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Siemens SIMATIC Power Line Booster Operating Instructions Manual

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SIMATIC
Power Line Booster
Operating Instructions
V2.00
11/2019
A5E36203125A-AG
Introduction
Device description
Plant planning
Plant installation
PROFINET/Ethernet
System configuration and
system status (web
interface)
Maintenance and service
Technical specifications and
approvals
Order numbers
1
2
3
4
5
6
7
8
9

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Summary of Contents for Siemens SIMATIC Power Line Booster

  • Page 1 Introduction Device description Plant planning SIMATIC Plant installation Power Line Booster PROFINET/Ethernet System configuration and system status (web Operating Instructions interface) Maintenance and service Technical specifications and approvals Order numbers V2.00 11/2019 A5E36203125A-AG...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of contents Introduction ............................. 7 Preface ............................7 System overview and introduction .................... 7 Rated conditions ........................10 Insulation ..........................10 Device description ..........................11 Introduction ..........................11 PLB Basic module ........................12 2.2.1 Reset button ..........................13 2.2.2 DIP switches ...........................
  • Page 4 Table of contents 3.6.1 Startup time ..........................45 3.6.2 Registration and transfer times ....................46 Data rate ..........................46 Plant installation ............................ 47 Cables in the powerline system and their shielding ............... 47 Rail connection of master and carrier power supply .............. 48 Connection of the PLB slave ....................
  • Page 5 Table of contents 6.2.1 Home page - System overview ....................80 6.2.2 Error status and warnings of the device ................. 81 6.2.3 Versions ..........................84 6.2.4 Log tables ..........................85 System ............................ 87 6.3.1 Restart & reset ........................87 6.3.2 Update ............................
  • Page 6 Table of contents Technical specifications and approvals ....................125 Technical specifications ....................... 125 8.1.1 Mechanics ..........................125 8.1.2 Shock values ........................126 8.1.3 Electrical characteristic values ..................... 126 8.1.4 MTBF ........................... 127 8.1.5 Climate ..........................127 Approvals ..........................127 8.2.1 CE conformity ........................

  • Page 7: Introduction

    Introduction Preface Purpose of the manual This manual describes the hardware and software components of the Power Line Booster system (PLB system). This manual provides information based on the requirements as defined by DIN EN 82079-1 regarding mechanical engineering documentation. This information relates to the place of use, transport, storage, installation, use and maintenance.
  • Page 8 Note If you have any questions regarding system design and installation, feel free to contact the technical support for the Power Line Booster (plb-support.industry@siemens.com (mailto:plb-support.industry@siemens.com)) or your local Siemens representative. The typical configuration of a Power Line Booster application is shown in the figure below.
  • Page 9 Introduction 1.2 System overview and introduction SIMATIC Controller legend: PLB Master PROFINET Powerline PLB TC PLB TC Powerline medium (Rail / Cable) vehicle vehicle PLB Slave PLB Slave devices Figure 1-1 Design example of a Power Line Booster system Technology The Power Line Booster uses communication technology that can be used to implement the transmission of Ethernet-based frames, especially PROFINET, over power cables and/or control cables.

  • Page 10: Rated Conditions

    Introduction 1.3 Rated conditions range from about 2 MHz up to about 28 MHz. By the same token, the device demodulates the data telegrams it receives from the other end. Rated conditions ● The operation of Power Line Booster devices in public supply networks is not permitted. ●...

  • Page 11: Device Description

    Device description Introduction You usually need the following components to implement a Power Line Booster system: ● Power Line Booster Module (PLB BM) as master and slave (see PLB Basis (Page 12)) with a Power Line Booster Modem Module (PLB MM) (see PLB Modem Module (Page 24)) and a BusAdapter (Page 21) ●...

  • Page 12: Plb Basic Module

    Device description 2.2 PLB Basic module Accessories include the 24 V DC power supply connection plug ➆ and the powerline connection plug ➇. You have the option to equip the Power Line Booster with ● the label ➄, ● the shield ➅ and ●...

  • Page 13: Reset Button

    Device description 2.2 PLB Basic module 2.2.1 Reset button The Factory RESET (FRES) button is located on the bottom of the PLB. Figure 2-3 FRES button Figure 2-4 Position of the FRES button Keeping the FRES button pressed for more than 5 seconds, results in a restart and the factory settings are restored on the device.

  • Page 14: Dip Switches

    Device description 2.2 PLB Basic module 2.2.2 DIP switches Figure 2-5 DIP switches No settings are necessary (factory state) when you use the Power Line Booster as slave. To use the PLB as master, however, you must set the DIP switch "M/S" accordingly. In some special cases, you may have to make additional settings.

  • Page 15: Led Display

    Device description 2.2 PLB Basic module By setting the channel you can separate communication on a logical level. Only devices (master and slaves) with identical channel settings can communicate with each other in a plant. Table 2- 2 Set master/slave operating mode Power Line Booster in slave operating mode Power Line Booster in master operating mode Table 2- 3...
  • Page 16 Device description 2.2 PLB Basic module Table 2- 4 LED PLB BM LED labeling Color State Description Meaning Green 24 V supply missing or too low Power LED test for about 0.5 s during startup 24 V supply PWR PL Green Normal operation Power - powerline...

  • Page 17: Slots

    Device description 2.2 PLB Basic module LED labeling Color State Description Meaning Note: If all LEDs are flashing permanently at a frequency of 1 Hz, you are dealing with a configuration or device fault. Changing the DIP switch settings 2.2.4 Slots ①...

