Input/output modules for CL150, B~IO Module

Antriebs- und Steuerungstechnik
CL150 / B~IO
Input/output modules for CL150, B~IO
Module Description
Edition
102
CL150 / B~IO
Input/output modules for CL150, B~IO
Module Description
1070 072 259-102 (02.03) GB
E
2002
by Robert Bosch GmbH, Erbach / Germany
All rights reserved, including applications for protective rights.
Reproduction or distribution by any means subject to our prior written permission.
Discretionary charge
12.–
Table of contents
I
Table of contents
Page
1070 072 259-102 (02.03) GB
1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–1
1.1
1.2
1.3
1.4
1.5
1.6
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety markings on components . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety instructions in this manual . . . . . . . . . . . . . . . . . . . . . . . . .
Safety instructions for the described product . . . . . . . . . . . . . . .
Documentation, software release and trademarks . . . . . . . . . . .
1–1
1–2
1–3
1–4
1–5
1–7
2
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–1
2.1
2.2
2.3
2.4
Area of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input/output modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–1
2–2
2–2
2–3
3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–1
3.1
3.2
3.3
3.4
Installation positions and distances . . . . . . . . . . . . . . . . . . . . . . . .
Combination of modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement of wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–1
3–4
3–5
3–6
4
Digital inputs 8DI, 16DI and 16DI-3 . . . . . . . . . . . . .
4–1
4.1
4.2
4.2.1
4.2.2
4.2.3
4.3
4.4
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displays and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, order numbers . . . . . . . . . . . . . . . .
Input characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
4–2
4–2
4–6
4–7
4–8
4–9
5
Digital outputs 8DO, 8DO/2A and 16DO . . . . . . . .
5–1
5.1
5.2
5.2.1
5.2.2
5.2.3
5.3
5.4
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displays and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, Order numbers . . . . . . . . . . . . . . .
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–1
5–2
5–2
5–7
5–7
5–8
5–9
6
Digital output 8DO R . . . . . . . . . . . . . . . . . . . . . . . . . .
6–1
6.1
6.2
6.2.1
6.2.2
6.2.3
6.3
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displays and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, Order numbers . . . . . . . . . . . . . . .
6–1
6–2
6–2
6–5
6–6
6–7
II
Table of contents
7
Digital Input/output module 8DI/DO . . . . . . . . . . . .
7–1
7.1
7.2
7.2.1
7.2.2
7.2.3
7.3
7.4
7.5
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displays and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, Order numbers . . . . . . . . . . . . . . .
Input characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–1
7–2
7–2
7–4
7–5
7–6
7–8
7–8
8
Analog input module 4AI_UI . . . . . . . . . . . . . . . . . . .
8–1
8.1
8.1.1
8.1.2
8.2
8.3
8.3.1
8.3.2
8.3.3
8.4
8.5
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration with DIP switch S1 . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring range and data formats . . . . . . . . . . . . . . . . . . . . . . . .
Voltage measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current measurement 0 to 20 mA . . . . . . . . . . . . . . . . . . . . . . . . .
Current measurement 4 to 20 mA . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, order numbers . . . . . . . . . . . . . . . .
Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8–1
8–2
8–3
8–4
8–6
8–6
8–7
8–8
8–9
8–10
9
Analog input module 4AI_UIT . . . . . . . . . . . . . . . . . .
9–1
9.1
9.2
9.2.1
9.2.2
9.2.3
9.3
9.4
9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
9.5
9.6
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displays and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration with DIP switch S1 . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring range and data formats . . . . . . . . . . . . . . . . . . . . . . . .
Voltage measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current measurement 0 to 20 mA . . . . . . . . . . . . . . . . . . . . . . . . .
Current measurement 4 to 20 mA . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature measurement with thermal elements . . . . . . . . . .
Temperature measurement with resistance thermometers . . . .
Technical data, accessories, order numbers . . . . . . . . . . . . . . . .
Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9–1
9–2
9–2
9–4
9–4
9–5
9–7
9–7
9–7
9–8
9–10
9–13
9–17
9–18
10
Analog output module 4AO_U . . . . . . . . . . . . . . . . .
10–1
10.1
10.2
10.2.1
10.2.2
10.2.3
10.3
10.4
10.5
10.6
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displays and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration with DIP switch S1 . . . . . . . . . . . . . . . . . . . . . . . . .
Data formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, order numbers . . . . . . . . . . . . . . . .
Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10–1
10–2
10–2
10–4
10–4
10–5
10–5
10–6
10–7
1070 072 259-102 (02.03) GB
Table of contents
1070 072 259-102 (02.03) GB
III
11
Analog output module 4AO_I . . . . . . . . . . . . . . . . . .
11–1
11.1
11.2
11.2.1
11.2.2
11.2.3
11.3
11.4
11.5
11.6
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Patching distribution frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displays and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration with DIP switch S1 . . . . . . . . . . . . . . . . . . . . . . . . .
Data formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, order numbers . . . . . . . . . . . . . . . .
Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11–1
11–2
11–2
11–4
11–4
11–5
11–6
11–7
11–8
12
I/O gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12–1
12.1
12.1.1
12.1.2
12.2
12.3
12.4
Layout, deployment options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration with DIP switch S1 . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data, accessories, order numbers . . . . . . . . . . . . . . . .
12–1
12–2
12–2
12–3
12–3
12–5
13
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . .
13–1
13.1
13.2
13.2.1
13.2.2
13.2.3
13.2.4
13.2.5
13.2.6
13.2.7
13.3
13.3.1
13.3.2
13.4
13.4.1
13.4.2
13.4.3
13.4.4
13.4.5
Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 V power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference lead connected to the protective earth . . . . . . . . . . .
Reference lead not connected to the protective earth . . . . . . . .
Capacitive load of the power supply . . . . . . . . . . . . . . . . . . . . . . .
Dimensioning of the power supply . . . . . . . . . . . . . . . . . . . . . . . .
Master switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal-to-interference ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC legislation and CE identification . . . . . . . . . . . . . . . . . . . . . .
EMC characteristics of I/O modules . . . . . . . . . . . . . . . . . . . . . . .
Installation measures to ensure interference immunity . . . . . . .
13–1
13–2
13–2
13–3
13–4
13–4
13–4
13–5
13–5
13–6
13–6
13–6
13–8
13–8
13–8
13–9
13–10
13–12
A
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A–1
A.1
A.2
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A–1
A–2
IV
Table of contents
1070 072 259-102 (02.03) GB
Safety Instructions
1
1–1
Safety Instructions
Read this manual before you put the input and output modules of the module
family B~IO into operation. Keep the manual in a location that is accessible
to all users at all times.
1.1
Intended use
This manual contains information concerning use in accordance with the
intended purpose. The products described are used as:
D decentralized input and output modules via bus connections for
PROFIBUS-DP, InterBus-S, CANopen and DeviceNet
D centralized input and output modules of the CL150 PLC family
The products described hereunder
D were developed, manufactured, tested and documented in accordance
with the relevant safety standards. In standard operation, and provided
that the specifications and safety instructions relating to the project
phase, installation and correct operation of the product are followed,
there should arise no risk of danger to personnel or property.
D are certified to be in full compliance with the requirements of
D the EMC Directives (89/336/EEC, 93/68/EEC and 93/44/EEC)
D the Low-Voltage Directive (73/23/EEC)
D the harmonized standards EN 50081-2 and EN 50082-2
D are designed for operation in an industrial environment (Class A
emissions). The following restrictions apply:
D No direct connection to the public low-voltage power supply is permitted.
D Connection to the medium and/or high-voltage system must be provided via transformer.
The following applies for application within a personal residence, in business areas, on retail premises or in a small-industry setting:
D Installation in a control cabinet or housing with high shield attenuation.
D Cables that exit the screened area must be provided with filtering or
screening measures.
D The user will be required to obtain a single operating license issued by
the appropriate national authority or approval body. In Germany, this
is the Federal Institute for Posts and Telecommunications, and/or its
local branch offices.
.
This is a Class A device. In a residential area, this device may cause
radio interference. In such case, the user may be required to introduce
suitable countermeasures, and to bear the cost of the same.
Proper transport, handling and storage, placement and installation of the
product are indispensable prerequisites for its subsequent flawless service
and safe operation.
1070 072 259-102 (02.03) GB
1–2
1.2
Safety Instructions
Qualified personnel
This instruction manual is designed for specially trained personnel. The relevant requirements are based on the job specifications as outlined by the
ZVEI and VDMA professional associations in Germany. Please refer to the
following German-Language publication:
Weiterbildung in der Automatisierungstechnik
Publishers: ZVEI and VDMA Maschinenbau Verlag
Postfach 71 08 64
60498 Frankfurt/Germany
This manual is aimed at construction engineers who equip the machines and
units with PLC s well as at skilled electrical technicians who install and put
the machines into operation. They require special knowledge of PLC, the
PROFIBUS-DP, the InterBus-S, the CANopen-Bus and the DeviceNet-Bus.
Interventions in the hardware and software of our products not described in
this instruction manual may only be performed by our skilled personnel.
Unqualified interventions in the hardware or software or non-compliance
with the warnings listed in this instruction manual or indicated on the product
may result in serious personal injury or damage to property.
Installation and maintenance of the products described hereunder is the exclusive domain of trained electricians as per IEV 826-09-01 (modified) who
are familiar with the contents of this manual.
Trained electricians are persons of whom the following is true:
D They are capable, due to their professional training, skills and expertise,
and based upon their knowledge of and familiarity with applicable technical standards, of assessing the work to be carried out, and of recognizing
possible dangers.
D They possess, subsequent to several years’ experience in a comparable
field of endeavour, a level of knowledge and skills that may be deemed
commensurate with that attainable in the course of a formal professional
education.
With regard to the foregoing, please read the information about our comprehensive training program. The professional staff at our training centre will
be pleased to provide detailed information. You may contact the centre by
telephone at (+49) 6062 78-258.
1070 072 259-102 (02.03) GB
Safety Instructions
1.3
Safety markings on components
DANGER! High voltage!
CAUTION! Electrostatically sensitive components!
Disconnect mains power before opening!
Lug for connecting PE conductor only!
Functional earthing or low-noise earth only!
Screened conductor only!
1070 072 259-102 (02.03) GB
1–3
1–4
1.4
Safety Instructions
Safety instructions in this manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol warns of the presence of a dangerous electrical voltage.
Insufficient of lacking compliance with this warning can result in personal
injury.
DANGER
This symbol is used wherever insufficient or lacking observance of this
instruction can result in personal injury.
CAUTION
This symbol is used wherever insufficient or lacking observance of
instructions can result in damage to equipment or data files.
.
This symbol is used to alert the user to an item of special interest.
L
This asterisk symbol indicates that the manual is describing an activity which
the user will be required to perform.
1070 072 259-102 (02.03) GB
Safety Instructions
1.5
1–5
Safety instructions for the described product
DANGER
Fatal injury hazard through ineffective Emergency-OFF devices!
Emergency-OFF safety devices must remain effective and
accessible during all operating modes of the system. The release of
functional locks imposed by Emergency-OFF devices must never be
allowed to cause an uncontrolled system restart! Before restoring
power to the system, test the Emergency-OFF sequence!
DANGER
Danger to persons and equipment!
Test every new program before operating the system!
DANGER
Retrofits or modifications may interfere with the safety of the
products described hereunder!
The consequences may be severe personal injury or damage to
equipment or the environment. Therefore, any system retrofitting or
modification utilizing equipment components from other
manufacturers will require express approval by Bosch.
DANGEROUS ELECTRICAL VOLTAGE
Unless described otherwise, maintenance procedures must always
be carried out only while the system is isolated from the power
supply. During this process, the system must be blocked to prevent
an unauthorized or inadvertent restart.
If measuring or testing procedures must be carried out on the active
system, these must be carried out by trained electricians.
CAUTION
Only Bosch-approved spare parts may be used!
1070 072 259-102 (02.03) GB
1–6
Safety Instructions
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the
module! Prevent electrostatic discharges!
Observe the following protective measures for electrostatically endangered
modules (EEM)!
D The Employees responsible for storage, transport and handling must be
trained in ESD protection.
D EEMs must be stored and transported in the protective packaging specified.
D Out of principle, EEMs may be handled only at special ESD work stations
equipped for this particular purpose.
D Employees, work surfaces and all devices and tools that could come into
contact with EEMs must be on the same potential (e.g. earthed).
D An approved earthing wrist strap must be worn. It must be connected to
the work surface via a cable with integrated 1 MW resistor.
D EEMs may under no circumstances come into contact with objects susceptible to accumulating an electrostatic charge. Most items made of
plastic belong to this category.
D When installing EEMs in or removing them from an electronic device, the
power supply of the device must be switched OFF.
1070 072 259-102 (02.03) GB
Safety Instructions
1.6
1–7
Documentation, software release and trademarks
Documentation
This manual provides information on the installation and operation of the
input and output modules of the module family B~IO.
It does not include generally applicable processes for project engineering
and installation of the bus systems PROFIBUS-DP, InterBus-S, CANopen
and DeviceNet.
Overview of available manuals:
Overview of the documentation
Order numbers
German
English
Italian
Spanish
CL150, CL151, CL150A, CL151A
Control manual/Operations list
1070 072 438
1070 072 188
1070 072 243
1070 072 344
Input / output modules for CL150, B~IO
1070 072 199
1070 072 259
1070 072 248
–
Trademarks
All trademarks referring to software that is installed on Bosch products when
shipped from the factory represent the property of their respective owners.
At the time of shipment from the factory, all installed software is protected by
copyright. Software may therefore be duplicated only with the prior permission of the respective manufacturer or copyright owner.
MS-DOSr and Windowst are registered trademarks of Microsoft Corporation.
PROFIBUSr is a registered trademark of the PROFIBUS Nutzerorganisation e.V. (user organization).
INTERBUS-Sr is a registered trade mark of Phoenix Contact.
DeviceNetr is a registered trade mark (TM) of ODVA (Open DeviceNet
Vendor Association, Inc.).
1070 072 259-102 (02.03) GB
1–8
Safety Instructions
Notes:
1070 072 259-102 (02.03) GB
System overview
2
System overview
2.1
Area of application
2–1
The bus-independent input and output modules of the module family B∼IO
can be used together with the decentralized bus connections of the B∼IO
family or with the miniaturized control CL 150.
Bus connection B∼IO
The bus connection is via a bus system with a higher-order control. The following bus connections can be used:
D
D
D
D
PROFIBUS-DP, B∼IO M-DP
InterBus-S, B∼IO M-IBS
CANopen, B∼IO M-CAN
DeviceNet, B∼IO M-DEV
Order no. 1070 079 751
Order no. 1070 079 753
Order no. 1070 079 755
Order no. 1070 079 950
Control CL150
If the miniaturized control CL150 is used, another higher-order control is not
required.
.
Information on the bus connection B∼IO and on the control CL150 can
be found in the appropriate manuals, see page 1–7.
Sample layout
Bus connection
Bus system
Bus
master
CL150
Switch as
command
provider
Contactor as
command recipient
1070 072 259-102 (02.03) GB
2–2
2.2
System overview
Input/output modules
Digital inputs and outputs
Module
Order no.
Description
8DI
1070 079 757
Module with 8 inputs, 24 V DC
16DI
1070 080 144
Module with 16 inputs, 24 V DC
16DI-3
1070 081 862
Module with 16 inputs, 24 V DC, 3-wire
connection
8DO
1070 079 759
Module with 8 outputs, 0.5 A
8DO/2A
1070 080 151
Module with 8 outputs, 2 A
16DO
1070 081 858
Module with 16 outputs, 0.5 A
8DI/DO
1070 080 709
Module with 8 connections that can be used bit
by bit as digital inputs, 24 V DC or as 0.5 A
semiconductor outputs
8DO R
1070 080 680
Module with 8 potential-free relay contacts, 2 A
Module
Order no.
Description
4AI_UI
1070 080 524
Module with 4 analog inputs, 4 voltage or
2 current measurement ranges
4AI_UIT
1070 080 526
Module with 4 analog inputs, 3 voltage or
2 current measurement ranges, or 6 resistance
thermometer types, or 7 thermal element types
4AO_U
1070 080 530
Module with 4 voltage outputs, –10 V to +10 V or
0 to 10 V
4AO_I
1070 080 528
Module with 4 current outputs, 0 to 20 mA or
4 to 20 mA
Analog inputs and outputs
2.3
Gateway
Module
Order no.
