Siemens SIMATIC S5 User manual

Notes for the Reader 1
IP 244 (-3AA22) Temperature
Controller Instructions 2
IP 244 B (-3AB31) Temperature
Controller Instructions 3
IP 244
Programming Instructions 4
FB 162 (64 Messages)
Programming Instructions 5
Test Program with FB 162
Utilization in S5 6
IP 244
Utilization in S7-400 7
IP 244
Checklist for Start-Up 8
Glossary 9
Index 10
Pocket Guide 11
C79000-G8576-C858-02
IP244
Temperature Controller
with Function Block FB 162
Manual
SIMATIC S5 and S7

SIMATICand SINECare registered trademarks of SIEMENS AG.
This manual contains notices which you should observe to ensure your own personal safety,
as well as to protect the product and connected equipment. These notices are highlighted in
the manual by a warning triangle and are marked as follows according to the level of danger:
!Gefahr
indicates that death, severe personal injury or substantial property damage
will result if proper precautions are not taken.
!Warnung
indicates that death, severe personal injury or substantial property damage
can result if proper precautions are not taken.
!Vorsicht
indicates that minor personal injury or property damage can result if proper
precautions are not taken.
Hinweis
draws your attention to particularly important information on the product, handling the pro-
duct or to a particular part of the documentation.
Only qualified personnel should be allowed to install and work on this equipment. Qualified
persons are defined as persons who are authorized to commission, to ground and to tag
equipment, systems and circuits in accordance with established safety practices and stan-
dards.
Note the following:
!Warnung
This device may only be used for the applications described in the catalog or technical
description, and only in connection with devices or components from other manufacturers
which have been approved or recommended by Siemens.
This product can only function correctly and safely if it is transported, stored and set up
carefully and correctly, and operated and maintained as recommended.
Copyright Siemens AG 1995 All Rights Reserved
The reproduction, transmission, or use of this document or its
contents is not permitted without express written authority. Offenders
will be liable for damages. All rights, including rights created by
patent grant or registration of a utility model or design, are reserved.
Siemens AG 1995 6ES5998-2AB24
Disclaimer of Liability
We have checked the contents of this manual for agreement with the
hardware and software described. Since deviations cannot be
precluded entirely, we cannot guarantee full agreement. However, the
data in this manual are reviewed regularly and any necessary
corrections included in subsequent editions. Suggestions for
improvement are welcomed.
Technical data subject to change.
Safety
guidelines
Qualified personnel
Correct usage

Notes for the Reader
1 - 3
IP244
C79000–D8576–C858–02
Notes for the Reader
This manual describes
the SIMATIC S5 temperature controller module IP 244
the software package FB 162 and the test program for the temperature controller module
The software is on the accompanying diskette and comprises the following parts:
– organization blocks OB 1, 20, 21, 22
– function block FB 62, 63, 162
– data blocks DB 162, 163, 164, 172, 173
The software package and IP 244 module combine to form a unit for machine controls in pro-
cess control applications.
To familiarize you with the application of the temperature controller and to make information as
accessible as possible, the manual has been divided into several separate functional sections.
Definitions of process control terms used in the manual can be found in the glossary.
Part 2 Instructions for the IP 244 describes the hardware requirements. This part
describes the environment in which the module can be used and explains the
required connections.
Part 3 Programming Instructions for the IP 244 describes the function of the firm-
ware on the module and how to program the module. Using this desription, you
can calculate the required parameters and structure them for the data ex-
change between the programmable controller and the module.
Part 4 Programming Instructions for the Function Block FB 162 (64 messages)
describes the program package with which you can operate the IP 244
temperature controller module.
Part 5 You can use the Test Program for the IP 244 Temperature Controller
Module (FB 62, 63) to test the complete operation of the IP 244.
Part 6 Checklist for Start-Up provides notes about the step-by-step installation and
start-up of the hardware and software for the IP 244 temperature controller.
Part 7 In the Glossary you can find definitions of process control terms used in the
manual.
Part 8 The Index helps you to find the section in the manual you need quickly and
easily by means of key words.
Part 9 The Pocket Guide ”IP 244 Temperature Controller with Function Block FB 162”
provides you with an overview of all messages and the assignment of the data
blocks DB-A, DB-B and DB-C. It serves as a practical guide to help you create
and enter parameters.

Notes for the Reader
IP244
C79000–D8576–C858–02
1 - 4
The following procedure is recommended for problem-free installation and start-up:
Load the contents of the supplied diskette into the CPU of the programmable
controller using the programmer. Then enter a parameter set.
The function block can then be used to transfer the parameters to the tempera
ture controller module. You can now test individual functions and start control
functions by connecting analog signals.
Using FB 162, communication and data exchange is now possible with the
temperature controller module. Temperature control is of course only possible
when the module has been completely wired up.
Once the module has been successfully installed, you can transfer programs from blocks OB 1,
20, 21, 22 and FB 62, 63 to your user program. You are then also in a position to modify data
blocks DB 162, 163 and 164 to suit the requirements of your system.
The following figure shows possible combinations between the IP 244 and the function block FB
162 in all versions delivered so far:
Versions of
the IP 244 Versions of the FB 162
FB 162
32 messages
FB 162
64 messages
version I
FB 162
64 messages
version II
6ES5 244–
3AA21
6ES5 244–
3AA22
6ES5 244–
3AA13
6ES5 244–
3AA22
6ES5 244–
3AB31 FC 162 for S7-400

