saia-burgess PCD0 User manual

Overview PCD0
26/766 E2 (HB_PCD0 26 766_E2.DOC) SAIA-Burgess Controls Ltd. Page 1
Operating manual
decentralised I/O-modules PCD0
for PROFIBUS DP
SAIA®PCD0: the well thought out RIO-System – clever in all project phases, from
planning to maintenance

PCD0 Overview
Page 2 ãSAIA-Burgess Controls Ltd. (HB_PCD0 26 766_E2.DOC) 26/766 E2
Maturity in conception and functionality
§The right RIO for every application
Economical, compact RIOs with up to 16 digital I/Os and
integral PROFIBUS-DP connection
Modular RIOs for up to 128 I/Os with wide range of I/O
modules (digital, analogue, counters) and 2 PROFIBUS-
DP connections (convenient bus coupler [BC] with
comprehensive service and diagnostic functions, or low-
cost economic coupler [EC])
Digital modules with dual-purpose channels that allow
flexible channel use: either as input or output.
§Compact form
The offset arrangement of terminals requires only 4.4
mm of switch cabinet width per I/O point.
§Efficient connection of I/O signals
Pretensioned spring terminals save time connecting I/O
signals. As a result, up to 30 % of wiring time is saved
when compared with conventional spring terminals.
Additional extension terminals allow I/Os to be
connected in 4-wire technology.
Smart diagnostic and service functions
§Efficient commissioning, maintenance and
diagnosis
Powerful service functions can be executed on site,
using the BC coupler’s integral keyboard and display.
Commissioning and diagnosis even without runnable
ROFIBUS DP
No additional software tools required
§Display and overwrite I/O signal states with or
without PROFIBUS-DP master connected:
- Display digital and analogue I/O states
- Display count values from counting and motion control
I/Os
- Set/reset digital I/O signal states
- Increment/decrement analogue I/O signal level
§Datalogging for fast signals
The last 20 signal states of all digital I/Os can be stored
in the BC coupler and viewed on the display.
§Built for ease of service
I/O module electronics are replaced without undoing the
wiring.
Operating manual
PCD0 EC/BC coupler since FW 0127
Copyright by
SAIA-Burgess Controls Ltd.
Bahnhofstrasse 18
CH-3280 Murten
Phone [phone]
Fax [phone]
Web site: www.saia-burgess.com
You can download all our operating manuals free of charge from our web site at www.sbc-support.ch
Operating manuals
Item Order no.
PCD0 RIO’s zu Profibus-DP deutsch 26/766 D
PCD0 RIO’s RIO for Profibus-DP englisch 26/766 E
Handbuch Profibus-DP deutsch 26/765 D
Manual Profibus-DP englisch 26/765 E
Previous versions of this operating manual
11/99

Overview PCD0
26/766 E2 (HB_PCD0 26 766_E2.DOC) SAIA-Burgess Controls Ltd. Page 3
Document conventions This operating manual uses the following signs to indicate safety-
related and handling warnings:
Possible injury to persons or damage to the automation system or the
equipment if relevant warnings are not observed.
Important information on the handling of the automation system or the
part described in the operating manual.
Please read and follow the safety-related warnings at the end of
this operating manual.
Other items are represented as follows.
Item Example
File names MANUAL.DOC
Menus / Menu items Insert / Picture / From file
Paths / directories C:\Windows\System
Hyperlinks www.saia-burgess.com
Program listings MaxTsdr_9.6 = 60
MaxTsdr_93.75 = 60
Keys <Esc> <Enter> (press first key and then next key)
<Ctrl+Alt+Del> (press all keys at the same time)

