Moeller HPL0213-2001/2002

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Contents

System overview Description PS416 modular PLC PS416-BGT-... rack PS416-POW-... power supply cards PS416-CPU-200/-300/-400 CPU cards PS416-INP-... digital input cards PS416-OUT-... digital output cards PS416-AIN-400, PS416-AIO-400 analog I/O cards PS416-CNT-200 digital counter card PS416-NET-220 INTERBUS card PS416-NET-230 PROFIBUS-FMS card PS416-NET-400 Suconet K card PS416-NET-440 PROFIBUS-DP card master PS416-NET-441 PROFIBUS-DP card slave PS416-COM-200 Serial communication card PS416-MOD-200 MODBUS/JBUS communication card Engineering Power supply cards PS416-CPU-200 CPU card PS416-CPU-300/-400 CPU cards Digital input cards Digital output cards Analog input/output cards Digital counter cards INTERBUS cards PROFIBUS-FMS cards Suconet K / PROFIBUS-DP card Communication cards Racks, power supply cards, CPU cards Digital input/output cards analog input/output cards Digital counter card, INTERBUS card PROFIBUS-FMS card Suconet K card, PROFIBUS-DP card Serial communication card, MODBUS/JBUS communication card Accessories Documentation Technical data Dimensions

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PS416 Modular PLC

04/002 System Overview

Moeller HPL0213-2001/2002

PS416 Modular PLC

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System Overview

Basic elements

Cards

Accessories

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Serial expansion with Suconet K Centralized (local) or decentralized (remote) as expansion card rack a Page 04/005

Analog I/O with 4 inputs and 4 outputs, software configuration as current or voltage I/O with max. 12-bit resolution 7

Memory card As a backup memory for user programs and operating systems, memory sizes 2 MB and 4 MB a Page 04/035

Power supply card 230 V AC 115 V AC 24 V DC a Page 04/006

Counter module with max. 6 inputs, up/down counting

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CPU card Storing/processing PLC programs Coordinating data exchange btw. the cards connected Main memory for up to 32 k instructions (normally) Integrated Suconet K interface can also be used as transparent interface (RS 485) (PS416-CPU-300-400 Programming under Windows to IEC/EN61131-3 with Sucosoft S40 a Page 04/007

Communication cards Different cards enhance the communication of the PS416 Suconet K: Master or slave with up to 30 stations INTERBUS: Master or slave with up to 256 stations PROFIBUS-FMS: Master or slave with up to 40 communications relations PROFIBUS-DP: Master with up to 124 stations (slaves); up to 30 without repeater Point-to-point communication with data terminal devices Terminal communication with the MOD-BUS/JBus protocol a Page 04/012

PS416 Modular PLC

Rack Contains the bus system for internal signal transmission Up to 19 card slots

Standard cards Digital input with 3 ms or 0.3 ms Make/break delay Digital output with 0.5 or 2 A output current per output Analog input with 8 inputs, software configuration as voltage or current input with a max. 12-bit resolution

Potential equalization bar For racks

04/004 Description PS416 Modular PLC

Moeller HPL0213-2001/2002

PS416 Modular PLC

Type overview PS416-BGT-.. PS416-POW-.. PS416-CPU-.. PS416-INP-.. PS416-OUT-.. PS416-AIN-.. PS416-AIO-.. PS416-CNT-.. PS416-NET-.. PS416-COM-.. PS416-MOD-.. Application The PS416 is a programmable logic controller for medium to high complexity applications. Thanks to its modular design it can be adapted easily to the automation tasks at hand. rack power supply card CPU card digital input card digital output card analog input card analog I/O card counter card network card communication card communication card

Features Modular design Allows connection of digital and analog sensors/actuators Digital and analog signal processing A range of fields systems allows problem-free and manufacturer-independent connection of remote peripherals Controls processes in machines and plants Controls complex processes; from measured value acquisition to the calculation of complex control algorithms to actuation of control actuators Processes and manages control and process data Local and/or remote expansion via Suconet K Real-time clock Programming with Sucosoft S40 according to IEC/EN 61 131-3 No external ventilation required

