Weidmuller SAI Active Universal Pro Series User manual

SAI Active Universal Pro - Manual
SAI-AU M12 PB GW 16DI
SAI-AU M8 PB GW 16DI
SAI-AU M8 SB 8DI
SAI-AU M12 SB 8DI
SAI-AU M8 SB 8DIO
SAI-AU M12 SB 8DIO
SAI-AU M8 SB 8DO 2A
SAI-AU M12 SB 8DO 2A
SAI-AU M12 SB 4AI
SAI-AU M12 SB 4AO
SAI-AU M12 SB 4THERMO
SAI-AU M12 SB 4PT100
SAI-AU M12 SB 2CNT

Foreword
Foreword
List of revisions
Version Date Change
1.0 04/08 First release
1.1 05/08 Technical data
1.2 07/08 Notes of safety
1.3 05/09 SAI-M8 PB 16DI, Techni-
cal Data, input and output
data, parameter data, di-
agnostic data
1.4 09/09 Plug-in stations, addi-
tional notices
Note on the document
The content of this manual is checked to conform
with the hardware and software described. Since
deviations still may appear, we cannot guarantee
complete conformance. The content of this manual
is regularly checked and necessary corrections are
considered in the next versions. We are grateful for
your improvement proposals.
Contact
Weidmüller Interface GmbH & Co. KG
Postfach 3030
32720 Detmold
Klingenbergstraße 16
32758 Detmold
Phone: [phone]
Fax: [phone]
E-Mail [email protected]
Internet: www.weidmueller.com
5663600000/1.4/09.09 3

Contents
Contents
Foreword ............................................................................................................................3
List of revisions................................................................................................................................................3
Contents.............................................................................................................................4
1. Notes on Safety.....................................................................................................7
1.1 Prescribed Use..................................................................................................................................8
1.2 Qualified staff ....................................................................................................................................8
1.3 Accuracy of the technical documentation......................................................................................8
1.4 CE label ..............................................................................................................................................8
1.5 Declaration of conformity.................................................................................................................8
1.6 Recycling in accordance with WEEE..............................................................................................9
2. SAI Pro.................................................................................................................11
2.1 Pro Description................................................................................................................................12
2.2 PROFIBUS-DP..................................................................................................................................14
3. Project Planning with the Universal Pro ...........................................................15
3.1 Project planning..............................................................................................................................16
3.2 Power supply...................................................................................................................................17
3.3 An example - calculation of power supply ...................................................................................18
4. Mounting SAIs.....................................................................................................21
4.1 Mounting position and mounting dimension...............................................................................22
4.2 Mounting SAI distributors..............................................................................................................24
4.3 Marking / labelling...........................................................................................................................26
4.4 Dismounting the SAI.......................................................................................................................27
5. Connecting the SAI Distributor..........................................................................29
5.1 Gateway I/O for PROFIBUS-DP: SAI-AU M12 PB GW 16DI .........................................................30
5.2 SAI-AU M12 PB GW 16DI................................................................................................................34
5.3 SAI-AU M8 PB GW 16DI..................................................................................................................38
5.4 SAI-AU M8 SB 8DI ...........................................................................................................................42
5.5 SAI-AU M12 SB 8DI .........................................................................................................................46
5.6 SAI-AU M8 SB 8DIO.........................................................................................................................50
5.7 SAI-AU M12 SB 8DIO.......................................................................................................................56
4 5663600000/1.4/09.09