  • Page 18: Power Supply Connection

    Device description 2.2 PLB Basic module 2.2.5 Power supply connection Figure 2-8 24 V DC power supply port X80 Terminal Connection X80.1 + 24 V DC (SELV or LV/C) X80.2 2.2.6 Powerline connection Figure 2-9 Powerline port X2 Terminal Connection Name X2.1 42 V AC...

  • Page 19: Plb Firmware Update

    Device description 2.2 PLB Basic module 2.2.7 PLB firmware update You can update the Power Line Booster firmware. As part of this update, the modem module (PLB MM) firmware may also be updated. Each PLB modem that is plugged into the PLB basic module automatically receives the modem firmware stored there.
  • Page 20 Device description 2.2 PLB Basic module Step 2: Update The PLB indicates that the update is in progress through flashing of the "MT", "RN" and "ER" LEDs. This display mode starts as soon as the check of the firmware files has been completed successfully.

  • Page 21: Busadapter

    Device description 2.3 BusAdapter BusAdapter Figure 2-10 BA 2xRJ45 (BusAdapter RJ-45) Figure 2-11 BA 2xFC (BusAdapter Fast Connect) Figure 2-12 Slot for the BusAdapter Power Line Booster Operating Instructions, 11/2019, A5E36203125A-AG...

  • Page 22: Led Display

    Device description 2.3 BusAdapter Device Area of application MLFB BusAdapter RJ-45 This module is used for 6ES7193-6AR00-0AA0 ET200SP BA 2xRJ45 ETHERNET or PROFINET connections to the PLB system via RJ45 plug connectors. BusAdapter Fast Connect This module is used for direct 6ES7193-6AF00-0AA0 ET200SP BA 2xFC connection of ETHERNET or...

  • Page 23: Network Cable Connection

    Device description 2.3 BusAdapter Table 2- 5 LED BusAdapter LED labeling Color State Description Meaning LK1/LK2 Green No link at Port 1 or Port 2 Link Port 1 / Link Port 2 Flashes Station flash test (PN) together with the MT, RN and ER (approx.

  • Page 24: Plb Modem Module

    Device description 2.4 PLB modem module PLB modem module Figure 2-15 PLB MM Figure 2-16 Slot for the PLB MM PLB device MLFB Modem module: 6ES7972-5AA51-0AB0 PLB MM This device modulates or demodulates the Ethernet data frames into a form that is suitable for the "Powerline"...

  • Page 25: Led Display

    Device description 2.4 PLB modem module NOTICE It is technically possible to plug the modem module into the right slot (X5). However, this configuration is not supported! If you are plugging the modem into slot X5 on the right or if you are not plugging a modem at all, the Power Line Booster signals an error.
  • Page 26 Device description 2.4 PLB modem module LED labeling Color State Description Meaning Flashes Powerline data traffic (approx. 8 Hz) LED test for about 0.5 s during startup Modem active, PL connection exists Note: If all LEDs are flashing permanently at a frequency of 1 Hz, you are dealing with a configuration or device fault. When updating the modem firmware, the power supply must not be switched off! Changing the DIP switch settings NOTICE...

  • Page 27: Plb Empty Module

    Device description 2.5 PLB Empty module PLB Empty module Figure 2-18 PLB EM Figure 2-19 Slot for the PLB EM PLB device MLFB PLB Empty Module: 6ES7972-5AA80-0XA0 PLB EM (5 pieces per packaging unit) The empty module is used to cover the module bay and the DIP switches. The degree of protection IP20 applies to the fully equipped device, i.e.

  • Page 28: Plb Tc Module

    Device description 2.6 PLB TC module PLB TC module Figure 2-20 PLB TC module The PLB TC is used termination of segments. Both ends of the communication cables of the respective segment are terminated by the termination module. Details on installation of the TC module are available in the section Rail connection of the TC module (Page 49).

  • Page 29: Accessories

    Device description 2.7 Accessories Accessories 2.7.1 Carrier power supply The AC carrier power supply, through its continuous current flow, keeps the contact between slider and rail clean. It is not necessary for actual powerline communication. No carrier voltage is required in applications without sliding contacts (e.g. communication over flexible cables) or those in which the materials used prevent oxidation of the contact surface.
  • Page 30 2-pole, 1 ampere, tripping charac- SIEMENS 3RV1011-1BA10 8JV00-0EA0) teristic B Secondary 2-pole, 2 amperes, tripping char- (1): SIEMENS 5SY4202-5 (2-pole, 2A, A char- acteristic B acteristic) (2): SIEMENS 5SY4202-6 (2-pole, 2A, B char- acteristic) Power Line Booster Operating Instructions, 11/2019, A5E36203125A-AG...
  • Page 31 Device description 2.7 Accessories Line filter The line filter prevents crosstalk of the communication signals to other cables as well as coupling of interference to the communication lines. This is particularly important when you are supplying multiple segments from one carrier voltage or when you are operating multiple carrier voltage transformers in a shared low-voltage network.

  • Page 32: Plb Connection Cable

    Device description 2.7 Accessories Example: Faulty contacting of the sliding contact can result in a connection between the system supply (L1/L2/L3) and the communication cables (Rail A/B). The communication lines will then carry a voltage of 230 V to ground, for example. These 230 V are then the rated voltage for the basic isolation of the filter, the PLBs as well as additional components connected to the communication cables.
  • Page 33 Device description 2.7 Accessories If you need cable lengths of > 1 meter, you can, with reduced configuration limit, use high- voltage and insulation-tested PLB cables with a length of 8 meters. Table 2- 11 PLB cables of 8 meters in length PLB cable 8 m length Without plug...

