Siemens SIMATIC EMS400S PSB-S User manual

Carrier controller
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SIMATIC
EMS400S
Carrier controller
Operating Instructions
09/2013
A5E03474162-02
Preface
Overview
1
Functional description
2
Safety instructions
3
Mounting and connection
4
Operator controls and
displays
5
Maintenance and repairs
6
Technical specifications
7
Appendix
A
Datasheet.Live

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03474162-02
Ⓟ09/2013 Technical data subject to change
Copyright © Siemens AG 2013.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury
will
result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury
may
result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Operating Instructions, 09/2013, A5E03474162-02 3
Preface
Purpose of the operating instructions
These operating instructions provide information based on the documentation requirements
specified in DIN EN 62079. This information relates to the place of use, transport, storage,
mounting, use and maintenance.
These operating instructions are intended for:
●Commissioning engineers
●Operators
●Maintenance personnel
Pay particular attention to the section "Safety instructions (Page 15)".
Scope of documentation
The following documents provide a full description of the "EMS400S Plant controller for
Electrical Monorail Systems":
The documents in the figure are available at:
EMS400S product documentation
(http://support.automation.siemens.com/WW/view/en/68156412/133300)
The documents supplementing the EMS400S carrier controller include:
●"EMS400S Carrier Controller" circuit diagrams

Preface
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4Operating Instructions, 09/2013, A5E03474162-02
Note
Read the "EMS400S Plant controller for Electrical Monorail Systems" system manual to
enhance your understanding of the function and interaction of the devices described in the
various documents.
The documents contain links to other relevant documents for standard modules from
Siemens that are used by the EMS400S carrier controller. This includes primarily the "S7-
1200 Automation System" system manual for the SIMATIC CPU.
Scope of validity
This documents applies to:
SIMATIC EMS400S Carrier Controller, order number 6ES7212-0AA50-0AA0
Note
These operating instructions describe the carrier controller with MICROMASTER 440
frequency converter and prepared connection for a brake resistor. Deviations compared to
other carrier versions are mentioned in the respective paragraphs.
Note
Observe the following points:
•This information supplements the "EMS400S Plant controller for Electric Monorail
Systems" system manual.
•You are also going to need this document whenever the syste
m is recommissioned. Keep
this supplementary documentation in a safe place for the entire life cycle of the device.
•Submit all of these documents to a future owner of the device.
Knowledge required
General knowledge in the fields of electrical engineering, automation technology and
process communication is prerequisite for comprehension of this documentation. This
includes knowledge of the "TIA Portal" engineering software.

Preface
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Operating Instructions, 09/2013, A5E03474162-02 5
Style conventions
Style Convention
Scope
"Add screen" •Terminology for the user interface, e.g. dialog name, tab,
button, menu command
•Necessary entries, e.g. limit value, tag value
•Path information
"File > Edit" Operational sequences, e.g, menu command, shortcut menu
command
<F1>, <Alt+P> Designation of a key on a keyboard
You should also observe the notes that are marked as follows:
Note
A note contains important information about the product described in the document and its
handling, or a specific section of the document to which you should pay particular attention.
Naming conventions
Term
Applies to
Device •EMS400S carrier controller
Controller •EMS400S plant control system
•EMS400S segment controller
Control cabinet •Installation cabinet
•Enclosure
•Terminal box
•Console
•Switchboard
Figures
This document contains illustrations of the described devices. The illustrations may deviate
from the particularities of the delivered device.

Preface
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6Operating Instructions, 09/2013, A5E03474162-02

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Operating Instructions, 09/2013, A5E03474162-02 7
Table of contents
Preface ................................................................................................................................................... 3
1 Overview................................................................................................................................................. 9
1.1 Product overview............................................................................................................................9
1.2 Scope of delivery..........................................................................................................................10
1.3 Accessories..................................................................................................................................10
2 Functional description ........................................................................................................................... 11
3 Safety instructions................................................................................................................................. 15
4 Mounting and connection ...................................................................................................................... 17
4.1 Check the scope of delivery.........................................................................................................17
4.2 Mounting location and free space for the carrier control..............................................................17
4.3 Mounting the carrier controller .....................................................................................................18
4.4 Installation location and clearances for the brake resistor...........................................................19
4.5 Wiring the carrier controller..........................................................................................................19
4.5.1 Wiring information ........................................................................................................................19
4.5.2 Preparing cables ..........................................................................................................................21
4.5.3 Interfaces .....................................................................................................................................22
4.5.4 Wiring protective earth .................................................................................................................23
4.5.5 Wire sensors, braking resistor, current collector carrier and geared motor.................................24
4.5.6 Securing the cables .....................................................................................................................26
4.6 Connecting a programming device ..............................................................................................27
4.6.1 Connecting the PROFINET cable ................................................................................................27
4.6.2 Connecting functional ground ......................................................................................................29
5 Operator controls and displays.............................................................................................................. 31
6 Maintenance and repairs....................................................................................................................... 33
6.1 Spare parts and repairs ...............................................................................................................33
6.2 Replacing modules of the EMS400S carrier controller ................................................................34
6.2.1 Overview ......................................................................................................................................34
6.2.2 Functionality of the EMS400S carrier controller ..........................................................................34
6.2.3 Replacing the EMS400S carrier controller...................................................................................36
6.2.4 Position of the modules of the EMS400S carrier controller .........................................................37
6.2.5 Replaceable modules ..................................................................................................................40

