Page 1 PS 416-CPU-x00 Central Unit PS 416-POW-4x0 Power Supply Card PS 416-BGT-4xx Rack 02/98 AWB 27-1208 GB 3rd edition 02/98 © Moeller GmbH, Bonn Author: Werner Albrecht Editor: Thomas Kracht Translator: Terence Osborn For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 2: For Immediate Delivery Call Kmparts.com At (866)
(printed, photocopy, microfilm or owner concerned. any otherprocess) or processed, duplicated or distributed by means of electronic systems without written permission of Moeller GmbH, Bonn. Subject to alterations without notice. For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 3 List of revisions to AWB 27-1208-GB Edition Page Revision Rev. n. a. 02/98 PS 416-CPU-200/-300 For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 4: Table Of Contents
Contents About the manual PS 416 system PS 416-BGT-4.. racks PS 416-POW-400/410/420 Power supply cards PS 416-CPU-200/-300/-400 Central unit Appendix Index For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 6: About The Manual
About This Manual The rack, power supply card and the central processing unit form the basis of the PS 416 system. Their tasks and functions are described in this manual. There are various cards which you can integrate in the modular system, depending on the requirements. The functions of these cards are described in separate manuals.
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Page 8: Ps 416 System
PS 416 System Contents 1 System Description Setup Hardware/software requirements Components 2 Configuration Master Slaves for remote I/O expansion Intelligent slaves 3 Engineering Electromagnetic compatibility (EMC) Reaction times Interference immunity For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 10: System Description
Networking and communication are implemented via standard interfaces or standard bus protocols. The Moeller Suconet K bus protocol is used as a system bus for connecting remote inputs/outputs or an expander rack. The Sucosoft S 40 software package forms the user interface for user-friendly programming, testing and commissioning.
Page 11: Components
System Description Table 1: Hardware and software requirements Sucosoft for PS 416-CPU-223 Operating system from version 1.32 S 30-S 316-D/-GB/-F from for PS 416-CPU-200/-300: version 2.31 Operating system from version 2.0 for PS 416-CPU 400: S 40-D/-GB/-F from version 2.0 Operating system from version 1.0 S 40-D/-GB/-F from version 1.0 Rack...
Page 12 Components Standard cards Digital input/output cards PS 416-INP-400/401 PS 416-OUT-400/410 Analogue input/output cards PS 416-AIO-400/PS 416-AIN-400 PS 416-CNT-200 counter card Networking/communications cards PS 416-NET-210 Suconet K card (only with PS 416-CPU-223 central unit) PS 416-NET-400 Suconet K card PS 416-NET-230 PROFIBUS card PS 416-NET-220 Interbus S card PS 416-COM-200 Communications card PS 416-COM-200 Communications card...
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Page 14: Configuration
Configuration Networks for different applications can be created with the Suconet K system bus. The network stations are configured according to their functions. The following functions are possible: Master Slaves for the expansion of the remote inputs/ outputs: Expander rack Expansion module Intelligent slaves EM 4-201-DX2...
Page 15: Master
Configuration Master The master manages the access to the remote input/ output cards. A master is any card that manages a network line. In a PS 416 system the PS 416-CPU-300/-400 and/or PS 416-NET-400 can be implemented as master. Both cards have a Suconet K interface.
Page 16: Slaves For Remote I/O Expansion
Slaves for remote I/O expansion 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 Figure 3: Maximum expansion Lines with PS 416-CPU-300/-400 PS 416-CPU-200 Lines with Stations Slaves for remote I/O Slaves for remote I/O expansion have no individual expansion central unit.
Page 17 Configuration Expander racks The remote expansion of the inputs/outputs in a PS 416 system is implemented with racks which do not have a CPU (expander racks). The required configuration parameters of the local inputs/outputs of these racks are sent to the PS 416-NET-400 card via the master.
Page 18: Intelligent Slaves
Intelligent slaves 784 bytes of memory are available for the communication with all connected stations of a line on the PS 416-CPU-300/-400. The following table shows the memory assignment of the cards to be used. Table 3: Memory assignment of the cards of an expander rack Card Input byte...
Page 19 Table 4: Data exchange memory of intelligent slaves Components Usable memory PS 416-CPU-300/-400 784 bytes PS 416-NET-400 1492 bytes PS 4-101-DD1 6 bytes Master Slave PS 4-111-DR1/DR5 7 bytes Slave Master PS 4-201-MM1 Total I/O 78 bytes PS 4-141-MM1 PS 4-151-MM1 PS 4-401-MM2 168 bytes 1) The available memory size depends on the number of...
Page 20: Engineering
Engineering Electromagnetic Observe the engineering instructions in the manual compatibility (EMC) “EMC Engineering Guidelines for Automation Systems” (AWB 27-1287-GB) Reaction times The shortest reaction time can be implemented with local cards that are addressed by the central unit via the internal bus. Only the program cycle time and the input/output delays of the cards determine the reaction time.
Page 21 Engineering PS 416 Ferrite ring 230 V AC Ensure that all signal cables of communications and analog cards are laid separately from power and control cables in order to prevent interference. Radiated interference Interference is either caused by radiation or via electromagentic fields or by static discharges.