  • Page 35: Plant Planning

    Plant planning Overview of PLB applications Depending on the application, we distinguish between "single-segment systems" and "multi- segment systems". If uninterruptible communication is required, two PLB slaves are used on the vehicle, each on its own slider (PDS = Powerline Double Slider). Otherwise, you only need one PLB slave per vehicle in case of a single slider application (PSS = Powerline Single Slider).

  • Page 36: Single Slider Solution (Pss)

    Plant planning 3.2 Single slider solution (PSS) Single slider solution (PSS) With the Powerline Single Slider (PSS) solution, data transmission via PROFINET, for example, takes place from the stationary end via a Power Line Booster configured as "master". The PLB converts the Ethernet data into a powerline signal and feeds this signal into the communication rails.

  • Page 37: Double Slider Solution (Pds)

    Plant planning 3.3 Double slider solution (PDS) An entire system can also contain multiple single segments that are all independent of each other. This means that, by design, a change of segments results in an interruption of communication. A communication segment must always be terminated by a PLB TC module at the ends. Closed loops are not permitted because a "circular"...

  • Page 38: Maximum Permissible Velocity During Segment Change

    Plant planning 3.3 Double slider solution (PDS) 3.3.1 Maximum permissible velocity during segment change There are generally no velocity limits for vehicles in PLB applications within a communication segment. Only a permanent electrical and mechanical connection between slider and rail must be ensured.

  • Page 39: Parallel And Redundant Communication Via Prp

    PRP section, these packets may be rejected, depending on the switch configuration. In the case of Siemens SCALANCE switches, for example, this can be prevented by activating "Oversize mode". PROFINET devices in the PRP section...

  • Page 40: System Limits

    Plant planning 3.4 System limits System limits 3.4.1 Segment length Plan the length of the communication segment so that it does not exceed the maximum permitted segment length of 250 meters. You must also ensure that the maximum number of permitted vehicles in the segment is never exceeded during operation (see the Maximum number of stations (Page 40)).
  • Page 41 Plant planning 3.4 System limits PLB connection cable with individual length If connection cables with individual length (Page 33) are used, this also results in smaller configuration limits. It does not matter in this case whether the cable is shorter or longer than 8 meters.

  • Page 42: Master Position

    Plant planning 3.4 System limits Summary The following table once again lists the most important indicators and examples of the configuration limit: Table 3- 1 Configuration limits Plant structure Reduction in percentage of Reduction compared to max- Maximum number of slaves maximum configuration imum configuration per segment...
  • Page 43 Plant planning 3.4 System limits The following examples are given to clarify the calculation of the master position. The position information in this case always refers to the distance from the rail start in traveling direction. Special case: Connection via TC module If you feed in your application through a rail interruption (e.g.
  • Page 44 Plant planning 3.4 System limits Example 3 (PSS application with PLB connection cable ≤ 1 meter and lifter) Based on example 1, a lifter is now going to be added to the communication area at the line start. This rail section is connected to the main segment using a TC module (see Special case: Connection via TC module (Page 42)).

  • Page 45: Comparison Pss To Pds

    Plant planning 3.5 Comparison PSS to PDS Comparison PSS to PDS Table 3- 2 Comparison Technical specifications Single slider solution (PSS) Double slider solution (PDS) Number of sliders per vehicle 1 slider 2 sliders Number of PLB slaves per vehicle 1 slave (Page 36) 2 slaves (Page 37) Max.

  • Page 46: Registration And Transfer Times

    Plant planning 3.7 Data rate 3.6.2 Registration and transfer times Registration time is the time that a PLB slave that is ready for operation needs to set up a connection to a master. This is the case, for example, when a vehicle in a PSS application travels from a segment without communication to a segment with communication.

  • Page 47: Plant Installation

    Plant installation The following subsections describe the installation of the required components. WARNING You must de-energize the plant before installation. Cables in the powerline system and their shielding Try to keep all cables in the powerline system as short as possible. It makes no difference whether these are grounding cables, the cables between the PLB and the rail or the slider, the cabling of the powerline cables in the control cabinet or the connection cables of the TC modules.

  • Page 48: Rail Connection Of Master And Carrier Power Supply

    Plant installation 4.2 Rail connection of master and carrier power supply Rail connection of master and carrier power supply We recommend installing the Power Line Booster Master and the carrier power supply in one common control cabinet and to connect them to the rail using the same powerline connection cable (see section "PLB connection cable (Page 32)").

  • Page 49: Connection Of The Plb Slave

    Plant installation 4.3 Connection of the PLB slave Connection of the PLB slave To connect the PLB slave to the communication sliders, use the cables specified in section "PLB connection cable (Page 32)". If you are not using the pre-fabricated 8 meter PLB connection cable, you must ensure that all cables in the entire system are of the same type and have the same length (+/- 5%).

  • Page 50: Plant Attenuation

    (e.g. through the cumulation of multiple faults or due to individual specific devices/machines), contact our Technical Support (mailto:PLB-Support.industry@siemens.com). If you are operating the Power Line Booster with the factory settings, interferences up to 73 dB µV (QPk, corresponds to 1 Vpp, see EN 61000-6-4:2007) do not result in...
  • Page 51 Maximum number of stations (Page 40) Note For more complex plants, it may be best to involve Technical Support (mailto:PLB- Support.industry@siemens.com) for the Power Line Booster as early as the planning phase. Power Line Booster Operating Instructions, 11/2019, A5E36203125A-AG...

