4.10 BAT – Battery module slot ..............4-6 Power supply LED behaviour Run / Stop button I/O Bus slots and I/O extension port 8.1 PCD2.M4160 .................. 8-1 8.2 PCD2.M4560 .................. 8-1 Data retention, Real time clock and battery module slot 9.1 Usage of optional battery module ............ 9-1 9.2 User program data ................ 9-1...
Page 3
Contents Saia-Burgess Controls AG PCD2.M4x60 Watchdog relay Communication ports 12.1 X1 - USB Port (Programming Interface) .......... 12-1 12.2 X2 – Isolated RS-485-Port/MPI ............. 12-2 12.3 X4 - RS-485 (Port #0, not electrically isolated) ........ 12-3 12.4 X5 - Sot A (Port #1) Terminalbloc ............ 12-4 12.5 X6 and X7 - Ethernet Switch Port #9 ............ 12-5 12.6 X9 - Slot C Profibus-DP-Master (Port #8) optional ....... 12-6 12.7 I/O module based interfaces PCD2.F2xxx .......... 12-9 Dimensions Mounting 14.1 Mounting with screws ................ 14-2 14.1.1 Mounting the PCD2.M4x60 and PCD2.C1000: ........ 14-3 14.1.2 Dismounting the PCD2.M4x60 and PCD2.C1000: ........ 14-3 14.2 ...
Contents Saia-Burgess Controls AG PCD2.M4x60 Document History Version Changes Comments ENG01 2015-10-26 First edition ENG02 2016-08-17 - Power supply - Mounting with screws and DIN-rails ENG03 2016-09-02 - New pictures for mounting with screws ENG04 2016-12-12 - R estrictions on communication port Slot ‘A’ 2017-03-08 - Chap. 10.3 Module internal counter - new ENG05 2018-05-16 - S ome pictures improved - T echn. Data added with watchdog relay. - P CD2.C1000 / 2000 Extension housing inserted - C orrected in the “Graphical Overview” link - ...
Graphical overview Saia-Burgess Controls AG PCD2.M4x60 Graphical Overview The graphical overview shows some of the main topics covered in the Operating Manual of the PCD2.M4160 and PCD2.M4560. By clicking on the highlighted components and/or connections, you can jump directly to the corresponding chapter in the document. “Kap. number” indicate the relevant chapter numbers. 2 free slots with SPI (faster serial bus) Communication port for IO modules or ‘C’ communications Ch4.8 modules Interrupt Input RUN/STOP button Ch10 USB/PGU connection Ch4.1 Ethernet connection (2 port switch) Ch4.6 Isolated RS-485 / MPI Ch4.2 Operation LEDs I/O Extension port Slot A connection terminal Ch4.5 Battery Ch9.1 Terminating resistance (RS-485) Ch4.2 Slot for memory ...
Important notes Saia-Burgess Controls AG Important notes Prerequisites The PCD2.M4x60 must be used with the PG5 Suite v2.2.050 or higher. Instructions for connecting Saia PCD controllers to the internet ® When Saia PCD controllers are connected directly to the internet, they are also a potential target of cyber attacks. For secure operation, appropriate pro- tective measures must always be taken. PCD controllers include simple, built-in protection features. However, secure operation on the internet is only ensured if external routers are used with a firewall and encrypted VPN connections. For more information, please refer to our support site: www.sbc-support.com/security User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Versions overview Saia-Burgess Controls AG General Technical Details Versions overview PCD2.M4160 PCD2.M4560 Number of onboard digital inputs 4 digital inputs (24 V, configurable: Normal, Interrupt, Counter) Number of digital inputs/outputs in the base unit Or I/O module slots in the base unit Number of digital inputs/outputs with – 1023 PCD2.C1000/PCD2.C2000 module holders or I/O module slots – Processing times [μs] Bit-Operation 0.1…0.8 μs Word-Operation 0.3 μs Real-time clock (RTC) Supercap to support the real-time clock > 10 days Slot for optional battery module Yes, to support the real-time clock for > 3 years Order article number: 4 639 4898 0 Onboard memory Program memory, DB/TEXT (Flash) 512 kByte 2 MByte Working memory, DB/TEXT (RAM) 128 Kbyte 1 Mbyte Flash memory (S-RIO, Konfiguration und 128 Mbyte 128 Mbyte...