Page 22 Interference immunity Static discharges may cause a system fault via conductive components which do not belong to the operating circuit (e. g. plugs, switches, mounting components). All freely accessible components which are not covered by a flap or covering are electrically connected to the rack.
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Page 24: Ps 416-Bgt-4
PS 416-BGT-4.. Racks Contents 1 Racks Task System description Setup 2 Engineering Coupling the racks Assignment of the rack 3 Installation Fixing the potential equalisation bar Connecting the protective earth Fitting/removing cards 4 Operation Monitoring For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 26: Racks
Racks Task The PS 416-BGT-4.. racks are used for the assembly of PS 416 programmable controllers. The racks house mechanically and electrically house the individual cards. They provide protection against mechanical and electromagnetic interference. An internal bus is used for the power supply and the signal exchange between the cards.
Page 27: Setup
Racks Setup Figure 4: Setup of the racks for mounting plate installation (left) and front mounting (right) Fixing holes for mounting/installation of the rack Protective earth connection (PE) Fixing holes for the potential equalisation bar Fast-release lock for fixing the card Rails for inserting the card For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 28 Setup Potential equalisation bar A suitable potential equalisation bar is supplied with each rack as an accessory. The bar is used for connecting the cable screens to the protective earth. Table 6 shows an overview of potential equalisation bars for the individual racks. Table 6: Type overview potential equalisation bars Racks Potential equalisation bar...
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Page 30: Engineering
Engineering All racks can be used as a basic unit (with central unit) or as an expander rack (without central unit). Each rack must be fitted with a power supply card which must always be fitted in the left "POW" slot. The other slots can be used as required.
Page 31 Engineering Figure 6 shows the possible assignments of the rack for the individual cards. PS 416-POW-4x0 PS 416-CPU- 200/-300/-400 PS 416-... PS 416-BGT-420/421 PS 416-BGT-410 PS 416-BGT-400 PS 416-POW-4x0 PS 416-NET-400 PS 416-... Figure 6: Slot assignment in the basic unit and the expander rack 1 slot = 4 space units (1 space unit = 5.08 mm)
Page 32: Installation
Installation The PS 416-BGT-400/410/420 racks are directly installed on a mounting plate in a control cabinet. The PS 416-BGT-421 rack can be installed via the mounting brackets on the front in a 19-inch mounting rail system or swing frame. Use type M6 25 screws for installing the rack on the mounting plate or for front installation.
Page 33 Installation Installation Fit the cards into the rack: the PS 416-POW-4x0 power supply card into the “POW ” slot, the PS 416-CPU-200/-300/-400 central unit into the slots 2 and 3, the Suconet K card into the slot 2, all other cards into any available slot. Insert the card into the rack until you hear the spring lug snap into position.
Page 34 Fitting/removing cards Figure 7: Installing/removing cards. The PS 416-POW-400 power supply card as an example For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 36: Operation
Operation Monitoring During operation, the rack monitors the 5 V system voltage. The function cards are disabled if the system voltage falls below the permissible minimum of 4.75 V. The rack also monitors the control of the internal bus by the central unit (basic unit) or the PS 416-NET-400 Suconet K card (expander rack).
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Page 38: Power Supply Cards
PS 416-POW-400/410/420 Power Supply Cards Contents 1 About the power supply card Task Setup 2 Engineering Number of power supply cards Mains filter Connection assignment Wiring PS 416-POW-400/-420 Wiring PS 416-POW-410 Cabling 3 Installation Connecting the mains supply 4 Operation Function of the card 5 Diagnostics For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 40: About The Power Supply Card
Power Supply Card Task The PS 416-POW-4x0 power supply card generates the 5 V stabilised system voltage required for the operation of the PS 416 automation system from the connected mains supply. The power supply card also monitors the power supply for voltage failures. Setup The PS 416-POW-4x0 power supply card can be operated in all racks of the PS 416 automation...
Page 41 Power Supply Card Figure 8: Setup of the PS 416-POW-400 and PS 416-POW-420 cards Spring lug Front cover Screw terminal for power supply PS 416-POW-400 L1/N: 230 V AC PS 416-POW-420 L1/N: 115 V AC PS 416-POW-400/420 protective earth LED for mains supply For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 42 Setup Figure 9: Setup of the PS 416-POW-410 card Spring lug Front cover Screw terminal for power supply 24 V/0 V: 24 V DC protective earth LED for mains supply For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 44: Engineering
Engineering Ensure that the relevant safety regulations and accident prevention requirements (EN, IEC regulations) are observed if required. With 24 V supplies the low voltages must be isolated electrically. Only power supply units produced according to IEC 364-4-41 must be used. Emergency-stop devices according to EN 60204/IEC 204 must be functional in all operating modes of the controller.
Page 45: Number Of Power Supply Cards
