Siemens SIMATIC ET 200R User manual

SIMATIC
Distributed I/0 Device
ET 200R
Manual
Foreword, Table of Contents
Product Overview 1
Possible Configurations 2
Installation 3
Wiring 4
Commissioning and
Diagnosis 5
General Technical
Data 6
Technical Data 7
Appendix A
Release 06/2004

Copyright © Siemens AG 2004 All rights reserved Disclaimer of liability
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utilization and revelation of its contents is not permitted
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tered. The designations used in this documentation
may be brands whose use by third parties for their own
pur-poses may violate the rights of the owners.
Although we have checked the contents of this publication
for correspondence to the described hardware and soft-
ware, errors cannot be excluded. The information in this
publication is checked at regular intervals and necessary
corrections included in the next edition. You comments and
ideas are welcome. Subject to technical change without
prior notice
Siemens Aktiengesellschaft (4)J31069-D0427-U001-A2-7618
Technical safety notes
This documentation contains information which you must adhere to for your own personal safety and
for the avoidance of property damage. The information is highlighted with a warning triangle. The de-
gree of danger is presented as shown below.
!
Danger
Means that death, severe injury or substantial property damage will occur if the appropriate precautions
are not taken.
!
Warning
Means that death, severe injury or substantial property damage may occur if the appropriate precau-
tions are not taken.
!
Caution
With a warning triangle: means that minor injury may occur if the appropriate precautions are not taken.
Caution
With no warning triangle: means that property damage may occur if the appropriate precautions are not
taken.
Attention
Means that an undesired result or an undesired state may occur if this information is not adhered to.
Note
Important information on the product, the handling of the product, or the particular part of the documen-
tation which requires special attention.
Intended use
!
Warning
The described product may only be used for the applications stated in this documentation and only in
connection with Siemens components or components and devices of other manufacturers which been
recommended or authorized by Siemens.
Brands
SIMATIC® is a registered brand of Siemens AG.
The other designations used in this publication may be brands whose use by third parties for their own
purposes may violate the rights of the owners.

Foreword
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 3
Foreword
Purpose of this manual
The information in this manual will enable you to operate the ET 200R distributed
I/O device on PROFIBUS-DP as a standard slave.
It is written for the people involved in the configuring, commissioning and servicing
of programmable controllers.
Required basic knowledge
Comprehension of this manual requires a general knowledge of automation tech-
nology.
In addition, a knowledge of the use of computers or PC-like resources (e.g., pro-
grammers) under the operating systems Windows 95/98/ME/NT or NT/2000 is re-
quired. Acknowledge of configuration methods (e.g., with COM PROFIBUS) is also
assumed.
Circle of readers
This manual is written for people who possess the necessary qualifications for
commissioning and running the ET 200R.
What this manual covers
This manual is valid for the ET 200R modules with the following order numbers:
ET 200R-H 6ES7 143 2BH00 0AB0 (handling module)
ET 200R-W 6ES7 143 2BH50 0AB0 (welding module)
Software prerequisites for hardware configuration
You will need the related GSD file (see current information on page 5) for configu-
ration of the ET 200R.
Scope of delivery
•ET 200R with seven M12 covering caps
•Short description
•Terminal strip for terminal field on the back (for the welding module)

Foreword
Distributed I/O Device ET 200R
4(4)J31069-D0427-U001-A2-7618
Licenses
The ET 200R distributed I/O device conforms to the following regulations:
•EG guideline 89/336/EWG on electromagnetic compatibility
•Certification as standard DP slave
•cULus
Underwriters Laboratories, Inc.: registered under UL 508 (Industrial Control
Equipment)
Standards and certifications
The ET 200R distributed I/O device is based on the standard EN 50170, volume 2
(IEC 61158), PROFIBUS. In addition, the ET 200R distributed I/O device meets the
requirements and criteria of IEC 1131, part 2 and the requirements of the CE seal.
Detailed information on certifications and standards is located in the technical data
(see chapter 7).
Other support
If you have technical questions, please contact your Siemens representative.
You will find the address in the manuals of the DP masters (e.g., in the appendix
("Siemens Worldwide") of the manual on the S7-300 programmable controller,
setup, CPU data and catalogs).
If you have questions or remarks on the manual itself, please fill in the reply card
located at the end of the manual and return it to the specified address. It would also
be greatly appreciated if you would take the time to enter your personal opinion of
the manual on the reply form.