I/O gateway 1070 083 150
Description
Gateway for linking 2 field bus systems, 8 or
20 byte data width
1070 072 259-102 (02.03) GB
System overview
2.4
2–3
General technical data
Technical data
corresponds to the general electrical
engineering standards
D
D
D
D
D
EN 61 131-2
EN 50 178
DIN VDE 0110
EN 60 204-1 (corresponds to VDE 0113)
EMC Directive 93/68/EEC and revised
legislation
Insulation testing voltage
D 350 V AC
D 500 V DC
D 500 V impulse 1.2/50 ms
Mechanical stress
D Vibration, sinusoidal oscillations in all
3 axles EN 61 131-2
D 10 to 57 Hz,
0.0375 mm amplitude constant,
0.075 mm amplitude occasional
D 57 to 150 Hz,
0.5 g constant, 1 g occasional
D Shock, impacts in all 3 axles
EN 61 131-2
D 11 ms semi-sinusoidal 15 g
Degree of contamination complying with
EN 61 131-2 and VDE 0470-1
2,
Installation areas, at least IP 54, dust-free air
Type of protection complying with
DIN VDE 0470-1
IP 20
Protection class complying with
EN 50 178
1
Humidity class complying with
EN 61 131-2
RH-2; 5 to 95 %, condensation not permitted
Operating temperature range
5 to 55 _C, average temperature over
24 hours maximum 50 °C
Air pressure complying with EN 61 131-2
Operation up to 2000 m above sea level
Transport resilience complying with
EN 61 131-2
Drop height with packaging 1.0 m
Interference emission
D Hard radiation
none
D Radio interference suppression,
housing complying with EN 50 081-2
Class A complying with EN 55 011
D Frequency 30 to 230 MHz
Limit value 40 dB (mV/m) in 10 m
D Frequency 230 to 1000 MHz
Limit value 47 dB (mV/m) in 10 m
Interference immunity
D High-frequency electromagnetic fields
complying with EN 61 131-2,
EN 50 082-2 and EN 61 000-4-3,
Criterion A
Test field strength 10 V/m;
Frequency band 27 to 1000 MHz AM, 80 %
with 1 kHz;
Throughput speed 0.0015 dec./s
D Electrostatic discharge on accessible
housing parts complying with
EN 50 082-2, EN 61 131-2 and
EN 61 000-4-2
D ESD resistance 4 for humidity class RH-2
D Testing voltage: air discharge 15 kV
contact discharge 4 kV
Conducted interference
D 24 V power supply complying with
EN 61 131-2 and EN 50 082-2
D HF interaction unsymmetrical 10 V,
150 kHz to 80 MHz, 80 % AM, 1 kHz
complying with EN 61000-4-6
D Digital inputs/outputs complying with
EN 61131- and EN 50082-2
D Rapid burst impulses, direct interaction
2 kV complying with EN 61000-4-4,
Criterion A damped sinus 1 MHz,
symmetrical 1 kV complying with
EN 61000-4-12
The above data applies to all of the components described in this manual.
It is supplemented by specific data of the assemblies.
1070 072 259-102 (02.03) GB
2–4
System overview
Notes:
1070 072 259-102 (02.03) GB
Installation
3
Installation
3.1
Installation positions and distances
3–1
The modules are placed directly on a 35 x 7.5 mm or 35 x 15 mm support rail
complying with EN 50 022 in the switch cabinet. The support rails must be
earthed, see page 13–5.
The modules are engaged to the right-hand side of a bus connection or
a CL150 on the support rail and connected by means of the module connector plugs.
Permitted installation positions:
D horizontal
D lying
D vertical, above bus connection or CL150
Horizontal installation position (normal position)
I/O modules to the right-hand side of the CL150 or bus connection.
Lying installation position
.
1070 072 259-102 (02.03) GB
Derating, see page 5–9.
3–2
Installation
Vertical installation position
Minimum spacing
For easier installation and deinstallation, a space of 2 cm should be allowed
above and below the modules. The free space at the front of the module is
determined by the dimensions of the connector plugs used and the cable
exits. Circulation of the surrounding air must be ensured.
Ensure that the ambient temperature is as low as possible, as high temperatures lead to more rapid ageing of components.
Space
Patching distribution
frame
1070 072 259-102 (02.03) GB
Installation
3–3
Fitting module
L
Insert module upwards in the rail.
L
Press module lightly downwards and engage.
L
Use module connector plug (ribbon cable) to attach connector X52 to connector X51 of the neighboring module on the left.
Labeling fields
Labeling fields are available for identification of the bus participant address
and the inputs/outputs. These can be written in with a permanent marker.
For labeling with an inkjet or laser printer, self-adhesive labels are available
as DIN A4 sheets (see ’Accessories’ in the relevant chapters of the modules).
Patching distribution frame
An optional patching distribution frame that might be required is inserted at
the bottom of the module until it engages. This extends the module in a
downward direction by 4 cm. Additional earthing is not required.
RV 2 x 10 M
RV 2 x 18 M
Maintenance
The modules are maintenance-free. If the housing needs to be cleaned,
cleaning agents containing solvents or abrasives must not be used.
1070 072 259-102 (02.03) GB
3–4
Installation
3.2
Combination of modules
Connection
The I/O modules are connected using module connector plugs (ribbon
cable) to the neighboring modules and the bus connection or the CL150:
D Connector X52 to connector X51 of the neighboring module on the left
D Connector X51 to connector X52 the neighboring module on the right.
D If there is no neighboring module on the right, connector X51 remains
open.
Arrangement
The sequence in which the I/O modules are connected to the CL150 or a bus
connection is unimportant, with a few exceptions.
The allocation of the PLC addresses to the inputs and outputs of the I/O modules is regulated in different ways for the various bus systems.
.
For detailed information on the arrangement and addressing, refer to
the documentation of the CL150 or the bus connection.
Number of modules
A maximum of 16 modules can be connected to a CL150 or a bus connection. If more than 16 modules are connected, a fault is displayed.
.
The number of input/output bytes is restricted. For more detailed information, refer to the documentation of the CL150 or the bus connection.
Sum current
Each CL150 or bus connection provides a maximum current of 500 mA for
the logic supply of the I/O modules. This level of current must not be exceeded.
Iv, ges = Iv, module 1 + Iv, module 2 + ... Iv, module n 500 mA
Module
Current consumption from internal bus
8DI
IV = maximum 10 mA
16DI
IV = maximum 20 mA
16DI-3
IV = maximum 20 mA
8DO
IV = maximum 15 mA
8DO/2A
IV = maximum 10 mA
16DO
IV = maximum 30 mA
8DO R
IV = maximum 10 mA
8DI/DO
IV = maximum 20 mA
4AI_UI
IVv50 mA
4AI_UIT
IVv50 mA
4AO_U
IVv30 mA
4AO_I
IVv30 mA
Gateway
IV = maximum 10 mA
1070 072 259-102 (02.03) GB
Installation
3.3
3–5
Arrangement of wiring
The wiring of the I/O modules is to be run from the distributor terminals in the
switch cabinet for each module individually to the corresponding terminals.
Two-wire sensors and actuators are connected directly at the relevant module. Three-wire or four-wire sensors and actuators are wired across the optional patching distribution frame.
.
The connected lines must be run with strain relief, e.g. through a cable
duct.
Parallel laying of data lines and power cables
A close parallel installation of data lines or input/output lines and interfering
cables such as motor cables or leads to contactors with poor interference
suppression must be avoided.
The smaller the spacing between the parallel installed cables, the greater
the interacting interference (see ’Electromagnetic compatibility’, section 13.4).
In cable ducts and switch cabinets, cables and data lines must be arranged
at the greatest possible distance to one another, spacing of at least 10 cm
and preferably in separate, shielded chambers.
Data lines to be crossed by power lines at an angle of 90_.
1070 072 259-102 (02.03) GB
3–6
3.4
Installation
Deinstallation
.
For deinstallation, ensure that the connectors are labeled. In this way,
you ensure that the connector positions cannot be confused on reinstallation.
L
Remove the module connector plugs to the left-hand and right-hand neighboring modules. To do so, unlock the connectors by pressing the engaging
lugs and draw off carefully.
L
Lightly press the module downwards – against the spring force – and disengage from the bottom.
L
Disengage the module from the rail from above.
1070 072 259-102 (02.03) GB
Digital inputs 8DI, 16DI and 16DI-3
4
4–1
Digital inputs 8DI, 16DI and 16DI-3
The input modules send the switching signals of the sensors via the module
connector plugs to the CL150 or via a bus connection to the higher-order
control.
4.1
Structure
There are 8 or 16 inputs available for sensors (switch, photosensors, induction sensors, etc.).
8DI
16DI
16DI-3
The modules contain the following elements:
D Connections for module connector plugs
D Labeling fields
D LED status indicators 0 to 7
D LED status indicator UI
D Connections to 24 V power supply of the module and the connected sensors
D Module 16DI-3 with additional connector strip GND for connection of
3-wire sensors
.
1070 072 259-102 (02.03) GB
Module connector plugs and socket terminal strip sets must be ordered separately.
4–2
4.2
Digital inputs 8DI, 16DI and 16DI-3
Connections and displays
LED status indicator
inputs 0 to 7 / 0 to 7
LED status indicator, 24 V
power supply
24 V sensor supply
(connector strip bridged)
24 V power supply
24 V power supply drawn
from next module
Inputs, byte 1
Inputs, byte 0
4.2.1
Connections
Power supply
D The module requires a 24 V power supply. It can be looped on from module to module using the terminals at the ends of the connector strip (24 V
and 0 V).
D The 24 V potentials for supply of the sensors are interconnected in the
module.
D The sensor supply is monitored for short-circuits or overload (total current > 0.6 A). In the event of a fault, the supply is cut for all sensors until
the fault is remedied.
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 4–8):
D Screw terminals
D Spring terminals
1070 072 259-102 (02.03) GB
Digital inputs 8DI, 16DI and 16DI-3
Connection allocation 8DI
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
S0 to S7
24 V power supply of sensors 0 to 7
(bridged)
E0 to E7
Inputs 0 to 7
Connection example 8DI
+24 V
0V
2-wire
Patching distribution frame, optional
0V
3-wire
Earth
4-wire
1070 072 259-102 (02.03) GB
4–3
4–4
Digital inputs 8DI, 16DI and 16DI-3
Connection allocation 16DI
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
S0 to S7 per byte
24 V power supply of sensors 0 to 15
E0 to E7 per byte
Inputs 0 to 15
Connection example 16DI
+24 V
0V
2-wire
Patching distribution frame, optional
0V
3-wire
Earth
4-wire
1070 072 259-102 (02.03) GB
Digital inputs 8DI, 16DI and 16DI-3
Connection allocation 16DI-3
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
S0 to S7 per byte
24 V power supply of sensors 0 to 15
E0 to E7 per byte
Inputs 0 to 15
0V
Power supply, 0 V potential
Connection example 16DI-3
+24 V
0V
2-wire
0V
1070 072 259-102 (02.03) GB
3-wire
4–5
4–6
4.2.2
Digital inputs 8DI, 16DI and 16DI-3
Patching distribution frame
Patching distribution frames can be used to extend modules 8DI and 16DI to
3-pole or 4-pole connection. Each patching distribution frame provides
2 additional connector strips, bridged in each case.
.
No patching distribution frame can be fitted to module 16DI-3!
Connection allocation RV 2 x 10 M
Connector strip X91A, internally bridged
Connector strip X91B, internally bridged
RV 2 x 10 M
Terminal
Allocation example
X91A
Power supply, 0 V potential
X91B
Potential earth
Connection allocation RV 2 x 18 M
Connector strips X91A and X92A,
internally bridged
Connector strips X91B and X92B,
internally bridged
RV 2 x 18 M
Terminal
Allocation example
X91A, X92A
Power supply, 0 V potential
X91B, X92B
Potential earth
1070 072 259-102 (02.03) GB
Digital inputs 8DI, 16DI and 16DI-3
4.2.3
Displays and fault messages
Name
LED
Meaning
0 to 7
green
State of the input: 1, active
off
State of the input: 0, not active
16DI-3 (all versions) and 8DI, 16DI up to version 104
UI
green
24 V power supply is OK
off
D 24 V power supply is not present
D Short-circuit in supply of sensors
D Overload in supply of sensors
8DI, 16DI as of version 104
UI
1070 072 259-102 (02.03) GB
green
24 V power supply is OK
red
Overload in supply of sensors
off
24 V power supply is not present/polarity inverted
4–7
4–8
Digital inputs 8DI, 16DI and 16DI-3
4.3
Technical data, accessories, order numbers
Technical data
Order no.
Inputs complying with EN 61 131-2
Current consumption off
D 24 V power supply
(without sensor supply)
D internal bus
8DI
16DI
16DI-3
1070 079 757
1070 080 144
1070 081 862
8 digital inputs, type 1
16 digital inputs, type 1
typ. 40 mA
typ. 80 mA
max. 10 mA
max. 20 mA
Input voltage
D Rated voltage
D 0 signal
D 1 signal
24 V
–3 to 5 V
11 to 30 V
Input current
D 0 signal
D 1 signal
≤ 2.5 mA
3 to 6 mA
Supply of sensors
D Output voltage
D Output nominal current (total)
D Short-circuit / overcurrent protection
typ. Uext. –1 V
0.6 A
≥ 1.2 A
Delay time
D 0→1
D 1→0
4 ms
4 ms
Status indicator
via LEDs, measured on load side
Contact load capacity
max. 8 A per contact / TU = 55 °C
Cable length, unshielded
max. 100 m
Connector grid
3.5 mm
2-wire proximity switch
D Quiescent current
D Voltage drop
≤ 2.6 mA
≤6V
Dimensions in mm (L x W x D)
48 x 105 x 38
76 x 105 x 38
76 x 121 x 38
Weight
approx. 150 g
approx. 210 g
approx. 240 g
Accessories
Module connector plugs
8DI
16DI
16DI-3
1070 079 782
1070 079 782
1070 079 782
Labels
10 DIN A4 sheets, each with 20 labels
1070 080 309
Socket terminal strip sets
D Screw terminals
D Spring terminals
1070 080 340
1070 080 347
1070 080 341
1070 080 348
Patching distribution frame
1070 080 159
1070 080 161
Socket terminal strip sets for
patching distribution frame
D Screw terminals
D Spring terminals
1070 080 340
1070 080 347
1070 080 341
1070 080 348
Pulling aid for socket terminal strips,
8-pole
1070 080 341
1070 080 348
–
–
1070 919 513
1070 072 259-102 (02.03) GB
Digital inputs 8DI, 16DI and 16DI-3
4.4
Input characteristic curve
8DI
U[V]
30
1 signal
max
20
typ
min
10
Switch range
0 signal
0
0
5
10
I[mA]
16DI and 16DI-3
U[V]
30
1 signal
max
20
typ
min
10
Switch range
0 signal
0
0
1070 072 259-102 (02.03) GB
5
10
I[mA]
4–9
4–10
Digital inputs 8DI, 16DI and 16DI-3
Notes:
1070 072 259-102 (02.03) GB
Digital outputs 8DO, 8DO/2A and 16DO
5
5–1
Digital outputs 8DO, 8DO/2A and 16DO
The output modules route the control commands to the connected actuators, for example valves, lamps or contactors.
5.1
Structure
There are 8 or 16 outputs available for actuators. These 24 V outputs are
non-storing; in the event of a power supply failure, the output signal is reset
without a fault message. On restarting, the outputs are switched again by the
signal of the control automatically.
.
8DO
The module 8DO/2A is used if the maximum current of 0.5 A that can be
supplied by an 8DO module output is not sufficient, that is, in the case
of typical loads in the range from 12 to 48 Ω, corresponding to a current
of 0.5 to maximum 2.0 A.
8DO/2A
16DO
The modules contain the following elements:
D Connections for module connector plugs
D Labeling fields
D LED status indicators 0 to 7
D LED status indicator UI
D Connections to 24 V power supply of the module and the outputs
.
1070 072 259-102 (02.03) GB
Module connector plugs and socket terminal strip sets must be ordered separately.
5–2
5.2
Digital outputs 8DO, 8DO/2A and 16DO
Connections and displays
LED status indicator
outputs 0 to 7 / 0 to 7
LED status indicator, 24 V
power supply
Outputs, 24 V signal
24 V power supply
24 V power supply drawn
from next module
Outputs, byte 1,
0 V potential (bridged)
Outputs, byte 0,
0 V potential (bridged)
5.2.1
Connections
Power supply
D The module requires a 24 V power supply. It can be looped on from module to module using the terminals at the ends of the connector strip (24 V
and 0 V).
D The 0 V potentials for 2-pole connection of the loads are interconnected
in the module.
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 5–8):
D Screw terminals
D Spring terminals
1070 072 259-102 (02.03) GB
Digital outputs 8DO, 8DO/2A and 16DO
5–3
Connection allocation 8DO
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential (bridged)
Q0 to Q7
Outputs 0 to 7, output current 0.5 A
To multiply the output current of 0.5 A, the outputs Q0, Q1, Q2 and Q3 or the
outputs Q4, Q5, Q6 and Q7 can be switched in parallel.
If a maximum of 4 outputs are switched in parallel, the output current is 2 A.
.
1070 072 259-102 (02.03) GB
Bridged outputs must also be activated in the PLC program in parallel.
5–4
Digital outputs 8DO, 8DO/2A and 16DO
Connection example 8DO
+24 V
0V
2-wire
Patching distribution frame, optional
+24 V
3-wire
Earth
4-wire
1070 072 259-102 (02.03) GB
Digital outputs 8DO, 8DO/2A and 16DO
5–5
Connection allocation 8DO/2A
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential (bridged)
Q0 to Q7
Outputs 0 to 7, output current 2.0 A
To double the output current of 2.0 A, the outputs Q0 + Q1, Q2 + Q3 or
Q4 + Q5, Q6 + Q7 can be switched in parallel.
.
Bridged outputs must also be activated in the PLC program in parallel.