PCD0 Overview
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Contents
1 Overview......................................................................................................................................................................8
1.1 Compact RIO............................................................................................................................................................9
1.1.1 Available compact RIO’s..................................................................................................................................9
1.2 Modular System......................................................................................................................................................10
1.2.1 Available Bus coupler for the modular system...............................................................................................10
1.2.2 Available I/O modules for the modular system...............................................................................................11
2 Compact RIO’s ..........................................................................................................................................................14
2.1 Overview compact RIO’s........................................................................................................................................14
2.2 Compact I/O RIO 16 I DP.......................................................................................................................................15
2.2.1 Data Width and Addressing RIO 16 I DP.......................................................................................................16
2.3 Compact I/O RIO 16 O DP......................................................................................................................................17
2.3.1 Data Width and Addressing RIO 16 O DP.....................................................................................................18
2.4 Compact I/O RIO 8 I/O DP......................................................................................................................................19
2.4.1 Data Width and Addressing RIO 8 I/O DP.....................................................................................................21
2.5 Compact I/O RIO 8 I 8 I/O DP.................................................................................................................................22
2.5.1 Data Width and Addressing RIO 8 I 8 I/O DP................................................................................................24
2.6 Control, Connection and Display Elements............................................................................................................25
2.7 Setting the PROFIBUS-DP Slave Address.............................................................................................................26
3 Modular system.........................................................................................................................................................27
3.1 Overview of bus coupler versions...........................................................................................................................29
3.2 Overview I/O modules for the modular system.......................................................................................................30
4 Technical data’s and circuit diagrams for the modular system...........................................................................33
4.1 RIO EC DP bus coupler..........................................................................................................................................33
4.1.1 LED displays on the EC bus coupler..............................................................................................................34
4.1.2 Dial for setting the PROFIBUS-DP slave address on the EC bus coupler..................................................... 34
4.1.3 PROFIBUS-DP Bus port on the EC bus coupler............................................................................................34
4.2 RIO BC DP bus coupler..........................................................................................................................................35
4.2.1 LED displays on the BC bus coupler..............................................................................................................36
4.2.2 Numerical display on the BC bus coupler......................................................................................................37
4.2.3 Keypad of the BC bus coupler.......................................................................................................................38
4.2.4 Setting the PROFIBUS-DP slave address for the BC bus coupler ................................................................38
4.2.5 PROFIBUS-DP Bus port on the BC bus coupler............................................................................................39
4.3 Compatibility of the EC economy bus coupler and the BC bus coupler..................................................................39
4.4 Digital I/O module 16 inputs RIO 16 I .....................................................................................................................40
4.4.1 LED displays RIO 16 I....................................................................................................................................41
4.4.2 Data width, addressing and terminal assignment RIO 16 I............................................................................41
4.4.3 Specifications RIO 16 I...................................................................................................................................42
4.5 Digital I/O module 4 inputs AC 120 V RIO 4 I 120 VAC......................................................................................43
4.5.1 LED displays RIO 4 I 120 VAC ......................................................................................................................43
4.5.2 Data width, addressing and terminal assignment RIO 4 I 120 VAC...............................................................44
4.5.3 Specifications RIO 4 I 120 VAC.....................................................................................................................44
4.6 Digital I/O module 4 inputs AC 230 V RIO 4 I 230 VAC......................................................................................45
4.6.1 LED displays RIO 4 I 230 VAC ......................................................................................................................45
4.6.2 Data width, addressing and terminal assignment RIO 4 I 230 VAC...............................................................46
4.6.3 Specifications RIO 4 I 230 VAC.....................................................................................................................46
4.7 Digital I/O module 16 outputs RIO 16 O .................................................................................................................47
4.7.1 LED displays RIO 16 O..................................................................................................................................48
4.7.2 Data width, addressing and terminal assignment RIO 16 O..........................................................................48
4.7.3 Specifications RIO 16 O.................................................................................................................................49
4.8 Digital I/O module 4 outputs relay RIO 4 O R.........................................................................................................50
4.8.1 LED displays RIO 4 O R ................................................................................................................................50
4.8.2 Data width, addressing and terminal assignment RIO 4 O R.........................................................................51
4.8.3 Specifications RIO 4 O R...............................................................................................................................51
4.9 Digital I/O module 8 inputs/outputs RIO 8 I/O.........................................................................................................52
4.9.1 LED displays RIO 8 I/O..................................................................................................................................53
4.9.2 Data width, addressing and terminal assignment RIO 8 I/O..........................................................................53
4.9.3 Specifications RIO 8 I/O.................................................................................................................................54