Page 8
Versions overview Saia-Burgess Controls AG General Technical Details Ambient conditions Ambient temperature With assembly on a vertical surface with verti- cally aligned terminals: 0…+55 °C For all other installation positions, a reduced temperature range of 0…+40 °C applies Storage temperature –25…+85 °C Relative humidity 10…95 % without condensation General specifications Supply voltages 24 VDC –20/+25% max. incl. 5% ripple ±15% (in accordance with EN/IEC 61131-2) Power consumption Typ. 15 W with 64 I/O Load capacity 5 V/ +V intern max. 800 mA/250 mA Order details PCD2.M4160 PCD2 processor unit with Ethernet-TCP/IP, 512 kB program memory, 64 I/O PCD2.M4560 PCD2 processor unit with Ethernet-TCP/IP, 2 MB program memory, 1023 I/O User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
System overview Saia-Burgess Controls AG On-board X1 – USB Device USB device (V1.1) on type ‘B’ connector. X2 – Isolated RS-485 / MPI SUBD 9p connector S-Net / M PI / R S-485 D-Sub signal Explanation PGND 0 V of 24 V supply RxD/TxD-P ) B (red) Receive / t ransmit data positive RTS/CNTR-P Control signal for repeater ...
System overview Saia-Burgess Controls AG On-board 4.3.1 Expansion module holder The PCD2.C1000 or PCD2.C2000 expansion module holder, also known as LIO module rack, provides space for 4 or 8 additional I/O modules each. The PCD2 expansion module holder are also snapped onto two 35 mm DIN rails mounted in parallel. LIO module Module Description External Internal rack places power Power supply supply I at +5 V PCD2.C1000 for 4 (or 8) I/O modules, serves as I/O 24 VDC 1400 mA PCD2.C2000 bus repeater and provides internally +5V and V+ for a segment of I/O modules. I/O bus connectors PCD2.K010 or I/O bus cables PCD2K106 can be used to con- nect the expansion boxes. PCD2.M4560 PCD2.C2000 PCD2.C1000 PCD2.K010...
Page 12
Power supply of the expansion module holder 24 VDC Error Désignation Signification Power Fail (Panne de courant) +5 V ou V+ non disponible Power Good Tensions présentes Port commun n.c. non connecté n.c. non connecté +24 V +24 V +24 V The PCD2.C1000/C2000 module holders provide the following internal supply currents for the inserted or connected modules: Type Maximal current Power consumption PCD2.C1000 1400 mA 800 mA In der Regel 2W PCD2.C2000 PCD-Bus (16,2V) When planning PCD2 systems, it is important to check that the internal power supplies to the I/O module racks are not overloaded. This check is especially important when using analog, counting and positioning modules, as some of these modules have a high power consumption. It is recommended to use the calculation table a www.sbc-support.com. User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
System overview Saia-Burgess Controls AG On-board Extension connection These connections can be used to connect the PCD2.C1000/C2000 expansion housing to other expansion housings using the PCD2.K010 connec- tor plug or the PCD2.K106 connecting cable. This 24 VDC allows up to 1023 digital I/Os to be implemented. Error LEDs ● ● 24 VDC (yellow): Power supply available (19 V...32 VDC) ● ● Power Fail (red): Short circuit (+5 V or V+ not present) X4 – S-Bus / Watchdog / Power supply Connector inscription Signal – – – Description S-Bus (RS-485) ...