Contents
5.8 SAI-AU M8 SB 8DO 2A....................................................................................................................62
5.9 SAI-AU M12 SB 8DO 2A..................................................................................................................67
5.10 SAI-AU M12 SB 4AI .........................................................................................................................72
5.11 SAI-AU M12 SB 4AO........................................................................................................................77
5.12 SAI-AU M12 SB 4THERMO.............................................................................................................81
5.13 SAI-AU M12 SB 4PT100 ..................................................................................................................85
5.14 SAI-AU M12 SB 2CNT......................................................................................................................89
6. Commissioning the PROFIBUS-DP ...................................................................96
6.1 The device database file (GSD) and bitmap files.........................................................................97
6.2 Copy the GSD files to the local directory .....................................................................................97
6.3 Install the GSD files in Step7 .........................................................................................................98
6.4 Adding an SAI module in the hardware configurator..................................................................99
6.4.1 Adding an Subbus module...............................................................................................101
6.5 Assign the input and output addresses......................................................................................107
6.6 Description of input and output data..........................................................................................108
6.6.1 SAI-AU Mx PB GW 16DI ................................................................................................108
6.6.2 SAI-AU Mx SB 8DI...........................................................................................................108
6.6.3 SAI-AU Mx SB 8DIO........................................................................................................108
6.6.4 SAI-AU Mx SB 8DO 2A ...................................................................................................108
6.6.5 SAI-AU M12 SB 4AI.........................................................................................................109
6.6.6 SAI-AU M12 SB 4AO.......................................................................................................109
6.6.7 SAI-AU M12 SB 4PT100 .................................................................................................110
6.6.8 SAI-AU M12 SB 4THERMO ............................................................................................110
6.6.9 SAI-AU M12 SB CNT.......................................................................................................111
6.7 Configuration and setting parameters........................................................................................113
6.8 SAI parameter data........................................................................................................................114
6.9 Diagnostic telegrams....................................................................................................................121
6.9.1 Diagnostics without channel referred information............................................................121
6.9.2 Diagnostics with channel referred information.................................................................128
6.9.3 Device-related diagnostic data ........................................................................................130
6.9.4 Identification-specific diagnostic data..............................................................................132
6.9.5 Channel-referred diagnostic data ....................................................................................133
6.10 Evaluating diagnostic data in Step7............................................................................................136
5663600000/1.4/09.09 5

Contents
6 5663600000/1.4/09.09
7. LED Displays .....................................................................................................138
7.1 Gateway I/O....................................................................................................................................139
7.2 Extension I/O .................................................................................................................................139
7.3 Layout of LEDs on the gateway I/O PROFIBUS-DP M12...........................................................141
7.4 Layout of LEDs on the gateway I/O PROFIBUS-DP M8.............................................................142
7.5 Layout of the LEDs on the extension I/O 8DI .............................................................................143
7.6 Layout of the LEDs on the extension I/O 8DIO ..........................................................................145
7.7 Layout of the LEDs on the extension I/O 8DO 2 amp................................................................147
7.8 Layout of the LEDs on the extension I/O 4AI .............................................................................149
7.9 Layout of the LEDs on the extension I/O 4AO ...........................................................................150
7.10 Layout of the LEDs on the extension I/O 4PT100......................................................................151
7.11 Layout of the LEDs on the extension I/O 4THERMO.................................................................152
7.12 Layout of the LEDs on the extension I/O 2CNT .........................................................................153
Appendix ........................................................................................................................155
Appendix A: Product Overview...................................................................................................................156
Appendix B: Drilling Templates..................................................................................................................159
Appendix C: Converting from Hexadecimal to Decimal...........................................................................162
Sources .........................................................................................................................................................163
Technical support.........................................................................................................................................163
Index .........................................................................................................................................................164
Glossary ........................................................................................................................................................170

Notes on Safety
1. Notes on Safety
1.1 Prescribed Use..................................................................................................................................8
1.2 Qualified staff ....................................................................................................................................8
1.3 Accuracy of the technical documentation......................................................................................8
1.4 CE label ..............................................................................................................................................8
1.5 Declaration of conformity.................................................................................................................8
1.6 Recycling in accordance with WEEE..............................................................................................9
5663600000/1.4/09.09 7

