SBC PCD2.M5 Series User manual

Document 26/856; Version EN 12 | 2014-07-24
Handbuch Hardware
of the PCD2.M5_ seriesManual of the PCD2.M5_ series

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2.M5_
Contents
0-1
0
0 Contents
0.1 Document-History ........................................................................................... 0-6
0.2 Trademarks..................................................................................................... 0-6
1 Graphical index
2 Overview
2.1 Introduction ..................................................................................................... 2-1
2.2 Instructions for connecting Saia-PCD®controllers to the internet................... 2-1
2.3 Planning an application with PCD2.M5_ components .................................... 2-2
2.4 Cabling............................................................................................................ 2-3
2.4.1 Cable routing................................................................................................... 2-3
2.5 Addressing ...................................................................................................... 2-4
2.6 HW Overview .................................................................................................. 2-5
2.6.1 PCD2.M5xx0................................................................................................... 2-5
2.6.2 PCD2.C2000 and PCD2.C1000...................................................................... 2-5
3 PCD2.M5xx0 CPUs and module holders
3.1 System overview............................................................................................. 3-1
3.2 General technical details................................................................................. 3-3
3.3 System resources ........................................................................................... 3-5
3.3.1 Program blocks ............................................................................................... 3-5
3.3.2 Computation ranges for count types ............................................................... 3-5
3.3.3 Media .............................................................................................................. 3-5
3.4 PCD2.M5_ CPUs ............................................................................................ 3-6
3.4.1 Block diagram for PCD2.M5_ ......................................................................... 3-8
3.4.2 HardwareandrmwareversionsforthePCD2.M5_ ...................................... 3-9
3.4.3 Extensions with various module holders......................................................... 3-10
3.4.4 Expansion housings........................................................................................ 3-11
3.4.5 Addressing of module holders and modules................................................... 3-15
3.4.6 Decentralised expansion of RIO with PCD3 components............................... 3-16
3.4.7 Dimensions ..................................................................................................... 3-17
3.5 Mounting ......................................................................................................... 3-18
3.5.1 Mounting position and ambient temperature................................................... 3-18
3.5.2 Remove cover from housing ........................................................................... 3-19
3.5.3 Replace housing cover ................................................................................... 3-20
3.5.4 Remove upper part of housing........................................................................ 3-21
3.5.5 Replace housing cover ................................................................................... 3-22
3.5.6 I/O module slots .............................................................................................. 3-22
3.6 Installation and addressing of PCD2 I/O modules .......................................... 3-23
3.6.1 Insertion of I/O modules.................................................................................. 3-23
3.6.2 Address and terminal designation................................................................... 3-23
3.7 Power supply, earthing scheme, cable layout................................................. 3-24
3.7.1 External power supply..................................................................................... 3-24
3.7.2 Internal power supply...................................................................................... 3-25
3.7.3 Earthing concept ............................................................................................. 3-25
3.7.4 Cable layout .................................................................................................... 3-26
3.8 Operating states.............................................................................................. 3-27
3.9 Connections to PCD2.M5_ ............................................................................. 3-28
3.10 Partitioning options for user memory .............................................................. 3-30
0 Contents