System overview Saia-Burgess Controls AG On-board X6 / X7 – Dual Ethernet (Switch) Dual Ethernet port with integrated switch 10/100M. X8 – Digital interruptive inputs Four digital inputs configurable interruptive functions. Connector inscription Signal DI_IX3 DI_IX2 DI_IX1 DI_IX0 – – X9 – Communication port Slot ‘C’ A hole is foreseen in the housing for the SUBD connector of module PCD2.F7500. M1 – Memory Slot Slot for memory modules like PCD7.R610 for example.
LED behaviour Saia-Burgess Controls AG LED behaviour Three LEDs (green, red and yellow) show the possible operating statuses of the CPU as set out in the following table: Meaning Stop Error(s) Key: ● ● Form ● LED off Colour green yellow ● ● LED on ● ● ● ● /● LED blink ● ● ● Run conditional ● ● Run with error ...
Run / Stop button Saia-Burgess Controls AG Requirements │ General Information Run / Stop button A push button is placed near the USB connector. The operating mode can be changed during operation or during power-up. If the button is pressed in Run mode for longer than ½ second and less than 3 seconds, the controller switches to Stop mode and vice versa. If the button is pressed for longer than 3 seconds, the last saved user program is loaded from the flash memory. User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
I/O Bus slots and I/O extension port Saia-Burgess Controls AG PCD2.M4160 | PCD2.M4560 I/O Bus slots and I/O extension port PCD2.M4160 Four I/O Slots available in the PCD, addresses from 0 to 63. The communication modules (PCD2.Fxxx) or memory modules (PCD2.Rxxxx) can be connected in slots 0 or 1, but not in slots 2 or 3. PCD2.M4560 Four I/O Slots available in the PCD, addresses from 0 to 63. The communication modules (PCD2.Fxxx) or memory modules (PCD2.Rxxxx) can be connected in the four I/O slots of the PCD. The extensions PCD2.C1000 or PCD2.C2000 can be chained up to address 1023 (including the 64 addresses available in the PCD itself. That means 64 I/O mod- ules can be connected to the system. Direct plug Cable connection connection PCD2.M4560 PCD2.C1000 PCD2.C2000 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Data retention Saia-Burgess Controls AG PCD2.M4160 | PCD2.M4560 Data retention, Real time clock and battery module slot Usage of optional battery module The slot for the PCD3 battery module will be unused for the most of applications. This option will be used only for customers they need to keep the real time clock up to date when the system stays unpowered more than 10 days. For an unpowered duration up to 10 days, the real time clock stays alive by a super-capacitor. User program data The user program medias (registers, flags, etc.) are stored in a non-volatile memo- ry. That means the information is not lost when the system is unpowered and even if the system has no battery module plugged. User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Interrupts Saia-Burgess Controls AG Usage as normal digital inputs - or digital inputs terminal block X8 Interruptive terminal block DI_IX3 Interrupt- DI_IX2 inputs DI_IX1 DI_IX0 Terminal block X8 Digital inputs respecting standard IEC 61131-2: Voltage input lower than 5 V is considered as state “low” and voltage higher than 15 V is considered as state “high”. Maximum input voltage = 30 V. 10.1 Usage as normal digital inputs Source operation terminal block DI_IX3 DI_IX2 Interrupt- inputs DI_IX1 DI_IX0 Terminal block X8...
