RS
232 interface, up to 115 kbps
 
RS 485 serial interface,
up to 115 kbps Port 2
Profi S-Net interface Port 2 up to 187.5 kbps Port 10 up to
1.5 Mbps
Ether-S-Net interface  
Field bus connections:
Serial-S-Net 
Profi S-Net 
Ether-S-Net (Ethernet TCP/IP)  
1) The USB port is type “USB 1.1 Slave Device 12 Mbps” and can only be used for programming and as an S-Bus
Slave, together with certain software products (Webconnect, ViSi-PLUS with S-Driver)
With a hub USB 2.0 the Download is two times fasterl.
Can also be used as a serial data port, e.g. to connect a terminal; but this hampers commissioning and
troubleshooting with the debugger

Hardware Manual for the PCD3 Series│Document 26/789; Version E 5│31.01.2005
Saia-Burgess Controls Ltd.
PCD3 CPUs
PCD3.Mxxx0 Classic CPUs and expansion housings
3-7
3
3.4.1 Block diagram for PCD3.Mxx0
1) Connection for the programming unit
2) Except PCD3.M3020
3) PCD3.M5xx0 only
4) With PCD3.M3330 or PCD3.M5540
When the power is switched on, no operations (such as moving jumpers or
(un)plugging I/O modules) should be attempted.
i
To prevent loss of data, batteries should be changed with the power switched on.
Supply I/O in Base unit
Addresses 0...63
I/O in Extensions
PCD3.C100/.C110/.C200
Addresses 64...1023
F1xx moduls
communication
slot#0
Serial
data interfaces/
connections of fieldbus
COM/PGU
CPU
CPU and I/O Bus
M
E
M
O
R
Y
M
A
P
E
E
P
R
O
M
DB
TX
P
T
vol
C
nvol
R
nvol
F
vol
F
nvol
Backup
user
memory
S-Net/
MPI
RS 485
user media
I/O Bus
user memory
register
timer
counter
flag
volatile
non volatile
program
text
data block
R
T
C
F
vol
nvol
P
TX
DB
Ethernet-
TCP/IP Modem RS232
“full handshaking”
USB
STOP
RUN
Interrupt-
inputs
Date-Time
nvol
Watch-Dog
1)
2)
3)3)
3)
3)
4)