Overview PCD0
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4.10 Digital I/O module 8 inputs/outputs RIO 8 I 8 I/O...................................................................................................55
4.10.1 LED displays RIO 8 I 8 I/O.............................................................................................................................56
4.10.2 Data width, addressing and terminal assignment RIO 8 I 8 I/O.....................................................................56
4.10.3 Specifications RIO 8 I 8 I/O............................................................................................................................57
4.11 Analog module 4 inputs ±10 V RIO 4AI ±10 V.......................................................................................................58
4.11.1 LED displays RIO 4AI ±10 V..........................................................................................................................59
4.11.2 Data width RIO 4AI ±10 V..............................................................................................................................59
4.11.3 Terminal assignment RIO 4AI ±10 V.............................................................................................................59
4.11.4 Specifications RIO 4AI ±10 V........................................................................................................................60
4.12 Analog module 4 inputs 20 mA RIO 4AI 20 mA......................................................................................................61
4.12.1 LED displays RIO 4AI 20mA..........................................................................................................................62
4.12.2 Data width RIO 4AI 20mA..............................................................................................................................62
4.12.3 Terminal assignment RIO 4AI 20mA..............................................................................................................62
4.12.4 Specifications RIO 4AI 20mA.........................................................................................................................63
4.13 Analog module 4 inputs 20 mA RIO 4AI 4-20 mA..................................................................................................64
4.13.1 LED displays RIO 4AI 4-20mA.......................................................................................................................65
4.13.2 Data width RIO 4AI 4-20mA...........................................................................................................................65
4.13.3 Terminal assignment RIO 4AI 4-20mA..........................................................................................................65
4.13.4 Specifications RIO 4AI 4-20mA......................................................................................................................66
4.14 Analog module 4 inputs 4 outputs ±10 V RIO 4AI/4AO ±10 V...............................................................................67
4.14.1 LED displays RIO 4AI/4AO ±10 V.................................................................................................................68
4.14.2 Data width RIO 4AI/4AO ±10 V.....................................................................................................................68
4.14.3 Terminal assignment RIO 4AI/4AO ±10 V.....................................................................................................68
4.14.4 Specifications RIO 4AI/4AO±10 V.................................................................................................................69
4.15 Analog module 4 inputs 4 outputs 20mA RIO 4AI/4AO 20mA................................................................................70
4.15.1 LED displays RIO 4AI/4AO 20mA..................................................................................................................71
4.15.2 Data width RIO 4AI/4AO 20mA......................................................................................................................71
4.15.3 Terminal assignment RIO 4AI/4AO 20mA .....................................................................................................71
4.15.4 Specifications RIO 4AI/4AO 20mA.................................................................................................................72
4.15.5 LED displays RIO 4AI/4AO 4-20mA...............................................................................................................74
4.15.6 Data width RIO 4AI/4AO 4-20mA...................................................................................................................74
4.15.7 Terminal assignment RIO 4AI/4AO 4-20mA..................................................................................................74
4.15.8 Specifications RIO 4AI/4AO 4-20mA .............................................................................................................75
4.16 Temperature module PT100/PT1000 RIO T10-10.................................................................................................76
4.16.1 LED displays RIO T10-10..............................................................................................................................77
4.16.2 Data width RIO T10-10..................................................................................................................................77
4.16.3 Data format RIO T10-10.................................................................................................................................77
4.16.4 Terminal assignment RIO T10-10..................................................................................................................78
4.16.5 Specifications RIO T10-10.............................................................................................................................78
4.17 Temperature module thermocouples RIO T20-10.................................................................................................79
4.17.1 LED displays RIO T20-10..............................................................................................................................80
4.17.2 Data width channel and terminal assignment RIO T20-10.............................................................................80
4.17.3 Data format RIO T20-10.................................................................................................................................81
4.17.4 Parameterizing RIO T20-10...........................................................................................................................82
4.17.5 Specifications RIO T20-10.............................................................................................................................83
4.18 Counter module RIO C24-10..................................................................................................................................84
4.18.1 Notes on connecting......................................................................................................................................85
4.18.2 LED displays RIO C24-10..............................................................................................................................85
4.18.3 Terminal assignment RIO C24-10..................................................................................................................86
4.18.4 Data width RIO C24-10..................................................................................................................................86
4.18.5 Basic functions RIO C24-10...........................................................................................................................87
4.18.6 Optional functions RIO C24-10......................................................................................................................88
4.18.7 Complete control data from the PLC to the module (outputs)........................................................................88
4.18.8 Process data from the module to the PLC (inputs)........................................................................................91
4.18.9 Examples.......................................................................................................................................................92
4.18.10 FORCE, LOCK and Display mode priorities..............................................................................................93
4.18.11 Specifications RIO C24-10 ........................................................................................................................94
4.19 Positioning module RIO P24-10..............................................................................................................................95
4.19.1 LED displays RIO P24-10..............................................................................................................................96
4.19.2 Terminal assignment RIO P24-10..................................................................................................................96
4.19.3 Functions........................................................................................................................................................97