CAUTION
Current load per connector pin maximum 8 A.
For the 24 V power supply, the critical limit is reached if all outputs
have a simultaneity factor of over 50 % (> 4 x 2 A = 8 A).
Distribute the power supply to the 2 pins for 24 V and the 2 pins for
0 V. A loop-through of the power supply is then no longer possible.
1070 072 259-102 (02.03) GB
5–6
Digital outputs 8DO, 8DO/2A and 16DO
Connection allocation 16DO
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential (bridged)
Q0 to Q7 per byte
Outputs 0 to 15, output current 0.5 A
To multiply the output current of 0.5 A, the outputs Q0, Q1, Q2 and Q3 or the
outputs Q4, Q5, Q6 and Q7 can be switched in parallel.
If a maximum of 4 outputs are switched in parallel, the output current is 2 A.
.
Bridged outputs must also be activated in the PLC program in parallel.
1070 072 259-102 (02.03) GB
Digital outputs 8DO, 8DO/2A and 16DO
5.2.2
5–7
Patching distribution frame
Patching distribution frames can be used to extend modules 8DO, 8DO/2A
and 16DO to 3-pole or 4-connection. Each patching distribution frame provides 2 additional connector strips, bridged in each case.
Connection allocation RV 2 x 10 M
Connector strip X91A, internally bridged
Connector strip X91B, internally bridged
RV 2 x 10 M
Terminal
Allocation example
X91A
Power supply, 0 V potential
X91B
Potential earth
Connection allocation RV 2 x 18 M
Connector strips X91A and X92A,
internally bridged
Connector strips X91B and X92B,
internally bridged
RV 2 x 18 M
5.2.3
Terminal
Allocation example
X91A, X92A
Power supply, 0 V potential
X91B, X92B
Potential earth
Displays and fault messages
Name
LED
Meaning
UI
green
24 V power supply is OK
off
24 V power supply is not present
red
Overload at one or more outputs
green
State of the output: 1, active
off
State of the output: 0, not active
0 to 7
1070 072 259-102 (02.03) GB
5–8
Digital outputs 8DO, 8DO/2A and 16DO
5.3
Technical data, accessories, Order numbers
Technical data
Order no.
8DO
1070 079 759
Power supply EN 61 131-2
Current consumption off
D 24 V power supply
(outputs activated, without load)
D internal bus
Outputs complying with EN 61 131-2
Overload protection
D Minimum current level that leads to
shutdown
D Automatic restart on removal of
overload after
Parallel switching of outputs
1070 081 858
typ. 55 mA
typ. 80 mA
max. 15 mA
max. 10 mA
max. 30 mA
8 semiconductor outputs, non-storing, protected,
supplying current
16 semiconductor outputs,
non-storing, protected,
supplying current
Rating 24 V, voltage drop at 1 signal ≤ 1.5 V ... ≤ 0.5 V
0.5 A
0.6 A
2 mA to 0.6 A
≤ 0.5 mA
2.0 A
2.0 A
2 mA to 2.0 A
≤ 0.5 mA
0.5 A
0.6 A
2 mA to 0.6 A
≤ 0.5 mA
0.6 A, typ. 1.2 A
2.0 A, typ. 3.6 A
0.6 A, typ. 1.2 A
approx. 10 ms
approx. 10 ms
approx. 10 ms
yes, max. 4
2 outputs each
yes, max. 4
100 Hz
1 Hz
Status indicator
via LEDs, measured on load side
< 500 µs
Output delay times
Cable length, unshielded
max. 100m
Simultaneity factor
see Derating curve
Inductive shutdown voltage
on Uext. - 50 V, nominal operation to typ. –26 V
max. 8 A per contact at TU = 55 °C
Contact load capacity
Lamp load at 8 Hz
1070 080 151
typ. 30 mA
Switching frequency
D ohmic load
D inductive load
Contactor size at 1 Hz
16DO
24 V; 19.2 to 30 V
Output voltage
Output current (Derating, see page 5–9)
D Rating
D Maximum value
D 1 signal
D 0 signal, leakage current
8DO/2A
SG1; 6.2 W
SG8; 30 W, NG6 Bosch
hydraulic valve
SG1; 6.2 W
5W
15 W
5W
Connector grid
3.5 mm
Dimensions in mm (L x W x D)
48 x 105 x 38
75.6 x 105 x 38
Weight
approx. 150 g
approx. 210 g
Accessories
Module connector plugs
8DO
8DO/2A
1070 079 782
Labels
D 10 DIN A4 sheets, each with
20 labels
16DO
1070 079 782
1070 080 309
Socket terminal strip sets
D Screw terminals
D Spring terminals
1070 080 340
1070 080 347
1070 080 341
1070 080 348
Patching distribution frame
1070 080 159
1070 080 161
Socket terminal strip sets for
patching distribution frame
D Screw terminals
D Spring terminals
1070 080 340
1070 080 347
1070 080 341
1070 080 353
Pulling aids for socket terminal strips,
8-pole
1070 919 513
1070 072 259-102 (02.03) GB
Digital outputs 8DO, 8DO/2A and 16DO
5.4
5–9
Derating
The derating specifies how strongly the power output is reduced at increased
temperature.
Derating 8DO
Sum current per byte
[A]
4
3
2
1
10
20
30
35
40
45
40
45
50
55
50
55
60
TEnvironment [°C]
Derating 16DO
Sum current per word
[A]
8
6
4
2
10
1070 072 259-102 (02.03) GB
20
30
35
60
TEnvironment[°C]
5–10
Digital outputs 8DO, 8DO/2A and 16DO
Derating 8DO/2A
The derating is additionally dependent on the installation position (permitted
installation positions, see page 3–1).
Sum current
[A]
16
(100%)
(100
12
(75%)
8
(50%)
horizontal
vertical
4
(25%)
lying
10
20
30
35
40
45
50
55
TEnvironment [°C]
In the case of vertical operation with more than one 8DO/2A module, the derating of the module with the greatest load increases further in accordance
with the following curve:
Sum current of the 2A module with the greatest load
[A]
16
(100%)
12
(75%)
8
(50%)
1 x 2A module
2 x 2A module
3 x 2A module
4 x 2A module
4
(25%)
10
20
30
35
40
45
50
55
T Environment[°C]
Sample calculation
The following I/O modules are to be operated in vertical installation position:
1. 8DI,
2. 8DO (0.5 A),
3. 8DO2A, maximum current 8 A,
4. 8DO2A, maximum current 5 A,
5. 8DI,
6. 8DI,
7. 8DO2A, maximum current 4 A,
.
The specified maximum currents are calculated from known loads to
be connected and the simultaneity ratios.
1070 072 259-102 (02.03) GB
Digital outputs 8DO, 8DO/2A and 16DO
5–11
What maximum ambient temperature is permitted for this system?
– for 8DI, 8DO (0.5 A), 50° are permitted in the vertical installation position,
– the module with the greatest load is 8DO2A, maximum current 8 A,
– a total of three 2A modules are in the system,
⇒ from derating curve, 2A module with the greatest load :
8 A at 3 x 2A module,
⇒ Ambient temperature: 37° permitted.
.
1070 072 259-102 (02.03) GB
If for example, there were only 2 8DO2A modules in the system, 42°
would be permitted.
5–12
Digital outputs 8DO, 8DO/2A and 16DO
Notes:
1070 072 259-102 (02.03) GB
Digital output 8DO R
6
6–1
Digital output 8DO R
The output module 8DO R with relay outputs routes the commands of the
control to the connected actuators, such as valves, lamps or contactors. It is
used for switching tasks at mains voltage and in the 24 V industrial mains up
to 2 A.
6.1
Structure
The relay output module has 8 potential-free relay contacts (close contacts)
for a rated current of 2 A. It meets the requirements of safe isolation complying with EN 50 178 for overvoltage class II. Within a 4-part plug-in terminal,
voltages of overvoltage class III can be switched if the voltages are separated by an unused terminal. The modules begin to output data directly after
’Power on’.
Connections for module connector plugs
LED status indicators 0 to 7
LED status indicator UI
Labeling fields
Connector strips for:
D 24 V power supply
D Relay outputs
.
1070 072 259-102 (02.03) GB
Module connector plugs and socket terminal strip sets must be ordered separately.
6–2
Digital output 8DO R
6.2
Connections and displays
6.2.1
Connections
Power supply
D The digital part is supplied via the module connector plug.
D The relay coils are supplied via an external 24 V auxiliary voltage.
Depending on the ambient temperature, the following auxiliary voltage
range is permitted.
Auxiliary voltage 24 V
[V]
30
27
24
Permitted range of
auxiliary voltage
21
18
10
20
30
35
40
50
55
60
Tambient [_C]
DANGEROUS ELECTRICAL VOLTAGE
The 24 V auxiliary voltage must always meet the requirements of
’Safe isolation’.
1070 072 259-102 (02.03) GB
Digital output 8DO R
6–3
Protective earth connection
The relay output module provides a total of 4 M3 screw bolts for connecting
the protective earth.
Housing 8DO R
U-SCH A3.2 DIN125
Cable lug 3–2.5 DIN 46234
SKM M3 DIN 934 (self-tightening)
Short-circuit protection
CAUTION
Module defect due to overloaded relay contact.
Secure the connected load current circuits against short-circuit
using suitable measures.
Connection of inductive loads
Inductive loads, such as solenoid valves or contactors, which are to be
switched via the relay contact, must be fitted with cancel connection directly
at the load. The relay module 8DO R is equipped with a varistor protective
connection. However, its primary purpose is to protect the switch contact
against burn-up and excessively rapid wear.
If no additional interference suppression measures are implemented at the
inductive load, thermal conditions require that the relative switching frequency of large contactors (contactor size 8) is kept below 0.1 Hz.
It must also be taken into account that interference occurring when an inductive load is switched can lead, via the cables, to disruptions in other parts of
the system. The recommendations described in the installation guidelines,
chapter 13, apply.
All commercially available interference suppression filters can be used as
cancel filters.
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 6–7):
D Screw terminals
D Spring terminals
CAUTION
Dangerous voltage at exposed relay contacts.
Ensure the module is free of voltage before removing a socket
terminal strip.
1070 072 259-102 (02.03) GB
6–4
Digital output 8DO R
Connection allocation 8DO R
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
13/0 to 7
Relay connection 13, 0 to 7
14/0 to 7
Relay connection 14, 0 to 7
Connection example
+
24
24V
V
–
Power
Load
Load
+
24VV
24
external distributor
–
.
In compliance with EN60204, insulated,
color-coded as follows:
Main power circuit for AC and DC:
Control power circuits for AC:
Control power circuits for DC:
Protective earth:
one-wire cables should be
black
red
blue
green/yellow
1070 072 259-102 (02.03) GB
Digital output 8DO R
6.2.2
6–5
Patching distribution frame
To facilitate connection of the relay output module, the patching distribution
frame RV 8DOR can be used. This has 16 protective earth connections as
well as 4 groups of return wire connections, each bridged to and isolated
from one another (overvoltage category II).
The protective earth connections are secured by screws and can only be removed using a tool:
D Connector strip X95 and the socket terminal strip are connected mechanically by 2 screws
D the patching distribution frame is plugged onto the module from below
and also screwed on by means of at least two nuts.
Housing 8DO R
Patching distribution frame 8DOR
U-SCH A3.2 DIN125
SKM M3 DIN 934 (self-tightening)
RV 8DOR
1070 072 259-102 (02.03) GB
Terminal
Allocation example
X91, N01 to N04
Distributor return wire 0
X92, N11 to N14
Distributor return wire 1
X93, N21 to N24
Distributor return wire 2
X94, N31 to N34
Distributor return wire 3
PE
Protective earth connection
6–6
Digital output 8DO R
Connection example 8DO R with patching distribution frame
+
24 V
–
Patching distribution
frame RV 8DOR
Power
Load
Load
+
24 V
–
6.2.3
Displays and fault messages
Name
LED
Meaning
UI
green
24 V power supply is OK
off
24 V power supply is not present
green
State of the output: 1, active
off
State of the output: 0, not active
0 to 7
1070 072 259-102 (02.03) GB
Digital output 8DO R
6.3
Technical data, accessories, Order numbers
Technical data
8DO R
Order no.
1070 080 680
Power supply
EN 61 131-2
24 V; 19.2 to 30 V
Current consumption off:
D 24 V power supply
D internal bus
1070 072 259-102 (02.03) GB
< 130 mA (relay activated, without load)
max. 10 mA
Outputs complying with
EN 61 131-2
8 relay outputs (make contacts)
Output voltage
Rating 250 V AC / 30 V DC
Output current
Rating 2 A
Overload protection
no
Parallel switching of outputs
no
Switching frequency
max. 6 Hz
Status indicator
via LEDs
Output delay times
< 6 ms
Cable length, unshielded
max. 100 m
Simultaneity factor
100 %
Contact load capacity
max. 8 A per contact at TU = 55 °C
Connector grid
3.5 / 7 mm
Potential isolation
500 V between 24 V auxiliary voltage and system
Dimensions in mm (LxWxD)
83 x 105 x 38
Weight
280 g
Accessories
Order no.
Module connector plugs
1070 079 782
Labels
10 DIN A4 sheets, each with 20 labels
1070 080 309
Socket terminal strip sets
D Screw terminals
D Spring terminals
1070 081 311
1070 081 312
Patching distribution frame
1070 080 895
Socket terminal strip sets for patching distribution frame
D Screw terminals
D Spring terminals
1070 081 315
1070 081 314
Pulling aids for socket terminal strips, 8-pole
1070 919 513
6–7
6–8
Digital output 8DO R
Notes:
1070 072 259-102 (02.03) GB
Digital Input/output module 8DI/DO
7
7–1
Digital Input/output module 8DI/DO
The main area of application for the combined module 8DI/DO is to supplement systems in which the deployment of individual 8DI and 8DO modules
would be uneconomical. The module contains 8 complete inputs or outputs.
7.1
Structure
The combined module provides 8 semiconductor outputs or alternatively
8 digital inputs. The desired combination of the inputs and outputs can be
used bit by bit and can be flexibly adapted to requirements, e.g. 3 inputs and
5 outputs in any allocation.
The module begins to read in and/or output data directly after ’Power on’.
Connections for module connector plugs
Labeling fields
LED status indicator 0 to 7
LED status indicator UI
Connector strips for:
D 24 V power supply
D Input or output signals
.
1070 072 259-102 (02.03) GB
Module connector plugs and socket terminal strip sets must be ordered separately.
7–2
7.2
Digital Input/output module 8DI/DO
Connections and displays
LED status indicator
inputs/outputs 0 to 7
LED status indicator,
24 V power supply
24 V sensor supply
(bridged)
24 V power supply
24 V power supply drawn
from next module
Inputs/outputs
7.2.1
Connections
Power supply
D The module requires a 24 V power supply. It can be looped on from module to module using the terminals at the ends of the connector strip (24 V
and 0 V).
D The 24 V potentials for supply of the sensors are interconnected in the
module.
D The sensor supply is monitored for short-circuits or overload (total current > 0.6 A). In the event of a fault, the supply is cut for all sensors until
the fault is remedied.
Inputs and outputs
The module contains 8 connections which can be set optionally as inputs or
outputs. In the PLC, one input byte and one output byte are set.
If used as an input, the corresponding output bit must not be activated by the
PLC, i. e. the state 0 must be specified.
If used as an output, no sensor may be connected.
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 7–6):
D Screw terminals
D Spring terminals
1070 072 259-102 (02.03) GB
Digital Input/output module 8DI/DO
7–3
Connection allocation 8DI/DO
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
IO0 to 7
Inputs/outputs 0 to 7
S0 to 7
Sensor supply 0 to 7
In order to multiply the output current, the outputs can be switched in parallel
within a half byte.
1070 072 259-102 (02.03) GB
7–4
7.2.2
Digital Input/output module 8DI/DO
Patching distribution frame
Patching distribution frames can be used to extend the module 8DI/DO to
3-pole or 4-pole connection. Each patching distribution frame provides
2 additional connector strips, bridged in each case.
Connection allocation RV 2 x 10 M
Connector strip X91A, internally bridged
Connector strip X91B, internally bridged
RV 2 x 10 M
Connection example
Terminal
Allocation example
X91A
Power supply, 0 V potential
X91B
Potential earth
(clearly laid out connection, as for each sensor/each load terminals
located one above the other can be used)
+
–
8DI/DO
24 V power supply
Sensor
Loads
Return 0 V
reference
to module
Patching
distribution
frame
1070 072 259-102 (02.03) GB
Digital Input/output module 8DI/DO
7.2.3
Displays and fault messages
Name
LED
Meaning
UI
green
24 V power supply is OK
off
24 V power supply is not present
red
D Overload at one or more outputs
D Overload in supply of sensors
0 to 7
1070 072 259-102 (02.03) GB
green
State of the input/output: 1, active
off
State of the input/output: 0, not active
7–5
7–6
7.3
Digital Input/output module 8DI/DO
Technical data, accessories, Order numbers
Technical data
8DI/DO
Order no.
