Siemens Simatic S5 IP 240 User manual

SIMATIC S5
IP 240
Counter/Positioning/
Position Decoder Module
Manual
EWA 4NEB 811 6120-02b
Edition 03

Only qualified personnel should install or maintain this equipment after becoming thoroughly familiar
with all warnings, safety notices, and maintenance procedures contained in this manual. The successful
and safe operation of this equipment is dependent upon proper handling, installation, operation, and
maintenance.
The following are definitions of the terms “qualified person,” “danger,” “warning,” and “caution,” as
applicable for this document.
Qualified Person
One who is familiar with the installation,
construction, and operation of this equipment and
the hazards involved. In addition, the person
should have the following qualifications:
• Be trained and authorized to use and tag
circuits and equipment in accordance with
established safety practices
• Be trained in the proper care and use of
protective equipment in accordance with
established safety practices
• Be trained in rendering first aid
Indicates loss of life, severe personal injury, or
substantial property damage will result if
proper precautions are not taken.
Indicates loss of life, severe personal injury, or
substantial property damage can result if
proper precautions are not taken.
Indicates minor personal injury or property
damage can result if proper precautions are not
taken.
CAUTION
WARNING
DANGER
Hazardous voltage.
Can cause death, severe
personal injury, or substantial
property damage.
Restrict use to qualified
personnel.
See safety instructions.
WARNING
!
STEP 5®and SIMATIC®are registered trademarks of Siemens AG.
Copyright ©Siemens AG 1990
First Printing, March 1991
Printed in the Federal Republic of Germany
Siemens has developed this document for its licensees and customers. The information contained herein
is the property of Siemens and may not be copied, used, or disclosed to others without prior written
approval from Siemens. Users are cautioned that the material contained herein is subject to change by
Siemens at any time and without prior notice.
Siemens shall not be responsible for any damages, including consequential damages, caused by reliance
on material presented, including but not limited to typographical, electronic, arithmetic, or listing
errors.

IP 240 Replacement Pages for IP 240 Manual, Edition 3
Supplement to the IP 240 Manual, Order No. 6ES5 998 0TB22, Edition 3
Use of the IP 240 in the S7-400 programmable controller
This manual has been supplemented by Appendices A, B and C. They include information on how
to install S5 modules in an S7-400 programmable controller when using an adapter casing.
Replacement Pages for IP 240 Manual, MLFB 6ES5 998 OTB22, Edition 3
The current manual is valid for the following modules:
• IP 240, MLFB 6ES5 240-1AA21 and
• IP 240, MLFB 6ES5 240-1AA12.
Use with the IP 240, MLFB 6ES5 240-1AA21
The IP 240, MLFB 6ES5 240-1AA21 is a further development of the IP 240, MLFB 6ES5 240-1AA12.
With this MLFB, the module was converted to SMD components as far as possible. The changes to
the module description required as a result of the changes have been included in Edition 3 of this
manual.
The replacement pages at the end of the manual can be ignored in this case.
Use with the IP 240, MLFB 6ES5 240-1AA12
Supplements and changes to the revised module IP 240, MLFB 6ES5 240-1AA21 have been included
in Edition 3 of this manual.
To use this manual with the IP 240, MLFB 6ES5 240-1AA12, you must replace the relevant pages of
the manual with the following pages 2-1 to 2-8, 3-1 to 3-2, 5-1 to 5-4 and 5-7 to 5-8 (at the end of
the manual).
The pages
• for MLFB 6ES5 240-1AA12 have the number 811 6120-01 in the footer
• for MLFB 6ES5 240-1AA21 have the number 811 6120-01a in the footer
EWA 4NEB 811 6120-02c

1
2
3
4
5
6
7
8
Preface
Introduction
Addressing
Hardware Installation
Operation
Functional Description
Position Decoding
Counting
IP 252 Expansion
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
9
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
Module Description and Accessories
System Overview
Error Messages
Appendices
Direct Data Interchange with the IP 240
Response Times
Positioning 10
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
11
a a a a a a a a a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a
a a a a a a a
a
a a a a a a a a a
12
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
Encoder Signals 13
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
14
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
A/B
C
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
a a a a a a a a a
Index
EWA4NEB8116120-02b

IP 240 Preface
Preface
In addition to open and closed-loop control, the programmable controllers of the SIMATIC S5 fa-
mily execute special tasks such as positioning and counting. So that these auxiliary functions do
not unnecessarily load the central processor (S5 CPU), they are handled by standalone "intelli-
gent" I/O modules. These have their own microprocessors and execute special time-critical tasks
autonomously.
The two-channel IP 240 module is suitable for the following applications:
•Position decoding
The IP 240 counts and processes pulses from incremental encoders. Cam controllers and limit
switches can be simulated by comparing the actual value with preset tracks.
•Counting
The IP 240 is suitable for gate-controlled counting of rapid pulse trains and for initiating
specific reactions when the count reaches zero.
•IP 252 expansion
The IP 240 operates as a slave for the IP 252 closed-loop control module, thus allowing the
connection of other incremental encoders to the IP 252. The acquired signals are transferred
direct to the IP 252.
•Positioning
The IP 240 enables controlled positioning with cutoff points. As many as 254 positions can be
stored on the IP for this purpose. When a position has been selected, either the direction of
travel or the traversing speed can be specified directly over the IP outputs. The approach is
controlled and monitored via three selectable operating distance ranges. Incremental enco-
ders are used for position sensing.
The module can intervene direct in the process or flag process states over four digital outputs
(two per channel).
The IP 240 has interrupt capability, making it possible to report certain events direct to the S5 CPU.
Standard software function blocks are available for handling the data interchange between the
S5 CPU and the IP 240.
EWA 4NEB 811 6120-02a v