Notes on Safety
8 5663600000/1.4/09.09
1.1 Prescribed Use
WARNING: Danger
- Using this product beyond the specifi-
cations or disregard of using instructions
and warnings may cause grave malfunc-
tions so that personal injury and material
damages occur.
- In the case of malfunction or failure of
the SAI Module cannot be predicted the
behaviour by other connected devices of
an arrangement. Personal damages and
material damages can occur. Make only
settings, if you are informed exactly
about all effects in the whole arrange-
ment.
NOTE
This device is intended for use in appli-
cations as described in the operating in-
structions only. Any other form of usage
is not permitted and can lead to acci-
dents or destruction of the device. Any
misuse will lead immediately to the ex-
piry of all guarantee and warranty claims
on the part of the operator against the
manufacturer.
1.2
Qualified staff
These operating instructions have been written for
trained and qualified personnel who are familiar with
the valid regulations and standards applicable to the
field of application.
1.3 Accuracy of the technical
documentation
These operating instructions have been written with
due care and attention. However, unless otherwise
required by law we do not guarantee that the data,
images and drawings are accurate or complete nor
do we accept liability for their contents. Weidmuel-
ler’s general terms and conditions of sale apply in
their respective valid form.
Subject to alteration without notice.
1.4 CE label
This product fulfils the guidelines issued by the
European Union (EU) and is therefore entitled to
carry the CE mark.
1.5 Declaration of conformity
The product fulfils both the Low Voltage Directive
73/23/EEC and the EMC Directive 89/336/EEC.

Notes on Safety
1.6 Recycling in accordance with WEEE
Disposal B2B (Business-to-Business)
Dear Weidmueller customer, by purchasing this
product you have the possibility to return the device
to Weidmueller at the end of its life cycle.
WEEE (EU-regulation 2002/96EG)
regulates how electric devices have to
be taken back and recycled. Since Au-
gust 13 2005 in range of B2C (Busi-
ness to Business) manufacturers of
electric devices that have been sold af-
ter the mentioned date are bound to
take back the devices free of charge
and to recycle them. Electric devices
must not be put to ordinary waste dis-
posal.
Electric devices have to be recycled and to be dis-
posed separately. All devices that fall under these
regulations are marked with this logo.
What can we do for you?
Weidmueller offers a possibility to return your old
device to us free of charge. Weidmueller will recycle
your device according to current law.
What do you have to do?
When your device has reached its life cycle, just
send to your Weidmueller distribution service it using
the parcel service. We will assume all recycling and
pollution abatements. There won’t be any costs or
inconveniences for you.
Disposal B2C (Business-to-Customer)
Dear Weidmueller customer, by purchasing this
product you have the possibility to return the device
to Weidmueller at the end of its life cycle.
WEEE (EU-regulation 2002/96EG)
regulates how electric devices have to
be taken back and recycled. Since Au-
gust 13 2005 in range of B2C (Busi-
ness to Customer) manufacturers of
electric devices that have been sold af-
ter the mentioned date are bound to
take back the devices free of charge
and to recycle them. Electric devices
must not be put to ordinary waste dis-
posal.
Electric devices have to be recycled and to be dis-
posed separately. All devices that fall under these
regulations are marked with this logo.
What can we do for you?
Weidmueller offers a possibility to return your old
device to us free of charge. Weidmueller will recycle
your device according to current law.
5663600000/1.4/09.09 9

Notes on Safety
10 5663600000/1.4/09.09

SAI Pro
2. SAI Pro
2.1 Pro Description................................................................................................................................12
2.2 PROFIBUS-DP..................................................................................................................................14
5663600000/1.4/09.09 11