1070 080 709
Power supply complying with
EN 61 131-2
24 V; 19.2 to 30 V
Current consumption off:
D 24 V power supply
max. 20 mA (outputs activated, without load)
D internal bus
max. 20 mA
Inputs complying with
EN 61 131-2
8 digital inputs, type 1
(see Input characteristic curve, section 7.4)
Input voltage
D Rated voltage
24 V
D 0 signal
-3 to 5 V
D 1 signal
11 to 30 V
Input current
D 0 signal
v2.5 mA
D 1 signal
3 to 6 mA
Supply of sensors
D Output voltage
typ. Uext. -1 V
D Output nominal current
(total)
0.5 A
D Short-circuit/overcurrent
protection
w1.2 A
Delay time
D 0!1
4 ms
D 1!0
4 ms
2-wire proximity switch
D Quiescent current
D Voltage drop
v2.6 mA
v6 V
Outputs complying with
EN 61 131-2
8 semiconductor outputs,
non-storing, protected, supplying current
Output voltage
Rating 24 V,
voltage drop at 1 signal v1.5 V
Output current
D Rating
0.5 A
D Maximum value
0.6 A
D 1 signal
2 mA to 0.6 A
D 0 signal, leakage current
v0.5 mA
Overload protection
D Minimum current level
that leads to shutdown
0.6 A, typ. 1.2 A
D Automatic restart after
approx. 10 ms
Parallel switching of outputs
yes, maximum 4
1070 072 259-102 (02.03) GB
Digital Input/output module 8DI/DO
Technical data
8DI/DO
Simultaneity factor
see ’Derating curve’, section 7.5
Switching frequency
D ohmic load
100 Hz
D inductive load
1 Hz
Status indicator
via LEDs, measured on load side
Output delay times
< 500 µs
Cable length, unshielded
Maximum 100 m
Inductive shutdown voltage
on Uext. -50 V,
thus nominal operation to typ. -26 V
Contact load capacity
maximum 8 A per contact at TU = 55 °C
Contactor size at 1 Hz
SG1; 6.2 W
Lamp load at 8 Hz
5W
Connector grid
3.5 mm
Dimensions in mm (LxWxD)
48 x 105 x 38
Weight
154 g
Accessories
Order no.
Module connector plugs
1070 079 782
Labels
10 DIN A4 sheets, each with 20 labels
1070 080 309
Socket terminal strip sets
D Screw terminals
1070 080 340
D Spring terminals
1070 080 347
Patching distribution frame
1070 080 159
Socket terminal strip sets for patching distribution
frame
1070 072 259-102 (02.03) GB
D Screw terminals
1070 080 340
D Spring terminals
1070 080 347
Pulling aid for socket terminal strips, 8-pole
1070 919 513
7–7
7–8
7.4
Digital Input/output module 8DI/DO
Input characteristic curve
U
[V]
30
1 signal
max
20
typ
min
10
Switch range
0 signal
0
I
5
0
7.5
[mA]
10
Derating
The derating specifies how strongly the power output is reduced at increased temperature.
Sum current per output byte
[V]
4
3
2
1
10
20
30
35
40
45
50
55
60
TEnvironment[°C]
1070 072 259-102 (02.03) GB
Analog input module 4AI_UI
8
8–1
Analog input module 4AI_UI
For the control of processes, there are often analog signals to be measured,
supplied by encoders (sensors), e.g. for pressure, temperature or speed.
The analog input module 4AI_UI can measure
D analog voltages and
D analog currents
on 4 channels and route them as digital values to the PLC. Mean values can
also be formed from the measured values; settings via DIP switch S1.
8.1
Structure
The analog input module sets 8 input bytes (2 bytes per channel). The input
bytes can be assigned to any PLC addresses:
D in the CL150 via the I/O configuration of the WinPLC
D in a bus connection via the relevant bus configurator
The module is configured using DIP switches. No function module is required for operation.
Connections for module connector plugs
DIP switch S1
Labeling fields
Connector strips for:
D 24 V power supply
D analog measured value inputs
1070 072 259-102 (02.03) GB
8–2
Analog input module 4AI_UI
Features
D
D
D
D
D
D
.
8.1.1
4 analog inputs
12-bit resolution
Measuring voltages and currents
Measuring range can be selected (applies to all channels)
Mean value formation via n measurements
Sensor break detection in the 4 to 20 mA measuring range
Module connector plugs and socket terminal strip sets must be ordered separately.
Connections
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 8–9):
D Screw terminals
D Spring terminals
Connection allocation 4AI_UI
Terminal
Allocation
Ux+
Analog inputs 0 to 3 / positive input
Ux–
Analog inputs 0 to 3 / negative input
--Ix--
Measuring shunt bridge for current measurement
The 4AI_UI module provides one terminal for shielded connection per channel, U+ and U–.
The input signals are related to 0 V; no differential inputs.
Connected sensors must lie at the same potential. Potential differences falsify the measured result.
1070 072 259-102 (02.03) GB
Analog input module 4AI_UI
8–3
Connection example
In the case of voltage measurement, the plus lead is connected at the Ux+
terminal and the minus lead at the Ux terminal.
In the case of current measurement, connection is the same as for voltage
measurement. In addition, a bridge must be inserted between the two terminals --Ix--, e.g. between terminals --I2--. This bridge enables the internal
measurement shunt.
Bridge for
current measurement
8.1.2
Patching distribution frame
The modules can be extended to include a patching distribution frame. This
provides a convenient shielded connection for each channel and ensures
the strain relief of the connections.
.
The patching distribution frames extend the modules in a downward
direction by approx. 4 cm.
Shielded connection
1070 072 259-102 (02.03) GB
8–4
8.2
Analog input module 4AI_UI
Configuration with DIP switch S1
The measurement method with measuring range is set for all channels at
DIP switch S1.
S1
DIP 1 to 5:
Measuring range
DIP 6 and 7: mean
value formation
DIP 8: Diagnosis
To enable modified settings, the module must be switch off and then on
again.
S1.1 to S1.3
The measuring range is set at the DIP switches S1.1 to S1.3.
DIP 1.1
DIP 1.2
DIP 1.3
Measuring range
0
0
0
$10 V
1
0
0
0 to 10 V
0
1
0
$5 V
1
1
0
0 to 5 V
0
0
1
0 to 20 mA
1
0
1
4 to 20 mA, SB detection < 3.8 mA
0
1
1
4 to 20 mA, SB detection < 3.3 mA
SB = sensor break
.
S1.4
Other switch settings are invalid.
The output format of the measured values is set at DIP switch S1.4.
DIP 1.4
Output format of measured values
0
Straight binary
1
Double complement
Representation of the measured values in the double complement is only
possible in the case of bipolar measuring ranges ($10 V and $5 V).
For unipolar measuring ranges, DIP 1.4 must always be set at 0.
1070 072 259-102 (02.03) GB
Analog input module 4AI_UI
S1.5
8–5
The position of the 12-bit measured value within the data word is set at DIP
switch S1.5.
DIP 1.5
Representation of the measured values
0
aligned left
1
aligned right
The measured values converted into digital values (12-bit resolution) can be
positioned optionally in a word aligned to the left or right.
In the case of right aligned representation in the double complement, the free
bits 15 to 12 are filled with the value of the preceding sign bit (bit 11).
S1.6 and S1.7
The number of measurements used to form a mean value is set at DIP
switches S1.6 and S1.7.
DIP 1.6
DIP 1.7
Number of measurements
0
0
no mean value formation
1
0
8
0
1
32
1
1
128
A mean value formation can filter out unwanted, high-frequency interference. The time for one measuring cycle increases linearly with the number of
mean value formations.
S1.8
1070 072 259-102 (02.03) GB
At the DIP switch S1.8, the setting is made as to whether the module sets a
diagnosis messageat the CL150 or bus connection in the measuring range 4
to 20 mA in the event of a sensor break. (See measuring range 4 to 20 mA.)
DIP 1.8
Diagnosis message in the event of sensor break
0
no message
1
message to CL150 or bus connection
8–6
8.3
Analog input module 4AI_UI
Measuring range and data formats
Validity of data after ’Power on’
The module begins to convert the analog values after ’Power on’. As some
time passes before all channels have measured values, FFFF Hex is entered in the measured values until this time. This value indicates that the
measured values are not yet valid.
8.3.1
Voltage measurement
Measuring range
0 to 5 V
Coding
$5 V
0 to 10 V
Straight binary
$10 V
aligned
right
aligned
left
4.99878 V
+4.99756 V
9.99756 V
+9.99512 V
0FFF
FFF0
2.50122 V
0.00244 V
5.00244 V
0.00488 V
0801
8010
+2.5 V
0V
+5 V
0V
0800
8000
0.00122 V
–4.99756 V
0.00244 V
–9.99512 V
0001
0010
0V
–5 V
0V
–10 V
0000
0000
invalid
invalid
invalid
invalid
FFFF
FFFF
Measuring range
Coding
$5 V
$10 V
Double
complement
aligned right
Double
complement
aligned left
+ 4.99756 V
+ 9.99512 V
07FF
7FF0
0.00244V
0.004884 V
0001
0010
0V
0V
0000
0000
–4.99756 V
–9.99512 V
F801
8010
–5 V
–10 V
F800
8000
invalid
invalid
FFFF
FFFF
In the case of right aligned representation in the double complement, the free
bits 15 to 12 are filled with the value of the preceding sign bit (bit 11). This has
the advantage that it can be recognized from the MSB (bit 15) whether a
positive or negative number is involved.
1070 072 259-102 (02.03) GB
Analog input module 4AI_UI
8.3.2
8–7
Current measurement 0 to 20 mA
For a current measurement, the integrated measuring shunt for each channel must be activated by inserting an External bridge. (Bridge between the
two contacts marked with --I--.)
In this measuring range, no sensor break detection is possible.
Measuring range
Coding
0 to 20 mA
Straight binary
aligned right
aligned left
19.99512 mA
0FFF
FFF0
10.00488 mA
0801
8010
10 mA
0800
8000
0.00488 mA
0001
0010
0 mA
0000
0000
invalid
FFFF
FFFF
CAUTION
Ensure that no voltages above 5 V are present at inputs + and – of the
module.
Higher voltages can destroy the module!
1070 072 259-102 (02.03) GB
8–8
8.3.3
Analog input module 4AI_UI
Current measurement 4 to 20 mA
For a current measurement, the integrated measuring shunt for each channel must be activated by inserting an External bridge. (Bridge between the
two contacts marked with --I--.)
Measuring range
Coding
4 to 20 mA
Straight binary
aligned right
aligned left
19.99603 mA
0FFF
FFF0
12.00397 mA
0801
8010
12 mA
0800
8000
4.00397 mA
0001
0010
v4 mA
0000
0000
invalid
FFFF
FFFF
Sensor break
1000
0001
Sample measured values
CAUTION
Ensure that no voltages above 5 V are present at inputs + and – of the
module.
Higher voltages can destroy the module!
Sensor break
In the case of sensor break detection, 2 monitoring ranges are distinguished,
switchable via S1:
D sensor break for currents < 3.8 mA or
D sensor break for currents < 3.3 mA
Sensor break is reported:
D in the measured value. With left aligned representation, the LSB = 1 is set
(0001). With right aligned representation, the MSB = 1 is set (1000).
D by means of additional diagnosis message if S1.8 is set to ON
Unused channels
Unused channels always cause a sensor break message. In these channels, always set a bridge between the contacts ––Ix––. This delivers a
measured value around 0x0000.
1070 072 259-102 (02.03) GB
Analog input module 4AI_UI
8.4
8–9
Technical data, accessories, order numbers
Technical data
4AI_UI
Order no.
1070 080 524
Power supply
via internal bus, Iv50 mA
Potential isolation
no
Inputs complying with
EN 61 131-2
4 inputs single ended
Input voltage
D $10 V
D 0 to 10 V
D $5 V
D 0 to 5 V
Input current
D 0 to 20 mA
D 4 to 20 mA
(200 Ω shunt integrated)
Resolution
12 bit incl. preceding sign
Representation
Straight binary or double complement aligned left
Configuration
via DIP switch
Measurement error
<1 % at Tambient = 5 to 55 °C
Matching
without
Diagnosis
Sensor break, with current measurement 4 to
20 mA
Conversion time
all channels within 500 µs
$10 V, without mean value formation
Dimensions in mm
(L x W x D)
48 x 105 x 38
Weight
154 g
Accessories
Order no.
Module connector plugs
1070 079 782
Labels 10 DIN A4 sheets, 1070 080 309
each with 20 labels
Socket terminal strip sets
1070 072 259-102 (02.03) GB
D Screw terminals
1070 080 340
D Spring terminals
1070 080 347
Pulling aids for socket
terminal strips, 8-pole
1070 919 513
Patching distribution
frame for shielded
connection
1070 081 247
8–10
8.5
Analog input module 4AI_UI
Installation notes
Potential equalization
As the inputs of the module are not potential-isolated, the minus input of the
module and the GND of all sensors must lie at the same potential.
CAUTION
If several 4AI_UI modules are deployed, the minus input of the
individual modules must be bridged so that any existing potential
difference is not equalized via the ribbon cable.
Otherwise, the ribbon cable could be destroyed!
BIO-M-DP
4AI_UI
4AI_UI
Internal 0 V
bridge in the
modules
24 V
External bridge
between two
4AI_UI modules
0V
Sensor2
U
= max 50 V
diff
Sensor1
Sensor3
24 V
0V
24 V
0V
24 V
Udiff = 0 V
Udiff = 0 V
0V
1070 072 259-102 (02.03) GB
Analog input module 4AI_UI
8–11
Protection against overvoltage
In relation to the maximum (permanent) input voltage of $12 V specified in
the technical data, the module withstands brief overvoltages of $16.5 V at
the $inputs.
This voltage can be exceeded due to external interference, for example during thunderstorms, and destroy the module.
Protection against overvoltage is provided by:
D e.g. so-called ’lighting ductors’ made by Dehn,
D ’bipolar transient diodes’. These should have a breakdown voltage of
14 V to 18 V
.
The diodes slightly falsify the measurement result due to corresponding offset currents.
Sensor
Selection of analog line
L
Use cables with braided shields.
Shielded cables twisted in pairs must be used for the analog lines. These
reduce the influence of external interference and guarantee optimum
transfer of the analog signals. If cables with foil shields are used, it should
be borne in mind that the foil can be very easily damaged by pull or push
stresses. This drastically reduces the shielding effect.
The cable length is limited to a maximum of 200 m.
To avoid interaction on the analog signals, the cables must not be installed parallel to high-energy lines (e.g. supply leads).
1070 072 259-102 (02.03) GB
8–12
Analog input module 4AI_UI
Shielded connection
Taking the EMC criteria into account, the cable shield must always be
earthed at both ends of the cable to increase interference immunity.
If potential differences between the analog inputs and the sensors occur
(e.g. due to cut power supply or earthing at various parts of the unit), high
compensatory currents can occur at the shield placed on both sides.
These can heavily distort the analog signal and even damage the lead.
L
In this case, lay additional low-impedance potential compensation cables
(at least 16 mm2 Cu), connected on a large surface area with the grounder/protective earth.
It is only in exceptional cases of low interference environments that a cable
shield earthed on one side of the analog module can be accepted.
The cable shield is connected as short as possible on the analog module
at the
D shield distributor
D or by means of a cable end sleeve at the connector X21B
L
Use cable end sleeves to connect the signal cables. In doing so, ensure that
the terminal connections are absolutely clean and firmly tightened.
Measured value encoder
Non-insulated encoders are linked to the local earth potential. As the encoders are attached at different positions, potential differences between the individual earth points in relation to the control potential can occur. This can be
avoided using potential compensation cables between the individual encoders.
.
Insulated measured value encoders may not be used, as the analog
module has no differential inputs.
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9
9–1
Analog input module 4AI_UIT
For the control of processes, there are often analog signals to be measured,
which are supplied by encoders (sensors), e.g. for pressure, temperature or
speed.
The analog input module 4AI_UIT can measure
D analog voltages
D analog currents and
D temperatures via thermal elements or resistance thermometers
on 4 channels and route them as digital values to the PLC. Mean values can
also be formed from the measured values; settings via DIP switch S1.
9.1
Structure
The analog input module sets 8 input bytes (2 bytes per channel). The input
bytes can be assigned to any PLC addresses:
D in the CL150 via the I/O configuration of the WinPLC
D in a bus connection via the relevant bus configurator
The module is configured using DIP switches. No function module is required for operation.
Connections for module
connector plugs
LED status indicators
DIP switch S1
Labeling fields
DIP switch S2
Connector strips for:
D 24 V power supply
D analog measured value inputs
1070 072 259-102 (02.03) GB
9–2
Analog input module 4AI_UIT
Features
D
D
D
D
D
D
D
D
D
D
.
4 potential-isolated differential inputs
14-bit resolution
Measuring range can be selected (applies to all channels)
Mean value formation via n measrements
Monitoring of compensation measurement exceeding range
Measuring voltages and currents
Measuring temperatures with thermal elements
Characteristic curve correction, compensation, conversion to degrees
Measuring temperatures with resistance thermometers
2 constant current sources, each with 2.5 mA
Module connector plugs and socket terminal strip sets must be ordered
separately.
9.2
Connections and displays
9.2.1
Connections
Power supply
D The digital part is supplied via the module connector plug.
D The constant power sources are supplied via an external 24 V auxiliary
voltage.