Interrupts Saia-Burgess Controls AG Usage as interruptive inputs 10.2 Usage as interruptive inputs Source operation terminal block DI_IX3 DI_IX2 Interrupt- inputs DI_IX1 DI_IX0 Terminal block X8 To use the digital inputs as interruptive inputs, choose the mode “Interrupt”. The interrupts can be triggered on rising edge, falling edge or both. A XOB is called when an interrupt is Input Assigned to detected. The XOB number is config- DI_IX0 XOB 20 ured by default at XOB 20 for input 0 DI_IX1 XOB 21 up to XOB23 for Input 3. DI_IX2 XOB 22 DI_IX3 XOB 23 Device configurator 10-2 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Interrupts Saia-Burgess Controls AG Usage as CPU onboard Counter 10.3 Usage as CPU onboard Counter Source operation terminal block DI_IX3 Counter 1 DI_IX2 Interrupt- inputs DI_IX1 Counter 0 DI_IX0 Terminal block X8 10.3.1 Introduction The four Interrupt Inputs can be used as two independent On board Counters. This On board Counter is counting independent of the CPU Cycle. As soon as “Counter” is selected in the Device Configurator for the interrupt con- nections, two interrupts are reserved for each of the two counters (clearly visible in the Device Configurator (red frame, second counter greyed out) and in the drawing above at the pin assignment counter 0 and 1). ¾ The onboard Counter is able to count bidirectional. ¾ The Overflow handling is configurable. If a configurable reference value is reached, it is possible to call a Process Alarm XOB. ¾ The max counter Frequency is limited to 1 kHz. 10-3 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Interrupts Saia-Burgess Controls AG Usage as CPU onboard Counter 10.3.2 Function Description 10.3.2.1 Function Block Diagram Start Count/Rotate Input IX1 Clock Counter 65000 65000 Input IX0 *(–1) Clock/Direction Call XOB Comparator Reference value XOB XOB Number Info Configurable Parameters with SFC Call 10.3.2.2 Function Description (applies to counter 0 as well as to counter 1) To configure, to start and stop the Onboard Counter there exist a system call ...
Interrupts Saia-Burgess Controls AG Usage as CPU onboard Counter 10.3.2.3 Counter Mode Description The Counter Mode is confugured in the IO-Configuration (On Board IO’s Inputs / Interrupts / Counter / Watchdog ) X1 Encoding In this mode, the counter is set on every positive edge of A and counts up or down depending on the B state. X2 Encoding The same behavior holds for X2 encoding except the counter increments or decre- ments on each edge of channel A, depending on which channel leads the other. Each cycle results in two increments or decrements, as shown in Figure. X4 Encoding The counter increments or decrements similarly on each edge of channels A and B for X4 encoding. Whether the counter increments or decrements depends on which channel leads the other. Each cycle results in four increments or decre- ments, as shown in Figure. 10-5 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Interrupts Saia-Burgess Controls AG Usage as CPU onboard Counter 10.3.2.4 System Function Parameters With the System Function Library Number 17 Function Number 1 it is possible to start / stop and Configure the OnBoard Counter. The following table displays the Parameters: Parameter Declaration Type Range Description COUNT_NUM Input 0: Counter 0 1: Counter 1 Wert START/STOP Input TRUE / FALSE Start or Stop the Counter CONT Input TRUE / FALSE True: Continuous counting False: Counting until the ref value is reached ROTATE Input TRUE / FALSE True: O verflow handling, see description Rotate False: ...
Watchdog Saia-Burgess Controls AG Watchdog relay PCD2.M4_ CPUs have a hardware watchdog as standard equipment. The watch- dog relay is at Pins 5 and 6 at Plug X4. Technical data Number of outputs 1× relay switching contact Function Watchdog function or user output (selectable) Max. voltage 48 VAC or VDC Switching capacity 1 A (with DC switch-on voltage, a freewheeling diode should be con- nected in parallel to the load) Functional description As soon as the watchdog relay is called at the address O 255 by a switch on/ off frequency of < 200ms (or other value configured in device configurator), the relay contact closes. It remains closed until the pulse time exceeds the configured value. Example of an instruction list (IL) sequence: Label Command Operand Comment ; or 1 … 15 WD_Flag ; invert the help flag WD_Flag O 255 ;...
Communication ports Saia-Burgess Controls AG X1 - USB Port (Programming Interface) Communication ports Portnumber (Software- Description adress) Programming Port #2 S-Bus, free protocol Port #10 Profi S-Net Port #0 Integrated RS-485 terminal Port #1 Slot A interface selectable with PCD7.F1xxS Port #9 Dual Ethernet Switch Port #8 Profibus-DP with PCD2.F7500 12.1 X1 - USB Port (Programming Interface) Plug: Standard vertical USB series B (device plug) Default: USB 1.1 device (slave), full speed 12 Mbps, with Softconnect Protection: transil...