Table of contents
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7 Technical specifications ........................................................................................................................ 41
7.1 Dimensional diagram .................................................................................................................. 41
7.2 Technical specifications .............................................................................................................. 42
7.3 Interface description.................................................................................................................... 44
7.3.1 Connectors and cables ............................................................................................................... 44
7.3.2 Interface –X1 ............................................................................................................................... 44
7.3.3 Interface –X2 ............................................................................................................................... 45
7.3.4 Interface –X3 ............................................................................................................................... 46
7.3.5 Interface –PN .............................................................................................................................. 46
7.3.6 Interfaces –X4 and –X5............................................................................................................... 47
7.3.7 Interface –X6 ............................................................................................................................... 47
7.4 Approvals and standards ............................................................................................................ 48
7.5 Wiring diagrams .......................................................................................................................... 49
7.6 Notes about usage ...................................................................................................................... 50
7.7 Electromagnetic compatibility...................................................................................................... 50
7.8 Environmental conditions ............................................................................................................ 52
7.8.1 Transportation and storage requirements................................................................................... 52
7.8.2 Operational requirements............................................................................................................ 52
7.8.3 Tests for compliance with environmental conditions .................................................................. 54
A Appendix .............................................................................................................................................. 55
A.1 Technical support........................................................................................................................ 55
A.2 Abbreviations .............................................................................................................................. 56
Glossary ............................................................................................................................................... 57
Index .................................................................................................................................................... 61

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Overview
1
1.1
Product overview
The EMS400S carrier controller is part of the EMS400S plant control system. The EMS400S
plant control system has been designed for an EMS plant.
The carrier controller has found its way into many areas of internal transporting. Thanks to its
advanced automation level, the controller enhances the flexibility and efficiency of rail-based
electric monorail systems primarily in the automotive industry. The EMS400S carrier
controller is particularly suited for use in the assembly and logistics processes.
Communication between the mobile carrier controllers and the corresponding stationary
EMS400S segment controllers is based on the interaction of the associated PSB modules.
Communication takes place via contact conductors integrated in the rail system.
The carrier controller converts the data received from the segment controller and the
installed sensors into control commands for the actuators of the associated EMS carrier. The
received data are primarily run commands. The system also sends error messages and
diagnostic messages for acknowledgment to the segment controller.
The interpretation of transmitted data and the corresponding acknowledgment can be
programmed in the TIA Portal to suit requirements.
The EMS400S carrier controller contains all modules that are necessary for implementing
the conveying tasks. Additional modules such as brake resistors may be connected. The
carrier controller can be expanded by digital and analog sensors, for example, for distance
control and positioning of the EMS carrier.

Overview
1.2 Scope of delivery
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The EMS400S carrier controller is an enclosure that is mounted in a control cabinet. The
compact enclosure makes for easy design of EMS carriers in compliance with VDI Guideline
3643 "Self powered carrier system, suspended carrier system, load 500 kg - requirements
profile for a compatible system" (C1 standard). The small enclosure dimensions make the
system particularly variable in terms of the design of the EMS carrier.
The open enclosure front panel of the carrier controller ensures simple and barrier-free
access to internal modules for maintenance and repairs. It is not necessary to remove the
carrier controller.
In addition to EMS400S carrier controller described, further equipment variants will be
available on order in the near future.
1.2
Scope of delivery
The scope of delivery includes the following order units:
●1 Carrier controller
EMS400S carrier controller with MICROMASTER 440 frequency converter, 4-Q mode
with motor temperature monitoring function
Order number 6ES7212-0AA50-0AA0
●1 key for the front panel lock
●1 Product information
1.3
Accessories
The following accessories are available on order:
●Connectors of Harting Technology Group
●Brake resistor, Micromaster 4, order number 6SE6400-4BC12-5CA0
This brake resistor is an example. You can select a brake resistor that suits operational
requirements.
●SIMATIC Memory Card 2 MB, 6ES7954-8LB01-0AA0
●IR remote control, order number 6ES7292-0CA50-0AA0
●EMS400S diagnostics unit, order number 6ES7292-0EA50-0AA0
Siemens accessories are available for selection and ordering at:
Industry Mall (http://mall.automation.siemens.com)

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Functional description
2
The EMS400S carrier controller consists of a CPU and a PSB-C module. It is used to control
the drive of the EMS carrier for travel along the rail system.
Relevant data is exchanged between the plant segment controller and carrier controller via
the two RAIL contact conductors that form part of the EMS rail.
The required S7 project can be programmed without restrictions in TIA Portal. A sample
program is available at:
EMS400S product documentation
(http://support.automation.siemens.com/WW/view/en/68156412/133300)
You may use the IR remote control to transmit commands directly to the carrier controller.
The respective receiver is installed in the display unit. Message that relate to the carrier
controller can be visualized on the display unit.