SAI Pro
2.1 Pro Description
The acronym SAI stands for Sensor – Actuator –
Interface. It is a compact-designed distributor or col-
lector of signal lines.
The SAI Active Universal Pro supplements compact
stand-alone devices with extendable sub-bus mod-
ules.
A Pro System consists of a gateway I/O module and
one or more extension I/O modules.
The gateway I/O is connected to the higher-level
Fieldbus and supplied with power. The gateway I/O
is also the starting point for the sub-bus. With M8
cables, up to fifteen extension I/O modules can be
connected sequentially.
There is a large selection of gateway I/Os for the
common Fieldbus standards. There are also many
different functions within the extension I/O modules.
The maximum expandability of the sub-bus network
is limited by the voltage drop over the line. A de-
tailed explanation of this is included in the manual.
The Pro System is represented as a modular device
in the hardware configuration on the SPS or IPC.
The Fieldbus address and the number and type of
extension I/O modules must be entered here. This
can easily be done with the configuration files which
are available for download from the Weidmueller
homepage.
The gateway I/O consists of the following compo-
nents:
•An I/O section: to connect the signal lines
•A settings section: to set the PROFIBUS-DP ad-
dresses and insert the jumpers for the different
electric potentials.
•A bus / power section: to connect and loop-
through the supply voltage, the Fieldbus interface,
and the sub-bus connection.
Figure 1 Basic design of the gateway I/O
A I/O section
B Settings range
C Bus / power section
Weidmueller offers the following gateway I/O
versions:
•PROFIBUS-DP gateway with 16 digital inputs
•DeviceNet gateway with 16 digital inputs
•Modbus TCP with 16 digital inputs
•USB / Modbus gateway (Modbus ASCII) with 16
digital inputs and 8 digital outputs
12 5663600000/1.4/09.09

SAI Pro
5663600000/1.4/09.09
Weidmueller offers the following extension I/O
versions: The extension I/O consists of the following com- ponents:
•8 digital inputs with M12 I/O connector •An I/O section: to connect the signal lines
•8 digital inputs with M8 I/O connector •A bus / power section: 2 sub-bus connections and
an extra power-supply plug for the digital output
modules
•8 digital 2A outputs with M12 I/O connector
•8 digital 2A outputs with M8 I/O connector
•8 digital inputs or 0.5A outputs with M12 I/O con-
nector
•8 digital inputs or 0.5A outputs with M8 I/O con-
nector
•4 analogue inputs with M12 I/O connector
•4 analogue outputs with M12 I/O connector
•4 thermal inputs with M12 I/O connector
•4 PT100 inputs with M12 I/O connector
•2 counter inputs with M12 I/O connector
System structure of the Universal Pro
•Max. no. of slaves: 15 Figure 2 Basic design of the extension I/O
•Bus structure: Line A I/O section
•Max. expansion: 10 – 50m B Bus / power section
•Addressing: automatic
13

SAI Pro
2.2 PROFIBUS-DP
PROFIBUS
PROFIBUS (PROcess Field BUS) is a part of the
international standards IEC 61158 and IEC 61784.
Physically, PROFIBUS is either an electrical network
based on a shielded, two conductor cable or an opti-
cal network based on a fibre optics cable.
PROFIBUS-DP (DP = Decentralised Periphery) is a
special application for automating factory production.
System
A typical PROFIBUS-DP system is made up of
•at least one PLC or industrial PC (master) operat-
ing as a control system
•various field devices, which can be digital or ana-
logue I/O devices, AC or DC drives, magnetic or
pneumatic valves, frequency converters, starters,
operating and display devices (slaves)
Data transfer
Data exchange within the system is carried out by
means of cyclic polling. The master establishes
communications with one slave at a time, makes
data available and/or requests data. The slave being
addressed responds immediately to the request for
data. Once completed, this procedure is repeated
with the other slave devices. This is a continuous
cyclic process.
GSD files (device database files)
The GSD file is the obligatory "ID card" of each and
every PROFIBUS device. It contains the characteris-
tic data of the device, details about its communica-
tion capabilities as well as further information such
as diagnostic values. All GSD files for the SAI Active
Universal range of SAI distributors can be
downloaded from Weidmueller’s website at:
http://www.weidmueller.com/54266/Downloads/Soft
ware/SAI-Active-Data/cw_index.aspx?newsid=
For more information, please refer to
Chapter “Commissioning the PROFIBUS-
DP”.
Figure 3 Basic PROFIBUS system configuration
14 5663600000/1.4/09.09

Project Planning with the Universal Pro
3. Project Planning with the Universal Pro
3.1 Project planning..............................................................................................................................16
3.2 Power supply...................................................................................................................................17
3.3 An example - calculation of power supply ...................................................................................18
5663600000/1.4/09.09 15