Communication ports Saia-Burgess Controls AG X2 – Isolated RS-485-Port/MPI 12.2 X2 – Isolated RS-485-Port/MPI 9-pole D-Sub-terminal (Port #2) PCD7.F7500 X3Ext Can be used as MPI interface or as Halt standard S-Bus RS-485. Error Do not remove PCD7FxxxS Slot A S-Net / M PI / R S-485 D-Sub-Pin Signal Explanation PGND 0 V from 24-V supply voltage RxD/TxD-P B (rot)
Communication ports Saia-Burgess Controls AG X4 - RS-485 (Port #0, not electrically isolated) 12.3 X4 - RS-485 ( 0, not electrically isolated) Port # In S-Bus, Modbus or MC4 communications mode, an RS-485 link can be established via port 0 with terminal block X4, terminals 8 and 9. PCD7.F7500 X3Ext terminal block RS 485 Bus-cable Halt RX - TX Error Open /RX - /TX Close Do not remove PCD7FxxxS Slot A Switch S1, connecting or disconnecting the RS-485 termination resistors ` With switch S1, the terminating resistors are switched on or off. Switch S1 must ...
Communication ports Saia-Burgess Controls AG X5 - Sot A (Port 1) Terminalbloc 12.4 X5 - Sot A ( 1) Terminalbloc Port # The interface type can be selected using the PCD7.F1xxS modules.. PCD7.F7500 terminal block X3Ext … … … … … Halt from/to … Error PCD7.F1xxS … Slot A … … … Do not remove PCD7FxxxS Slot A ...
Communication ports Saia-Burgess Controls AG X6 and X7 - Ethernet Switch Port #9 12.5 X6 and X7 - Ethernet Switch Port #9 ` A 10/100 Mbits switch on X6 and X7 is used for the Ethernet connection, which automatically adapts to the two speeds. PCD7.F7500 ` The two sockets with the same Ethernet address can be used independently of each other in terms of speed. X3Ext ` Data transfer and programming or debugging are possible without restrictions. Halt Error Do not remove PCD7FxxxS Slot A Function 2 Port Switch Socket type RJ45, metal housing, 2 LEDs LEDs yellow...
Communication ports Saia-Burgess Controls AG X9 - Slot C Profibus-DP-Master (Port #8) optional 12.6 X9 - Slot C Profibus-DP-Master (Port #8) optional Profibus-DP master can be upgraded by retrofitting the PCD7.F7500 module to enabled Slot C . Anschluss Slot D-Sub PCD7.F7500 9 pole (feminine) MBit/s X3Ext PG5 port adress Pin Nr. Signal Halt Error RxD / T xD-P B (rot) RTS / C NTR-P DP GND DP +5 V Do not...
Page 33
Communication ports Saia-Burgess Controls AG X9 - Slot C Profibus-DP-Master (Port #8) optional Mounting on slot C ● Remove the power supply from the PCD2.M4_. ● Remove all cables (UBS, Ethernet, Profibus, RS-232) that may be present and that may interfere with the removal of the housing. ● Remove the upper part of the housing. ● Next, insert the spacer supplied (Fig. 2) on the back of the PCD2.F7500 to be attached. The round end of the spacer must be inserted into the round hole of the CPU board. PCD7.F7500 X3Ext Halt Error Fig. 1 Fig. 2 Fig. 3 Do not remove ● When plugging the spacer into the multi-board connector, make sure that it snaps into the round hole (Fig. 3) provided on the CPU board! Slot A ● Screw in the Torx T10 screw supplied to secure it on the pre-assembled spacer with screw thread. 12-7 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Page 34
Communication ports Saia-Burgess Controls AG X9 - Slot C Profibus-DP-Master (Port #8) optional ● Process the upper part of the housing as follows: Pre-punched recess in the cover, break out the cut-outs on the left of the two D-Sub plugs. Put on the upper part of the housing and secure it with the two Torx screws. 12-8 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Communication ports Saia-Burgess Controls AG I/O module based interfaces PCD2.F2xxx 12.7 I/O module based interfaces PCD2.F2xxx Two further serial interfaces allow the use of special I/O modules PCD2.F2xxx on suitable I/O slots. The modules of type PCD2.F2xxx are intended for the inclusion in the I/O slots 0…3 of the PCD2.M_. PCD4.M4160 PCD2.M4560 PCD2.F2xxx Module PCD2.F2xxx Module P C D 7 . F 1 x x S P C D 7 . F 1 x x S P C D 7 .