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 9–17):
D Screw terminals
D Spring terminals
Connection allocation 4AI_UIT
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9–3
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
Ux+
Analog inputs 0 to 3 / positive input
Ux-
Analog inputs 0 to 3 / negative input
Sx+
Integrated constant current source / positive connection
Sx–
Integrated constant current source / negative connection
The 4AI_UIT module provides one terminal for shielded connection per
channel, U+ and U–.
Connection example
In the case of voltage measurement, the positive signal lead is connected
to the Ux+ terminal and the negative signal lead to the Ux– terminal.
In the case of current measurement, connection is the same as for voltage
measurement. In addition, a DIP switch (S2.0 to 2.3) must be closed for each
channel to activate the measurement shunt in each case.
24 V DC
I
.
1070 072 259-102 (02.03) GB
Example of temperature measurement, see section 9.4.4 and 9.4.5.
9–4
9.2.2
Analog input module 4AI_UIT
Patching distribution frame
The modules can be extended to include a patching distribution frame. This
provides a convenient shielded connection for each channel and ensures
the strain relief of the connections.
.
The patching distribution frames extend the modules in a downward
direction by approx. 4 cm.
Shielded
connection
9.2.3
Displays and fault messages
Name
LED
Meaning
RUN
green
fault-free operation
RUN +
DIAG
flashing
Hardware defect, module must be replaced
DIAG
red
Fault:
D Sensor break (see page 9–8)
D Compensation measurement exceeding range
D no 24 V power supply (UI flashes)
If DIP switch S1.7 = ON, the diagnosis message is routed
to the PLC.
UI
.
green
24 V power supply is OK
flashes
24 V power supply is not present (LEDs RUN and DIAG
light up)
There is also a hardware defect if all the LED displays remain dark although the module connector plug X52 is inserted, i.e. the module is
supplied with voltage.
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9.3
9–5
Configuration with DIP switch S1
The measurement method with measuring range is set for all channels at
DIP switch S1.
S1
DIP 1 to 5:
Measuring range
DIP 6 and 7: mean
value formation
DIP 8: Diagnosis
To enable modified settings, the module must be switch off and then on
again.
S1.1 to S1.3
.
1070 072 259-102 (02.03) GB
The measuring range is set at the DIP switches S1.1 to S1.5.
DIP 1.1
DIP 1.2
DIP 1.3
DIP1.4
DIP1.5
0
0
0
0
0
$10 V straight binary
1
0
0
0
0
$1 V straight binary
0
1
0
0
0
$0.1 V straight binary
1
1
0
0
0
0 to 20 mA
0
0
1
0
0
4 to 20 mA, SB < 3.8 mA
1
0
1
0
0
4 to 20 mA, SB < 3.3 mA
0
1
1
0
0
PT100
1
1
1
0
0
PT500
0
0
0
1
0
PT1000
1
0
0
1
0
NI100
0
1
0
1
0
NI500
1
1
0
1
0
NI1000
0
0
1
1
0
Type R
1
0
1
1
0
Type S
0
1
1
1
0
Type B
1
1
1
1
0
Type J
0
0
0
0
1
Type T
1
0
0
0
1
Type E
0
1
0
0
1
Type K
1
1
0
0
1
$10 V double complement
0
0
1
0
1
$1 V double complement
1
0
1
0
1
$0.1 V double complement
Other switch settings are invalid.
Measuring range
9–6
Analog input module 4AI_UIT
S1.6 and S1.7
The number of measurements used to form a mean value is set at DIP
switches S1.6 and S1.7.
DIP 1.6
DIP 1.7
Number of measurements
0
0
no mean value formation
0
1
8
1
0
32
1
1
128
A mean value formation can filter out unwanted, high-frequency interference.
The time for one measuring cycle increases linearly with the number of mean
value formations.
S1.8
At DIP switch S1.8, the setting is made as to whether the module sets a diagnosis message at the CL150 or bus connection in the event of a fault.
DIP 1.7
Diagnosis message in the event of a fault
0
no message
1
message to CL150 or bus connection
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9.4
9–7
Measuring range and data formats
Validity of data after ’Power on’
The module begins to convert the analog values after ’Power on’. As some
time passes before all channels have measured values, FFFF Hex is entered in the measured values until this time. This value indicates to the user
that the measured values are not yet valid.
9.4.1
Voltage measurement
Measuring range
$10 V
$1 V
Coding
$0.1 V
Double
complement
left aligned1)
Straight
binary
left aligned1)
Sample measured values
+9.99878 V
+0.999878 V
+0.0999878 V
7FFC
FFFC
0.00122 V
0.000122 V
0.0000122 V
0004
8004
0V
0V
0V
0000
8000
–9.99878 V
–0.999878 V
–0.0999878 V
8004
0004
–10 V
–1 V
–0.1 V
8000
0000
invalid
invalid
invalid
FFFF
FFFF
1) In
9.4.2
the voltage measurement ranges, bits 0 and 1 remain at the value 0.
Current measurement 0 to 20 mA
For a current measurement, the integrated measuring shunt for each channel must be activated by DIP switches S2.0 to 2.3.
Measuring range
Coding
0 to 20 mA
Straight binary, aligned left
Sample measured values
19.99878 mA
FFFC
10.00122 mA
8004
10 mA
8000
0.00122 mA
0004
0 mA
0000
invalid
FFFF
CAUTION
Ensure that no voltages above 5 V are present at the inputs of the
module during current measurement.
Higher voltages can destroy the module!
1070 072 259-102 (02.03) GB
9–8
Analog input module 4AI_UIT
Sensor break
In this measuring range, no sensor break detection is possible.
In the event of currents < 4 mA through the measurement shunt, the
measured value 0x0000 is output. This could also be a sensor break.
.
Negative currents, e.g. due to polarity inversion, lead to the diagnosis
message ’sensor break’ of DIP switch S1.8 is set to ON.
Unused channels
Unused channels always deliver an invalid message. If DIP switch S1.8 = ON,
this can lead to a diagnosis message. For this reason, activate the measuring shunt for unused channels. These channels the deliver a measured
value around 0x0000.
9.4.3
Current measurement 4 to 20 mA
For a current measurement, the integrated measuring shunt for each channel must be activated by DIP switches S2.0 to 2.3.
Measuring range
Coding
4 to 20 mA
Straight binary, aligned left
Sample measured values
19.99902 mA
FFFC
12.00097 mA
8004
12 mA
8000
4.000976 mA
0004
v4 mA
0000
invalid
FFFF
Sensor break
0001
CAUTION
Ensure that no voltages above 5 V are present at the inputs of the
module during current measurement.
Higher voltages can destroy the module!
Sensor break
In the case of sensor break detection, 2 monitoring ranges are distinguished,
switchable via S1:
D Sensor break for currents < 3.8 mA or
D Sensor break for currents < 3.3 mA
Sensor break is reported:
D in the measured value; the LSB = 1 is set (0001)
D by means of additional diagnosis message if S1.8 is set to ON
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9–9
Unused channels
Unused channels always cause a sensor break message. This can be prevented by connecting a 160 Ω resistance on both constant current sources.
The voltage drop across this resistance (approx. 4 V) is then given to the
open inputs. The measuring shunts of the open channels must not be activated (DIP2.x = OFF).
24 V DC
180 Ω
1070 072 259-102 (02.03) GB
9–10
9.4.4
Analog input module 4AI_UIT
Temperature measurement with thermal elements
The module 4AI_UIT supports the thermal elements TYPE R, S, B, J, T, E, K
as standardized in IEC 584. The voltage supplied by the elements is converted directly into degrees.
Two-wire potential-linked and potential-free thermal elements can be connected.
Output format
Temperatures are always represented in the format 0.1 degree = 1 bit. Values less than 0x8000 are negative temperatures. Values greater than
0x8000 are positive temperatures.
If a measured temperature is above or below the value range applicable to
the particular element, 0xFFFF or 0x0000 is displayed as measured value.
There is no monitoring of whether the range is exceeded.
Measuring principle
Thermal elements consist of the thermocouple (two different metals welded
at one end) and the required connection parts.
Thermocouple
Measuring
point
Comparison
point
4AI_UIT
Equalizing
cables
Measurement
cables
If the measuring point is exposed to a different temperature to that of the free
ends of the thermocouple, the thermoelectric force is created between the
free ends. It is dependent on the materials used and is proportional to the
temperature difference between measuring point and comparison point.
If required, the connections of the thermocouple can be extended by means
of equalizing cables to the comparison point. So that the thermoelectric force
is not falsified, these cables must always be made of the same material as
the thermocouples.
Use copper wires from the comparison point to the input module.
As it is always a temperature difference that is registered, the temperature of
the comparison point must be kept constant. However, as this is not possible
in practice, the module computes a compensation for the temperature
change.
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9–11
Compensation
To compensate the temperature change, the temperature must be
measured at the comparison point. To do so, always connect a 2-wire PT100
resistance thermometer to S0.
Thermocouple
+
–C0
Comparison
point
PT100
+–S0
Iconstant = 2.5 mA
If the temperature determined lies outside the temperature range of a
PT100, the LED DIAG lights up and a compensation is performed. With DIP
switch S1.8 at ON, this diagnosis message is routed to the CL150 or bus
connection.
Connection example
24 V DC
Comparison point
1070 072 259-102 (02.03) GB
9–12
Analog input module 4AI_UIT
Value ranges of the elements
Thermal element type R: Platinum 13 % Rhodium / Platinum
Binary value / hex Measured value in degrees
Range
FFFF
>1769.1
ER exceeding range
C51A to 7E0C
1769 to -50
NR nominal range
0000
< 50.1
SB sensor break
Thermal element type S: Platinum 10 % Rhodium / Platinum
Binary value / hex Measured value in degrees
Range
FFFF
> 1769.1
ER exceeding range
C51A to 7E0C
1769 to -50
NR nominal range
0000
< 50.1
SB sensor break
Thermal element type B: Platinum 30% Rhodium / Platinum 6% Rhodium
Binary value / hex Measured value in degrees
Range
FFFF
> 1200.1
ER exceeding range
AEE0 to 77CC
1200 to -210
NR nominal range
0000
< 210.1
SB sensor break
Thermal element type J: Iron / Copper - Nickel
Binary value / hex Measured value in degrees
Range
FFFF
> 1820.1
ER exceeding range
C718 to 8000
1820 to -0
NR nominal range
0000
< 0.1
SB sensor break
Thermal element type T: Copper / Copper - Nickel
Binary value / hex Measured value in degrees
Range
FFFF
> 400.1
ER exceeding range
8FA0 to 7574
400 to -270
NR nominal range
0000
< 270.1
SB sensor break
Thermal element type E: Nickel - Chromium / Copper - Nickel
Binary value / hex Measured value in degrees
Range
FFFF
>1000.1
ER exceeding range
A710 to 7574
1000 to -270
NR nominal range
0000
< 270.1
SB sensor break
Thermal element type K: Nickel - Chromium / Nickel
Binary value / hex Measured value in degrees
Range
FFFF
>1372.1
ER exceeding range
B598 to 7574
1372 to -270
NR nominal range
0000
< 270.1
SB sensor break
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9.4.5
9–13
Temperature measurement with resistance thermometers
The module 4AI_UIT supports the resistance thermometers PT100, PT500,
PT1000, NI100, NI500 and NI1000.
4-wire, 3-wire or 2-wire resistance thermometers can be connected.
Output format
Temperatures are always represented in the format 0.1 degree = 1 bit. Values less than 0x8000 are negative temperatures. Values greater than
0x8000 are positive temperatures.
If a measured temperature is above or below the value range applicable to
the particular element, 0xFFFF or 0x0000 is displayed as measured value.
There is no monitoring of whether the range is exceeded.
Measuring principle
Resistance thermometers change their resistance in proportion to the temperature.
The constant power source in the module supplies the resistor with constant
current of 2.5 mA. The voltage drop across the resistor is measured and converted into degrees. The load resistance of a constant power source must
not exceed 4 KΩ.
If you want to supply a number of resistance thermometers from one current
source, you have to loop the current from one resistor to the next. To do so,
you can use the two jumpers on connector strip X22A/B.
The greatest precision is achieved with a 4-wire connection. With this type of
connection, the 4 wires lead to the resistor. The voltage drop is measured
locally.
The 3-wire or 2-wire versions save on wiring, but as a rule lead to poorer results.
1070 072 259-102 (02.03) GB
9–14
Analog input module 4AI_UIT
Connection examples
Resistance thermometer with 4-wire connection
24 V DC
Resistance thermometer with 3-wire connection
24 V DC
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9–15
Resistance thermometer with 2-wire connection
24 V DC
One constant power source supplies 2 resistance thermometers
24 V DC
1070 072 259-102 (02.03) GB
9–16
Analog input module 4AI_UIT
Value ranges of the elements
Resistance thermometer PT100 / PT500 / PT1000
Binary value / hex
Measured value in degrees
Range
FFFF
> 850
SB sensor break
A134 to 7830
850 to –200
NR nominal range
0000
< 200
SB sensor break
Resistance thermometer NI100 / NI500 / NI1000
Binary value / hex
Measured value in degrees
Range
FFFF
> 250
SB sensor break
89C4 to 7DA8
250 to –60
NR nominal range
0000
< –60
SB sensor break
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9.5
9–17
Technical data, accessories, order numbers
Technical data
4AI_UIT
Order no.
1070 080 526
Power supply complying
with EN 61 131-2
24 V; 19.2 to 30 V
Current consumption off
D 24 V power supply
D internal bus
v50 mA
v50 mA
Potential isolation
yes
Inputs complying with
EN 61 131-2
4 differential inputs
Input voltage
D $100 mV
D $1 mV
D $10 V
measuring ranges via GAIN
Input current
D 0 to 20 mA
D 4 to 20 mA
50 Ω shunt integrated
Equipment features
D 2 constant current sources
D Compensation at thermal elements
Resolution
14 bit incl. preceding sign
Representation
Straight binary or double complement aligned left
Configuration
via DIP switch
Measurement error at
Tambient = 5 to 55 °C
<1 %,
<2 % in the measuring range $100 mV
Matching
fully automatic with power on
Diagnosis
D 24 V
D Sensor break, with current measurement 4 to
20 mA
D Compensation measurement exceeding range
Conversion time
all channels within 1 ms,
$10 V, without mean value formation
Dimensions in mm
(L x W x D)
102.6 x 105 x 38
Weight
294 g
Accessories
Order no.
Module connector plugs
1070 079 782
Labels
10 DIN A4 sheets, each with 20 labels
1070 080 309
Socket terminal strip sets
1070 072 259-102 (02.03) GB
D Screw terminals
1070 081 239
D Spring terminals
1070 081 238
Pulling aid for socket terminal strips, 8-pole
1070 919 513
Patching distribution frame for shielded
connection
1070 081 248
9–18
9.6
Analog input module 4AI_UIT
Installation notes
Selection of analog line
L
Use cables with braided shields.
Shielded cables twisted in pairs must be used for the analog lines. These
reduce the influence of external interference and guarantee optimum
transfer of the analog signals. If cables with foil shields are used, it should
be borne in mind that the foil can be very easily damaged by pull or push
stresses. This drastically reduces the shielding effect.
The cable length is limited to a maximum of 200 m.
To avoid interaction on the analog signals, the cables must not be installed parallel to high-energy lines (e.g. supply leads).
Shielded connection
Taking the EMC criteria into account, the cable shield must always be
earthed at both ends of the cable to increase interference immunity.
If potential differences between the analog inputs and the sensors occur
(e.g. due to cut power supply or earthing at various parts of the unit), high
compensatory currents can occur at the shield placed on both sides.
These can heavily distort the analog signal and even damage the lead.
L
In this case, lay additional low-impedance potential compensation cables
(at least 16 mm2 Cu), connected on a large surface area with the grounder/
protective earth.
It is only in exceptional cases of low interference environments that a
cable shield earthed on one side of the analog module can be accepted.
The cable shield is connected as short as possible on the analog module
at the
D shield distributor
D or by means of a cable end sleeve at the connector X21B.
L
Use cable end sleeves to connect the signal cables. In doing so, ensure that
the terminal connections are absolutely clean and firmly tightened.
Non-insulated measured
value encoders
Non-insulated encoders are linked to the local earth potential. As the encoders are attached at different positions, potential differences between the individual earth points in relation to the control potential can occur.
.
This can be avoided using potential compensation cables between the
individual encoders.
L
These encoders are not linked to the local earth potential.
When connecting the thermal elements, ensure that the positive pole of the
elements is connected to the positive pole of the input module.
On most sensors, the positive pole is red in color.
Insulated measured
value encoder
1070 072 259-102 (02.03) GB
Analog input module 4AI_UIT
9–19
Protection against overvoltage
In relation to the maximum (permanent) input voltage of $14 V specified in
the technical data, the module withstands brief overvoltages of $20 V at the
$inputs.
This voltage can be exceeded due to external interference, for exampleduring thunderstorms, and destroy the module.
Protection against overvoltage is provided by:
D e.g. so-called ’lighting ductors’ made by Dehn,
D ’bipolar transient diodes’. These should have a breakdown voltage of
14 V to 18 V
.
The diodes slightly falsify the measurement result due to corresponding offset currents.