Functional description
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12 Operating Instructions, 09/2013, A5E03474162-02
The following figure shows a block diagram of the carrier controller on which all connections
are in use.
①
Current collector carrier with 6 collectors
⑧
Sensors (optional)
②
24 V DC power supply module
⑨
Display unit
③
Circuit breaker
⑩
Brake resistor (optional)
④
On-off switch
⑪
Geared motor for travel of the EMS carrier
along the rail system
⑤
S7-1212C CPU
⑫
Programming unit (optional)
⑥
PSB-C module
⑬
IR remote control (optional)
⑦
Frequency converter

Functional description
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Main modules
Main modules of the EMS400S carrier controller:
●S7-1212C CPU
The CPU generates the setpoint and the control signals for the frequency converter,
controls the communication with the plant segment controller and the display unit; it also
polls the sensors and monitors the fan.
The CPU controls the frequency converter and therefore acceleration, velocity and
stopping of the EMS carrier.
●PSB-C module
The PSB-C module communicates with the PSB-S module of the plant segment controller
that is assigned to the plant segment in which the EMS carrier is currently present. Data
is sent and received serially.
The PSB-C module also communicates with the display unit.
●Display unit
The display unit is located on the front of the carrier controller. If configured, it displays
the current operating states and messages regarding the EMS carrier.
For information about the display unit, refer to the "EMS400S Display Unit and IR Remote
Control" operating instructions.
●Frequency converter
You need an MM440 frequency converter to control the geared motor for driving the EMS
carrier. You can adjust the speed of the geared motor along a linear ramp from zero to
maximum.
If a non-self-locking gear is used, the geared motor can act as generator during coasting.
The converted energy is dissipated as heat energy by means of a brake resistor.
The operating instructions for the main modules mentioned are available at:
Overall SIMATIC documentation (http://www.siemens.com/simatic-tech-doku-portal)
Geared motor on the EMS carrier
The EMS400S carrier controller has been designed for the following types of gears:
●Geared motor with non-self-locking gear
You frequently need to connect a brake resistor when using a gear without self-locking
function, for example, a helical gear or bevel gear. The result mainly depends on the
characteristics of the travel. The brake resistor is activated automatically when the motor
feeds back regenerative energy to the DC link of the frequency converter.
●Geared motor with self-locking gear
Use of a self-locking gear on the EMS carrier prevents the generator mode. Its is not
necessary to connect a brake resistor.

Functional description
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14 Operating Instructions, 09/2013, A5E03474162-02

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Safety instructions
3
WARNING
Injury or material damage
You risk the development of danger sources and deactivation of safety functions if you
neglect the safety and handling instructions provided in this document. This can result in
personal injuries or material damage.
Strictly adhere to the safety and handling instructions.
Always adhere to the safety instructions and accident prevention regulations for the
respective application, independent of the safety instructions provided in this document.
Safety in the project
WARNING
Injury or material damage
The configuration engineer for a plant controller must take appropriate measures to ensure
the proper restart of an interrupted program after a voltage dip or power failure.
Dangerous operating states may not develop at any time during runtime of the program and
during troubleshooting.
Safety during commissioning and operation
Note
It is strictly prohibited to commission the carrier controller unless compliance with Machinery
Directive 2006/42/EC has been verified for the EMS in which the carrier controller is being
operated. Verify that all requirements of the machinery directive have been met before you
start commissioning.
Observe the relevant safety guidelines when using the EMS400S carrier controller in an
EMS. Detailed information on this topic is available in the section "Safety instructions" in the
"EMS400S Plant controller for Electric Monorail Systems" system manual.
The documents belonging to the EMS400S plant controller are listed in the preface.

Safety instructions
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16 Operating Instructions, 09/2013, A5E03474162-02
Safety when working in and on electrical systems
Only authorized persons are allowed to work in or on electrical equipment. The following
safety regulations for prevention of electrical shock are valid in Germany:
1. Isolation of the system from power
2. Securing the system against restart
3. Verification of isolation from power at all poles
4. Grounding and shorting the system
5. Covering or fencing off adjacent live parts
These safety regulations are based on DIN VDE 0105.
Note
The safety regulations must be applied in the aforementioned order before any work is
carried out on electrical systems. The safety regulations must be applied in reverse order on
completion of all tasks on the electrical system.
Identify the electrical system in accordance with valid safety regulations when working on
this system.
Observe the valid safety regulations of the respective country.
Warranty
Prerequisites for trouble-free and safe operation of the device:
●Proper transportation and storage
●Proper mounting and wiring
●Proper operation and repairs
Non-compliance with these regulations shall render the device warranty void.