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2.M5_
Contents
0-2
0
3.11 Data storage in case of power failure ............................................................. 3-31
3.11.1 Battery changing ............................................................................................. 3-31
3.12 Memory space on the PCD............................................................................. 3-32
3.12.1 General ........................................................................................................... 3-32
3.12.2 Programbackupandrestoreonbackupash ................................................ 3-35
3.12.3 Transferringanapplicationwithashcard ..................................................... 3-36
3.12.4 Backup program after download option .......................................................... 3-37
3.12.5 Backup/restore of RAM texts/DBs at run-time ................................................ 3-38
3.13 MemorymodulePCD2.R6000forashcards(FCs) ...................................... 3-43
3.13.1 System overview............................................................................................. 3-43
3.13.2 Technical data ................................................................................................. 3-43
3.13.3 Operation ....................................................................................................... 3-44
3.13.4 Displays and switches..................................................................................... 3-46
3.13.5 Flashcard ....................................................................................................... 3-47
3.13.6 Userprogrambackuptotheashcard........................................................... 3-48
3.13.7 Order details ................................................................................................... 3-49
3.14 Hardwareclock(RealTimeClock).................................................................. 3-50
3.15 Hardware watchdog ........................................................................................ 3-50
3.16 Software watchdog ......................................................................................... 3-52
3.17 User inputs and outputs .................................................................................. 3-53
3.17.1 Basics ............................................................................................................. 3-53
3.17.2 PCD2.M5_ 24 VDC interrupt inputs ................................................................ 3-53
3.17.3 PCD2.M5_ user outputs.................................................................................. 3-54
3.18 Operatingmodeswitch(Run/Halt).................................................................. 3-55
3.18.1 Run/halt push button....................................................................................... 3-55
3.18.2 Run/halt switch................................................................................................ 3-55
3.19 E-display with PCD7.D3100E nano-browser .................................................. 3-56
3.19.1 Technical data ................................................................................................. 3-56
3.19.2 Installing the display........................................................................................ 3-56
3.19.3 FunctionanduseofJoystick........................................................................... 3-57
3.19.4 Structure of the setup menu............................................................................ 3-59
3.19.5 PG5DevicecongurationforeDisplay ........................................................... 3-62
3.19.6 USER project .................................................................................................. 3-63
3.19.7 Web-Editor ...................................................................................................... 3-66
3.19.8 Browse the eDisplay pages on the PC ........................................................... 3-69
4 RIO (remote input/output) head stations

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2.M5_
Contents
0-3
0
5 PCD2.M5xx0 Communication interfaces
5.1 Onboard interfaces ......................................................................................... 5-2
5.2 Plug-in communication interfaces ................................................................... 5-2
5.3 Onboard interfaces ......................................................................................... 5-3
5.3.1 PGUconnector(PORT# 0)(RS-232)forconnectingprogrammingdevices... 5-3
5.3.2 PGUconnection(PORT# 0)(RS-232)ascommunicationinterface ............... 5-4
5.3.3 PGUconnection(PORT# 0)(RS-485)ascommunicationinterface ............... 5-5
5.3.4 USB port as PGU interface ............................................................................. 5-6
5.3.5 D-Sub x1 S-Net/MPI ....................................................................................... 5-7
5.4 Plug-in interface modules - Slots A1 and A2................................................... 5-8
5.4.1 RS-485 / 422withPCD7.F110,Port#1 & Port#2 ............................................. 5-8
5.4.2 RS-232withPCD7.F121,Port#1 & Port#2..................................................... 5-10
5.4.3 CurrentloopwithPCD7.F130,Port#1&Port#2 ............................................. 5-11
5.4.4 RS-485withPCD7.F150,Port#1 & Port#2..................................................... 5-13
5.4.5 MP-BuswithPCD7.F180,Port#1&Port#2 .................................................... 5-15
5.5 Serial interfaces on I/O module slots 0 - 3 ...................................................... 5-16
5.5.1 GeneralremarksonthePCD2.F2xxx............................................................. 5-16
5.5.2 Communication ports on the PCD2.M5_ ........................................................ 5-16
5.5.3 Module overview ............................................................................................. 5-17
5.5.4 Portx.0:RS-422/RS-485onthemodulPCD2.F2100................................... 5-21
5.5.5 Portx.0:RS-232onthemodulPCD2.F2210(formodem) ............................. 5-22
5.5.6 Portx.0:BelimoMP-BusonmodulePCD2.F2810 ......................................... 5-23
5.6 Modem module for I/O module socket ............................................................ 5-24
5.7 Communication on Slot C ............................................................................... 5-25
5.7.1 CANbus,modulePCD7.F7400...................................................................... 5-26
5.7.2 ProbusDPMaster,modulePCD7.F7500 ..................................................... 5-27
6 Input/output (I/O) modules
6.1 Module overview ............................................................................................. 6-1
6.1.1 Power consumption of PCD2 input/output modules ....................................... 6-5
6.1.2 Capacity of basic units .................................................................................... 6-5
6.2 Digital input modules....................................................................................... 6-6
6.2.1 PCD2.E11x, 8 digital inputs ............................................................................ 6-7
6.2.2 PCD2.E160/161, 16 digital inputs, ribbon cable connector............................. 6-9
6.2.3 PCD3.E165/166, 16 digital inputs, cage clamp terminal connectors .............. 6-12
6.3 Digital input modules, electrically isolated ...................................................... 6-14
6.3.1 PCD2.E500, 6 digital inputs for 115 - 230 VAC............................................... 6-15
6.3.2 PCD3.E61x, 8 digital inputs, electrically isolated ............................................ 6-17
6.4 Digital output modules .................................................................................... 6-19
6.4.1 PCD2.A300, 6 digital outputs for 2 A each...................................................... 6-20
6.4.2 PCD2.A400, 8 digital outputs for 0.5 A each................................................... 6-22
6.4.3 PCD2.A460, 16 digital outputs for 0.5 A each, with ribbon connector............. 6-24
6.4.4 PCD2.A465, 16 digital outputs for 0.5 A each................................................. 6-27
6.5 Digital output modules, electrically isolated .................................................... 6-29
6.5.1 PCD2.A200, 4 relays with make contacts, with contact protection................. 6-30
6.5.2 PCD2.A210, 4 relays with break contacts, with contact protection................. 6-32
6.5.3 PCD2.A220, 6 relays with make contacts, without contact protection............ 6-34
6.5.4 PCD2.A250, 8 relays with make contacts, without contact protection............ 6-36
6.5.5 PCD2.A410, 8 digital outputs for 0.5 A each, electrically isolated................... 6-38