Engineering Potential isolation Overvoltage Overvoltage protection protection Filter transformer 5 V/ Power Control unit Power Fail Indicator PS 416-POW-400/420 Figure 10: Block diagram for the PS 416-POW-4x0 power supply card Number of power Each rack requires one power supply card. The fitting supply cards of several power supply cards on one rack is not possible.
Page 46: Connection Assignment
Connection assignment Connection The card is connected to the mains supply via a assignment 3-pole screw terminal which is located behind the front cover. Figure 11: Terminal for mains supply Left: Terminal block for a voltage of 230 V AC (PS 416-POW-400) 115 V AC (PS 416-POW-420) Right: Terminal block for a voltage of...
Page 47: Wiring Ps 416-Pow-400/-420
Engineering Wiring Figure 12 shows the direct connection of the mains PS 416-POW-400/-420 supply to the PS 416-POW-400/420 power supply cards. PS 416-POW-400/420 PS 416 Figure 12: Direct connection of the mains supply 230 V or 115 V AC PS 416-ZBX-405 ferrite ring Mounting see “Cabling”...
Page 48 Wiring PS 416-POW-400/-420 An isolation monitoring device must be implemented with unearthed mains supply (EN 60 204-1). I > I > I > PS 416-POW-400/420 PS 416 Figure 13: Connection of the mains supply 230 or 115 V AC via control transformer with earthed operation PS 416-ZBX-405 ferrite ring Mounting see “Cabling”...
Page 49 Engineering I > I > I > Isolation monitoring PS 416-POW-400/420 PS 416 Figure 14: Connection of the mains supply 230 or 115 V AC via control transformer with unearthed operation PS 416-ZBX-405 ferrite ring Mounting see “Cabling” on page 49. The ferrite ring is not supplied with the card.
Page 50: Wiring Ps 416-Pow-410
Wiring PS 416-POW-410 Wiring Figure 15 shows the external wiring of the PS 416-POW-410 PS 416-POW-410 power supply card with earthed operation; figure 16 with unearthed operation. An isolation monitoring device must be implemented with unearthed mains supply (EN 60 204-1). I >...
Page 51 Engineering I > I > I > Isolation monitoring PS 416-POW-410 PS 416 24 V Figure 16: Connection of the 24 V DC mains supply, unearthed operation For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 52: Cabling
Cabling Cabling Use a 3-core cable (with protective conductor) for the connection of the mains supply.The core cross- section must not exceed 1.5 mm (solid or flexible). Connect twisted mains cables and with a sufficient distance to power cables in order to prevent inductive interference.
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Page 54: Installation
Installation Connecting the mains Observe the following safety instructions before supply connecting the power supply card! Caution Ensure that the mains connection cables are de-energized before connecting them to the power supply card. Always connect the protective earth conductor. A protective conductor that is not connected may be dangerous to persons and machine/system! Connect the protective conductor and the mains...
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Page 56: Operation
Operation Function of the card The power supply card generates the 5 V DC stabilised system voltage once the mains supply is switched on. The regulated voltage is potentially isolated from the mains supply. The card operates as a switched mode power supply unit in compliance with protection class 1.
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Page 58: Diagnostics
Switch off the mains supply. Contact your Moeller sales office. The system voltage is not directly indicated via a LED. If none of the LED on all the cards (except...
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Page 60: Ps 416-Cpu-200/-300/-400 Central Unit
PS 416-CPU-200/-300/-400 Central Unit Contents 1 About the Central Unit Task Setup 2 Engineering Slot Power supply Interfaces PRG interface SBI interface (only PS 416-CPU-300/-400) Screening/potential equalisation 3 Hardware Configuration Setting the PRG address Selecting the PRG interface Switching on the PRG terminating resistors Selecting SBI interface (PS 416-CPU-300/-400 only) 4 Installation...
Page 61 Contents Stop of the user program Restart behaviour 6 Test/Commissioning/Diagnostics LED display Self test Loading the operating system Loading the user program Error messages Acknowledging errors on NOT-READY Clearing the diagnostic status word Saving data after a battery failure Checking the connection between PLC and PRG 7 Direct Communication with Data Terminal Units via the COM Function Block...
Page 62: About The Central Unit
Central Unit Task The central unit controls and monitors the automation process. It stores and processes the user program and manages the data exchange with the connected slaves. The central unit is provided with the required interfaces for communication, programming and data exchange. Setup The central unit consists of two printed circuit boards and occupies two slots in the rack (= 8 space units).
Page 63 Central Unit PS 416-CPU-200 PS 416-ZBB-410 PS 416-ZBB-410 Figure 18: Setup of the PS 416-CPU-200 Plug-in backup battery (on the front) Spring lug Switch for bus terminating resistors (PRG: RS 485) Plug-in reserve battery (internal) Address switch (PRG) For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 64 Setup Plug-in backup battery (on the front); for saving the data if the operating voltage fails (see sections “Installation ” , “Operation ” ). Spring lug: Push down before removing Switch for bus terminating resistors (PRG: RS 485); for activating/de-activating the bus terminating resistors if the PRG interface is operated in RS 485 mode (see section “Hardware configuration ”...