  • Page 52: Rail System And Arrangement

    Plant installation 4.6 Rail system and arrangement Rail system and arrangement Select a combination for the rail/slider system which ensures a permanent low resistance contact (< 1 Ohm) when being operated under the conditions specified by the manufacturer. You must ensure that the contact is also guaranteed at transitions and expansion points. Arrangement of the sliding contact lines The examples and calculations shown in the preceding sections are based on the following arrangement which is recommended for reliable communication.

  • Page 53: Rail Grounding (Pe Rail)

    Please contact Technical Support (mailto:PLB- Support.industry@siemens.com) for more information. Rail quality An electrical connection (contact resistance across the entire distance < 1 Ohm) of the sliding contacts is required to ensure the function of the Power Line Booster.

  • Page 54: Segment Cut

    Plant installation 4.8 Segment cut Segment cut At a change from one segment to another, you must cut the rails as shown in the following figure "Sample segment cut". The separating piece with the double cuts prevents a slider from directly interconnecting the two neighboring segments when traveling over the cut. You must terminate each segment with a PLB TC module.

  • Page 55: Rail Interruptions (E.g. Lifter)

    Plant installation 4.9 Rail interruptions (e.g. lifter) Rail interruptions (e.g. lifter) If it becomes necessary to interrupt the powerline rail and to route the powerline signal over a cable to another rail section, this entails a reduction in the number of stations in the segment according to the section Maximum number of stations (Page 40).
  • Page 56 Plant installation 4.10 Loops section Master position (Page 42) regarding vehicles between master and the most remote slave must be observed. From this value, you must then still subtract the number for the additional segment (see "Interruptions of the communication rail (Page 40)"). For the connection between master and rail, we recommend using the 8 meter PLB connection cable (Page 33).

  • Page 57: Switches

    Plant installation 4.11 Switches 4.11 Switches If possible, use switches only for separation of segments during plant planning (as segment cut). If the switch must be used within a communication segment, this is possible with a reduction of the number of devices in the segment according to the section Maximum number of stations (Page 40).

  • Page 58: Switch In The Communication Segment

    Plant installation 4.11 Switches Figure 4-7 Wiring of the switch (switch as segment cut) See also Segment cut (Page 54) 4.11.2 Switch in the communication segment If it is necessary to move across the switch without communication being interrupted, the switch can also be installed in the segment with a reduction of the maximum number of PLB slaves.
  • Page 59 Plant installation 4.11 Switches The master and the two moving rail sections on the switch are also connected using the 8 meter PLB connection cable, for example. The signal is routed via a PLB TC module in this case. This TC module is used to attenuate the powerline signal. This prevents a closed loop from forming via the two connection cables when a slider bridges the cut.

  • Page 60: Insulation Monitor

    Plant installation 4.12 Insulation monitor See also PLB connection cable (Page 32) 4.12 Insulation monitor The operation of an insulation monitor may be necessary for safety reasons. This remains the responsibility of the plant constructor. WARNING The Power Line Booster system can be operated in low-voltage plants up to 500 V AC. A single short-circuit between a phase (L1 or L2 or L3) and Rail A or Rail B may represent a fault for this device as indicated by the error LED, but this does not prevent communication.

  • Page 61: Installation

    Plant installation 4.13 Installation 4.13 Installation 4.13.1 Power Line Booster (PLB BM) Install the Power Line Booster onto a vertically mounted DIN rail (TS 35; DIN Rail) (see photo). Figure 4-9 PLB mounted on a DIN rail; rear view If you plug the Power Line Booster onto a vertical DIN rail or one installed horizontally, however, the maximum permissible ambient temperature is reduced to 50 °C.

  • Page 62: Plb Modem Module/Busadapter

    Plant installation 4.13 Installation 4.13.2 PLB modem module/BusAdapter Figure 4-10 Installation of the modules and the BusAdapter Plug the modem and the empty module as well as the BusAdapter into the Power Line Booster and fasten the respective module with its fixing screw (tightening torque 0.2 Nm). Suitable tool: Preferably Torx screwdriver TX10 or slotted (Philips) screwdriver 0.5x3 (0.5x3.5).

  • Page 63: Profinet/Ethernet

    "Timing and runtimes (Page 72)". For additional information on "PROFINET IO", refer to the STEP 7 online help and the PROFINET System Description (http://support.automation.siemens.com/WW/view/en/19292127). 5.1.2 Startup parameters The Power Line Booster does not require adjustable startup parameters.

  • Page 64: Io Address Space (Cyclic Data)

    PROFINET/Ethernet 5.1 PROFINET IO 5.1.3 IO address space (cyclic data) The figure below shows the IO address space of the Power Line Booster. Depending on the requirement, so-called slots with different input and output data can be plugged during configuration. The individual slots and the meaning of the data they contain are listed below. Input data is labeled with the letter 'I' and output data with the letter 'O' according to the SIMATIC configuration software STEP 7.
  • Page 65 PROFINET/Ethernet 5.1 PROFINET IO Input word PLB cycle: IW x+1 (unsigned 16, master only): 16-bit value of the Power Line Booster cycle time (Page 72) in ms For PLB slave: 0 word x+1 Input word number of active slaves: IWB x+3 (unsigned 16, master only) For PLB slave: 0 word x+3 Input word PL channel: IW x+5 (unsigned16):...
  • Page 66 PROFINET/Ethernet 5.1 PROFINET IO Slot 4 (Powerline status) IW x: Input word PLB Errors: IW x (unsigned 16): Bit 0: Short circuit PL – Phase Bit 1: Short-circuit PL-B – FE Bit 2: Short-circuit PL-A – FE Bit 3: Overvoltage Bit 4: Core Dump Bit 5: Error at left modem Bit 6: Right modem inserted...
  • Page 67 PROFINET/Ethernet 5.1 PROFINET IO Slot 5 (In Out notification) IW x (master only): Input byte Slave In counter: IW x+0 (unsigned 8): Infinite counter when slave enters. Identifies the entry of a slave or connection setup to a slave. A counter overflow occurs when the maximum value of 255 is reached. For PLB slave: 0 Byte x Input byte Slave Out counter: IW x+1 (unsigned 8):...