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2.M5_
Contents
0-4
0
6.6 Digital combined input/output modules ........................................................... 6-40
6.6.1 PCD2.B100,2inputs+2outputs+4digitalinputs/outputs(selectable)........ 6-41
6.7 Multi-functional input/output modules ............................................................. 6-44
6.7.1 PCD2.G400, multi-functional input/output module.......................................... 6-45
6.7.2 PCD2.G410, multi-functional I/O module with elect. isolated digital I/O ......... 6-46
6.8 Analogue input modules ................................................................................. 6-48
6.8.1 PCD2.W2x0, analogue inputs, 8 channels, 10 bit resolution.......................... 6-49
6.8.2 PCD2.W3x0, analogue inputs, 8 channels, 12 bit resolution.......................... 6-55
6.9 Analogue input modules, electrically isolated ................................................. 6-60
6.9.1 PCD2.W3x5, analogue inputs, electrically isolated, 7 channels,
12 bit resolution .............................................................................................. 6-61
6.10 Analogue output modules ............................................................................... 6-66
6.10.1 PCD2.W4x0, analogue inputs, 4 channels, 8 bit resolution............................ 6-66
6.10.2 PCD2.W6x0, analogue outputs, 4 channels, 12 bit resolution........................ 6-70
6.11 Analogue output modules, electrically isolated ............................................... 6-74
6.11.1 PCD2.W6x5,analogueoutputs,electricallyisolated,6(4)channels,
10 bit resolution .............................................................................................. 6-74
6.12 Analogue combined input/output modules...................................................... 6-79
6.12.1 PCD2.W525 analogue combined input/output module with
electrical isolation............................................................................................ 6-79
6.13 Weighing modules .......................................................................................... 6-85
6.13.1 PCD2.W720 weighing modul .......................................................................... 6-85
6.14 General-purpose temperature modules .......................................................... 6-86
6.14.1 PCD2.W745 weighing modul .......................................................................... 6-86
6.15 Fastcountermodules ..................................................................................... 6-88
6.15.1 PCD2.H100, counting module up to 20 kHz, 1 channel.................................. 6-89
6.15.2 PCD2.H110, general purpose counting and measuring module
up to 100 kHz, 1 channel ................................................................................ 6-94
6.15.3 PCD2.H112, general purpose counting and measuring module
up to 100 kHz, 2 channel ................................................................................ 6-96
6.16 SSI encoder module ....................................................................................... 6-97
6.16.1 PCD2.H150, SSI interface module for absolute encoder................................ 6-97
6.17 Motion control modules for stepper motors..................................................... 6-99
6.17.1 PCD2.H210, Motion control module for stepper motors ................................. 6-99
6.18 Motion control modules for servo drives ......................................................... 6-103
6.18.1 PCD2.H31x, motion control module for servo-motors, 1-axis encoder........... 6-103
6.18.2 PCD2.H32x, motion control modules for servo-drives .................................... 6-107
7 System cables and adapters
7.1 System cables with I/O module connections to the PCD................................ 7-1
8 Congurationandprogramming
8.1 CPUs............................................................................................................... 8-1
8.1.1 ConguringthePCDwithPG5 ....................................................................... 8-1
8.1.2 "Hardware settings" option.............................................................................. 8-5
9 Maintenance
9.1 Changing the battery on the PCD2.M5xx0 ..................................................... 9-1