Project Planning with the Universal Pro
3.1 Project planning
Planning the bus system
The following steps must be taken into consideration
when designing an installation:
1 Location of the machine or facility
2 Assignment of the signals to the installation to a
logical group
3 Selection of the field devices
4 Assignment of the signals to the field devices
5 Determination of where the field devices are to
be installed
Criteria for determining the correct SAI distributor:
Size of the connectors Determine the size of the connectors to suit you application, the de-
sign of the sensors or according to your personal preferences.
Weidmueller offers both M12 and M8 variants for purely digital sig-
nals.
Number of poles of the I/O connec-
tions Please consider the sensor/actuator cable to be connected; possi- ble options are 3 or 5 poles.
T-piece Specifically for 5-pole M12 sensor connections, you can feed two
cables to a distributor input by means of a Y-piece.
Inputs / outputs Weidmueller has a variety of SAI distributors on offer such as a
variant with 16 digital inputs, with mixed digital inputs/outputs as
well as an analogue/digital version (for more information please re-
fer to Chapter 4: (Connecting SAIs).
Shielding Shielding by means of metal connectors is necessary for bus con-
nections. We recommend the same approach for analogue signals
to restrict the susceptibility to interference.
Signals Please consider if you wish to transmit analogue or digital signals.
Table 1 Determining the correct SAI distributor
You can find more information about determining the correct selection of products in Appendix A:
Product Overview.
16 5663600000/1.4/09.09

Project Planning with the Universal Pro
3.2 Power supply
Gateway I/O
The gateway I/O modules are supplied with power
by an M12 A-encoded connector. With this you can
provide power to two different potentials. These
voltages can be connected with the help of a jumper
in the address range.
Extension I/O without outputs
These modules get their power supply from the 4-
pole M8 combi-cable. The electronics and the inputs
are both supplied with this UI potential.
Extension I/O with outputs
The modules with digital outputs are easy to identify
with their extra M12 plug. This is where the power is
fed in for the outputs. The electronics and the inputs
are also supplied with the M8 combi-cable.
CAUTION
No external voltage should be applied to
the outputs.
Current carrying capacity
The connector can carry up to 3 A DC per pin. This
limits that total number of loads on a sub-bus sys-
tem.
In order to calculate the required current, the follow-
ing values must be added up:
•The power consumption of the extension I/O mod-
ule
•The current requirement of each individual input
Current requirement of the extension I/O mod-
ules
1938600000 The 8DI M8 sub-bus
module 50mA
1938610000 The 8DI M12 sub-bus
module 50mA
1938630000 The 8DI/DO M8 sub-bus
module 50mA
1938640000 The 8DI/DO M12 sub-
bus module 50mA
1938660000 The 8DO M8 2A sub-
bus module 50mA
1938680000 The 8DO M12 2A sub-
bus module 50mA
1938690000 The AI M12 sub-bus
module 50mA
1938700000 The AO M12 sub-bus
module 50mA
1938710000 The PT100 M12 sub-
bus module 50mA
1938720000 The Thermal M12 sub-
bus module 50mA
1938730000 The Counter M12 sub-
bus module 50mA
Table 2 Current requirement of the extension
I/O modules
Please refer to the sensor manufacturer's data
sheet, for the current requirement of the sensors.
The maximum current-carrying capacity of the digital
inputs in 50 mA.
CAUTION
The residual current should not be more
than 3 amps higher than the max. cur-
rent-carrying capacity of the connector.
5663600000/1.4/09.09 17