  • Page 68: Identification And Maintenance Data

    PROFINET/Ethernet 5.1 PROFINET IO 5.1.4 Identification and maintenance data Definition and features The identification and maintenance data (I&M) is information saved in a module which supports you in the following tasks: ● Checking the plant configuration ● Locating hardware modifications in a plant Identification data (I data) consists of module information (some of which may be printed on the module housing) such as the order number and serial number.

  • Page 69: Device-Specific Data Records

    Access Default Description Identification data 0: (data record index AFF0 hex) VendorIDHigh Read (1 byte) The vendor name is stored here (42D = SIEMENS AG). VendorIDLow Read (1 byte) Order_ID Read (20 bytes) 6ES7972-5AA10-0AB0 Article number of the module IM_SERIAL_NUMBER...
  • Page 70 PROFINET/Ethernet 5.1 PROFINET IO Note All values within the device-specific data records are transferred in BIG ENDIAN format. Data record slave list of the master Context: MM Index: 100 Type: Read Only The data record returns the following information: Header ●...

  • Page 71: Interrupts/Diagnostic Message

    Note For additional information on "PROFINET IO", refer to the STEP 7 online help and the PROFINET System Description (http://support.automation.siemens.com/WW/view/en/19292127) Note The Power Line Booster supports a packet size of 1522 / 1518 bytes (VLAN tagged / untagged). Any larger packet sizes are discarded.

  • Page 72: Timing And Runtimes

    PROFINET/Ethernet 5.3 Timing and runtimes Timing and runtimes 5.3.1 Overview The Power Line Booster system implements a transparent transmission of Ethernet frames via powerline. In addition, it ensures optimum utilization of the media with regard to real-time capability of IO data. To do this, the PLB master runs the PLB cycle in which it contacts each accessible PLB slave one after the other;...

  • Page 73: Configuration Of The Monitoring Time

    PROFINET/Ethernet 5.3 Timing and runtimes 5.3.3 Configuration of the monitoring time Due to the following effects, the average PLB cycle time calculated in the section Configuration of the PN update time (Page 72) is regularly exceeded: 1. Registration of PLB slaves in a segment. Sounding of the carrier frequencies of the master and slave modem occurring during registration results in a media assignment that makes the media unavailable for the cycle.
  • Page 74 PROFINET/Ethernet 5.3 Timing and runtimes ① Cycle of the controller at which it can process IO data. ② PROFINET update time that is configured between controller and device. ③ PLB cycle at which the powerline system forwards data to the slaves. This cycle is independent of the number of slaves and from interference.
  • Page 75 PROFINET/Ethernet 5.3 Timing and runtimes Figure 5-3 Maximum latency time for bidirectional communication Bidirectional communication here means that the IO controller sends a query and the IO device responds using the same communication path, e.g. by sending an acknowledgment. Bidirectional communication results in the chart as seen in the figure above. We assume here that the PN update time T is significantly shorter than the latency time caused by the PLB system T...
  • Page 76 PROFINET/Ethernet 5.3 Timing and runtimes Figure 5-4 Graphic for determining the PROFINET times For PDS applications, it is the maximum number of possible slaves in the segment that is the decisive factor for determining the PROFINET/PROFIsafe watchdog times, because the likelihood of faults and the times for sounding of the carrier frequencies grow exponentially with the number of slaves.

  • Page 77: System Configuration And System Status (Web Interface)

    System configuration and system status (web interface) Overview of web interface The Power Line Booster is commissioned and configured via the integrated web interface. The web pages of the Power Line Booster differ depending on whether you are configuring a PLB master or a PLB slave.

  • Page 78: Tooltip On The Parameters

    System configuration and system status (web interface) 6.1 Overview of web interface 6.1.2 Tooltip on the parameters If you move the mouse pointer over a configuration field or a header (e.g. of tables), you receive additional information on the respective parameters. In the case of configuration parameters, for example, the selectable limit values and the recommended default value are displayed directly.
  • Page 79 System configuration and system status (web interface) 6.1 Overview of web interface One "admin" and five "users" can be logged in simultaneously. Table 6- 1 Default password (delivery state) User name Password Description admin admin The administrator has write permissions and can therefore configure the device.

  • Page 80: Information

    System configuration and system status (web interface) 6.2 Information Information 6.2.1 Home page - System overview Overview On the start page you will see an overview with the most important information about the connected device. ① Language selection "de" (German) or "en" (English) ②...