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2.M5_
Contents
0-5
0
A Annex
A.1 Icons ............................................................................................................... A-1
A.2 Denitionsofserialinterfaces......................................................................... A-2
A.2.1 RS-232............................................................................................................ A-2
A.2.2 RS-485/422..................................................................................................... A-3
A.2.3 TTY/current loop ............................................................................................. A-4
A.3 Installation instructions and relay contacts ..................................................... A-5
A.3.1 Installation instructions for carrying extra-low voltage .................................... A-5
A.3.2 Installation instructions for carrying low voltage.............................................. A-5
A.3.3 Carrying inductive loads.................................................................................. A-7
A.3.4 Details of relay manufacturers for sizing of RC elements ............................... A-7
A.4 Order details ................................................................................................... A-9

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2.M5_
Contents
0-6
0
0.1 Document-History
Version Changed Published Remarks
pEN01 07.01.2008 30.05.2008 New document,
copied from PCD1|2|3 Manual
EN02 2009-02-16
2009-06-01
2009-02-16
2009-06-30
Modications
Minormodications
EN03 2009-09-30
2009-10-01
2009-10-01
2009-10-01
ControlunitforPCD7.F180“MST”→“MFT”
Memory Card is called
PCD2.R6000 not PCD3.R6000
EN04 2010-03-01
2010-04-13
2010-03-01
2010-04-13
DenitionofthesignalsPort#3or#10,Pin6,in
Chapter 3.9
Chapter 5.3.1
EN05 2010-05-10
2011-01-20
2011-01-15
2011-01-20
eDisplay in detail
PCD2.C1000 added in chapter 3
Hardware Watchdog: Example of IL-Code
stringmodied
Standards added in chapter 3
EN06 2011-04-08 2011-04-11 Switch off the +24 V before plug/unplug the I/O
modules and I/O terminals
EN07 2011-06-23 2011-06-23 Chapter3:NewspecicationsforFWupgrade,
Chapter 5: LED, adjustment of status reports
EN08 2011-11-22 2011-11-25 Correction HW watchdog error. Maximum load
for on-board outputs
EN09 2012-01-24 2012-01-25 Reintegrated the description
of the I/O-modules
EN10 2012-04-10
2012-11-09
2013-03-13
2013-03-13
Storage temperature changed of -20 to -25°C.
PWMoutputsviaFBox
EN11 2013-03-21
2013-04-23
2013-05-10
2013-11-19
2014-01-07
2014-01-07
2014-01-07
2014-01-07
2014-01-07
2014-01-07
Chapter 2.5: «Hardware Overview»
Internal wiring PCD2.K111
Behavior of the Diagnostic LED
Logo and company names changed
Chapter2.2:“Instructionsforconnecting
Saia-PCD®controllerstotheinternet”
EN12 2014-07-24 2014-07-24 Changed wrong connection diagramm
PCD2.E165/E166
0.2 Trademarks
Saia PCD
®
is a registered trademark of Saia-Burgess Controls AG.
Siemens®, SIMATIC®and STEP®are registered trademarks of Siemens AG.
Technical changes are subject to the state of technology
Saia-Burgess Controls AG, 2013. © All rights reserved.
Published in Switzerland

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2.M5_
Graphical index
1-1
1
1 Graphical index
The graphical index singles out some highlights from the Hardware Manual for the
PCD2.M5_ Series, and allows you to click 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.
A1
A2
C
Port #0
ETH1
ETH2
USB Port #0
Port #2
Port #1
Port #8
X4 Port #1
X3 Port #2
LEDs
User
inputs
Flash-
cards
Lithium-
battery
Port #10
or #3
Aperture for
LCD display
and keys
Run/Halt-
Switch
Supply
I/O Slots
I/O Slots