Foreword
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 5
Current information
You will receive continuously updated current information on SIMATIC products.
In addition, SIMATIC Customer Support provides you with current information and
downloads which may be useful when using SIMATIC products.
•From the Internet at http://www.ad.siemens.de/simatic-cs or
http://www.ad.siemens.de/csi/gsd
•From the SIMATIC Customer Support mailbox under the number
[phone]
If you need the GSD file, this is available for downloading at
http://www.ad.siemens.de/csi/gsd .
SIMATIC Customer Support can be reached by telephone at +49 0180/5050222
and by fax at +49 0180/5050223.
Send e-mail inquiries to [e-mail]

Foreword
Distributed I/O Device ET 200R
6(4)J31069-D0427-U001-A2-7618

Table of Contents
Distributed I/O Device ET 200R
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Table of Contents
1 Product Overview ......................................................................... 1-1
1.1 What are distributed I/O Devices? ..........................................................1-1
1.2 What is the ET 200R distributed I/O Device? .........................................1-3
2 Possible Configurations .............................................................. 2-1
2.1 Feeding in and connecting through the voltage for
Electronics/Encoders and PROFIBUS-DP..............................................2-1
2.2 Restriction of the modules which can be connected...............................2-2
3 Installation..................................................................................... 3-1
3.1 Mounting/Demounting the ET 200R........................................................3-2
3.2 Setting/Changing the PROFIBUS address .............................................3-3
3.3 Providing PROFIBUS with terminating resistance ..................................3-4
4 Wiring ............................................................................................ 4-1
4.1 General rules and regulations for operating the ET 200R ......................4-2
4.2 Wiring the ET 200R ................................................................................4-3
4.2.1 Connecting the terminal field on the back...............................................4-4
4.2.2 Connecting the bus plugs .......................................................................4-5
4.2.3 Plug Connectors for the Digital Inputs and Outputs................................4-6
5 Commissioning and Diagnosis ................................................... 5-1
5.1 Configuring the ET 200R ........................................................................5-1
5.2 Commissioning and startup of the ET 200R...........................................5-2
5.3 Diagnosis with LED indicators ................................................................5-4
5.4 Diagnostic Messages..............................................................................5-6
5.4.1 Reading the diagnosis ............................................................................5-6

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Distributed I/O Device ET 200R
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5.5 Layout of the ET 200R slave diagnosis ..................................................5-7
5.5.1 Station status 1 to 3 ................................................................................5-8
5.5.2 Master PROFIBUS Address ...................................................................5-9
5.5.3 Manufacturer's ID..................................................................................5-10
5.5.4 ID-Related Diagnosis ............................................................................5-10
5.5.5 Module status........................................................................................5-11
5.5.6 Device-specific diagnosis......................................................................5-11
6 General Technical Data................................................................6-1
6.1 Standards and certifications....................................................................6-1
6.2 Electromagnetic compatibility .................................................................6-2
6.3 Physical and climatic ambient conditions................................................6-3
6.4 Information on isolation tests, protection class, protection rating
and nominal voltage of the ET 200R.......................................................6-4
7 Technical Data .............................................................................. 7-1
A Appendix ...................................................................................... A-1

Table of Contents
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 9
Figures
Figure 1–1 Typical configuration of a PROFIBUS-DP network ..............................................1-2
Figure 1–2 Allocation of the plug connectors and LEDs on the ET 200R ..............................1-4
Figure 2–1 Feeding in and connecting through power and PROFIBUS-DP in a hybrid line...2-2
Figure 3–1 Dimensions for the mounting holes......................................................................3-2
Figure 3–2 Accessing the rotary switches for setting the PROFIBUS address......................3-3
Figure 3–3 Rotary switches (tens on left-hand switch, ones on right-hand switch)................3-4
Figure 4–1 Floor cutout on welding module ET 200R-W .......................................................4-4
Figure 4–2 Ejector for the terminal strip .................................................................................4-5
Figure 4–3 Allocation of plugs X01 / X02 ...............................................................................4-6
Figure 4–4 Y connection piece ...............................................................................................4-7
Figure 5–1 Startup of the ET 200R.........................................................................................5-3
Figure 5–2 Layout of the ET 200R slave diagnosis................................................................5-7
Figure 5–3 Layout of the ID-related diagnosis for ET 200R .................................................5-10
Figure 5–4 Layout of the module status for the ET 200R.....................................................5-11
Figure 5–5 Layout of the device-specific diagnosis..............................................................5-12