  • Page 81: Error Status And Warnings Of The Device

    System configuration and system status (web interface) 6.2 Information ⑪ Log off Time until automatic "Log off" ⑫ Expert function active If visible, the expert function is active. ⑬ Current position Current position of the PLB (only if this is transmitted via PROFINET IO) Figure 6-3 System overview...
  • Page 82 6.2 Information Rescue mode This error indicates that the PLB is restarted with the Rescue firmware after a fatal error. For more details on this error, see the Log tables (Page 85). Contact SIEMENS Support (mailto:PLB-support.industry@siemens.com). Log backup available A backup of the log files is created before the restart in Rescue mode. This is the corresponding signal.
  • Page 83 System configuration and system status (web interface) 6.2 Information Short circuit PL A/B to L The PLB has detected a short circuit between the Powerline rail "A" and/or "B" and a line conductor. WARNING A voltage that is dangerous to the touch is present on all Powerline rails and all cables and plant units connected to them.

  • Page 84: Versions

    System configuration and system status (web interface) 6.2 Information 6.2.3 Versions Version information of the device On this page, you can see the version information of the existing hardware and software. Note The MAC address of the PLB Modem module is only required for the powerline communication and is not visible to the outside.

  • Page 85: Log Tables

    System configuration and system status (web interface) 6.2 Information 6.2.4 Log tables Figure 6-6 Log information of the device Log information of the device On this page, you can see the log information of the device. From left to right, a log message consists of ●...
  • Page 86 Mode" (see the section "Rescue Mode" and its log backup in the Device status (Page 103)). You can receive a more detailed evaluation of the logs by contacting the SIEMENS hotline. To do so, send the log to the PLB Support (mailto:plb-support.industry@siemens.com).

  • Page 87: System

    System configuration and system status (web interface) 6.3 System System 6.3.1 Restart & reset Figure 6-7 PLB restart and factory settings Restart and reset to factory settings On this page you can restart the Power Line Booster and reset it to the factory settings. Restart Press the "Restart"...

  • Page 88: Update

    System configuration and system status (web interface) 6.3 System Reset to factory settings After clicking the "Reset" button and confirming a dialog, the Power Line Booster runs a factory reset and restarts. The factory reset resets all settings as well as the login passwords to the default values.

  • Page 89: Loading And Saving

    System configuration and system status (web interface) 6.3 System A basic functionality of the system is also given in mixed operation with different firmware versions. However, there may be a restriction in the status- and diagnostics data. It is recommended to avoid mixed operation as far as possible in productive systems and to upgrade the masters first in case of a system update.
  • Page 90 System configuration and system status (web interface) 6.3 System Log files Press this button to download the log files of the device as compressed zip archive. The archive contains the "long-term log" as well as the "detail log". Current configuration You can export, import or reset the configuration of the device to the default values.

  • Page 91: Automatic Logout

    System configuration and system status (web interface) 6.3 System 6.3.4 Automatic logout Figure 6-10 Automatic logout For security reasons, a user is automatically logged off after a defined period of inactivity. You can configure this period on this page. As long as you are actively logged in on the device, the timer for automatic logout is reset with each interaction.

  • Page 92: User

    System configuration and system status (web interface) 6.3 System 6.3.5 User Figure 6-11 User functions Change password On this page, you can change the password as the logged in user. To assign a new password, you must first enter your old password. Then enter the new password into the respective field.

  • Page 93: System Time

    System configuration and system status (web interface) 6.3 System 6.3.6 System time System time (master only) You can synchronize the system time of the Power Line Booster either automatically via an NTP server or enter it manually. You make the setting in the two tabs on this page. You can set synchronization of the time only on the master.

  • Page 94: Setting The Time-Of-Day Of The Ntp Client

    System configuration and system status (web interface) 6.3 System 6.3.6.2 Setting the time-of-day of the NTP client Figure 6-13 Setting the time-of-day of the NTP client Setting the time-of-day of the NTP client On this page you can activate the NTP client to synchronize the system time of the Power Line Booster.

  • Page 95: Powerline

    System configuration and system status (web interface) 6.4 Powerline Powerline 6.4.1 Traffic Manager Below you can change the system configuration. These parameters have already been optimized for standard applications and must not be changed. Please note that the stability of the system can be significantly reduced by just a minor change of the parameters. 6.4.1.1 Traffic Manager time configuration Figure 6-14...

  • Page 96: Traffic Manager Buffer Configuration

    System configuration and system status (web interface) 6.4 Powerline For a slave that has been newly introduced into a segment to be polled by the master in the future, the master sends a "Hello frame" at the beginning of each cycle. Communication is then paused according to the "Hello Phase"...
  • Page 97 System configuration and system status (web interface) 6.4 Powerline Buffer The Traffic Manager has various buffers to cache the incoming Ethernet frames until they can be packaged and send in a container. Buffers that are not in use do not have an effect on the bandwidth of the PLB communication.

  • Page 98: Traffic Manager Communication

    System configuration and system status (web interface) 6.4 Powerline 6.4.1.3 Traffic Manager communication Figure 6-16 Communication configuration Communication The PLB packages all frames of a station into a container (according to prioritization). The container is filled until either all buffers were emptied for the container is full. The transmission cycle of the container depends on its size.

  • Page 99: Traffic Manager User Priority

    System configuration and system status (web interface) 6.4 Powerline Transmission stability (only in Master operating mode) There are a total of four different transmission modes: ● Medium stability: High data transmission rate, medium interference sensitivity of the data transmission. ● High stability: Compromise between data transmission rate and interference sensitivity. ●...

  • Page 100: Modem Configuration

    System configuration and system status (web interface) 6.4 Powerline Use the check box to activate or deactivate the user-defined prioritization. You can select UDP or TCP as protocol. Valid target ports are 1 to 65535. You can select the port as follows: ●...