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
Introduction
Overview
2-1
2
2 Overview
2.1 Introduction
This manual covers the technical aspects of the PCD2.M5_ components. The
following terms are used frequently:
● CPU Centralprocessingunit:theheartofthePCD
● LIOs LocalI/Os:theseareconnectedtotheCPUviatheI/Obus
● Modules Input/outputelementsdesignedforthePCD2.M5_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 PCD2.M5_ components. It covers the following topics:
● Planninganapplication
● Cabling
Detailsofhardware,software,conguration,maintenanceandtroubleshootingare
described in separate sections.
2.2 InstructionsforconnectingSaia-PCD®controllers to the internet
When Saia PCD controllers are connected directly to the internet, they are also
apotentialtargetofcyberattacks.Forsecureoperation,appropriateprotective
measures must always be taken.
PCD controllers include simple, built-in protection features. However, secure op-
erationontheinternetisonlyensuredifexternalroutersareusedwitharewall
and encrypted VPN connections.
Formoreinformation,pleaserefertooursupportsite:
www.sbc-support.com/security

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
Planning an application
Overview
2-2
2
2.3 PlanninganapplicationwithPCD2.M5_components
The following aspects should be considered when planning PCD2.M5_ applications:
● TheinternalloadcurrenttakenbytheI/Omodulesfromthe+5VandV+supply
 mustnotexceedthemaximumsupplycurrentspeciedfortheCPUsorLIOs
 (PCD2.C2000/C1000)
● TheCPUtypedeterminesthemaximumnumberofmodules
● ThetotallengthoftheI/Obusislimitedbytechnicalfactors;theshorter,the
better
When planning an application, we recommend the following procedure:
Select the I/O modules according to your requirements.
Check that the number of module holders is allowed:
PCD type Max. number of I/O modules Max. 1) digital I/Os
PCD2.M5_ PCD2 CPU PCD2
expansion
Total PCD2 CPU PCD2
expansion
Total
8 56 64 128 896(-1) 1024(-1)
1)UsingdigitalI/Omoduleswith16I/Oseach
The values in brackets have to be subtracted from the maximum number of digital I/
Os because of the watchdog relay.
To expand PCD2 CPUs with PCD3 RIOs, the planning instructions in the PCD3
Manual 26/789 should be followed.
If necessary, select the PCD2.C2000/C1000 expansion housing:
 ● PCD2.C2000 8moduleslotsorPCD2.C10004moduleslots
 ● PCD2.K106 26-coreextensioncabletoconnectPCD2CPUs.
 ● PCD3.K1x6 26-coreextensioncabletoconnectthelastPCD2.C2000
/C1000 expansion housing in a row to attached further
rows of PCD2.C2000/C1000 expansion housings.
 ● PCD2.K010 ConnectortolinkPCD2.C2000expansionhousings
for mounting side-by-side.
Fortheconnecingcablesandplugsrequired,seealsosection3.4.3.
If PCD2.Wxxx and PCD2.Hxxx modules are used, calculate the load current
 attheinternal+5VandV+supply(usetheworst,i.e.highestvalues)
 Checkthatthemax.supplycurrentfortheCPUissufcient;itgenerallyshould
be.
Estimate consumption from the 24 V supply. Use estimated values. The
estimated values can be found in the section on the Current consumption of the
PCD2 input/output modules.
Note that in most applications the outputs place the heaviest load on the 24 V
supply.For16outputswithaloadcurrentof0.5Aeach,theloadingwillbe8Awith
all outputs connected.

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
Cabling
Overview
2-3
2
2.4 Cabling
2.4.1 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signicantly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eld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 PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
Addressing and cabling of series
Overview
2-4
2
2.5 Addressing
Theaddressofamoduleisdeterminedbyitsmodulepositionintheconguration
(seesection3.4.5).
PCD2CPUs: Themoduleaddressesbeginatbaseaddress0(zero)on
 Slot0(addresses0to15)andgoupinincrementsof16to
 address127onSlot7,regerdlessofthenumberofI/Os(16,8or4).
PCD2.C2000 Determinedbythemodulepositionintheconguration;alsogoesup
and C1000: in increments of 16
Extension cables connect the expansion housing at the right-hand end of a row with
therstexpansionhousingattheleftofthenextrow.Theaddressoftherstmodule
in a second or third row equals the address of the last module in the previous row
+16.
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".
Each additional PCD2.C2000/C1000 expansion housing provides space for 8/4 more
I/O modules. The connection to the next row is made via the 26-core extenstion cable
ortheconnector(seesection3.4.3).
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.

