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
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4
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7
8
Preface
Introduction
Addressing
Hardware Installation
Operation
Functional Description
Position Decoding
Counting
IP 252 Expansion
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Module Description and Accessories
System Overview
Error Messages
Appendices
Direct Data Interchange with the IP 240
Response Times
Positioning 10
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Encoder Signals 13
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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
2 Module Description and Accessories
3 Addressing
4 Hardware Installation
5 Operation
6 Functional Description
7 Position Decoding
8 Counting
9 IP 252 Expansion
10 Positioning
11 Direct Data Interchange with the IP 240
12 Response Times
13 Encoder Signals
14 Error Messages
1 System Overview
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EWA 4NEB 811 6120-02a
Figures
1-1. Modes of the IP 240 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 1
1-2. IP 240 with and without Adapter Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 2
1-3. S5-115U with the IP 240 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 2
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EWA 4NEB 811 6120-02a
IP 240 System Overview
1 System Overview
Intelligent input/output modules (I/Os) extend the field of applications of the SIMATIC S5
programmable controller system. They are technology-oriented and off-load the central pro-
cessor by preprocessing the input signals.
Digital input modules can resolve pulses up to a frequency of 100 Hz. The IP 240 can be used for
applications with higher frequencies and for connecting incremental encoders.
The module can be used in four modes:
• Position decoding
• Counting
• IP 252 expansion (only in the S5-115U programmable controller)
• Positioning
It is configured in the desired mode by the user program.
Fig. 1-1. Modes of the IP 240 Module
Mint
5 V
•
•
S5 bus
Interrupt circuit
•
Outputs, channel 2
Position decoding
Counting
IP 252 expansion
Positioning
IP 240
Outputs, channel 1
Position decoding
Positioning
•
Counting
IP 252 expansion Configuration
for channel 1
Configuration
for channel 2
EWA 4NEB 811 6120-02a
1-1
System Overview
1P
240
In the position decoding, counting and positioning modes, the
1P
240
can be used as a standalone
module in the U-range programmable controllers
S5-1
15U, S5-135U (CPU 922 and 928), S5-150U
and S5-155U. Operation as an expansion to the
1P
252 closed-loop control module with direct data
exchange between the 1/0 modules is only possible in the
S5-1
15U programmable controller.
.
The
1P
240 can be operated in the central controllers of the
S5-1
15U,
S5-135U
and S5-155U and in
expansion units with a central controller bus. In the S5-115U programmable controller, the
compact module can be plugged in by means of an adapter casing.
Standard function blocks are available as user support for the exchange of data between the
1P
240 and the S5 central processor.
g. 1-2.
1P
240 with and without
Adapter Casing Fig. 1-3. S5-115U
with the
1P
240 Module
1-2
EWA4NEB811 6120-02a
3 Addressing
4 Hardware Installation
5 Operation
6 Functional Description
7 Position Decoding
8 Counting
9 IP 252 Expansion
10 Positioning
11 Direct Data Interchange with the IP 240
12 Response Times
13 Encoder Signals
14 Error Messages
2 Module Description and Accessories
2.1 General Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 1
2.2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 2
2.2.1 Position Decoding and Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 2
2.2.2 Counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 3
2.2.3 Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 4
2.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 7
2.4 Order Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 8
1 System Overview
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EWA 4NEB 811 6120-02a
Figures
2-1. Front Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 4
2-2. Block Diagram of the Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 5
2-3. Block Diagram of the Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 6
2-4. LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 7
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EWA 4NEB 811 6120-02a
IP 240 Module Description and Accessories
2 Module Description and Accessories
2.1 General Technical Specifications
Temperature
Operation 0 to +55 °C
(Intake air tem-
perature,
measured at the
bottom of the
module)
Storage/shipping - 25 to + 70 °C
Temperature change
- Operation 10 °C/h max.
- Storage/shipping 20 °C/h max.
Relative humidity to DIN 40040
15 to 95% (indoors)
noncondensing
Atmospheric pressure
- Operation 860 to 1060 hPa
- Storage/shipping 660 to 1060 hPa
Damped oscillatory
wave test (1 MHz) to IEC 255-4
Digital-
inputs and outputs 1 kV
Static electricity to IEC 801-2
(discharge on all
parts accessible to
the user during
normal operation)
Test voltage 3 kV
Radiated electro-
magnetic field test to IEC 801-3
Test field strength
3 V/m
Fast-transient
burst test to IEC 801-4
Digital-
inputs and outputs 1 kV
Vibration to IEC 68-2-6
- Tested with 10 to 57 Hz,
(constant ampli-
tude 0.15 mm)
57 to 150 Hz,
(constant acceler-
ation 2 g)
Shock IEC 68-2-27
-Tested with 12 shocks
(semisinusiodal
15 g/11 ms)
Free Fall IEC 68-2-32
- Tested with Height of fall 1 m
Degree of protection to IEC 529
- Implementation IP 20
- Class I to IEC 536
Insulation rating
for the digital outputs to VDE 0160
- Nominal insulation
voltage between
electrically
independent circuits
and
circuits connected
to central ground 30 V DC
Test voltage sinusoidal, 50 Hz
at a rate voltage Ue500 V
of the AC or DC
circuit of
Ue=0 to 50 V
Climatic Environmental Conditions Mechanical Environmental Conditions
Specifications on IEC/VDE safety
Electromagnetic Compatibility (EMC)
Noise Immunity
EWA 4NEB 811 6120-02a
2-1
Module Description and Accessories IP 240
2.2 Technical Specifications
The IP 240 has two independent channels.