  • Page 101: Segment Configuration (Master Only)

    System configuration and system status (web interface) 6.4 Powerline recommend lowering the signal level by about 4 dB for these types of applications so that there is no signal overmodulation in the receiver. Two signal elements are installed in the receive path of the Power Line Booster. The "Static receive gain"...

  • Page 102: Status Tables (Master Only)

    System configuration and system status (web interface) 6.4 Powerline 6.4.3 Status tables (master only) The Power Line Booster system provides the user with a large number of current status parameters and measured values. The information on the slaves is listed on the following pages in two tables each.

  • Page 103: Device Status (Master Only)

    System configuration and system status (web interface) 6.4 Powerline 6.4.3.1 Device status (master only) You can view the current status of the slaves on this page. These are mainly static values that the slave only transmits to the master during the login process. You can find a general description of the tables in Status tables (Page 102).

  • Page 104: Cycle Time

    System configuration and system status (web interface) 6.4 Powerline 6.4.3.2 Cycle time Cycle time Figure 6-20 Cycle times (long-term measurement) This page gives you an overview of the cycle times of the connected PLB master and its slaves. The cycle time is the time that the master needs to query all connected slaves one after the other.
  • Page 105 System configuration and system status (web interface) 6.4 Powerline ● "Gap Avg": Average time between two frames to one slave. Typical: "Poll Avg" • times number of stations in the segment + "Hello Phase" (Page 72). In a completely full segment, the "Gap Avg" should be shorter than the configured PROFINET update time.

  • Page 106: Signal Quality (Master Only)

    System configuration and system status (web interface) 6.4 Powerline 6.4.4 Signal quality (master only) 6.4.4.1 Signal gain and transmission quality Figure 6-21 Signal gain and transmission quality (short-term measurement) On this page you can view the signal quality and get information on the receive gain and modulation.
  • Page 107 System configuration and system status (web interface) 6.4 Powerline The parameters "RX M" and "RX S" show the current dynamic receive gain. The maximum value is configured by means of "Limit dynamic receive gain" in Signal configuration (Page 100). The configured limit value should only be reached by a few vehicles in a full segment.

  • Page 108: Signal Graphs

    System configuration and system status (web interface) 6.4 Powerline 6.4.4.2 Signal graphs The following tabs give you various options to show and evaluate the signal quality of the Power Line Booster system in form of a graph. First you must specify the communication partner of which you want to determine the graph using the "Connected devices"...

  • Page 109: Tone Map

    System configuration and system status (web interface) 6.4 Powerline 6.4.4.3 Tone Map Figure 6-22 Tone Map of the current modulation The Tone Map shows the current modulation between two connection partners in form of a graph. You can find a general explanation of operating this metering function under Signal graphs (Page 108).

  • Page 110: Signal Strength

    System configuration and system status (web interface) 6.4 Powerline 6.4.4.4 Signal strength Figure 6-23 Signal strength (Power Spectral Density) By measuring the PSD (power spectral density), you can display the signal strength trend of the powerline signal. You can find a general explanation of operating this metering function under Signal graphs (Page 108).

  • Page 111: Signal-To-Noise Ratio

    System configuration and system status (web interface) 6.4 Powerline 6.4.4.5 Signal-to-noise ratio Figure 6-24 Signal-to-noise ratio The signal-to-noise ratio (SNR) measures the quality of the powerline useful signal that is covered by noise. You can find a general explanation of operating this metering function under Signal graphs (Page 108).

  • Page 112: Voltage Measurement (Master Only)

    System configuration and system status (web interface) 6.4 Powerline 6.4.5 Voltage measurement (master only) Figure 6-25 Voltage measurement This page gives you an overview of the current voltage states of the connected master as well as the connected slaves. You can use the displayed states, for example, to determine whether there is a short circuit, overvoltage or undervoltage on the powerline rail.

  • Page 113: Expert Functions

    System configuration and system status (web interface) 6.5 Expert functions ● "Short circuit PL B to PE": The PLB has detected a short circuit between the Powerline rail "B" and the earth. ● "Short circuit A/B to L": The PLB has detected a short circuit between the Powerline rail "A"...

  • Page 114: Changing Nmk (Channel) Temporarily

    System configuration and system status (web interface) 6.5 Expert functions 6.5.1 Changing NMK (channel) temporarily Figure 6-26 Changing NMK temporarily The NMK (Network Management Key) of the Power Line Boosters is set with the DIP switches on the basic device for regular operation. This key ensures that only PLB devices with identical NMK can communicate with each other, which is why all devices must have the same NMK for regular operation.

  • Page 115: Temporary Level Change

    System configuration and system status (web interface) 6.5 Expert functions 6.5.2 Temporary level change Figure 6-27 Temporary level change To determine the system limits during commissioning, for example, you can temporarily change the sending and receiving levels on the master. The master transmits this temporary level configuration to all slaves in the segment that are connected to it.

  • Page 116: Crosstalk Measurement

    System configuration and system status (web interface) 6.5 Expert functions 6.5.3 Crosstalk measurement Figure 6-28 Crosstalk measurement (positive example) Power Line Booster Operating Instructions, 11/2019, A5E36203125A-AG...
  • Page 117 System configuration and system status (web interface) 6.5 Expert functions Figure 6-29 Crosstalk measurement (negative example) Stable communication requires that the level of the powerline signal is relatively high to achieve an ideal signal-to-noise ratio. Because each vehicle dampens the signal level, this is especially important in a full segment.
  • Page 118 System configuration and system status (web interface) 6.5 Expert functions To run the crosstalk measurement, you must first enter the IP address as well as the "admin" password of the PLB master of the neighboring segment (remote master). Note that the master on which you are logged in will set up a connection to the remote PLB master during the measurement.