Page 65 Central Unit READY NOT READY ERROR CHANGE PRG-BUS-ADDR. HALT M-RESET Figure 19: Setup of the PS 416-CPU-200 central unit (front view) Plug-in backup battery Multi-function button LED display Front cover Space for marking strip Socket for memory card Eject button for memory card Operating mode selector switch Selector switch for PRG interface (RS 232/RS 485) PRG interface...
Page 66 Setup Multi-function button; enables several system functions in conjunction with the operating mode selector switch (see section “Operation ” ). LED display; indicates the states of the CPU (see section “Test/ Commissioning/Diagnostics ” ). Space for marking strip; the currently set PRG bus address can be written here (see “Hardware configuration ”...
Page 67 PS 416-CPU-300/-400 PS 416-ZBB-410 PS 416-ZBB-410 Figure 20: Setup of the PS 416-CPU-300/-400 central unit Plug-in backup battery (front) Spring lug Switch for bus terminating resistors (PRG: RS 485) Plug-in reserve battery (internal) Switch for bus terminating resistors (SB: RS 485) Address switch (PRG) For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 68 Plug-in backup battery (on the front); for saving the data if the operating voltage fails (see sections “Installation ” , “Operation ” ). Spring lug: Push down before removing Switch for bus terminating resistors (PRG: RS 485); for activating/de-activating the bus terminating resistors if the PRG interface is operated in RS 485 mode (see section “Hardware configuration ”...
Page 69 Central Unit READY NOT READY ERROR CHANGE PRG-BUS-ADDR. HALT M-RESET Figure 21: Setup of the PS 416-CPU-300/-400 central unit (front view) Plug-in backup battery Multi-function button LED display Front cover Space for marking strip Socket for memory card Eject button for memory card Operating mode selector switch SBI-Interface Selector switch for PRG interface (RS 232/RS 485)
Page 70 Setup Multi-function button; enables several system functions in conjunction with the operating mode selector switch (see section “Operation ” ). LED display; indicates the states of the CPU (see section “Test/ Commissioning/Diagnostics ” ). Space for marking strip; the currently set PRG bus address can be written here (see “Hardware configuration ”...
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Page 72: Engineering
Engineering Slot The slots 2 and 3 are provided for the central unit. Power supply The central unit is supplied by the power supply unit in the rack. Power consumption, see Technical data in the Appendix. Interfaces PS 416-CPU-200 A programming (PRG) interface is located on the front of the card.
Page 73 Engineering Sucosoft S 40. 9600 bit/s is recommended as a standard value. A prepared cable is offered as connection cable in the Accessories. PS 416-CPU-200/-300/-400 Figure 22: Point-to-point connection Interface parameters: The parameters required for operating the interface are set directly in the Connection List window of the Sucosoft S 40 test and commissioning tool.
Page 74 PRG interface Possible settings are: 2400, 4800, 9600 19200, 38400 and 57600 bit/s. If the CPU is started via a cold start, the PRG is automatically connected with the selected baud rate and transfers the new parameters. If no communication is posible with these parameters, the connection is aborted and the CPU must be restarted with new values.
Page 75 Engineering If the RS 485 interface cable is lengthened, the UM1.5 interface converter must be provided a separate 5 V DC power supply. UM 1.5 Figure 24: Connection between programming device and PS 416 controller in RS 485 mode Pin assignment SGND +5 V PGND...
Page 76 PRG interface The table shows the meaning of the signals depending on the selected interface. Note Pin 9 is assigned to the + 5V internal power supply and Pin 5 is assigned to ground (internal chassis). These pins must not be connected otherwise this will destroy the card.
Page 77 PRG/RS232 Programming device Signal Signal (sender) (receiver) – SGND SGND Screen Figure 26: Wiring of the central unit and programming device via PRG/RS 232 PRG interface/RS 485: If the PRG interface on the central unit is used as a RS 485 interface, the UM 1.5 interface converter must be used in the connection between the RS 485 interface and the RS 232 interface of the programming device.
Page 78: Sbi Interface (Only Ps 416-Cpu-300/-400)
SBI interface (only The communication with the Suconet K stations or PS 416-CPU-300/-400) data terminal units is carried out via the SBI interface of the central unit. Transparent or Suconet K mode can be set for the SBI interface (see Hardware configuration), depending on the application at hand.
Page 79 Engineering Pin assignment SGND +5 V PGND TA/RA TB/RB Figure 28: SBI interface, top view Table 9: Meaning of signals RS 485 Function – – – – TA/RA Send/receive data Potential ground over 100 Ω PGND SGND Signal ground for UM 1.5 interface converter –...
Page 80 SBI interface (only PS 416- CPU-300/-400) Note Pin 9 is assigned to the + 5V internal power supply and Pin 5 is assigned to ground (internal chassis). These pins must not be connected otherwise this will destroy the card. SBI/RS 485 Suconet K Stn.
Page 81: Screening/Potential Equalisation
Screening/potential Connect the screen of the data cables with the equalisation potential equalisation bar in order to prevent interference (for mounting instructions see chapter “Interference immunity ” ). Potential equalisation must be provided between the two cards when using R S485 interfaces if the potential difference is greater than 7 V.
Page 82: Hardware Configuration