In the IP 252 expansion mode, the encoder signals are acquired as in the position decoding and
positioning modes. The data relating to pulse inputs for position decoding therefore also apply to
the IP 252 expansion.
Current consumption, internal Max. 0.5 A at 5 V without encoder supply
Weight Approx. 450 g
Width of the module 1 SPS=20 mm
2.2.1 Position Decoding and Positioning
Pulse inputs
Encoders Incremental encoders
with the following characteristics:
- Encoder signals Two pulse trains displaced by 90 ° (Channels A and B),
one reference signal (Channel Z)
The Z signal is evaluated in zero mark monitoring and
reference point approach during signal state A=”1”
and B=”1”. For the duration of signal Z, states A=”1”
and B=”1” may only occur once ( Section 13.1.1).
- Encoder output circuits with symmetrical pulse train to RS 422 A
or similar,
rated encoder voltage 5 V,
connection to inputs:
A and A, B and B, Z and Z
with asymmetrical pulse train, e.g. push-pull,
open collector (external pull-up resistors required),
rated encoder voltage 5 V or 24 V,
connection to inputs:
A*, B*, Z*
Binary input
Encoders e.g. BERO proximity switches
- Encoder output circuit Switching to P potential
Operating voltage 5 V or 24 V,
connection to input:
IN (preliminary contact)
2-2
EWA 4NEB 811 6120-02a
IP 240 Module Description and Accessories
Input frequencies
Pulse inputs:
-Symmetrical signals max. 500 kHz in position decoding and
positioning mode
max. 200 kHz in IP 252 expansion mode
- Asymmetrical signals
5 V 1max. 50 kHz
24 V 2max. 25 kHz for 100 m cable
max. 50 kHz for 25 m cable
Binary input: max. 100 Hz
2.2.2 Counting
Pulse input
Encoders e.g. incremental encoders
- Encoder output circuit Switching to P potential,
encoder voltage rating 5 V or 24 V,
connection to input:
CLK (clock)
Binary input
Encoders e.g. BERO proximity switches
- Encoder output circuit Switching to P potential,
operating voltage 5 V or 24 V,
connection to input:
GT (gate)
Input frequencies
Pulse input: 5 V 1max. 70 kHz
24 V 2max. 25 kHz for 100 m cable
max. 70 kHz for 25 m cable
Binary input: max. 100 Hz
1max. encoder output resistance 330
max. capacitance per unit length of cable 100 pF/m
2max. encoder output resistance 1 k
max. capacitance per unit length of cable 100 pF/m
Encoder output circuit series-mode
EWA 4NEB 811 6120-02a
2-3
Module Description and Accessories IP 240
2.2.3 Inputs/Outputs
The IP 240 provides two options for connecting sensors to the pulse inputs:
• All sensor signals can be routed to the 15-pin subminiature D socket connectors X2/X4
( Section 4.2.2)
• Clock signals up to 10 kHz can also be routed over the 7-pin plug connectors X3/X5
( Section 4.2.2).
The sensor power supply is only available at the 15-pin subminiature D socket connectors.
Fig. 2-1. Front Connectors
X4
X2
Pulse
Inputs
Shield potential
Digital outputs
Binary inputs
5 V
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S5 bus
L+
M (L -)
Pulse
Inputs Channel 1
Channel 2
Digital outputs
Binary inputs Channel 1
Channel 2
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X5
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X6
Position
decoding
Counting
IP 252-
expansion
Positioning
Mint
Warning
To ensure noise immunity, all inputs, outputs and the 24 V supply on the IP 240
must be connected using shielded, twisted-pair cables.
Terminal M (L-) is connected on the IP 240 to the module ground (Mint).
Inputs
Terminals A and A A* IN (prelim. contact)
B and B B* CLK (CLOCK)
Z and Z Z* GT (GATE)
Encoder signals Symmetrical Asymmetrical
(RS 422 A)
Rated voltage 5 V 5 V or 24 V 5 V or 24 V
Galvanic isolation no no no
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2-4
EWA 4NEB 811 6120-02a
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