  • Page 119: Modem Core Dump

    (core dump) for error diagnostics by SIEMENS PLB Support (mailto:PLB- support.industry@siemens.com). The fact that a core dump is available is shown under Errors and warnings and in the header area of all web pages. In the first step, the core dump must be imported from the modem and saved on the system to be downloaded later.

  • Page 120: Commissioning Sequence

    System configuration and system status (web interface) 6.6 Commissioning sequence Commissioning sequence The following section is intended to serve as a starting point for the commissioning of a new PLB system. The example refers to a PDS multi-segment system. However, for the most part you can also project it onto other systems.

  • Page 121: Segment Damping

    System configuration and system status (web interface) 6.6 Commissioning sequence 6.6.3 Segment damping The elementary requirement for a stable powerline connection is that there is no crosstalk between adjacent segments at any time. For this reason, you should now carry out Crosstalk measurement on all segments.

  • Page 122: Test Mode With Reduced Levels

    System configuration and system status (web interface) 6.7 Error diagnostics 6.6.6 Test mode with reduced levels In the last step, we recommend temporarily reducing the signal levels (see Temporary level change). Reduce the level until the first communication disturbances occur or you notice a deterioration of the measured values in the Cycle time table.

  • Page 123: Maintenance And Service

    Depending on the work necessary to repair the device, the Center may decide to give you a credit. A credit note is only granted if the sender orders a new device. The address is: Siemens AG Retouren-Center c/o Geis Industrie-Service GmbH Tor 1-4 Kraftwerkstr.
  • Page 124 Maintenance and service 7.2 Recycling and disposal Power Line Booster Operating Instructions, 11/2019, A5E36203125A-AG...

  • Page 125: Technical Specifications And Approvals

    Technical specifications and approvals Technical specifications 8.1.1 Mechanics Dimensions and weight Table 8- 1 Power Line Booster BM with equipped BA, MM, EM Width Length Depth Weight 146 mm 130 mm 83 mm 0.90 kg Note: Information without DIN rail mounting bracket Table 8- 2 PLB TC Width...

  • Page 126: Shock Values

    Technical specifications and approvals 8.1 Technical specifications 8.1.2 Shock values Table 8- 5 Vibratory load IEC 61131-2, IEC 60068-2-6, Test Fc frequency / deflection or accelera- 5 – 8.4 Hz / 3.5 mm tion: 8.4 – 150 Hz / 9.8 m/s² 10 cycles per axis, all three axes, Throughflow time 1 min /octave Table 8- 6...

  • Page 127: Mtbf

    Technical specifications and approvals 8.2 Approvals 8.1.4 MTBF Mean Time Between Failures MTBF PLB BM 2532 394,944 h or 45.1 years PLB MM 1185 843,881 h or 96.2 years BA 2xRJ45 [BA 2xFC] 917.6 years [1,024 years] Power Line Booster (PLB BM, PLB MM, BA 3319 301,296h or 34.4 years 2xRJ45)

  • Page 128: Culus Approval

    Technical specifications and approvals 8.2 Approvals Compatibility with the directives is verified by compliance with the following standards: EN 61000-6-2:2005 (PLB BM, PLB MM) EN 61000-6-4:2007+A1:2011 (PLB BM, PLB MM) EN 61010-1:2010 (PLB BM, PLB MM, PLB TC) EN 61010-2-201:2013 (PLB BM, PLB MM, PLB TC) 8.2.2 cULus approval Underwriters Laboratories Inc., to...

  • Page 129: Order Numbers

    Power Line Booster components Table 9- 1 Order numbers of the components PMD product name Component Order number SIMATIC Power Line Booster PLB BM LV M/S 6ES7972-5AA00-0AB0 Base Module Low Voltage Mas- ter/Slave SIMATIC Power Line Booster PLB BM HV M/S...
  • Page 130 Line filter (1) Schurter: 5500.2349 (clip DIN rail) (2) Schurter: 5500.2218.01 (screw-type lugs) Primary circuit breaker SIEMENS: 3RV1011-1BA10 Secondary circuit (1) SIEMENS: 5SY4202-5 (2-pole, 2A, A charac- breaker teristic) (2) SIEMENS: 5SY4202-6 (2-pole, 2A, B charac- teristic) PLB cable PLB cable with variable length Lapp: Order no.: 2170322...

  • Page 131: Index

    Index Ambient temperature, 127 I&M data, 68 Attenuation, 31, 50, 73 Input data, 64 Automatic circuit breaker, 30 IO controller, 71 IP address, 13 Bidirectional communication, 75 Jumbo frames, 39 Carrier frequency, 9, 50, 73 CE conformity, 127 Latency, 73 Channel, 14, 15, 15, 51 Latency time, 75 Channel setting, 15...
  • Page 132 Index Plant controller, 7, 74 PLB BM, 11, 127, 128 Vehicle controller, 74 PLB cycle time VLAN tagged / untagged, 71 average, 72 PLB EM, 11, 14, 27 PLB master, 10, 11, 12, 14, 16, 42, 72 PLB master, 10, 11, 12, 14, 16, 42, 72 PLB MM, 11, 11, 24, 127, 128 PLB slave, 10, 11, 14, 16, 72, 76 PLB Slave, 12...

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