Table of Contents
Distributed I/O Device ET 200R
10 (4)J31069-D0427-U001-A2-7618
Tables
Table 4–1 Allocation of the terminal field on the back...........................................................4-5
Table 4–2 Pin allocation of the coupling plug of the digital inputs/outputs (X0 to X7)...........4-7
Table 4–3 Pin allocation of the coupling plugs for digital inputs/outputs when the
Y connection piece is used...................................................................................4-8
Table 5–1 Pin allocation of the sockets for 8-channel digital inputs......................................5-1
Table 5–2 Software pre-requisites for commissioning the ET 200R.....................................5-2
Table 5–3 Hardware pre-requisites for commissioning the ET 200R ...................................5-2
Table 5–4 Allocation of the LEDs ..........................................................................................5-4
Table 5–5 Status and error indicators on the ET 200R.........................................................5-4
Table 5–6 Reading the diagnosis from the ET 200R ............................................................5-6
Table 5–7 Layout of station status 1 (byte 0), ET 200R ........................................................5-8
Table 5–8 Layout of station status 2 (byte 1), ET 200R ........................................................5-9
Table 5–9 Layout of station status 3 .....................................................................................5-9
Table 6–1 Ambient conditions ...............................................................................................6-1
Table 7–1 Technical data ......................................................................................................7-2

Product Overview
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 1–1
Product Overview
1.1 What are distributed I/O Devices?
Distributed I/O devices - application area
When a plant is being set up, the inputs and outputs to and from the process are
frequently installed centrally in the programmable controller.
When the inputs/outputs are located a long way from the programmable controller,
this can make wiring very time-consuming and confusing. Electromagnetic distur-
bances can also affect reliability.
Use of distributed I/O devices is very helpful in such situations:
•The controller CPU is installed at a central location.
•The I/O devices (inputs and outputs) are distributed on site.
•The powerful PROFIBUS-DP with its high-speed data transmission ensures that
communication between the controller CPU and I/O devices is smooth.
What is PROFIBUS-DP?
PROFIBUS-DP is an open bus system based on the standard EN 50170, volume 2
(IEC 61158), PROFIBUS with the "DP" transmission protocol (DP stands for Dis-
tributed Periphery).
Physically PROFIBUS-DP is either an electrical network using shielded two-wire li-
nes or an optical network using fiber-optic conductors.
The "DP" transmission protocol permits fast, cyclic and, if necessary, non-cyclic
data communication between the controller CPU and the distributed I/O devices.
What are DP master and DP slaves?
The DP master is the link between the controller CPU and the distributed I/O de-
vices. The DP master exchanges data with the distributed I/O devices via
PROFIBUS-DP and monitors PROFIBUS-DP.
The distributed I/O devices (i.e., DP slaves) condition the data from the encoders
and actuators on site so that this information can be transferred to the controller
CPU via PROFIBUS-DP.
1

Product Overview
Distributed I/O Device ET 200R
1–2 (4)J31069-D0427-U001-A2-7618
Which devices can be connected to PROFIBUS-DP?
A wide variety of devices can be connected as DP master to PROFIBUS-DP or as
DP slaves provided they correspond to standard EN 50170, volume 2 (IEC 61158),
PROFIBUS.
Among others, devices of the following product families can be used:
•SIMATIC S5
•SIMATIC S7/M7/C7
•SIMATIC PG/PC
•SIMATIC HMI (user interfaces OP, OS, TD)
•Distributed I/O devices
•Devices from other manufacturers
Configuration of a PROFIBUS-DP network
The following figure shows a typical configuration of a PROFIBUS-DP network. The
DP masters are integrated in the particular device. For example, if the S7-400 has
a PROFIBUS-DP interface, the IM 308-C master interface is installed in an S5-
115U. The DP slaves are the distributed I/O devices which are connected to the DP
masters with PROFIBUS-DP.
DP-Master
DP-Slaves
PROFIBUS-DP
S7-400 PG/PC
ET 200L ET 200M ET 200B
weitere Feldgeräte
mit IM 308-C
S5-115
ET 200X OP/OS
S7-200
Antrieb
ET 200eco
ET 200R
Figure 1-1 Typical configuration of a PROFIBUS-DP network