Contents
IP244
C79000–B8576–C859–02
2–2
Contents Page
1 Technical Description 2–3
1.1 Application 2–3
1.2 Design 2–3
1.3 Mode of Operation 2–5
1.4 Technical Data 2–7
2 Installation and Operation 2–11
2.1 Inserting and Removing the Module 2–11
2.2 Connecting Signal Lines and the Power Supply 2–11
2.2.1 Analog Inputs (Plug Connector X3) 2–11
2.2.2 Digital Outputs and One Digital Input (Socket Connector X4) 2–12
2.3 Slots 2–14
2.4 Wiring between the PLC and the Plant 2–15
3 Operation 2–19
3.1 Configuring and Connecting the Analog Inputs 2–19
3.1.1 Wiring the Inputs for Channels 0 to 12 when Connecting Thermocouples 2–19
3.1.2 Wiring the Inputs for Channels 13 and 14 to Connect Transducers 2–21
3.1.3 Wiring the Inputs for Channel 15 (Compensation Channel) 2–22
3.1.4 Using the Module for Resistance-Type Sensors (Pt 100) 2–24
3.1.5 Configuring Analog Inputs 0 to 6 2–25
3.1.6 Configuring Analog Inputs 7 to 14 (15) 2–25
3.1.7 Line Break Monitoring 2–26
3.2 Digital Outputs and Comparator Channel 2–26
3.2.1 Digital Outputs 2–26
3.2.2 Comparator Channel 2–26
3.3 Interface to the CPU 2–27
3.4 Jumpers, Switches and Resistors RS and RP 2–28
3.4.1 Setting the Module Address 2–32
3.4.2 Setting the Conversion Time Per Channel 2–33
3.4.3 Setting the Clock 2–34
3.4.4 BASP Evaluation 2–34
3.5 Pin Assignment 2–35
3.6 Pin Assignment of Connecting Cables 2–35
4 Spare Parts 2–37

Technical Description
2–3
IP244
C79000–B8576–C859–02
1 Technical Description
1.1 Application
The IP 244 temperature controller can be used in SIMATIC S5-115U, S5-135U and S5-155U
programmable controllers and expansion units as an intelligent I/O module for automatic control
of machines. When used in the S5-115U, an adapter casing is required (order number:
6ES5 491-0LA11). The IP 244 module is used in S5 systems not only for temperature control
but also for measured value acquisition and limit value monitoring of analog transmitter signals.
The manipulated variables output by the controller are digital. One special application of the
module is in the temperature control of plastic injection molding machines and monitoring the
injection pressure and mold clamping force.
The module is configured as follows:
either: – 15 analog input channels to connect voltage sensors directly.
When delivered, channels 0 to 12 are prepared for thermocouples
(0 to 51.2 mV)
Channels 13 and 14 are used to acquire transducer signals    
Channel 15 is used as a compensation channel for thermocouples and is
suitable for the direct connection of a Pt 100 resistance thermometer
or: – 8 analog input channels for connecting resistance-type sensors
directly using a 4-wire connection (0 to 512 mV)
– A comparator output and 17 digital output channels to output the manipulated variable of the
controller (pulse-duration modulated). Actuators can be operated directly (rated output
current).
– Automatic controller for up to 13 control loops.
– Control function independent of the status of the CPU of the PLC.
1.2 Design
The IP 244 temperature controller module is a compact module in a double-height Eurocard
format belonging to the ES 902 packaging system with a 48-pin backplane connector. The
backplane connector is the interface to the SIMATIC S5 bus.
The front panel contains a 37-pin socket connector for the analog inputs (X3)
L+ (24 V load voltage) is supplied via a tab connector on the front panel, L– is connected to the
reference potential of the controller (central grounding point in the cabinet). L– is supplied to the
module via the Mext pin (external chassis).
20 green LEDs on the front panel indicate the operating status of the temperature controller
module, the input and outputs. A red LED indicates that one or more digital outputs are
short-circuited.

Technical Description
IP244
C79000–B8576–C859–02
2–4
So ket onne tor with 1
digital input (DI) and 17
digital outputs (DQ) and 1
omparator output
R = run LED lit when
module is in operation
E = on LED lit when
ontroller is in operation
i.e. signal 1 at input
K = omparator LED lit
when input voltage on
hannel 13 is greater
than the preset
threshold voltage (see
Se tion 3.2.2)
Plug onne tor with
15 analog inputs (AI)
(13 thermo ouple inputs,
2 transdu er inputs)
and
1 ompensation hannel
Controller
Operation
Short ir uit indi ator
(red)
K
16
14
12
10
8
6
4
2
U
L+
X4
DA
AE
X3
Fig 1.2/1 Front panel