PCD0 Overview
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4.19.4 Data width RIO P24-10..................................................................................................................................98
4.19.5 Control data from the PLC to the module (outputs).......................................................................................99
4.19.6 Process data from the module to the PLC (inputs)......................................................................................102
4.19.7 Operation / operating modes........................................................................................................................103
4.19.8 Operation on the RIO bus coupler...............................................................................................................105
4.19.9 Example.......................................................................................................................................................106
4.19.10 Specifications RIO P24-10.......................................................................................................................107
4.20 Potential distributor RIO KE 16.............................................................................................................................108
4.20.1 Specifications Potential distributor RIO KE 16.............................................................................................108
5 Installation...............................................................................................................................................................109
5.1 Mechanical installation..........................................................................................................................................109
5.1.1 Mounting position for the EC and BC bus couplers.....................................................................................109
5.1.2 Mounting dimensions and distance between modules – EC bus coupler....................................................109
5.1.3 Mounting dimensions and distance between modules – BC bus coupler....................................................110
5.1.4 Mounting dimensions and distance compact RIO’s.....................................................................................110
5.1.5 DIN rail installation.......................................................................................................................................111
5.1.6 Connecting modules with each other..........................................................................................................112
6 Electrical installation.............................................................................................................................................. 113
6.1 Spring terminals of the EC bus coupler................................................................................................................113
6.2 Spring terminals of the BC bus coupler, I/O modules modular system and compact RIO’s.................................114
6.3 Conductor sizes and stripping length....................................................................................................................115
6.4 Connecting the power supply................................................................................................................................116
6.5 Installation guidelines............................................................................................................................................116
6.6 Connecting signal sources to analog modules.....................................................................................................120
6.7 Emergency stop switches.....................................................................................................................................122
6.8 Bus node power consumption...............................................................................................................................125
7 User lock-out of the BC bus coupler.....................................................................................................................127
8 Operating modes of the BC bus coupler..............................................................................................................129
8.1 Overview of operating modes...............................................................................................................................129
8.2 RUN......................................................................................................................................................................131
8.3 FORCE.................................................................................................................................................................132
8.4 TRIGGER..............................................................................................................................................................134
8.5 LOCK....................................................................................................................................................................136
8.6 STOP....................................................................................................................................................................138
9 Service functions on the BC bus coupler.............................................................................................................139
9.1 Overview of service functions...............................................................................................................................139
9.2 Selecting and using a service function..................................................................................................................139
9.3 Service function 1.................................................................................................................................................140
9.4 Service function 2.................................................................................................................................................140
9.5 Service function 3 Display process data width of inputs.....................................................................................140
9.6 Service function 4 Display process data width of outputs...................................................................................141
9.7 Service function 5 Switch bus coupler diagnosis on/off......................................................................................141
9.8 Service function 6 Save bus node configuration.................................................................................................141
9.9 Service function 7 User lock-out.........................................................................................................................141
9.10 Service function 8 Deactivate user lock-out with password................................................................................141
9.11 Service function 9 Advanced PROFIBUS-DP diagnosis ON/OFF......................................................................141
9.12 Service function 10 Byte swap mode..................................................................................................................142
9.13 Service function 11 Delete bus coupler EEPROM..............................................................................................142
9.14 Service function 12 Display/set bus address......................................................................................................142
9.15 Service function 13 Set data width of counter and positioning modules.............................................................143
10 Parameterizing and diagnosis functions for all bus couplers............................................................................144
10.1 Overview...............................................................................................................................................................144
10.2 Data structure.......................................................................................................................................................145
10.3 Sequence..............................................................................................................................................................145
10.4 Function 0 Output group error ............................................................................................................................146
10.5 Function 1 Monitor module power supply...........................................................................................................147
10.6 Function 2 Monitor output driver overload..........................................................................................................148
10.7 Function 3 Determine bus node process data width...........................................................................................149
10.8 Function 4 Output bus node module configuration.............................................................................................150
10.9 Function 5 Set preferred shut-off state...............................................................................................................151
10.10 Function 6 Activate / deactivate bus node user lock-out................................................................................152