Product Overview
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 1–3
1.2 What is the ET 200R distributed I/O Device?
Definition
The ET 200R distributed I/O device is a DP slave with a protection rating of IP65.
The design permits, among others, direct mounting on the Kempf box for the pro-
cessing of welding signals.
Application area
•Its robust construction and IP65 protection rating make the ET 200R distributed
I/O device exceptionally suited to use in rugged industrial environments.
It was especially developed for use in the raw product manufacturing of the auto-
motive industry.
The ET 200R is used in the following applications:
•On the fixed part of the robot (on the arm) to non-reactively couple or decouple
PROFIBUS and to control or monitor the tool coupling with relatively few digital
inputs and outputs
•On the tool to control and monitor the handling or the welding procedure there
with relatively few digital inputs and outputs and to directly loop through the ana-
log signals of a welding tong to the welding controller. These two models will
now be called handling module and welding module.
•Two versions are available:
- Repeater or handling module (ET 200R-H)
- Welding module (ET 200R-W) – same as the handling module but with floor
hole and place to plug in analog signals SKÜ and KSR as well as tempera-
ture input.
Features of the ET 200R
•Compact design.
•Suitable for rugged industrial environments.
•Non-reactive coupling and decoupling of two PROFIBUS segments via inte-
grated repeater function.
•8 parametrizable digital inputs/outputs and 8 fixed digital inputs.
•Compatible with the Kempf box (splitting box for welding applications).
•The power supply for the electronics and encoder, PROFIBUS-DP and signal
lines are fed in a common cable to the first ET 200R and then on to the next ET
200R in another common cable.
•The PROFIBUS address of the ET 200R can be set from 1 to 99 with two rotary
switches.

Product Overview
Distributed I/O Device ET 200R
1–4 (4)J31069-D0427-U001-A2-7618
•The front of the module has 6 LEDs for indication of functions and errors of the
hardware of the ET 200R.
•Another 16 LEDs indicate the states of the digital inputs and outputs.
•Baud rates from 9.6 kBaud to 12 MBaud can be used for the ET 200R.
•PROFIBUS; galvanical isolated.
DP master for ET 200R
The ET 200R can communicate with all DP masters which behave in accordance
with standard EN 50170, volume 2 (IEC 61158), PROFIBUS. Some DP masters
can only process limited telegram lengths.
Check to determine whether your DP master is able to receive the telegrams from
the ET 200R in the their full length. A list is provided of the maximum telegram
lengths for the configuration and parameterization telegrams for the ET 200R.
See chapter 5.
Figure 1-2 Allocation of the plug connectors and LEDs on the ET 200R
X01
Actuator/
sensor
connections
X0 to X7
Status LEDs
Function LEDs Address setting
for PROFIBUS
X02

Possible Configurations
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 2–1
Possible Configurations
This chapter gives you an overview of possible configurations. The restrictions per-
taining to the number of modules within a configuration are described in a separate
section.
Setup guidelines for PROFIBUS networks
The setup guidelines and information in the manual for SIMATIC NET PROFIBUS
NETWORKS (order no. 6GK1970-5CA20-0AA0) always apply to the setup of a
PROFIBUS network with ET 200R.
In addition the following notes must be adhered to.
Terminating resistance
Terminating resistance must be provided on the first and the last station of a
PROFIBUS-DP network with copper conductors (see chapter 3.3).
Due to the implemented repeater function this terminating resistance is perma-
nently integrated on the ET 200R for every bus segment. This means that when the
ET 200R is used as the last module of the PROFIBUS segment, no external termi-
nating resistance is required.
2.1 Feeding in and connecting through the voltage for
Electronics/Encoders and PROFIBUS-DP
Connection
With the ET 200R all power and signal lines are installed in one cable and connec-
ted to plug connector X01.
The second plug connector (X02) is used for looping through connections.
The pins of X01 and X02 can carry a maximum current of 9 A.
2

Possible Configurations
Distributed I/O Device ET 200R
2–2 (4)J31069-D0427-U001-A2-7618
Feeding in and looping through with one cable:
The power for the electronics, encoder and load are fed together with the
PROFIBUS-DP and other signal lines in one cable to the first ET 200R and then
connected through to the ET 200Rs behind.
Power Supply +
PROFIBUS-DP
ET 200R (DP-Slave 1) ET 200R (DP-Slave 2)
Figure 2-1 Feeding in and connecting through power and PROFIBUS-DP in a hybrid line
2.2 Restriction of the modules which can be connected
Current consumption
The maximum configuration depends on the current consumption of the individual
modules. For more information see the technical data (chapter 7).
Setting the address
The number of modules is limited by the number of addresses which can be set
(1 to 99).
Number of repeaters
Due to the permanently integrated repeater the number of ET 200R devices which
can be installed in one PROFIBUS branch is limited to nine.