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
HW Overview
Overview
2-5
2
X1 X2
M1
Slot A1
X3
X4
X10
M2
X6
X5
Slot A2
Slot C
8 I/O-module slots 0…7
Connection for I/O expansion
I/O 7 I/O 6 I/O 5 I/O 4
I/O 0 I/O 1 I/O 2 I/O 3
Flash cards
USB port
2-port Ethernet switch
(PCD2.M5540 only)
Interrupt-Eingänge
Lithium battery
On-Board interface
and power supply
Run/stop switch
LEDs
Opening for LCD display
C slot for Probus Master module
Connections for On-Board interfaces
Slot for communication module with
X3 connection
Slot for communication module with
X4 connection
PCD2.M5xx0
Module slot
Module slot
I/O bus for
standard
modules
Fast serial bus (SPI)
for running up to 4
intelligent modules
I/O bus for
standard
modules
2.6 HW Overview
8 I/O-module slots 0…7
Power supply
I/O bus
4 I/O-module slots 0…3
PCD2.C2000 PCD2.C1000
I/O bus for
standard
modules
Ground
connection
for I/O
modules
I/O 7 I/O 6 I/O 5 I/O 4
I/O 0 I/O 1 I/O 2 I/O 3 I/O 0 I/O 1
I/O 3 I/O 2
2.6.2 PCD2.C2000 and PCD2.C1000
2.6.1 PCD2.M5xx0

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
System overview
PCD2.M5_ Classic CPUs and expansion housings
3-1
3
3 PCD2.M5xx0 CPUs and module holders
3.1 System overview
The PCD2.M5_ series is basically a combination of the PCD2 housing design
and circuitry with extensive compatibility and ease of upgrading along with PCD3
technology. The proven functions of the PCD2 series have been supplemented with
newfunctionssuchasUSBand"onboard"Ethernet,andthefacilitytouseashcards
and/orfutureSDmemorycards(forprogrambackup,lesystemforwebpages,data,
documents,etc.).ForeasylabellingoftheI/Osignals,therearepreprintedsheets
that can be protected by the transparent covering. I/O modules can be reconnected
or replaced without removing the central housing.
The circuitry and labelling have been completely revised. When I/O modules are
replaced, the electronic components on the CPU are protected. However, the I/O
modules themselves must not be plugged in or removed with the power on, the
supply voltage and the external +24 V must be disconnected. As with the PCD3, the
CPUhasnojumpers;alltherequiredfunctionshavetobeconguredin"Hardware
Settings".Theunitprovides4integratedportsandtwoRJ-45Ethernetsockets,
including switch. These make the PCD2.M5_ an extremely powerful communication
system.FTPandwebaccessarealsosupporteddirectlyviahttp.
Onthemotherboardtherearealso6digitalinputs(4interruptinputsoroneencoder
connection)and2outputs.Theoptiontoconguretheinputsasinterruptorencoder
inputsandtheoutputsaspulse-width-modulated(PWM)meansthatthePCD2.M5_
can be used as a "low-cost solution" for machinery and systems.
SBC S-Net networking concept
SBC S-Netisthenameofthenew,exiblenetworkingconceptforinnovativeand
economical automation systems with Saia PCD®.
● BasedontheEthernet-TCP/IP(Ether-S-Net)andProbus(ProS-Net)open
standards:useofexistingnetworkinfrastructure→noduplicatecabling
required