Sensor
1070 072 259-102 (02.03) GB
9–20
Analog input module 4AI_UIT
Notes:
1070 072 259-102 (02.03) GB
Analog output module 4AO_U
10
10–1
Analog output module 4AO_U
To control processes, it is required to output analog signals that are processed by actuators, such as values etc.
The 4AO_U has 4 voltage outputs which can be individually configured for
the ranges –10 V to +10 V or 0 to 10 V.
10.1
Structure
The output module sets 8 output bytes (2 bytes per channel). The output
data can be assigned to any PLC addresses:
D in the CL150 via the I/O configuration of the WinPLC
D in a bus connection via the relevant bus configurator
The module is configured using DIP switches. No function module is required for operation.
Connections for
module connector plugs
Labeling fields
LED status indicator UI
DIP switch S1
Connector strips for:
D 24 V power supply
D analog outputs
Features
D
D
D
D
.
1070 072 259-102 (02.03) GB
4 analog outputs referred to shared ground
12-bit resolution
output range that can be set separately for each channel
monitoring of missing external power supply
Module connector plugs and socket terminal strip sets must be ordered separately.
10–2
10.2
Analog output module 4AO_U
Connections and displays
LED status indicator
24 V power supply
Analog outputs
Power supply
Power supply drawn
from next module
Shielded connection
CAUTION
Applying external voltage to the output terminals can lead to destruction of the analog assembly!
10.2.1
Connections
The analog output module provides connector strips for a 3-wire connection
(+signal, –signal and shield).
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 10–6):
D Screw terminals
D Spring terminals
1070 072 259-102 (02.03) GB
Analog output module 4AO_U
10–3
Connection allocation
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
U+
Analog outputs 0 to 4 / positive output
U–
Analog outputs 0 to 4 / negative output
Shielded connection
.
All [–] outputs of the channels as well as the 0 V connection terminal
are bridged.
Connection example
24 Vext
24 Vext
from power
connection
or auxiliary
module
to next
module
Load
1070 072 259-102 (02.03) GB
10–4
10.2.2
Analog output module 4AO_U
Patching distribution frame
The modules can be extended to include a patching distribution frame. This
provides a convenient shielded connection for each channel and ensures
the strain relief of the connections.
.
The patching distribution frames extend the modules in a downward
direction by approx. 4 cm.
Shielded
connection
10.2.3
Displays and fault messages
LED
Status
Meaning
UI
green
24 V power supply is OK
off
24 V power supply is not present
Diagnosis message
A missing 24 V supply of the module is reported via a diagnosis bit at the
CL150 or bus connection. This diagnosis message cannot be deactivated.
1070 072 259-102 (02.03) GB
Analog output module 4AO_U
10.3
10–5
Configuration with DIP switch S1
Output range
The voltage outputs can be separately configured using the DIP switch S1
for each channel for the output ranges 0 to 10 V or $10 V.
0
S1
1
2
3
4
5
6
7
ON
OFF
Position
DIP 1.0
(channel 0)
DIP 1.1
(channel 1)
DIP 1.2
(channel 2)
DIP 1.3
(channel 3)
ON
$10 V
$10V
$10V
$10 V
OFF
0 to 10 V
0 to 10 V
0 to 10 V
0 to 10 V
S1.4 to S1.7 are not used.
10.4
Data formats
Digital value
Analog value for
output range
0 to 10 V
Straight binary
left aligned
Analog value for
output range
$10 V
Double
complement
left aligned
000xh! 0000 0000 0000 xxxx
0V
0V
001xh! 0000 0000 0001 xxxx
2.44 mV
4.88 mV
7FFxh! 0111 1111 1111 xxxx
4.9975 V
9.9951 V
800xh! 1000 0000 0000 xxxx
5V
– 10 V
FFFxh! 1111 1111 1111 xxx
9.9975 V
– 4.88 mV
Resolution 1 LSB = OR * 1/4096
2.44 mV
4.88 mV
Sample values
x = any, OR = 10 V (unipolar) or 20 V (bipolar)
1070 072 259-102 (02.03) GB
10–6
10.5
Analog output module 4AO_U
Technical data, accessories, order numbers
Technical data
4A0_U
Order no.
1070 080 530
Power supply complying with
EN 61 131-2
24 V; 19.2 to 30 V
Current consumption off
D 24 V power supply,
outputs activated, without
load
≤ 200 mA
D internal bus
≤ 30 mA
Potential isolation
yes, in relation to internal bus, outputs have
shared GND potential
Outputs complying with
EN 61 131-2
4 analog outputs
Outputs
D Voltage
0 to 10 V
$10 V
Permitted load impedance
≥1 KΩ
Resolution
12-bit
Data format
0 to 10 V: Straight binary (binary code)
$10 V: Double complement
Configuration
via DIP switches for each channel
Greatest error across
temperature range
< 0.8 % from SKE
Short-circuit characteristics
Short-circuit-protected outputs, short-circuit current typ. 15 mA
Capacitive interaction
88 nF/500 V between shield and GND
88 nF/500 V between shield and 24ext
Output value on switching
power supply on/off
0V
Dimensions in mm
(L x W x D)
75.6 x 105 x 38
Weight
approx. 230 g
Accessories
4A0_U
Module connector plugs
1070 079 782
Labels
10 DIN A4 sheets, each with
20 labels
1070 080 309
Socket terminal strip sets
D Screw terminals
1070 080 340
D Spring terminals
1070 080 347
Pulling aid for socket terminal
strips, 8-pole
1070 919 513
Patching distribution frame
for shielded connection
1070 081 249
1070 072 259-102 (02.03) GB
Analog output module 4AO_U
10.6
10–7
Installation notes
Selection of analog line
L
Use cables with braided shields.
Shielded cables twisted in pairs must be used for the analog lines. These
reduce the influence of external interference and guarantee optimum
transfer of the analog signals. If cables with foil shields are used, it should
be borne in mind that the foil can be very easily damaged by pull or push
stresses. This drastically reduces the shielding effect.
The cable length is limited to a maximum of 200 m.
To avoid interaction on the analog signals, the cables must not be installed parallel to high-energy lines (e.g. supply leads).
Shielded connection
Taking the EMC criteria into account, the cable shield must always be
earthed at both ends of the cable to increase interference immunity.
If potential differences between the analog inputs and the sensors occur
(e.g. due to cut power supply or earthing at various parts of the unit), high
compensatory currents can occur at the shield placed on both sides.
These can heavily distort the analog signal and even damage the lead.
L
In this case, lay additional low-impedance potential compensation cables
(at least 16 mm2 Cu), connected on a large surface area with the grounder/
protective earth.
It is only in exceptional cases of low interference environments that a
cable shield earthed on one side of the analog module can be accepted.
The cable shield is connected as short as possible on the analog module
at the
D shield distributor
D or by means of a cable end sleeve at the connector X21B.
L
1070 072 259-102 (02.03) GB
Use cable end sleeves to connect the signal cables. In doing so, ensure that
the terminal connections are absolutely clean and firmly tightened.
10–8
Analog output module 4AO_U
Notes:
1070 072 259-102 (02.03) GB
Analog output module 4AO_I
11
11–1
Analog output module 4AO_I
To control processes, it is required to output analog signals that are processed by actuators, such as values etc.
The 4AO_I has 4 voltage outputs which can be individually configured for the
ranges 0 to 20 mA or 4 to 20 mA using DIP switches.
11.1
Structure
The output module sets 8 output bytes (2 bytes per channel). The output
data can be assigned to any PLC addresses:
D in the CL150 via the I/O configuration of the WinPLC
D in a bus connection via the relevant bus configurator
The module is configured using DIP switches. No function module is required for operation.
Connection for
module connector plug
Switch S1
Labeling fields
LED status indicator
Connector strips for:
D 24 V power supply
D analog outputs
Features
The output module has the following features:
D 4 analog outputs, 0 to 20 mA or 4 to 20 mA, shared ground
D 16-bit resolution
D output range that can be set separately for each channel
D monitoring for wire break
D monitoring of missing external power supply
.
1070 072 259-102 (02.03) GB
Module connector plugs and socket terminal strip sets must be ordered separately.
11–2
11.2
Analog output module 4AO_I
Connections and displays
LED status indicator
24 V power supply
Analog outputs
Power supply
Power supply drawn
from next module
Shielded connection
CAUTION
Applying external voltage to the output terminals can lead to destruction of the analog assembly!
11.2.1
Connections
The analog output module provides connector strips for a 3-wire connection
(+signal, –signal and shield).
Socket terminal strips
For each module and patching distribution frame, socket terminal strip sets
with various connection technologies are available (ordering information,
see page 11–7):
D Screw terminals
D Spring terminals
1070 072 259-102 (02.03) GB
Analog output module 4AO_I
11–3
Connection allocation
Terminal
Allocation
24 V
24 V power supply, 24 V potential
0V
Power supply, 0 V potential
I+
Analog outputs 0 to 4 / positive output
I–
Analog outputs 0 to 4 / negative output
Shielded connection
.
All [–] outputs of the channels as well as the 0 V connection terminal
are bridged.
Connection example
24 Vext
24 Vext
from power
connection
or auxiliary
module
to next
module
Load
1070 072 259-102 (02.03) GB
11–4
11.2.2
Analog output module 4AO_I
Patching distribution frame
The modules can be extended to include a patching distribution frame. This
provides a convenient shielded connection for each channel and ensures
the strain relief of the connections.
.
The patching distribution frames extend the modules in a downward
direction by approx. 4 cm.
Shielded
connection
11.2.3
Displays and fault messages
LED
Status
Meaning
UI
green
24 V power supply is OK
off
24 V power supply is not present
red
D Wire break
DIAG
D RLoad > 600 Ω in the case of one or more
(non-deactivated) output channels
off
Outputs are OK
1070 072 259-102 (02.03) GB
Analog output module 4AO_I
11.3
11–5
Configuration with DIP switch S1
Output range
The current outputs can be separately configured using the DIP switch S1 for
each channel for the output ranges 0 to 20 mA or 4 to 20 mA.
0
S1
1
2
3
4
5
6
7
ON
OFF
Position
DIP 1.0
(channel 0)
DIP 1.1
(channel 1)
DIP 1.2
(channel 2)
DIP 1.3
(channel 3)
ON
4 to 20 mA
4 to 20 mA
4 to 20 mA
4 to 20 mA
OFF
0 to 20 mA
0 to 20 mA
0 to 20 mA
0 to 20 mA
Diagnosis message
Each current output is monitored for wire breaks.
If a current output does not reach the given target value (cause: wire break or
load impedance > 600 Ω), this is signaled to the CL150 or bus connection via
a shared module diagnosis bit.
The diagnosis messages on the output channels that are not connected
must be deactivated using DIP switch S1. Otherwise, fault messages are
generated.
0
S1
ON
OFF
Position
ON
1
2
3
4
5
6
7
ÎÎÎÎ
DIP 1.4
(channel 0)
DIP 1.5
(channel 1)
DIP 1.6
(channel 2)
DIP 1.7
(channel 3)
Diagnosis message, if:
D 24 V power supply is not OK or
D cable break / overload
OFF
.
1070 072 259-102 (02.03) GB
Diagnosis message if
24 V power supply not OK
Diagnosis message regarding 24 V power supply cannot be deactivated.
11–6
11.4
Analog output module 4AO_I
Data formats
Digital value
Analog value for
output range
0 to 20 mA
Analog value for
output range
4 to 20 mA
0000 0000 0000 0000
0 mA
4 mA
0000 0000 0000 0001
0.305 µA
4.000244 mA
1111 1111 111 1 1111
20 mA
20 mA
Resolution 1 LSB = 1/65536
0.305 µA
0.244 µA
1070 072 259-102 (02.03) GB
Analog output module 4AO_I
11.5
11–7
Technical data, accessories, order numbers
Technical data
4A0_I
Order no.
1070 080 528
Power supply complying with
EN 61 131-2
24 V; 19.2 to 30 V
Current consumption off
D 24 V power supply
≤ 200 mA (outputs activated, without load)
D internal bus
≤ 30 mA
Potential isolation
yes, in relation to internal bus, outputs have
shared GND potential
Outputs complying with
EN 61 131-2
4 analog outputs
Outputs
D Current
0 to 20 mA
4 to 20 mA
Permitted load impedance
v600 KΩ
Resolution
16 bit
Data format
Straight binary
Configuration
via DIP switches for each channel
Greatest error across temperature range
t0.4 % from SKE
Capacitive interaction
22 nF/500 V between shield and GND
22 nF/500 V between shield and 24ext
Output value on switching
power supply on/off
depending on measuring range, 0 mA or 4 mA
Dimensions in mm
(L x W x D)
75.6 x 105 x 38
Weight
approx. 220 g
Accessories
4A0_I
Module connector plugs
1070 079 782
Labels
10 DIN A4 sheets, each with
20 labels
1070 080 309
Socket terminal strip sets
1070 072 259-102 (02.03) GB
D Screw terminals
1070 080 340
D Spring terminals
1070 080 347
Pulling aid for socket terminal
strips, 8-pole
1070 919 513
Patching distribution frame
for shielded connection
1070 081 249
11–8
11.6
Analog output module 4AO_I
Installation notes
Selection of analog line
L
Use cables with braided shields.
Shielded cables twisted in pairs must be used for the analog lines. These
reduce the influence of external interference and guarantee optimum
transfer of the analog signals. If cables with foil shields are used, it should
be borne in mind that the foil can be very easily damaged by pull or push
stresses. This drastically reduces the shielding effect.
The cable length is limited to a maximum of 200 m.
To avoid interaction on the analog signals, the cables must not be installed parallel to high-energy lines (e.g. supply leads).
Shielded connection
Taking the EMC criteria into account, the cable shield must always be
earthed at both ends of the cable to increase interference immunity.
If potential differences between the analog inputs and the sensors occur
(e.g. due to cut power supply or earthing at various parts of the unit), high
compensatory currents can occur at the shield placed on both sides.
These can heavily distort the analog signal and even damage the lead.
L
In this case, lay additional low-impedance potential compensation cables
(at least 16 mm2 Cu), connected on a large surface area with the grounder/
protective earth.
It is only in exceptional cases of low interference environments that a
cable shield earthed on one side of the analog module can be accepted.
The cable shield is connected as short as possible on the analog module at
the
D shield distributor
D or by means of a cable end sleeve at the connector X21B.
L
Use cable end sleeves to connect the signal cables. In doing so, ensure that
the terminal connections are absolutely clean and firmly tightened.
1070 072 259-102 (02.03) GB
I/O gateway
12
12–1
I/O gateway
The I/O gateway enables the transfer of data between two different field bus
systems (PROFIBUS-DP, CANopen, CANrho, DeviceNet and INTERBUS-S)
or between a field bus system and a CL150. The I/O gateway can also be
used between two bus systems of the same type. Here, the linked systems
exchange 20 bytes of input and 20 bytes of output information (reduction to
8 bytes I / 8 bytes O possible).
12.1
Layout, deployment options
The I/O gateway links two standard bus connections or a CL150 and a standard bus connection.
Bus
master
Bus
master
Field bus
node 1
Field
bus A
Field bus
node 2
Field bus I/O
Field bus
node n
gateway node m
Field bus
node 1
Field bus
node 2
I/O
gateway
The following restrictions apply:
D Any B~IO modules can be connected to the left-hand modular system
(field bus system B~IO or CL150). The I/O gateway must be connected
as the last module by means of a module connector plug.
1070 072 259-102 (02.03) GB
12–2
I/O gateway
D No other B~IO modules can be connected to the right-hand modular system (only field bus system B~IO). A fixed module connector plug is used
to connect the I/O gateway to the B~IO bus connection.
12.1.1
Connections
The I/O gateway has no external power supply.
The current consumption from the left-hand modular system is a maximum
of 10 mA. This must be taken into account in the sum current analysis of the
left-hand system.
The current consumption from the right-hand modular system (maximum
10 mA) is irrelevant, as no other I/O modules may be connected to it.
12.1.2
Configuration with DIP switch S1
The switching matrix width of the I/O gateway module is 20 bytes of input and
20 bytes of output data. DIP switch S1 can be used to reduce this to 8 input
bytes/8 output bytes if other I/O modules are connected to the left-hand field
bus node.
Example of switching matrix reduction:
In the case of INTERBUS-S, the maximum number of I/O bytes has already
been reached with the I/O gateway (20 bytes I/20 bytes O). If there are other
modules in the system, the switching range must be reduced to 8 bytes
I/8 bytes O.
Position
Switching matrix width
left
20 bytes I/O
right
8 bytes I/O
1070 072 259-102 (02.03) GB
I/O gateway
12.2
12–3
Diagnosis message
The I/O gateway is ready for operation when 5 V is applied from both sides
across the connector plugs.
If one side is not connected to the I/O gateway, the module diagnosis message ’No 5 V from other side’ is generated on the ’other’ supplied side:
D This message is displayed at the modular bus connection by the flashing
red LED DIA.
D In the CL150, a corresponding field message is created in the system
area (see CL150, control manual).
12.3
Data consistency
PROFIBUS-DP
The I/O gateway can be selected as a consistent or non-consistent module
in the PROFIBUS configurator (e.g. WinDP). For the selection of consistency/non-consistency, no setting is necessary on the assembly.