Technical Description
2–5
IP244
C79000–B8576–C859–02
1.3 Mode of Operation
As shown in the block diagram (Fig. 1.3/1), the analog input signals are switched to an analog
to digital converter (ADC) by a multiplexer. With a maximum conversion time of 80 ms, the ADC
digitalizes the input voltage using the dual slope technique. The 13 control loops (8 with Pt 100
sensors) are processed cyclically. Before the voltage is digitalized, the signal lines are checked
for line breaks and any detected faults are signalled.
A line break is recognized when the total line resistance is greater than 1 kohm or when the
transmitter (thermocouple or resistance-type sensor) has a contact resistance greater than 1
kohm compared with the reference potential. If voltage dividers or shunt resistors are used to
adapt the measuring range, no line break can be signalled. When delivered, no line break signal
is possible for channels 13 and 14.
The parameters and control commands transferred from the CPU via the data bus are stored in
a 2048 byte RAM area which is divided into 64 messages each 32 bytes long. The module
occupies 32 bytes in the address area of the PLC.
A microprocessor controls the functions of the controller module according to the firmware
which is stored in a 64 Kbyte EPROM.
The calculated manipulated variables are output in digital form (pulse-duration modulated) to
output drivers via an output register. If the 5 V power supply fails, the module is reset.
If the 24 V load voltage fails, the module continues to operate; the digital outputs can, however,
no longer be activated. The NAU (power failure) signal is not evaluated by the module.
The digital outputs can be disabled with the BASP signal, the content of the registers is retained
(see Section 3.4.4 BASP Evaluation).
The controller’s integrator values are buffered if the IP 244 controller module is inserted in a slot
with battery back-up (UBATT). The presence of battery back-up is detected by the module
automatically.

Technical Description
IP244
C79000–B8576–C859–02
2–6
The various functions of the controller module are processed by the microprocessor:
– measured value acquisition via multiplexer and ADC
– measured value processing according to the control algorithm, (system error formation,
manipulated variable calculation, self-optimization)
– monitoring limit values of measured values and generation of interrupts
– output of manipulated variables via registers and output drivers
– calculation of the temperature compensation value according to the reference junction
temperature (Pt 100)
– comparison of an analog input value with a digital value (limit value monitoring disabled)
– controlling the interface to the S5 system bus
LED
red ( )
Comparator
M1
M13-
L -
LED (K)
DA
L+
DQ 18
(K)
Differential
amplifier
5Ćbit
subĆaddresses
0
Channel no.
LED
(E)
15
1


7
Pt 100
Digital inputControl ON/OFF
L +
LED 1
    
     
R/W
13 BASP
Module address
8


14
LED
(R)
Analog signal
distribution
Wire break
detecton
internal data bus
Output
drivers
Semiconductor
multiplexer
Address
8/12Ćbit
address
+PESP
A
D
Register
17 Bit
P
Interface
logic
Collision
control
LED 17
DA 1DA17
EPROM
RAM
8Ćbit
data
Data/address
selection
S5 bus
D
A
Fig. 1.3/1 Block diagram of the temperature controller 244-3AA22
The module can be operated as a switching two or three step controller with percentage output
according to the control algorithm stored in the EPROM.
The controller action (P, PI, PD, PID) is selected by inputting the appropriate parameters. Data
(setpoints and parameters) is exchanged between the CPU and the temperature control module
by means of 64 messages each with a length of 32 bytes.

Technical Description
2–7
IP244
C79000–B8576–C859–02
1.4 Technical Data
Analog inputs
Number of input channels and input voltages:
as delivered
–0 to 51.2 mV = 2048
units for thermocouples 13 (channels 0 to 12)
–0 to 20.48 V = 2048 E 2 (channels 13 and 14)
–for Pt 100 resistance thermometer in 3-wire connection
to compensate the reference junction temperature 1 (channel 15)
configurable
–0 to 512 mV = 2048 units
for resistance-type sensor in 4-wire connection
or
0 to 999 mV = 3997 units
for voltage sensors
 
15 
–selectable current/voltage ranges by means
of soldered divider/shunt resistors 9 (channels 7 to 15)
Temperature ranges:
FE-constantan (type L and type J) 0 to 700 C
NiCr-Ni (type K) 0 to 1200 C
Pt 10 % Rh-Pt (type S) 0 to 1600 C
Pt 13 % Rh-Pt (type R) 0 to 1600 C
Pt 100 0 to 830 C
reference junction via Pt 100 –20 to +60C
Auxiliary current for resistance measurement 2.56 mA
Isolated no
Permissible potential difference between sensor
and reference potential of the controller (UCM) < 1 V pp
Max. permissible input voltage without damage 18 V for channels without
series and shunt resistors
 60 V for channels 13 and
14 as supplied
0 V for channel 15 (only for
passive sensors) as supplied
Input resistance
–for 0 to 51.2 mV or 512 mV > 10 Mohm
–for 0 to 20 V > 50 kohm
Errors, related to rated value (internal)
linearity 1 unit
digitalization error 1 unit
polarity reversal error 1 unit
Interference suppression for 50/60 Hz
–mains frequency with common mode interference –86 dB, max. 1 Vpp
–with series mode interference 40 dB, max. 100 % of the
measuring range, relative to
the peak value