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
System overview
PCD2.M5_ Classic CPUs and expansion housings
3-2
3
● Supportsmulti-vendorandmulti-protocoloperation:
Reduces costs for project planning, programming, commissioning and
maintenancebygeneraluseofEthernetTCP/IPandProbuswithS-Net,the
PrivateControlNetwork(PCN)forSaia PCD®
● GeneraluseofwebtechnologiesviaEthernetTCP/IPandProbusfor
commissioning, operation, monitoring and diagnostics
● Networkconnectionsintegratedintothebaseunit;Probusinterfaceintegrated
intotheoperatingsystemofthenewPCDcontrollersandPCD3RIOs(included
inthebaseunit,atnoextracharge)
● ProS-Netwithoptimizedprotocolsandservicesforefcientoperationof
PCD3RIOsandPCD3controllersontheProbus
● Multi-protocoloperation:
ThenewPCDcontrollersandPCD3RIOssupportProbus-DPandS-Neton
the same socket
● Continuityandsecurityofinvestment:
All PCD systems can be integrated into almost any design using existing
ProbusandEthernetTCP/IPconnections
Forfurtherdetails,seeManual26/845.
SBC PCD web server
All PCD controllers and PCD3 RIOs come with an integrated web server as standard:
● Webbrowserasatoolforcommissioning,supportandvisualization:
Access to the SBC 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-deneddeviceandsystem-specic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(RS-232, RS-485,modemetc.)andvia
Probus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SBC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 PCD controllers and the PCD3 RIOs,
the web server is already included in the base units, at no extra cost.

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
General technical details
PCD2.M5_ Classic CPUs and expansion housings
3-3
3
3.2 General technical details
Supply (external and internal)
Supply voltage 24 VDC -20...+25% smoothed or
19 VAC±15%full-waverectied(18VDC)
Power consumption1) typically 15 W
Capacity of internal
5 V bus2)
1,400 mA
Capacity of internal
+Vbus(16...24V)2)
The capacity of the +V bus depends on the capacity of the 5V
bus,asfollows(themorepreciselythe24Varemaintained,the
higherthepossiblecapacity):
24 V
24 V
24 V
1)Theloadshandledbytheoutputsandotherconsumersaregenerallymoreimportantforsizingthesupplythan
the internal power consumption of the PCD2.M5.
2)WhenplanningPCD2systems,itisessentialtocheckthatthetwointernalsuppliesarenotoverloaded.This
check is especially important when using analogue, counter and positioning modules, as these may have a very
large power consumption.
Itisadvisabletousethe“devicecongurator”fromthePG52.0whichautomaticallycalculatestheinternalpower
consumption of the modules.
Atmospheric conditions
Ambient temperature When mounted on vertical surface with vertically aligned
terminals: 0...+55 °C
In all other mounting positions, a reduced temperature range of
0..+40 °C applies
Storage temperature -25...+85 °C
Relative humidity 10...95 % without condensation
Vibration resistance
Vibration according to EN/IEC61131-2:
5...13.2Hzconstantamplitude(1.42mm)
13.2...150Hz,constantacceleration(1G)
Electrical safety
Protection type IP20 according to EN60529
Air/leakage paths according to EN 61 131-2 and EN50178: between circuits and
bodies and between electrically isolated circuits: surge category
II, fouling level 2
Test voltage 350 V / 50 Hz AC for nominal unit voltage 24 VDC
Electromagnetic compatibility
Electrostatic discharge according to EN61000-4-2: 8 kV: contact discharge
Electromagneticelds accordingtoEN61000-4-3:eldintensity10V/m,
80...1000 MHz
Bursts according to EN61000-4-4: 4 kV on DC supply lines, 4 kV on
I/O signal lines, 1 kV on interface lines
Noise emission accordingtoEN61,000-4-6:ClassA(forindustrialareas).
Guidance on the correct use of these controls in residential
areascanbefoundatwww.saia-support.com(additional
measures).

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
General technical details
PCD2.M5_ Classic CPUs and expansion housings
3-4
3
Noise immunity acc. to EN61000-6-4
Mechanism and mounting
Housing material Base:
Cover:
Fibreoptics:  PC,crystal-clear
Mounting rail 2top-hatrailsacc.toEN50022-35(2x35mm)
Connections
Terminal
blocks
Spring
terminals
10-pole,
4-pole
Spring
terminals
10-pole
Spring
terminals
14-pole,
12-pole,
8-pole
Spring
terminals
24-pole,
6-pole
Earth
terminal
Terminal
2-pole
supply
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 onto 20 times. They must then be replaced, to
guarantee a reliable contact
Length of
insulation
7 mm 7 mm 7 mm 7 mm 5...6 mm 7 mm
Standards / approvals
EN/IEC EN/IEC61131-2“Programmablecontrollers”
Shipbuilding ABS, BV, DNV, GL, LRS, PRS.
Please verify if your chosen product is mentioned in the
list of corresponding Type-Approval-Company under
www.saia-support.com.
cULus-listed Please verify if your chosen product is listed in the corresponding
Certicateunderwww.saia-support.com. The condition for cULus
Compliance are mentioned on the sheet annexed to the product
or can be required under www.saia-support.com.