INTERBUS-S (IBS)
The data interchange to the IBS bus master is always constant due to the
system itself. Further consistency in the direction of the PLC is dependent on
the possibilities of the bus master.
CAN
The bus connection B~IO-M CAN supports up to a maximum of 32 bytes of
process data inputs and up to 32 bytes of process data outputs.
Here, the process data is arranged in 4 PDOs, each consisting of 8 bytes.
Due to the system itself, data consistency can only be guaranteed within a
PDO.
In the factory settings, the bus connection uses the default mapping, i.e., that
the input and/or output data of all I/O modules is arranged in sequence dependent on the installation sequence. If data consistency is required for the
gateway switching data, observe the order of the connected I/O modules.
Example:
In the order 16DI – 16 DO – 8DO – I/O gateway(8):
D the input range of the I/O gateway is consistent within the first 6 bytes.
The following 2 bytes are in turn consistent, but not with the first 6 bytes.
D the output range of the I/O gateway is consistent within the first 5 bytes.
The following 3 bytes are in turn consistent, but not with the first 5 bytes.
1070 072 259-102 (02.03) GB
12–4
I/O gateway
Input range
PDO 1 (NODE-ID)
0
1
16 DI
2
3
4
PDO 2 (NODE-ID)
5
6
7
0
1
2
3
4
PDO 1 (NODE-ID + 1)
5
6
7
0
1
2
3
4
5
PDO 2 (NODE-ID + 1)
6
7
0
1
2
3
4
5
6
7
z I/O gateway (8 bytes) !
z consistent range !
z consistent range !
z consistent range !
z consistent range !
PDO 2 (NODE-ID)
PDO 1 (NODE-ID + 1)
PDO 2 (NODE-ID + 1)
Output range
PDO 1 (NODE-ID)
0
1
16 DI
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
8 z I/O gateway (8 bytes) !
D
O
z consistent range !
z consistent range !
z consistent range !
z consistent range !
DeviceNet
Consistency handling is completely dependent on the bus master.
CL 150
Consistency is assured across the entire switching range.
1070 072 259-102 (02.03) GB
I/O gateway
12.4
Technical data, accessories, order numbers
Technical data
I/O gateway
Order no.
1070 083 150
Switching matrix width
20 bytes I/20 bytes O
(8 bytes I/8 bytes O)
1070 072 259-102 (02.03) GB
Power supply
via internal bus
Current consumption
10 mA at X51
10 mA at X52
Dimensions in mm
(W x H x D)
75.6 x 105 x 38
Weight
240 g
Accessories
I/O gateway
Module connector plugs
1070 079 782
Labels
10 DIN A4 sheets, each with
20 labels
1070 080 309
Pulling aid for socket terminal
strips, 8-pole
1070 919 513
12–5
12–6
I/O gateway
Notes:
1070 072 259-102 (02.03) GB
Installation guidelines
13
13–1
Installation guidelines
On setting up a system in which electrical equipment such as control systems are deployed, the following regulations must always be complied with:
D DIN VDE 0100
D EN 60 204-1
D EN 50 178
DANGER
Hazard to persons and property!
D Dangerous states of the system that can lead to personal injury
or damage to property must be prevented!
D The regulations for the setup of EMERGENCY STOP devices in accordance with EN 60 204-1 must be observed!
D It must be excluded that machines start up of their own accord
after reconnection of the mains voltage, e.g. following an EMERGENCY STOP!
D Protection against direct and indirect contact must be ensured by
the prescribed measures (connection with protective earth, insulation, etc.)!
13.1
Power connection
The power connection must be equipped with safe isolation complying with
EN 50 178, section 5.2.18.1. Transformers with safe isolation must be designed complying with EN 60 742.
The 24 V power supply is then regarded as extra-low voltage with safe isolation complying with EN 50 178, section 5.2.8.1. It can be designed either as
safety extra-low voltage (SELV) without earthing of the reference lead or as
protective extra-low voltage (PELV) with earthing of the reference lead.
A 3-phase power connection with simple full-bridge rectification is adequate.
The superimposed AC voltage proportion must not exceed 5 %.
All cables of the 24 V power supply must
D be laid separate from cables with higher voltages or
D be specially insulated, whereby the insulation must be designed for the
highest occurring voltage, see EN 60 204-1: 1997, section 14.1.3.
The isolated supply of output supplies means that these, for example in the
event of EMERGENCY STOP, can be deactivated byte by byte. This means
that the inputs and the outputs not assigned to the EMERGENCY STOP circuit remain functional.
.
1070 072 259-102 (02.03) GB
All peripheral devices such as digital sensors/actuators or other bus
connections connected to the interfaces of the I/O modules must also
meet the criteria of safe isolation from power circuits.
13–2
13.2
Installation guidelines
24 V power supply
There are two connection options for the 24 V power supply:
D Reference lead connected to the protective earth, see item 13.2.1.
D Reference lead not connected to the protective earth, see item 13.2.2.
13.2.1
Reference lead connected to the protective earth
If the reference lead (N, 0 V) is connected to the protective earth system, this
connection must be arranged at a central position, e.g. at the load power
connection or the isolating transformer, and it must be separable for
measurement of earth currents. This type of connection is to be used where
possible. The supply circuit is thus a PELV circuit, see also section 13.1.
L1
L2
L3
N
PE
24 V –
0V +
24 V –
0V +
separable
connection
1070 072 259-102 (02.03) GB
Installation guidelines
13.2.2
13–3
Reference lead not connected to the protective earth
If the reference lead (N, 0 V) is not connected to the protective earth system,
a corresponding earth fault monitoring device must be deployed to detect
earth faults in order to avoid inadvertent activation in the case of insulation
faults. The supply circuit is thus a SELV circuit, see also section 13.1. Please
note that other connected resources can nullify the earth-free layout.
L1
L2
L3
N
PE
E1
E2
Earth
leakage
monitor
1070 072 259-102 (02.03) GB
24 V –
0V +
24 V –
0V +
13–4
13.2.3
Installation guidelines
Capacitive load of the power supply
Capacitances are installed in the I/O modules between the supply leads and
protective earth for interference suppression. This is to be taken into account
if an earth fault monitoring device is deployed.
Module
13.2.4
Order number
Capacitance
Capacitance
24 V → PE
0 V → PE
8DO
1070 079 759
5 nF
5 nF
8DO/2A
1070 080 151
5 nF
5 nF
8DO R
1070 080 680
5 nF
5 nF
16 DO
1070 081 858
5 nF
5 nF
8DI
1070 079 757
5 nF
5 nF
16DI
1070 080 144
5 nF
5 nF
8 DO/DI
1070 080 709
5 nF
5 nF
4AI_UI
1070 080 526
–
–
4AI_UIT
1070 080 526
88 nF
88 nF
4AO_U
1070 080 530
88 nF
88 nF
4AO_I
1070 080 528
22 nF
22 nF
I/O gateway
1070 083 150
–
–
Dimensioning of the power supply
When dimensioning the power supply, the maximum currents are to be taken
into account, see VDE 0100-523. Directly at the device, there must be a voltage of 24 V (+ 20 %, – 15 %).
The voltage must also be retained in the case of
D fluctuations in the mains voltage, e.g. caused by varying loads on the
power supply
D different load states, e.g. short-circuit, normal load, lamp load or idling.
The maximum cable cross-section for the power supply of I/O modules
is 1.5 mm2.
13.2.5
Master switch
A master switch complying with VDE 0100 must be fitted for modules, sensors and actuators.
1070 072 259-102 (02.03) GB
Installation guidelines
13.2.6
13–5
Fuses
Fuses and cable circuit breakers are used to protect the supply leads in a
network. The cables of the power supply for I/O modules must be secured
with fuses/circuit breakers. Here, the supply of sensors and actuators should
be secured separately with fuses/circuit breakers. If the supply leads are
shorter than 3 m, and installed so that they are secured against earth faults
and short circuits, these fuses/circuit breakers can be omitted.
In choosing fuses/circuit breakers, a large number of criteria must be considered. The most important aspect is the rated current of the circuit to be
protected, see also VDE 0100-430. The rated current determines the cable
cross-section, see VDE 0100-523.
Other criteria regarding the selection of fuses/circuit breakers include:
D Rated voltage
D Temperature
D Internal resistance of the fuses
D Activation currents
D Cable lengths
D Pre-impedance of the power supply
D Possible defect location
D Vibrations
Other information, see:
Manual no. 32
VDE publications
Rating and protection of leads and cable complying with DIN 57 100,
VDE 0100-430 and -523.
In addition, many manufacturers of fuses and circuit breakers offer appropriate information.
13.2.7
Earthing
Function earthing
The I/O modules must be fitted on a metallic, earthed support, e.g. rear panel
of switching cabinet.
Installation is on 35 x 7.5 mm support rails complying with EN 50 022. The
support rail must be earthed, whereby any chrome coating or similar at the
connection point must be removed.
For optimum interference immunity, function earthing is required. The function earthing must be connected across a cable that is as short as possible,
or better an earthing strap.
Guide value:
Cable length
max. 1 m
Cross-section 6 mm2
If low interference levels are to be expected, function earthing via the earth
contacts of the power supply connections is also possible.
Guide value:
Cable length
max. 0.5 m
Cross-section 1.5 mm2
Potential equalization
Between the system components and the power supply, potential equalization in accordance with VDE 0100 Part 540 must be ensured.
1070 072 259-102 (02.03) GB
13–6
Installation guidelines
13.3
I/O connections
13.3.1
Inputs
All inputs have shared 24 V and 0 V potentials.
Any two-wire encoder (sensor) that meets the following conditions can be
connected:
D Quiescent current, low state
≤ 2.6 mA
D Voltage drop, high state
≤6V
The following two-wire encoders cannot be connected:
D 2-wire proximity switches largely using the standard IEC 947-5-2
D 2-wire proximity switches based on the NAMUR standard
13.3.2
Outputs
Inductive loads
In general, most outputs limit inductive deactivation peaks to a level that
causes no problems by means of built-in terminal diodes.
However, the occurrence of a wire break, pulling off a connector for inductive
load, e.g. solenoid valve, contactor etc., or the deliberate deactivation by
means of a mechanical contact lead to very high interference levels. This
can spread in the system due to galvanic, inductive or capacitive interaction
and under certain circumstances lead to malfunctions of the system or other
systems. To dampen this interference level, a corresponding interference
suppression element (free-wheeling diodes, varistors, RC elements) must
be fitted directly at the inductive load. Especially when a switch is fitted in line
with the inductive load, e.g. for safety locks, the cancel connection must not
be omitted.
All commercially available interference suppression filters can be used.
Due to their universal application, it is recommended to use bidirectional
suppressor diodes. These consist either of two opposingly poled, in-line
switched suppressor diodes or one poled suppressor diode with bridge rectification. Corresponding modules are commercially available.
Also suitable are varistor modules which, for example, are offered by the
manufacturers of contactors for the relevant contactors.
Other information can be found, for example, in the manual for interference
suppression of switched inductivities. This can be ordered from:
Friedrich Lütze GmbH & Co
Abteilung Marketing
Bruckwiesenstraße 17–19
D-71384 Weinstadt (Großheppach)
1070 072 259-102 (02.03) GB
Installation guidelines
13–7
Polarity inversion
Protection against polarity inversion is only guaranteed without load connection.
CAUTION
Modules can be destroyed by polarity inversion with simultaneous
short-circuit of the output leads, polarity inversion with simultaneous
connection of external poled cancel diodes on the output leads or application of external voltage greater than the power supply!
GND protection against breaks
The 0 V reference of the connected loads must be returned to the 0 V terminal of the output modules (2-pole connection of load). If the 0 V reference
is not returned (1-pole connection), the GND protection against breaks is not
guaranteed.
If in this case the outputs are activated (logical 1), a load current can flow
although the module has no 0 V connection.
If the outputs are not activated (logical 0), a leakage current of up to 25 mA
per output can flow.
In the case of parallel-switched outputs, the current is multiplied accordingly.
1070 072 259-102 (02.03) GB
13–8
13.4
Installation guidelines
Electromagnetic compatibility
The electromagnetic compatibility (EMC) is the capability of an electrical unit
to operate satisfactorily in its electromagnetic environment without influencing this environment, to which other units belong, to more than a permitted
degree (EN 61 000-4-1).
13.4.1
Interference
An important aim in automation technology is to achieve the greatest possible level of system availability. For this reason, there is a strong interest in
avoiding standstill times due to interference.
Possible sources of interference for the user are:
D self-generated interference, e.g. by frequency converter, inductive loads
etc.
D externally generated interference, e.g. lightning discharge, mains fluctuations etc.
These sources of interference affect the device, the interference trough, in
different ways. The main interaction paths of the interference are:
D emitted interference interaction
D conducted interference interaction
D electrostatic discharges
Conducted interference can change into emitted interference and vice
versa. For example, the conducted interference on a cable causes a field
which emits onto a cable fitted in parallel and also causes conducted interference.
13.4.2
Signal-to-interference ratio
The signal-to-interference ratio is the ability of a device or component to tolerate interference up to a certain level without restriction. Electronic units
such as control units have a significantly lower signal-to-interference ratio
than other electrical equipment, e.g. contactors.
1070 072 259-102 (02.03) GB
Installation guidelines
13.4.3
13–9
EMC legislation and CE identification
As a whole, the system must meet certain minimum requirements as regards
interference immunity. The system manufacturer or seller of the overall machine is responsible for complying with these specifications. This is specified
by the EMC legislation based on the EMC Directive of the Council of Europe.
The minimum requirements to comply with EMC legislation is specified in
product (family) standards. If these standards do not exist, basic technical
standards are applied. Conformity with the corresponding regulations is indicated by attachment of the CE identification.
The CE identification indicates conformity with all the relevant directives of
the Council of Europe. However, it is not a seal of approval, and does not
guarantee any properties; it is only intended for the monitoring authorities.
Depending on the product and area of application, a number of directives
can be relevant. In addition, the manufacturer must draw up a corresponding
declaration of conformity, which must be made available to the authorities on
request.
Conformity is usually evidenced by standard tests, described in the so-called
base standards, e.g. in EN 61 000-4-x = VDE 0847-4-x. However, to ensure
interference immunity on site, the user must also adhere to the installation
conditions specified by the manufacturer.
On setting up the system or machine, the EMC Directive, the Low Voltage
Directive, the Machine Directive and possibly other directives relating to
special types of system must be observed.
1070 072 259-102 (02.03) GB
13–10 Installation guidelines
13.4.4
EMC characteristics of I/O modules
The I/O modules already meet the EMC requirements from the relevant
standards (see descriptions of the individual assemblies or specifications).
Compliance with standards has been tested on certain system configurations. However, this fact certainly does not mean that the required electromagnetic compatibility of the system is ensured in every configuration.
Responsibility for the overall system lies with the system/plant manufacturer
alone.
Adequate electromagnetic compatibility can only be achieved with conscientious adherence to the installation guidelines. It is only when this condition is met that it can be assumed that an entire system composed of units –
each with their own CE identification – will comply with the aims for protection in the Council of Europe directive.
A comprehensive summary of the application of the directive is provided by
the publication ’Guidelines on the application of Council Directive
89/336/EEC of May 1989 on the approximation of the laws of the Member
States relating to electromagnetic compatibility’, issued on 23 May 1997 by
the European Commission. A German translation is available from the regulating authority for telecommunications and post, RegTP, and the Central
Association of the Electrical and Electronics Industry, ZVEI.
Test of transient overvoltages (surge)
The appendix of the technical base standard EN 50 082-2, which is currently
not part of the standard, contains a description of the surge test for direct current supplies and interfaces used for process control. This test is significant if
cables exit from the building, e.g. danger of lightning, or are linked to power
cables with interference.
Under the following conditions, the requirements of a system with I/O modules can be met:
D All power supplies of the control must be equipped with external varistor
modules (e.g. Phoenix MODUTRAB VAR/3S-24AC) or with overvoltage
protection modules.
D All digital inputs and outputs to be protected must be fitted with overvoltage protection terminals (e.g. Phoenix TERMITRAB SLKK 5/24DC,
TERMITRAB UK5/24V or corresponding modules from the MODUTRAB
range).
1070 072 259-102 (02.03) GB
Installation guidelines 13–11
Emissions, radio interference
I/O modules meet the technical base standard EN 50 081-2 that specify the
limit values for interference emissions. This standard only applies to use in
the industrial area. In contrast to a residential area, the industrial area is
characterized by the following specifications:
D no connection to the public low voltage power supply
D existence of a separate high-voltage or medium-voltage transformer
D operation in industrial environments or in the immediate vicinity of industrial supply networks
The expression ’industrial area’ has nothing to do with the legal division
(in part, specifically German) between industrial and residential areas.
The limit values for use in industry are higher than those for use in residential
areas. For this reason, the user must implement additional measures if the
system is to be used in residential areas:
D Installation of the system in a switch cabinet or a housing with high transmission loss shielding.
D An I/O system usually has a large number of peripheral interfaces. These
are the major path for the emission of radio interference. To comply with
the reduced emission values, all cables that exit from the shielded area
must be fitted with filters and shielding.