Project Planning with the Universal Pro
18 5663600000/1.4/09.09
Voltage drop / max. expansion
The maximum expansion of the sub-bus system de-
pends on four factors:
•The number of stations
•The distance between stations
•The current load of each participant and there in-
puts
•The resistance of the wires in use
The following formula results:
Voltage drop of the line =
current consumption of module x (line resistance x
line length x 2)
Total voltage drop =
voltage drop of line 1 + voltage drop of line 2 + volt-
age drop of line x
Voltage on last module =
Supply voltage to gateway I/O - 0.9V - total voltage
drop
Result:
When voltage to last module is greater then 18V DC
= Okay
When voltage to last module is less than 18V DC =
Not okay
We have made available a software tool to help you
calculate the residual current and voltage drop. It
can be downloaded from the Weidmueller home-
page at www.weidmueller.com.
3.3 An example - calculation of
power supply
A sub-bus system should be set up for 45 sensors
and 14 actuators. The extension distance is 30 m.
The following modules have been selected:
1 x 1938550000 Gateway IO Module 16DI M12
6 x 1938610000 Extension IO Module 8DI M12
2 x 1938640000 Extension IO Module 8DI/DO M12
1 x 1938680000 Extension I/O Module 8DO M12 2A
All sensors consume 10 mA current each.
No. Cat. No. Current for module Current for sensors Total current
1 1938610000 50 mA 6 x 10 mA = 60 mA 110 mA
2 1938680000 50 mA 50 mA
3 1938610000 50 mA 6 x 10 mA = 60 mA 110 mA
4 1938610000 50 mA 6 x 10 mA = 60 mA 110 mA
5 1938640000 50 mA 4 x 10 mA = 40 mA 90 mA
6 1938610000 50 mA 6 x 10 mA = 60 mA 110 mA
7 1938640000 50 mA 4 x 10 mA = 40 mA 90 mA
8 1938610000 50 mA 6 x 10 mA = 60 mA 110 mA
9 1938610000 50 mA 6 x 10 mA = 60 mA 110 mA
Table 3 Current consumption of the modules

Project Planning with the Universal Pro
Figure 4 Example of system structure
The cable length of the sub-bus line:
between the modules
1 and 2 = 10 m = L1
2 and 3 = 5 m = L2
3 and 4 = 0.3 m = L3
4 and 5 = 0.3 m = L4
5 and 6 = 4m = L5
6 and 7 = 0.3 m = L6
7 and 8 = 0.3 m = L7
8 and 9 = 10 m = L8
9 and 10 = 1 m = L9
The max. residual current on the sub-bus line is the
sum of all currents and in this example is 0.89A.
Thus the max. current-carrying capacity of 3A is not
reached.
Voltage drop L9 = 0.011 V
110 mA x (0.05 Ohm/m x 1 m x 2)
Voltage drop L8 = 0.22 V
(110 mA + 110 mA) x (0.05 Ohm/m x 10 m x 2)
Voltage drop L7 = 0.0093 V
(90 mA + 110 mA + 110 mA) x (0.05 Ohm/m x 0.3 m
x 2)
Voltage drop L6 = 0.0126 V
(110 mA + 90 mA + 110 mA + 110 mA) x (0.05
Ohm/m x 0.3 m x 2)
Voltage drop L5 = 0.204 V
(90 mA + 110 mA + 90 mA + 110 mA + 110 mA) x
(0.05 Ohm/m x 4 m x 2)
Voltage drop L4 = 0.0186 V
(110 mA + 90 mA + 110 mA + 90 mA + 110 mA +
110 mA) x (0.05 Ohm/m x 0.3 m x 2)
Voltage drop L3 = 0.0219 V
(110 mA + 110 mA + 90 mA + 110 mA + 90 mA +
110 mA + 110 mA) x (0.05 Ohm/m x 0.3 m x 2)
Voltage drop L2 = 0.39 V
(50 mA + 110 mA + 110 mA + 90 mA + 110 mA +
90 mA + 110 mA + 110 mA) x (0.05 Ohm/m x 5 m x
2)
Voltage drop L1 = 0.89 V
(110 mA + 50 mA + 110 mA + 110 mA + 90 mA +
110 mA + 90 mA + 110 mA + 110 mA) x (0.05
Ohm/m x 10 m x 2)
Total voltage drop = 1.7774 V
0.89 V + 0.39 V + 0.0219 V + 0.0186 V + 0.204 V +
0.0126 V + 0.0093 V + 0.22 V + 0.011 V
Voltage at module 9 = 21.3226 V
24 V – 0.9 V – 1.7774 V
Voltage at module 9 is greater than 18V DC →Okay
5663600000/1.4/09.09 19

Project Planning with the Universal Pro
20 5663600000/1.4/09.09