Hardware Configuration Setting the PRG The default address of the programming device address interface is set to 1. The interface can be connected with the programming device (PRG) if you have configured an appropriate communication relation in Sucosoft S40. Proceed as follows if you wish to use an address for addressing the programming device: Set the address via the address switch (see coding table).
Page 83 Hardware Configuration Table 10: Address coding Address Switch For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 84: Selecting The Prg Interface
Selecting the PRG interface Example The switch for a CPU with the address 4 is set as follows: 2 3 4 5 6 7 8 Figure 31: Switch position for address 4 Selecting the PRG Set the selector switch for the PRG interface as interface follows: Push the switch to the left to connect the...
Page 85 Hardware Configuration Set the poles 1 and 2 of the switch for bus terminating resistors to position ON. Figure 33: Activated bus terminating resistors Note Both poles must always be in the same position in order to ensure the correct functioning of the card.
Page 86: Selecting Sbi Interface
Selecting SBI interface (PS 416-CPU-300/-400 only) Selecting SBI interface Set the address and the baud rate in the Sucosoft (PS 416-CPU-300/-400 S 40 Topology Configurator. The following baud only) rates are available: Suconet K mode: 187.5/375 Kbaud Transparent mode: 300/600/1200/2400/4800/9600/19200 bit/s Figure 34: Setting the baud rate in Suconet K mode For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 87 Hardware Configuration Figure 35: Setting the baud rate in Transparent mode For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 88: (Ps 416-Cpu-300/-400 Only)
Selecting SBI interface (PS 416-CPU-300/-400 only) Switching on the SBI terminating resistors (PS 416-CPU-300/-400 only) The terminating resistors of the physically first and last bus station must be switched on (ON) when the SBI is run in Suconet K mode. In all other cases the bus terminating resistors must be inactive (OFF).
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Page 90: Installation
Installation ESD measures Before touching operating elements, interfaces and/ or data connectors during the installation, make sure that you are free of electrostatic charge by touching a surface with a good earth (control cabinet, device frame). Ensure the following during normal operation ("RUN" mode): the front covers should be closed the front covers should be snapped into position...
Page 91: Fitting/Removing The Memory Card
Installation Open the front cover Push the retaining clip downwards Remove the battery Insert the new battery into the space provided until the retaining clip snaps into position Close the front cover Fitting/removing the Fitting memory card Insert the memory card into the socket until the eject button appears.
Page 92 Fitting/removing the memory card Removing Press the eject button and remove the memory card. PS 416-CPU-400 PS 416-ZBB-410 ¬ ® HALT M-RESET ¯ PS 416-MEM-430/440 Figure 37: Fitting/removing the memory card and backup battery For Immediate Delivery call KMParts.com at (866) 595-9616...
Page 93: Changing The Reserve Battery
Installation Changing the reserve The reserve battery is not discharged during normal battery operation and has a very long lifespan. The battery must be changed every five years since the central unit is not provided with a monitoring device for the battery.
Page 94: Changing The Mc Battery
Changing the MC battery Changing the MC Proceed as follows to change the MC battery on the battery memory card : PS 416-ZBB-300 Figure 39: Changing the MC battery For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 96: Operation
Operation ESD measures Before touching operating elements, interfaces and/ or data connectors during the installation, make sure that you are free of electrostatic charge by touching a surface with a good earth (control cabinet, device frame). Ensure the following during normal operation ("RUN" mode): the front covers should be closed the front covers should be snapped into position...
Page 97 Operation The PS 416-CPU-200 contains the following elements required for the operation of the PS 416 automation system: Control processor for program processing Memory elements for operating system, programs and data Real-time clock Interface to parallel bus and bit bus Batteries for data backup in the event of voltage drops Monitoring device for battery function...
Page 98 ESD measures PS 416-CPU-300 Realtime clock User Operating Memory program system card memory memory 512 KBytes 512 KBytes 512 KBytes 1 MByte Voltage monitoring System bus Control interface processor processor ASIC RS 485 RS 485 pluggable/ RS 232C optional Suconet K PS 416 Transparent mode (COM) Figure 41: Block diagram of the PS 416-CPU-300...
Page 99 Operation PS 416-CPU-400 Real- time clock Memory Memory- Main card card memory 1 MByte (optional) (optional) Voltage monitoring System bus Mutual monitoring Control interface processor processor ASIC RS 485 RS 485 Pluggable RS 232C PS 416 Suconet K Figure 42: Block diagram PS 416-CPU-400 The PS 416-CPU-300/-400 contains the following elements required for the operation of the PS 416 automation system:...
Page 100: Memory Elements
Backup batteries are not part of the central unit, and the user must fit suitable batteries in the unit. Only Moeller battery modules must be used. The entire main memory of the CPU is protected by a backup battery against data loss in the event of power failure.
Page 101: Memory Card
As Flash for Backup (non-volatile memory). Only use the memory cards mentioned under “Accessories ” . Contact your Moeller sales office if you require more memory. Note Ensure that you are free of electrostatic charge before fitting the memory card.