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2 CPUs
PCD2.M5_ Classic CPUs and expansion housings
3-5
3
3.3 System resources
3.3.1 Programblocks
Type Quantity Addresses Remarks
Cyclic organization blocks
(COB) 32*(16) 0...31(0...15) Main program elements
Exception/system-dependent
organizationblocks(XOB) 32 0...31 called from the system
Programblocks(PB) 1000*(300) 0...999(0...299) Sub-programs
Functionblocks(FB) 2000*(1000) 0...1999(0...999) Sub-programs with
parameters
Sequentialblocks(SB)
total 6000 steps and transitions
each(withPG5≥1.3and
rmwareversion≥≥xxx)
96 0...95
for Graftec programming
of sequential processes
*Thisinformationisvalidforrmware1.10.16andlater.Beforethisversion16COBs,300PBsand1000FBswere
supported.
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 – 9.223,37 × 1018 to
– 5.421,01 × 10-20
+ 9.223,37 × 1018 to
+ 5.421,01 × 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 Quantity Addresses Remarks
Flags(1bit) 14’336**
(8192) F0...8191 Bydefault,agsarenotvolatile,but
avolatilerangecanbecongured,
beginning with address 0
Registers(32bit) 16384 R 0...16383 Forintegeroroatingpointvalues
Text/data blocks
8191
XorDB
0...8190
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
congured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congurable.Timersareperiodically
decrementedbytheoperatingsystem;
the basic time unit can be set between
10 ms and 10 seconds
Constants with media
code K
any Values0...16383;maybeusedinin-
structions instead of registers
Constants with no
media code
any 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conguredshouldbeonlyasmanyasrequired,topreventunnecessaryCPUloading
**Sincermware1.14.2314’336agsaresupported,beforeitwas8192.Inordertouseags>8191PG52.6.150is

Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2 CPUs
PCD2.M5_ Classic CPUs and expansion housings
3-6
3
required.
3.4 PCD2.M5_CPUs
Differences between base
units PCD2.M 5440 5540
General features
I/O bus extension yes
Number of inputs/outputs or
I/O module sockets
up to 10231)2)
64
Processor(Motorola) CF5272/66MHz
Processing time
Bit instruction:
Word instruction:
0.3...1.5 µs3)
0.9 µs3)
Firmware,rmwareupdate
(rmwarememorysolderedon) Downloadable from the PG5 environment
Programmable with PG5 from 1.4.200
Main memory for user program,
text,DB(RAM) 1 MB
Backup memory onboard
(Flash) 1MByteashcard(optional)
Hardware clock
Accuracy Yes, better than 1 min/month
Data backup Renata CR2032 lithium battery, 1...3 years 4)
User inputs
Max. input frequency
4
1 kHz5)
User outputs 2
Interfaces
Programming interface USB 6)
Optional serial data interface
Port 1, 2
2 x
RS-232, RS-422/485 or TTY current loop 20 mA
Port0(PGU)alsoasRS-232
interface(D-Sub)orRS-485
(X5terminalblock),upto
115 kbit/s


Hardware Manual for the PCD2.M5 Series│Document 26/856; Version EN 12│2014-07-24
Saia-Burgess Controls AG
PCD2 CPUs
PCD2.M5_ Classic CPUs and expansion housings
3-7
3
Differences between base
units PCD2.M 5440 5540
Pro-S-Netinterface Port 10 up to 1.5 Mbps
Ether-S-Net interface 2
Field bus connections
Serial-S-Net 
Pro-S-Net 
1)UsingdigitalI/OmodulesPCD2.E16xorA46xwith16I/Oseach
2)OnallPCD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1kHzapplieswithapulse/pauseratioof1:1andreferstothetotalfrequenciesoftheinputs
6)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 USB 2.0 hub, the download runs twice as fast
 Canalsobeusedasaserialdataport,e.g.toconnectaterminal;butthishamperscommissioningandtrouble-
shooting with the debugger