Overview PCD0
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10.11 Function 7 Determine bus node system status..............................................................................................153
10.12 Function 8 Output firmware version................................................................................................................154
10.13 Function 9 Set data formats for analog modules............................................................................................155
10.14 Function 10 Output temperature module PT100/PT1000 sensor information.................................................156
10.15 Function 11 Mode word for temperature module with thermo elements........................................................157
10.16 Function 17 Output bus address....................................................................................................................158
10.17 Function 18 Byte swap mode ON/OFF...........................................................................................................159
10.18 Function 19 Advanced PROFIBUS-DP diagnosis ON/OFF...........................................................................160
10.19 Function 20 Delete error messages...............................................................................................................160
10.20 Function 21 Save/delete bus node configuration.............................................................................................161
10.21 Function 255 Reset........................................................................................................................................161
11 Technical data.........................................................................................................................................................162
11.1 Specifications Analog inputs/outputs....................................................................................................................163
11.2 Dimensions...........................................................................................................................................................165
12 Error messages.......................................................................................................................................................166
13 PROFIBUS-DP field bus..........................................................................................................................................167
13.1 PROFIBUS-DP bus topology................................................................................................................................167
13.2 Setup guidelines for PROFIBUS networks...........................................................................................................168
13.3 PROFIBUS-DP bus cable parameters..................................................................................................................169
13.4 PROFIBUS-DP bus segment length.....................................................................................................................169
13.5 Pin configuration and wiring of PROFIBUS-DP....................................................................................................170
13.6 Configuring PROFIBUS-DP..................................................................................................................................172
13.7 Process data width and address configuration.....................................................................................................173
13.8 Commissioning PROFIBUS-DP............................................................................................................................175
13.9 Diagnosis on the PROFIBUS-DP..........................................................................................................................175
13.10 PROFIBUS-DP response times........................................................................................................................177
14 What if... ?................................................................................................................................................................178
15 Appendix..................................................................................................................................................................180
15.1 Input signal delay..................................................................................................................................................180
15.2 Analog module data formats.................................................................................................................................181
15.2.1 Voltage input/output data formats................................................................................................................181
15.2.2 Current input/output data formats................................................................................................................182
15.3 Module IDs............................................................................................................................................................184
15.4 Replacing electronic parts in the module..............................................................................................................185
16 Glossary...................................................................................................................................................................186
17 Trademarks..............................................................................................................................................................186
18 Safety-related information......................................................................................................................................187
18.1 Correct use of the system.....................................................................................................................................187
18.2 Selection and qualification of personnel...............................................................................................................187
18.3 Configuration, programming, installation, commissioning and operation..............................................................188
18.4 Maintenance and servicing...................................................................................................................................188
18.5 High voltage..........................................................................................................................................................188
18.6 Used batteries.......................................................................................................................................................189
19 Index.........................................................................................................................................................................190

PCD0 Overview
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1Overview
PCD0 RIO forPROFIBUS-DP
Compact RIO
Compact I/Os are particularly suitable for applications with widely distributed bus nodes with up to 16
I/O points.
Real decentralisation through compact size, fasts data transmission and integrated 4-wire system.
Modular system
The modular design makes it possible to realize bus nodes with widely differing I/O specifications.
Up to 8 modules can be operated per bus coupler, allowing extension up to 128 I/O points.
Two different Profibus DP bus couplers are at the disposal for the user: The comfortable bus coupler
(BC) permits extensive diagnosis and service functions or the inexpensive Economic coupler (EC).
The bus coupler BC of the modular system provides the operator with valuable support in diagnosis
and commissioning of plant and machine sections, before connection to the field bus and PLC has
been realized.
17 different digital, analogue, counting or positioning modules can be connected at will to both bus
couplers.

Overview PCD0
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1.1 Compact RIO
Supply 24 VDC
Battery
Watch Dog
Run
Halt
Error
PGU
PCD0 Compact I/O on a PCD2 with Profibus-DP card.
1.1.1 Available compact RIO’s
Digital module
RIO 16 I DP
16 24V DC inputs
Two-wire connection
system
Part no. PCD0.G120
RIO 8 I/O DP
8 combination I/Os
All combination I/Os can be used
individually as 24V DC inputs or
1A outputs.
Four-wire connection system
Part no. PCD0.G110
RIO 16 O DP
16 1A outputs
Two-wire connection
system
Part no. PCD0.G130
RIO 8 I 8 I/O DP
8 24V DC inputs
8 combination I/Os
All combination I/Os can be used
individually as 24V DC inputs or
1A outputs.
Two-wire connection system
Part no. PCD0.G140
Potential distributor (terminal expansion)
RIO KE 16
2 rows with
10 Terminals
Only for module with location notch
for voltage bus.
Part no. PCD0.K300

PCD0 Overview
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1.2 Modular System
Supply 24 VDC
Battery
Watch Dog
Run
Halt
Error
PGU
PCD0 modular system on a PCD2 with Profibus-DP card
1.2.1 Available Bus coupler for the modular system
PROFIBUS-DP
RIO EC DP
Part no.
PCD0.T780
RIO BC DP
Part no.
PCD0.T770