Page 102: Function
Function Function The user program is started once all required activities are processed in the system section. Fixed and event-driven system activities which are taken from the system pulse interrupt program processing. A consistent process image is maintained between the creation of the input and output image in the user program cycle.
Page 103 Operation Program system activities (TP) Program system activities occur each 10 ms for monitoring the following system components: Communication interfaces Indicated interrupts Suconet P system task Watchdog user program (parameters can be set). Interrupts (I) The controller reacts by interrupt request on rare but urgent events.
Page 104 Stop, Watchdog Start 0 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 20 1 2 3 4 5 Tcyc Tcyc Tcycmax Tcycmax Tprog Tprog Tprogmax Tprogmax Tintv Tintv Figure 43: Time diagram of the system routine activities I = Interrupt PP = Program, periodically PC = Program, cyclically...
Page 105: Startup Behaviour
Operation Note The cycle time of a minimum program lasts at most 0.5 ms. Short-time d.c. voltage drops of 3 ms (hot start) are not indicated and must thus be taken into account when calculating the minimum program cycle time. Startup behaviour The position of the operating mode selector switch defines the startup behaviour of the central unit.
Page 106: Stop Of The User Program
Stop of the user program Device cold start All variables are set to the initial value. The program processing starts with the first instruction. Device warm start The interrupted program cycle with the saved process data of the interrupt is terminated. Normal program processing is resumed.
Page 107 Operation Table 12: System functions depending on the position of the operating mode selector switch Function Device status SET button Switch position RUN M-RESET Device cold start READY – – Device warm start READY – – Stop program – – Halt on return of voltage OFF –...
Page 108: Test/Commissioning/Diagnostics
Test/Commissioning/Diagnostics LED display The following system states are possible and are indicated via LEDs: Table 13: LEDs of the system states Device status READY NOT-READY ERROR CHANGE Self test, load OS Flashes No OS loaded Flashes Flashes Flashes Flashes Error detected Ready for operation Operation running No master CPU...
Page 109: Loading The User Program
Test/Commissioning/ Diagnostics If a program is saved as well, the action can be finished with RUN if the start attribute is set to AUTOSTART. A new operating system can be loaded from the memory card as follows: Note All programs and data are deleted from the CPU memory! Table 14: Loading the operating system (OS) from the memory card...
Page 110: Error Messages
Error messages The following start attributes can be set before loading the user program onto the memory card: AUTOSTART: The program is started automatically after being loaded. LOAD: The program is loaded and not started. The startup behaviour is not set for active. A program start is only possible via the PRG programming device.
Page 111: Acknowledging Errors On Not-Ready
Test/Commissioning/ Diagnostics Acknowledging errors Errors that cause a NOT-READY program abort can on NOT-READY be acknowledged as follows: Set the operating mode selector switch to HALT. Press the SET button. Clearing the diagnostic The diagnostic status word can be cleared when the CPU is either in “ready ”...
Page 112: Checking The Connection Between Plc And Prg
Checking the connection between PLC and PRG Memory card fitted: If the LED does not go out after the backup battery has been changed and the signal acknowledged, the battery for the memory card (MC battery) has discharged. Change the MC battery (see section “Installation ”...
Page 113 Proceed as follows if none of the points mentioned above are relevant: Check the connection cable Exit Sucosoft S 40 and restart the PC (cold start) Press the SET button for 5 seconds in order to reset the PRG baud rate to 9600 baud and re-activate the “Connect ”...
Page 114: Direct Communication With Data Terminal Units Via The Com Function Block
Direct Communication with Data Terminal Units via the COM Function Block This chapter only applies to PS 416-CPU-300/400. The SBI interface on the CPU is used for direct communication in Transparent mode with data terminal units. The interface is addressed via the COM function block.
Page 115: Structure Of The Com Function Block
Direct Communication with Data Terminal Units via the COM Function Block Structure of the COM The COM function block has the following structure: function block COM-Funktionsbaustein BOOL ReSet BOOL TransmitActive USINT Mode ReceiveActive BOOL TransmitStrobe TransmitError UINT BOOL BOOL UINT ReceiveStrobe ReceiveError UINT...
Page 116: Inputs Of The Com Function Block
Inputs of the COM function block Inputs of the COM Table 15: Overview of function block inputs function block Name Data type Meaning ReSet BOOL Signal status 1 aborts all transmit and receive activities. Mode USINT Operating mode 1 = Transparent mode 1 TransmitStrobe BOOL...
Page 117: Outputs Of The Com Function Block
Direct Communication with Data Terminal Units via the COM Function Block Outputs of the COM Table 16: Overview of the function block outputs function block Name Data type Meaning TransmitActive BOOL Function block processing send job (TACT) when signal status 1. ReceiveActive BOOL Function block processing receive...