Page 36
Communication ports Saia-Burgess Controls AG I/O module based interfaces PCD2.F2xxx Further documents on the subject of communication are recommended as supple- ments: Thema document number System Catalog (serves as an overview) 26-215 Programming tool Saia PG5 26-732 ® Programming by instructionlist 26-733 Ethernet-TCP/IP 26-776 RS-485 networks / components 26-740 Serial interface module PCD7.F1xxx 27-664 I/O based interface module PCD2.F2xxx 27-649 12-10 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Mounting Saia-Burgess Controls AG PCD2.M4160 | PCD2.M4560 Mounting There are 2 different types of installation: mounted with screws snapped on 2 DIN rails 14-1 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Mounting Saia-Burgess Controls AG Mounting with screws 14.1 Mounting with screws Screw diameter: less than Ø 4.9 Screw head diameter: less than Ø 8.0 125 mm 14-2 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Mounting Saia-Burgess Controls AG Mounting with screws 14.1.1 Mounting the PCD2.M4x60 and PCD2.C1000: Step 1 Step 2 Step 3 Fit the base plate over the screw Slide bottom Tighten the screws heads and press gently to the wall panel downwards Step 4 Step 5 Snap lid onto base plate Fixed 14.1.2 Dismounting the PCD2.M4x60 and PCD2.C1000: Step 1 Step 2 Step 3 Step 4 Remove the cover Loosen the screws Push the Lift the base plate base plate upwards 14-3 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Mounting Saia-Burgess Controls AG DIN rail mounting 14.2.1 Mounting the PCD2.M4x60 and PCD2.C1000: Step 1 Step 2 Step 3 Press the bottom of the Now press the upper half Fixed module to the wall and towards of the wall until it snaps slide it slowly upwards until it stops at the lower DIN rail 14.2.2 Dismounting the PCD2.M4x60 and PCD2.C1000: Press the module upwards and simultaneously pull the upper half of the module from the wall 14-5 User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Annex Saia-Burgess Controls AG Icons Annex Icons In manuals, this symbol refers the reader to further information in this manual or other manuals or technical information documents. As a rule there is no direct link to such documents. This symbol warns the reader of the risk to components from electrostatic discharges caused by touch. Recommendation: Before coming into contact with electrical components, you should at least touch the system’s negative pole (cabinet of PGU connector). However, it is better to use a grounding wrist strap with its cable permanently attached to the system’s negative pole. This sign accompanies instructions that must always be followed. Waste of Electrical and Electronic Equipment (WEEE) disposal WEEE Directive 2012/19/EC Waste Electrical and Electronic Equipment directive This symbol on our product shows a crossed-out “wheelie-bin” as required by law regarding the Waste of Electrical and Electronic Equipment (WEEE) disposal. This indicates your responsibility to contribute in protecting the environment by proper disposal of this waste, i.e., not disposing of this product with your other wastes. To know the right disposal mechanism, please check the applicable law.” User Manual PCD2.M4x60 │ Document 27-648 │ Edition ENG06 │ 2020-10-21...
Need help?
Do you have a question about the PCD2.M4160 and is the answer not in the manual?
Questions and answers