For systems in residential areas (residential, office and commercial areas,
small enterprises), specific approval must be obtained from authorities or inspection bodies. In Germany, this specific approval is given the Federal Bureau of Post and Telecommunications and local bureaus.
Protection against electrostatic discharges
All modules contain components that can be destroyed by electrostatic discharges (ESD). A defective assembly will not necessarily be recognizable
immediately, but can become apparent in the form of occasional or delayed
failures.
The relevant measures for handling electronic components and assemblies
must be observed without fail. In particular, it is not permitted to connect or
disconnect plugs under voltage. Before an assembly is touched directly, the
person involved must be electrostatically discharged.
1070 072 259-102 (02.03) GB
13–12 Installation guidelines
13.4.5
Installation measures to ensure interference immunity
As a general principle, prevention and rectification of interference at the
source have priority. In this connection, the following points must be noted:
Earthing
To draw off interference potentials that take effect between the device and
the reference earth, the device housing must be connected to earth by a lowimpedance connection. Especially in the case impulse interference with rise
times in the nanosecond range, the very inductive lining of simple cables inhibits the distributed leakage of interference to a considerable extent. Earthing straps have considerably better high-frequency characteristics and
should therefore definitely be used.
Shielding
A significant source of interference results from magnetic or electrical interaction. Interactions can be avoided by adequate shielding and spatial separation. This means that it is a requirement that potentially interfering
components (e.g. power supply and motor cables, contactors, frequency
converters, etc.) are installed isolated or shielded from components with low
signal-to-interference ratios (e.g. signal circuitry, electronic controls).
This systematic spatial separation of potential sources of interference and
interference troughs as early as the planning phase of a system is the
cheapest way to maximize the interference immunity of the system.
Deployment of transformers with shielded coils is preferred, as these produce very good damping of the interference in the higher voltage level.
Twisting
Mainly in the data lines, but also in the power supply lines, the technique of
twisting in pairs is used. The close intermingling of the wires means that interference voltages caused by interaction between the wires cannot occur.
It is important that the twisted cable consists of a two-way line, i.e. that the
flowing currents add up to zero. This is the case with many data interchange
processes, but also as a rule with power supplies.
Parallel laying of data lines and power cables with interference
A close parallel installation of data lines or input/output lines and interfering
cables such as motor cables or leads to contactors with poor interference
suppression must be avoided. The smaller the spacing between the parallel
installed cables, the greater the interacting interference.
In cable ducts and switch cabinets, cables and data lines must be arranged
at the greatest possible distance to one another, spacing of at least 10 cm
and preferably in separate, shielded chambers. Data lines to be crossed by
power lines at an angle of 90_.
1070 072 259-102 (02.03) GB
Installation guidelines 13–13
Interference suppression of inductive loads
In general, most control outputs limit inductive deactivation peaks to a level
that causes no problems by means of built-in terminal diodes. This also
applies to the output modules described.
However, the occurrence of a cable break, pulling put a connector for inductive load, e.g. valves, lamps or contactors etc.) or the deliberate deactivation
by means of a mechanical contact lead to very high interference levels which
can spread in the system due to galvanic, inductive or capacitive interaction.
To dampen this, a corresponding interference suppression element (freewheeling diodes, varistors, RC elements) must be fitted directly at the inductive load.
Due to their universal application, it is recommended to use bidirectional
suppressor diodes. These consist either of two opposingly poled, in-line
switched suppressor diodes or one poled suppressor diode with bridge rectification. Corresponding modules are commercially available.
Also suitable are varistor modules which, for example, are offered by the
manufacturers of contactors for the relevant contactors.
Filters
Normally, the interference immunity of the modules is sufficient that a function is assured even in an environment with relatively strong interference. To
improve the EMC properties even further, it might be necessary to implement additional filtering measures. These measures are to be examined for
each individual case. Suitable filters can be selected from the wide range
available.
Voltage drops
The logic supply can bridge voltage drops of up to 10 milliseconds to ensure
the continuity of your operation. This means that a disruption of bus operation by brief voltage drops is unlikely. Drops in supply at outputs are not covered here. This means that, in the event of voltage drops of this kind,
contactors and other actuators can be de-energized.
Falsified input data due to voltage drops are usually prevented by filters in
the input circuits. The usual activation times are approx. 3 ms. If longer interruptions in the power supply occur, suitable measures must be initiated. For
example, magnetic voltage stabilizers can be used on the AC voltage side or
stand-by batteries or support capacitors on the DC voltage side.
1070 072 259-102 (02.03) GB
13–14 Installation guidelines
Notes:
1070 072 259-102 (02.03) GB
Appendix
A
Appendix
A.1
Abbreviations
Abbreviation Description
LED
light emitting diode, i.e. status indicator
AC
alternating current
AO
analog output
LSB
least significant bit
CAN
Controller Area Network
M
modular
Cu
copper
MSB
most significant bit
DC
direct current
PE
Protective Earth
Dev
DeviceNet
PDO
process data object
DI
digital input
PLC
Programmable Logic Control
DO
digital output
R
relay
DP
PROFIBUS-DP
RV
Patching distribution frame
DIP
Dual Inline Package
S
switch
EGB
electrostatically endangered components!
T
temperature
EMC
electromagnetic compatibility
U
voltage
ESD
Electro-Static Discharge
Abbreviation for all terms relating to
electro-static discharge, e.g.
ESD protection, ESD hazards, etc.
GND
ground
GSD
device master data
I
current
IBS
InterBus-S
1070 072 259-102 (02.03) GB
A–1
A–2
A.2
Appendix
Index
A
Accessories, 5–8
16DI, 4–8
16DI–3, 4–8
16DO, 5–8
4AI_UI, 8–9
4AI_UIT, 9–17
4AO_I, 11–7
4AO_U, 10–6
8DI, 4–8
8DI/DO, 7–6
8DO, 5–8
8DO R, 6–7
8DO/2A, 5–8
I/O gateway, 12–5
Air circulation, 3–2
Air pressure, 2–3
Analog line, 8–11 , 9–18 , 10–7 , 11–8
Arrangement of wiring, 3–5
B
B~IO
16DI, 2–2 , 4–1 , 5–1
16DI–3, 4–1
16DI-3, 2–2 , 5–1
4AI_UI, 2–2 , 8–1
4AI_UIT, 9–1
4AO_I, 2–2 , 11–1
4AO_U, 2–2 , 10–1
8DI, 2–2 , 4–1 , 5–1
8DI/DO, 2–2
8DO, 2–2
8DO R, 2–2 , 6–1
8DO/2A, 2–2
Bus connection, 2–1
Gateway, 2–2 , 12–1
Bridged outputs, 5–3
Bus connection, 2–1
C
CANopen, 2–1
Capacitive load, 13–4
CE identification, 13–9
Combination of modules, 3–4
Combined module, 7–1
Compensation for temperature measurement, 9–11
Conducted interference, 2–3
Configuration
4AI_UI, 8–4
4AI_UIT, 9–5
4AO_I, 11–5
4AO_U, 10–5
I/O gateway, 12–2
Connection allocation
16DI, 4–4
16DI–3, 4–5
16DO, 5–6
4AI_UI, 8–2
4AI_UIT, 9–2
4AO_I, 11–3
4AO_U, 10–3
8DI, 4–3
8DI/DO, 7–3
8DO, 5–3
8DO R, 6–4
8DO/2A, 5–5
RV 2 x 10 M, 4–6 , 5–7 , 7–4
RV 2 x 18 M, 4–6 , 5–7
Connection example
16DI, 4–4
16DI–3, 4–5
4AI_UI, 8–3
4AI_UIT (constant power source), 9–15
4AI_UIT with current / voltage measurement, 9–3
4AI_UIT with resistance thermometer, 9–14
4AI_UIT with thermal element, 9–11
4AO_U, 10–3 , 11–3
8DI, 4–3
8DI/DO, 7–4
8DO, 5–4
8DO R, 6–4
8DO R with patching distribution frame, 6–6
Connector
X21B, 8–12 , 9–18 , 10–7 , 11–8
X51, 3–3 , 3–4
X52, 3–4
Control CL150, 2–1
Current measurement
0 to 20 mA
4AI_UI, 8–7
4AI_UIT, 9–7
4 to 20 mA
4AI_UI, 8–8
4AI_UIT, 9–8
4AI_UI, 8–3
4AI_UIT, 9–3
D
Data consistency, 12–3
Data formats
4AI_UI, 8–6
4AI_UIT, 9–7
4AO_I, 11–6
AO_U, 10–5
Deinstallation, 3–6
Derating, 5–9
16DO, 5–9
8DI/DO, 7–8
8DO, 5–9
8DO2A, 5–10
Vertical installation position, 3–2
1070 072 259-102 (02.03) GB
Appendix
DeviceNet, 2–1
Diagnosis message, 10–4
4AI_UI, 8–5
4AO_I, 11–5
I/O gateway, 12–3
DIP switch
4AI_UI, 8–4 , 8–5
4AI_UIT, 9–3 , 9–5
4AO_I, 11–5
4AO_U, 10–5
I/O gateway, 12–2
Displays, 4–7
16DI, 4–7
16DI–3, 4–7
16DO, 5–7
4AI_UIT, 9–4
4AO_I, 11–4
4AO_U, 10–4
8DI, 4–7
8DI/DO, 7–5
8DO, 5–7
8DO R, 6–6
8DO/2A, 5–7
Documentation, 1–7
E
Earthing, 13–12
earthing wrist strap, 1–6
EEM, 1–6
Electromagnetic compatibility, 13–8
EMC legislation, 13–9
Electrostatic discharge, 13–11
Electrostatically endangered modules, 1–6
EMC Directive, 1–1
Emergency–OFF–devices, 1–5
Emissions, 13–11
ESD protection, 1–6
ESD work stations, 1–6
External bridge, 4AI_UI, 8–7 , 8–8
F
Fault messages, 4–7
16DI, 4–7
16DI–3, 4–7
16DO, 5–7
4AI_UIT, 9–4
4AO_I, 11–4
4AO_U, 10–4
8DI, 4–7
8DI/DO, 7–5
8DO, 5–7
8DO R, 6–6
8DO/2A, 5–7
Filters, 13–13
Function earthing, 13–5
Fuses, 13–5
G
Gateway, 2–2 , 12–1
Deployment options, 12–1
GND protection against breaks, 13–7
1070 072 259-102 (02.03) GB
H
Humidity class, 2–3
I
Inductive loads, 13–6
Connection 8DO R, 6–3
Interference suppression, 13–13
Input / output module, digital, 8DI/DO, 7–1
Input characteristic curve
16DI, 4–9
16DI–3, 4–9
8DI, 4–9
8DI/DO, 7–8
Inputs
analog
4AI_UI, 8–1
4AI_UIT, 9–1
digital
16DI, 4–1
16DI–3, 4–1
8DI, 4–1
8DI/DO, 7–1 , 7–2
Inputs and outputs
analog, 2–2
digital, 2–2
Installation, 3–1
Installation position, Vertical, 3–2
installation position, lying, 3–1
Insulation testing voltage, 2–3
InterBus–S, 2–1
Interference, 13–8
Interference emission, 2–3
Interference immunity, 2–3
L
Labeling fields, 3–3
Low–Voltage Directive, 1–1
Lying installation position, 3–1
M
Maintenance, 3–3
Master switch, 13–4
Mean value formation
4AI_UI, 8–5
4AI_UIT, 9–6
Measured value encoders
4AI_UI, 8–12
4AI_UIT, 9–18
Measuring or testing procedures, 1–5
Measuring principle
with resistance thermometer, 9–13
with thermal elements, 9–10
Measuring range
bipolar, 8–4
unipolar, 8–4
Mechanical stress, 2–3
Minimum spacing, 3–2
Module family B~IO, 2–1
O
Operating temperature range, 2–3
A–3
A–4
Appendix
Order numbers
16DI, 4–8
16DI–3, 4–8
16DO, 5–8
4A0_I, 11–7
4A0_U, 10–6
4AI_UI, 8–9
4AI_UIT, 9–17
8DI, 4–8
8DI/DO, 7–6
8DO, 5–8
8DO R, 6–7
8DO/2A, 5–8
I/O gateway, 12–5
Output format, Temperatures, 9–10 , 9–13
Output range
4AO_I, 11–5
4AO_U, 10–5
Outputs
Actuators, 6–1
analog
4AO_I, 11–1
4AO_U, 10–1
digital
16DO, 5–1
8DI/DO, 7–1 , 7–2
8DO, 5–1
8DO R, 6–1
8DO/2A, 5–1
Overvoltage class II, 6–1
Overvoltage class III, 6–1
P
Parallel laying of cables, 3–5
Patching distribution frame
4AI_UI, 8–3
4AI_UIT, 9–4
4AO_I, 11–4
4AO_U, 10–4
8DI, 16DI, 16DI–3, 4–6
8DI/DO, 7–4
8DO, 8DO/2A, 16DO, 5–7
8DOR, 6–5
Polarity inversion, 13–7
Potential equalization, 13–5
4AI_UI, 8–10
Power connection, 13–1
Power supply
16DI, 4–2
16DI–3, 4–2
16DO, 5–2
4AI_UIT, 9–2
8DI, 4–2
8DI/DO, 7–2
8DO, 5–2
8DO R, 6–2
8DO/2A, 5–2
PROFIBUS–DP, 2–1
Protection against overvoltage
4AI_UI, 8–11
4AI_UIT, 9–19
Protection class, 2–3
Protective earth connection, 6–3
Q
Qualified personnel, 1–2
R
Radio interference, 13–11
Radio interference suppression, housing, 2–3
Reference lead
connected to protective earth, 13–2
not connected to the protective earth, 13–3
Resistance thermometer, 9–16
2–wire connection, 9–15
3–wire connection, 9–14
4–wire connection, 9–14
Connection, 9–13
Value range, 9–16
Ribbon cable, 3–3
S
Safe isolation, 6–1
Safety instructions, 1–4
Safety markings, 1–3
Semiconductor outputs, 7–1
Sensor break
4AI_UI, 8–7 , 8–8
4AI_UIT, 9–8
Shielded connection, 8–12 , 9–18 , 10–7 , 11–8
Shielding, 13–12
Short–circuit protection, 6–3
Signal–to–interference ratio, 13–8
Socket terminal strips, 4–2 , 5–2 , 6–3 , 7–2 , 8–2 , 9–2 ,
10–2 , 11–2
Spare parts, 1–5
Standard operation, 1–1
Strain relief, 3–5 , 8–3 , 9–4 , 10–4 , 11–4
Sum current, 3–4
Surge, 13–10
Switching matrix width, 12–2
T
Technical data, 5–8
16DI, 4–8
16DI–3, 4–8
4AI_UI, 8–9
4AI_UIT, 9–17
4AO_I, 11–7
4AO_U, 10–6
8DI, 4–8
8DI/DO, 7–6
8DO, 5–8
8DO R, 6–7
8DO/2A, 5–8
I/O gateway, 12–5
Temperature measurement
with resistance thermometers, 9–13
with thermal element, 9–10
Thermal element, 9–2 , 9–12
Connection, 9–10 , 9–18
Value ranges, 9–12
1070 072 259-102 (02.03) GB
Appendix
Trademarks, 1–7
Transient overvoltages, 13–10
Transport resilience, 2–3
Twisting, 13–12
Type of protection, 2–3
U
Unused channels
4AI_UI, 8–8
4AI_UIT, 9–8 , 9–9
V
Voltage drops, 13–13
Voltage measurement
4AI_UI, 8–3 , 8–6
4AI_UIT, 9–3 , 9–7
W
Wire break, 4AO_I, 11–4 , 11–5
1070 072 259-102 (02.03) GB
A–5
A–6
Appendix
Notes:
1070 072 259-102 (02.03) GB
A–1
Bosch Automation Technology
Australia
Robert Bosch (Australia) Pty. Ltd.
Head Office
Cnr. Centre - McNaughton Roads
P.O. Box 66
AUS-3168 Clayton, Victoria
Fax (03) 95 41 77 03
Great Britain
Robert Bosch Limited
Automation Technology Division
Meridian South Meridian Business Park
GB-LE3 2WY Braunstone
Leicestershire
Fax (01 16) 28-9 28 78
USA
Robert Bosch Corporation
Automation Technology Division
Fluid Power Products
7505 Durand Avenue
USA-Racine, Wisconsin 53406
Fax (414) 5 54-81 03
Canada
Robert Bosch Corporation
Automation Technology Division
6811 Century Avenue
CAN-Mississauga, Ontario L5N 1R1
Fax (905) 5 42-42 81
Robert Bosch Corporation
Automation Technology Division
Factory Automation Products
816 East Third Street
USA-Buchanan, MI 49107
Fax (616) 6 95-53 63
Robert Bosch Corporation
Automation Technology Division
Industrial Electronic Products
40 Darling Drive
USA-Avon, CT 0 60 01-42 17
Fax (860) 4 09-70 80
We reserve the right to make technical alterations
Your concessionary
Robert Bosch GmbH
Geschäftsbereich
Automationstechnik
Antriebs- und Steuerungstechnik
Postfach 11 62
D-64701 Erbach
Fax +49 (0) 60 62 78-4 28
1070 072 259-102 (02.03) GB · HB IN · BRC/EPY · Printed in Germany
1070 072 259-102 (02.03) GB
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