Page 118 Addressing the COM function block Example Device configuration String Rack/stn. Slot/module Type Index Parameter PS 416-INP/OUT-400 – Highest input address: IB10 Highest output address: QB10 PS 416-CPU-300/400 – Bus status: master Station address: 1 Protocol: Transparent mode Baud rate: 9600 baud Parity: even Data format: 8 bits Stop bit: 1 stop bit...
Page 119 Direct Communication with Data Terminal Units via the COM Function Block (*Load Send data*) ld com_no st tra_array[1] BYTE_TO_UINT st com_tst.TransmitNumber st com_tst.ReceiveNumber ld tra_value st tra_array[2] (*Invoke function*) CAL com_tst( ReSet :=reset, Mode :=1, TransmitStrobe :=tra_strobe, ReceiveStrobe :=rec_strobe, SlotNumber :=0, TransmitNumber :=, ReceiveNumber :=, TransmitVariable :=tra_array,...
Page 120: Refreshing Inputs/Outputs
Refreshing inputs/outputs In order to maintain a “close contact ” as possible Refreshing inputs/ outputs with the interface, the COM function block should be invoked once in every cycle. A multiple invocation is also possible for time-critical data transfers although this should be avoided in order to ensure simple programming and a constant cycle time.
Page 121: Startup Behaviour
Startup behaviour After the power supply is switched on, the interface is ready for operation when the “run ” or “ready ” LEDs are lit. Data transfer The interface can only be operated in half-duplex mode due to the RS 485 drivers. If in a program cycle the start is simultaneous, first the send job and then the receive job are executed.
Page 122: Data Block Length
Data block length Data block length The data block length specifies how many data bytes are to be sent and/or received. The block length of the send data is normally set via the “TransmitNumber ” parameter on the COM function block.
Page 123: Starting A Job
Direct Communication with Data Terminal Units via the COM Function Block Starting a job A job is started by generating a rising edge on the appropriate Strobe input (TransmitStrobe/ ReceiveStrobe). The input parameters are accepted with the next invocation of the COM function block, and a plausibility test is carried out.
Page 124: Receiving Data
Receiving data Receiving data ReceiveStrobe ReceiveActive Figure 47: Receiving data The COM function block is invoked and accepts a rising edge on its ReceiveStrobe input. It reads all function block parameter inputs and carries out a plausibility check. The COM function block acknowledges the receive job with ReceiveActive = 1 if hardware and parameter settings are error-free.
Page 125: Monitoring A Job
Direct Communication with Data Terminal Units via the COM Function Block Monitoring a job If a job has been started, it should be permanently monitored until a positive or negative result is obtained. The following block function outputs are provided: TransmitActive/ReceiveActive: the ACTIVE flags are “1 ”...
Page 126 Aborting a job ReceiveStrobe = 0 Data that has already been received is not transferred to the receive array defined on the “ReceiveVariable ” function block input. ReceiveStrobe = 1 Data that has already been received is transferred to the receive array defined on the “ReceiveVariable ” function block.
Page 127: Test And Commissioning
Direct Communication with Data Terminal Units via the COM Function Block Test and The interface is ready for operation after the power supply is switched on and the “run ” and “ready ” commissioning LEDs are lit. In order for a data transfer to be possible, the interface parameters must correspond with those of the data terminal unit and the data cable must be connected correctly.
Page 128: Sloterror
SlotError InterfaceStatus This function block output provides information on the status of the interface. COM PAR SPM Table 17: Indication mode for the interface status Bit no. Type Status Meaning IFM 0 RS 485 interface present IFM 1 IFM 2 SPM 0 None SPM 1...
Page 129: Error Messages
Direct Communication with Data Terminal Units via the COM Function Block Table 18: Indication mode for slot assignment Bit no. Type Status Meaning The slot number specified is valid The slot number specified is not valid Type A card with a COM function is located in the slot specified A card with a COM function is not located in the slot specified...
Page 130 Error messages Function block output Code Meaning Warnings 0040 The data format is 8 bits but 7 bits selected as sent parameters ReceiveError Receive job Coding of error messages and warnings with a receive job (in HEX format) 0000 No error occurred Job not executed 0001 Incorrect mode setting...
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Page 132: Appendix
Appendix Contents Calculating reaction times Suconet K/K1 stations Technical data Accessories For Immediate Delivery call KMParts.com at (866) 595-9616...
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Page 134 Appendix Calculating reaction The reaction time is the time difference between the times occurrence of an input signal, the transfer via the bus to the master, the program processing, the return via the bus and the sending of the ouput signal. The reaction time is therefore the sum of all times that depend on the Suconet operating mode selected, the bus stations used and the program...
Page 135 Appendix System/data times Table 21: System/data times without CRC with CRC Factor 187.5 Kbaud 375 Kbaud 187.5 Kbaud 375 Kbaud 1.65 1.42 1.65 1.42 0.078 0.048 0.19 0.162 TS = System time (ms) TD = Data time (ms) The cycle time can be approximated using the following equations: ×...