Installation
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 3–1
Installation
Caution
To avoid damaging module electronics, all voltages for the ET 200R must be
turned off (i.e., de-energized) before the modules can be installed or removed.
Mounting dimensions
Dimensions of the ET 200R: 54 mm x 150 mm x 55 mm (W x L x H). Including the
X01/X02 screw connections, height is 64 mm.
Settings to be made
The PROFIBUS address is set with 2 rotary switches on the ET 200R module.
When the ET 200R distributed I/O device is the first or the last DP slave in a
PROFIBUS-DP network with copper conductors (RS 485 bus configuration), the
bus does not need to be equipped with a terminal resistor since this is integrated in
the module.
How to install
Depending on which model of the device you have the module is mounted on the
robot arm or on the tool.
You will need the following to mount the module on the Kempf box:
•1 pan head screw (DIN 6912-M4x60)
•2 pan head screws (DIN 6912-M4x54)
If you mount the module in a different place, use screws of the same type. You
must then select the length to meet the requirements.
Mounting position
The ET 200R can be mounted in any position.
3

Installation
Distributed I/O Device ET 200R
3–2 (4)J31069-D0427-U001-A2-7618
3.1 Mounting/Demounting the ET 200R
Mounting the ET 200R
•If necessary, clean coarse soil from the base.
•Mount the module on the 3 mounting positions on the base with Phillips screws.
Tightening moment: 2 Nm (max. of 3 Nm).
Before mounting a welding module on the Kempf box, for example, connect the
transformer signals with the plug connector in the floor opening. Make sure that
the terminal allocation is correct (see chapter 4.2.1).
Caution
Make absolutely sure that the floor seals of the module are in perfect condition.
Otherwise protection rating IP65 is no longer provided.
Demounting the ET 200R
The module is demounted in reverse order.
Dimensional drawing showing the mounting holes
The following figure shows the dimensions for the position of the holes for the
mounting screws for an ET 200R module.
Figure 3-1 Dimensions for the mounting holes

Installation
Distributed I/O Device ET 200R
(4)J31069-D0427-U001-A2-7618 3–3
3.2 Setting/Changing the PROFIBUS Address
The PROFIBUS address specifies the address under which the ET 200R distrib-
uted I/O device will be addressed by the DP master on PROFIBUS-DP.
The PROFIBUS address is set with the two decimal-coded, rotary switches in the
module.
Permissible PROFIBUS address
A PROFIBUS address can from 1 to 125.
Note
On delivery the PROFIBUS address is set to 0. This address must be changed
since it is reserved on the ET 200 distributed I/O system for the PG/PC.
Note
Due to the rotary switch only the addresses 1 to 99 can be set on the ET 200R
module. Valid address area: 3 to 99.
Setting the PROFIBUS address
The rotary switches for setting the PROFIBUS address are located inside the
module behind the metric PG covering caps on the front.
•Unscrew the covering cap and pull it off.
•Set the PROFIBUS address with the rotary switches (see figure 3–3). Set the
tens with the left-hand rotary switch and the ones with the right-hand rotary
switch (for direction of viewing see figure 3–2).
•Screw on the covering cap again. Make sure that the seals are positioned cor-
rectly!
Figure 3-2 Accessing the rotary switches for setting the PROFIBUS address

Installation
Distributed I/O Device ET 200R
3–4 (4)J31069-D0427-U001-A2-7618
Attention
The metric PG covering caps and the seals must be in perfect condition. Otherwise
protection rating IP65 is no longer ensured!
Attention
Do not use the metric covering caps to cover the actuator/sensor connections.
Using the rotary switches
The rotary switches are adjusted with a screwdriver. The point of the arrow indi-
cates the setting.
Tens
5
4
3
2
1
0
9
8
7
6
5
4
3
2
1
0
9
8
7
6
Ones
Figure 3-3 Rotary switches (tens on left-hand switch, ones on right-hand switch )
Changing the PROFIBUS address
The PROFIBUS address is changed using the same procedure you used to set the
address the first time. A changed PROFIBUS address does not take effect until
POWER-OFF/ON on the ET 200R.
3.3 Providing PROFIBUS with terminating resistance
Purpose of the terminating resistance
Both ends of a bus cable (i.e., on the first station and the last station of the net-
work) must be terminated with its impedance.
Due to the implemented repeater function this terminating resistance is perma-
nently integrated on the ET 200R for each bus segment. This means that, when the
ET 200R is used as the first or last module in a segment, no external terminating
resistance is required.