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Mounting and connection 4
4.1 Check the scope of delivery
Check the scope of delivery for completeness and visible signs of transport damage.
Note
You risk malfunctions if using faulty parts that have were delivered to you. Always use part
that do not disclose any fault. Contact your Siemens partner for support for faulty parts.
4.2 Mounting location and free space for the carrier control
Selecting the mounting location
The carrier controller is designed for operation in vertical mounting position. The following
figure shows the vertical mounting position:
Select a mounting location that does not obstruct the visibility of the display unit.
Note
Observe the following points:
Valid environmental conditions
Non-compliance with valid environmental conditions at the mounting location may lead to
malfunctions. Observe the valid environmental conditions for operation when selecting
the mounting location. The valid environmental conditions are specified in chapter
"Environmental conditions (Page 56)".
Radiated heat
Exposure to sunlight and other heat sources may possibly increase the internal
temperature of the carrier controller. You should therefore take suitable measures to
prevent the carrier controller from being exposed to sources of heat.

Mounting and connection
4.3 Mounting the carrier controller
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18 Operating Instructions, 09/2013, A5E03474162-02
Bolting surface
The bolting surface must support the weight of the carrier controller and meet the following
requirements:
Material property
Value
Material thickness 2 to 6 mm
Planarity ≤0.5 mm
Clearance
You need to provide the following clearance around the carrier controller:
On all sides, except on the rear 50 mm
Rear side 20 mm
This restriction does not apply to situations in which a component of the EMS plant briefly
passes the carrier controller at a clearance of less than 50 mm when the EMS carrier is
moving.
4.3
Mounting the carrier controller
It is not necessary to open the carrier controller for mounting.
The mounting fixture on the EMS carrier provides several options of mounting the carrier
controller:
●Tapped holes for threaded pins or screws
●Through-holes for threaded bolts or screws
●Threaded bolts on the mounting surface
The bolting surface must allow for full surface contact of the fastening hooks on the carrier
controller. The fastening hooks are designed for M8 threads.
The following drill pattern shows the distances between the mounting elements.
Observe the specifications in the section "Operational requirements (Page 52)".

Mounting and connection
4.4 Installation location and clearances for the brake resistor
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4.4
Installation location and clearances for the brake resistor
A Micromaster 4 brake resistor is required when you use a non-self-locking gear for the drive
unit of the EMS carrier. Plant engineering specifies the type of brake resistor that suits the
plant conditions.
The brake resistor dissipates heat in form of radiation and convection. Install the brake
resistor so that a thermal effect on the carrier controller is prevented. Observe the necessary
clearances around the carrier controller.
For information about the mounting and wiring of the Micromaster 4 brake resistor, refer to
the corresponding product documentation. This documentation is available at:
Industry Mall (http://mall.automation.siemens.com)
4.5
Wiring the carrier controller
4.5.1
Wiring information
Note
Observe the following points:
•Safety instructions
Read the "Safety instructions" section in the "EMS400S Carrier Controller for Electric
Monorail Systems" system manual.
•Device failure
Moisture and condensation lead to malfunction. Moisture in form of condensation at or in
the device is the result of extreme fluctuations in temperature that occur, for example,
when the device is transported at low temperatures. Bring the device to room
temperature before operating.
•Condensation
Wait for approximately 4 hours to completely dry out any condensation before you
connect or power up the device. Do not expose the device to direct heat radiation from a
heater.

Mounting and connection
4.5 Wiring the carrier controller
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20 Operating Instructions, 09/2013, A5E03474162-02
Wiring sequence
Note
Observe the following points:
•Switch off the carrier controller before you start.
•You will risk damage to the device if you ignore the specified wiring sequence.
Wire the carrier controller in the following order:
1. Protective earth to –PE
2. Sensors
3. Brake resistor, if necessary
4. Current collector carrier on the EMS carrier
5. Geared motor
6. Programming device, if necessary
You can disconnect the device in reverse order.
Overvoltage category
The device is compliant with overvoltage category II to EN 61010-1. Keep this overvoltage
category in mind during system planning.
Selecting cables
System project planning is responsible for selecting the cables that are necessary to
interconnect the carrier controller and the EMS carrier. The cables must be selected to suit
the mechanical and electrical requirements as well as other environmental conditions at the
location of use.
Observe the specifications and permitted cable lengths – see section "Technical
specifications (Page 42)".