Page 136 Calculating reaction times Example The following cards are located in the expansion rack: Table 22: Number of input/output bytes per card Type Input byte Output byte 416-INP-400 – 416-OUT-400 – 416-AIO-400 416-CNT-200 – Total + 10 = 32 With six expansion racks fitted with the above cards, a program cycle time of 25 ms and a transfer rate of 375 Kbaud the reaction times (T ) are:...
Page 137 Appendix Suconet K/K1 stations Table 23: Number of input/output bytes per Suconet K/K1 station Station Input byte Output byte A 4-220.1 CM 4-501-FS1 CM 4-504-GS1 max. 120 max. 120 CM 4-505-GS1 max. 120 max. 120 DE 4-NET-K EBE 295.1 EM 4-101-AA1 EM 4-101-AA1 B63 EM 4-101-AA1 B64 EM 4-101-AA1 W31...
Page 138 Suconet K/K1 stations Station Input byte Output byte LE 4-622-CX1 – MI 4-...-... PS 3-8 PS 3-AC PS 3-DC PS 306 PS 4-101-DD1 PS 4-111-DR1 PS 4-141-MM1 78 byte (total I/O) PS 4-151-MM1 78 byte (total I/O) PS 4-201-MM1 max. 78 I/O PS 4-401-MM1 (Suconet K1) PS 4-401-MM2 (Suconet K) max.
Page 139 Appendix Technical data General Regulations EN 61131-2, EN 50178 Ambient temperature 0 °C ... +55 °C Storage temperature –25 °C ... +70 °C Shock 2 shocks with sinusoidal wave 11 ms duration 15 g peak value Impact resistance 15 g/11 ms Vibration 1 g, f = 10-150 Hz see Table on Page 139...
Page 140 Technical data PS 416-POW-400 Rated voltage U 230 V AC Permissible range 195 ... 264 V Rated frequency F 47 ... 440 Hz Inrush current up to 50 A, 2 ms Rated current I 0.5 A Switch frequency 66 kHz Power factor Test voltage 2.5 kV DC...
Page 141 Appendix Central units General Current consumption approx. 1.5 A Heat dissipation 7.5 W Weight approx. 375 g Space requirement 2 slots, 8 space units Voltage supply 5 V DC Status indication 5 LED ready not ready error change PRG interface (RS 232/RS 485) Baud rates 2,4;...
Page 142 Technical data PS 416-CPU-300/-400 Battery backup time of memory min. 0.5 years with power supply switched off SBI interface (Suconet K) Transfer rate 187.5/375 KBit/s Cable lengths 600/300 m Number of stations max. 30 Terminal design 9pole SUB-D data connector (female) SBI interface (Transparent mode) Transfer rate...
Page 143 Appendix Accessories Cable PS 416-ZBK-210 RS 232C programming cable, prepared Batteries PS 416-ZBB-300 Spare battery for memory card SRAM PS 416-ZBB-410 Battery module for SRAM backup Memory PS 416-MEM-430 SRAM memory card (512 Kbyte) PS 416-MEM-431 SRAM memory card (1 Mbyte) PS 416-MEM-440 Flash EPROM memory card (512 Kbyte)
Page 144: Index
Index Acknowledging errors, NOT-READY ......108 Activating terminating resistors PRG interface ............. 81 SBI interface ............... 85 Address coding .............. 80 AUTOSTART ..............107 Backup ................98 Backup battery ............... 97 Changing ..............87 Fitting ................87 Basic elements ..............8 Basic unit ...............
Page 145 Index COM function block ............. 111 Addressing ..............114 Setting parameters ........... 119 Structure ..............112 Components, PS 416 system ........... 8 Connecting mains supply ..........51 Connecting programming device Point-to-point connection ........... 70 Connecting protective earth ........... 29 Connection assignment Power supply card ............
Page 146 Index Half-duplex ..............118 Hardware requirements, PS 416 system ......7 Hot start ............... 102 Input/output byte, number per Suconet K/K1 station . 134 Inputs (COM function block) ........113 Inserting Memory card .............. 88 Inserting/removing cards ..........30 Inserting/removing memory card ........88 Intelligent slaves .............
Page 147 Index Master ................12 Memory Memory card ............... 98 Non-volatile ..............98 Volatile ................ 98 Memory capacity, intelligent slaves ....... 16 Memory card ..............98 Mounting, rack ............... 29 Network cards ..............9 NOT-SET ..............107 Operating mode selector switch ........104 Outputs (COM function block) ........
Page 148 Index Rack Coupling ..............27 Mounting ..............29 Setup ................24 Task ................23 Type overview ............23 Rack, suitable cards ............27 RAM ................97 Reaction times ............... 17 Calculation ..............131 ReceiveError ............126, 127 Refreshing inputs/outputs (COM function block) ..117 Removing Cards ................
Page 149 Index Slots Assignment in the rack ..........28 Display mode in COM function block ....... 126 Number in the rack ............. 23 Software requirements, PS 416 system ......7 SRAM card ..............98 Standard cards ..............9 Start attributes .............. 107 Startup behaviour ............
Page 150 BTS = Identificazione del sistema operativo – BTS = Identificación del sistema operativo 2) Download 416M_307.OSF http://www.moeller.net/auto- mation r updates 3) Download 416M_409.OSF Moeller GmbH, Industrieautomation, D-53105 Bonn Änderungen 11/01 BL2700-8800 DMD/Ki For Immediate Delivery call KMParts.com at (866) 595-9616 © 2001 by Moeller GmbH...

Moeller PS 416-POW-400 Hardware And Engineering

Table of Contents

Ps 416 System

1 System Description

2 Configuration

3 Engineering

Ps 416-Bgt-4 Racks

1 Racks

2 Engineering

3 Installation

4 Operation

Ps 416-Pow-400/410/420 Power Supply Cards

1 About the Power Supply Card

2 Engineering

3 Installation

4 Operation

5 Diagnostics

Ps 416-Cpu-200/-300/-400 Central Unit

1 About the Central Unit

2 Engineering

3 Hardware Configuration

4 Installation

5 Operation

6 Test/Commissioning/Diagnostics

7 Direct Communication with Data Terminal Units Via the COM Function Block

Appendix

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Table of Contents