IP 240 Introduction
Introduction
The following pages contain information which will help you to use this manual.
Description of Contents
The contents of this manual can be divided into blocks according to topic:
• Module description
• Addressing
• Hardware installation and notes on operation
• Functional description
• Position decoding, counting, IP 252 expansion, positioning
• Direct data interchange with the IP 240
• Response times, encoder signals
• Error messages
At the end of the book you will find correction forms. Please enter any suggestions you may have
in the way of improvements or corrections in this form and send it to us. Your comments will help
us to improve the next edition.
Courses
SIEMENS provide SIMATIC S5 users with extensive opportunities for training.
For more information, please contact your SIEMENS representative.
Reference Literature
This manual is a comprehensive description of the IP 240. Topics not specific to the IP 240,
however, are only briefly dealt with. You will find more detailed information in the following
literature:
•Speicherprogrammierbare Steuerungen SPS (available in German only)
Volume 1: Logic and sequential controls; from the control problem to the control program.
Günter Wellenreuther, Dieter Zastrow
Braunschweig 1987
Contents:
- How a programmable controller works
- The theory of logic control using the STEP 5 programming language for SIMATIC S5 pro-
grammable controllers.
Order No.: ISBN 3-528-04464-0
EWA 4NEB 811 6120-02a vii

Introduction IP 240
•Automating with the S5-115U
SIMATIC S5 programmable controllers
Hans Berger
Siemens AG, Berlin and Munich 1989
Contents:
- STEP 5 programming language
- Program processing
- Integral blocks
- Interfaces to the peripherals
Order No.: ISBN 3-8009-1526-X
• Automating with the S5-135U
SIMATIC S5 programmable controllers
Hans Berger
Siemens AG, Berlin and Munich 1989
Contents:
- STEP 5 programming language
- Program processing
- Integral blocks
- Interfaces to the peripherals
- Multiprocessor operation
Order No.: ISBN 3-8009-1537-5
• Automating with the SIMATIC S5-155U
SIMATIC S5 programmable controllers
Hans Berger
Siemens AG, Berlin and Munich 1989
Order No.: ISBN 3-8009-1538-3
You can find information on the range of units in the following catalogs:
• ST 52.3 ”S5-115U Programmable Controller”
• ST 57 ”Standard Function Blocks and Drivers for U-Range Programmable Controllers”
• ST 59 ”S5 Programmers”
• ET 1.1 ”ES 902 C Modular Packaging System 19 in. Design”
• MP 11 Thermocouples, Compensating Boxes
There are separate manuals for other components and modules (e.g. CPUs and SINEC L1). We refer
to these information sources at the appropriate points in the text.
viii EWA 4NEB 811 6120-02a

IP 240 Introduction
Conventions
In order to improve the readability of the manual, a menu-style breakdown was used, i.e.:
• The individual chapters can be quickly located by means of a thumb register.
• There is an overview containing the headings of the individual chapters at the beginning of
the manual.
• Each chapter is preceded by a breakdown of its subject matter.
The individual chapters are subdivided into sections and subsections. Bold face type is used for
further subdivisions.
• Pages, figures and tables are numbered separately in each chapter. The page following the
chapter breakdown contains a list of the figures and tables appearing in that particular
chapter.
Certain conventions were observed when writing the manual. These are explained below.
• A number of abbreviations have been used.
Example: Central processing unit (CPU)
• Footnotes are identified by a superscript consisting of a small digit (e.g. ”1”) or ”*”. The actual
footnote is generally at the bottom of the page or underneath a table.
• Cross-references are shown as follows:
”( Section 7.3.2)” refers to subsection 7.3.2.
No references are made to individual pages.
• Actions required from the user are introduced by the symbol .
• All dimensions in drawings etc. are given in millimetres (mm). This is followed by the value in
inches in parentheses. Example: 187 (7.29).
• Values can be expressed by binary, decimal or hexadecimal numbers. The number system is in-
dicated by a subscript; example: F000H.
• Especially important imformation is written in text boxes. A heading in the upper part of the
text box defines the meaning of the note.
Note
is important imformation on the product, the handling of the product or parts of
documentation that have to be observed very carefully.
Warning
means that loss of life, severe personal injury or substantial property damage can
result if proper precautions are not taken.
EWA 4NEB 811 6120-02a ix

Introduction IP 240
Manuals can only describe the current version of the programmable controller. Should
modifications or supplements become necessary in the course of time, a supplement will be
prepared and included in the manual the next time it is revised. The relevant version or edition of
the manual appears on the cover. In the event of a revision, the edition number will be
incremented by ”1”.
x EWA 4NEB 811 6120-02a

IP 240 Introduction
Conventions
The following conventions are used in this book and are listed for your reference:
Convention Definition Example
A box that indicates a type of hazard,
describes its implications, and tells you
how to avoid the hazard is a cautionary
statement. Some cautionary statements
include a graphic symbol representing
an electrical or radio-frequency hazard.
All cautionary statements have one of
the following levels of caution:
• A danger indicates that loss of
life, severe personal injury, or
substantial property damage
will result if proper precautions
are not taken.
• A warning indicates that loss of
life, severe personal injury, or
substantial property damage
can result if proper precautions
are not taken.
• A caution indicates that minor
personal injury or property
damage can result if proper
precautions are not taken.
GWA 4NEB 811 6120-02a xi