CPU

S40

NET 400

NET 400

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Description PS416-BGT-... Rack

Type overview

Engineering For mounting plate or front mounting

Type Surface/flush mounting

PS416-BGT... -400 Surface mounting 9 -410 Surface mounting 13 -420 Surface mounting 19 -421 Flush mounting 19 Accessories a Page 04/035 Documentation

Free slots

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Application The racks are used to form the programmable controllers. All racks can be used as basic units or expander racks. Features Provides slots for the cards Protects the cards from mechanical stress and electromagnetic interference; both in terms of interference and emission Provides the internal bus for exchanging signals between the cards Monitors the voltage, and generates the watchdog enable signal for the internal bus Each rack is fitted with a PE terminal for grounding faults A potential equalization bar can be fitted for connecting screened cables and grounding interference. The expander rack is linked to the basic unit via Suconet K The expander rack can be fitted with: Power supply card Suconet K card Digital and analog I/O cards Counter cards Other data: a Page 04/040

PS416 Modular PLC

04/006 Description PS416-POW-... Power Supply Cards

Moeller HPL0213-2001/2002

PS416 Modular PLC

Type overview

Engineering Back of hand proof and fingerproof terminals to VDE 0106 Part 100 a Page 04/019 -410 24 V DC 5V 10 A -420 115 V AC 5V 8A Accessories a Page 04/035 Documentation a Page 04/038

Type Supply voltage Internal system voltage Internal system current

PS416-POW.. -400 230 V AC 5V 8A

Application The PS416-POW-.. uses the external supply voltage to supply the stabilized 5 V system voltage required to operate the PS 416. Features Space requirement: 2 slots The PS416-POW-.. is placed in the left most slot of each rack A PS416-POW-.. can be fitted in each rack The PFI signal (power fail indicator) reports to the CPU whenever the primary voltage fails so that data can be backed up in time The supply voltage is connected via screw terminals An LED indicates whether or not the supply voltage is present An integrated filter suppresses interference The supply voltage and the internal bus are isolated The PS416-POW-.. complies with protection class 1 Other data: a Page 04/041

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Description PS416-CPU-200/-300/-400 CPU Cards

Basic rack
POW CPU

not CPU-200

Expander rack Suconet K1/K

NET-400 POW

"Intelligent slave"
NET-400 POW CPU

Type overview

Networking/expansion Networking/expansion via an SBI interface

Type: Memory size Suconet K interface Programming interface PCMIA interface (type 1)

PS416-CPU.. -200 256 KBytes No Yes Yes -300 512 KBytes Yes Yes Yes -400 1 MByte Yes Yes Yes Interfaces Connection via 9-pole SUB-D socket PRG interface: As RS 232C interface Length of programming cable max. 10 m Number of stations max. 1 As RS 485 interface Length of programming cable max. 600 m Number of stations max. 30 SBI interface Suconet K mode Length of the data cable max. 600 m/187.5 Kbit/s or 300 m/375 Kbit/s Number of stations max. 30 Transparent mode Length of data cable max. 1200 m Number of stations max. 1 Engineering a Page 04/020 Accessories a Page 04/035 Documentation a Page 04/038

Application The PS416-CPU-.. processes and saves PLC programs. The Sucosoft S40 programming software is used to program the PLC for complex automation solutions. Features Space requirement: 2 slots 16-bit microcontroller with RISC architecture 36 MHz clock frequency Loadable, modular operating system Cycle time/instruction: approx. 0.5 s for standard bit, byte and word commands Real-time clock The operating system is stored in a separate memory range that is reserved for this purpose Two independent batteries ensure data security for at least half a year. Batteries must be ordered separately Dynamic memory management Floating-point arithmetic Provides the user program memory Using the Suconet K interface the PS416 can be Expanded local and remote inputs and outputs Networked with intelligent slaves Connected to operator and display units The programming interface of the PS416 can be configured for use as: A point-to-point connection via RS 232C An RS 485 multi-drop interface. Several PS416s can be networked and programmed centrally with a programming device.

PS416 Modular PLC

04/008 Description PS416-INP-... Digital Input Cards

Moeller HPL0213-2001/2002

PS416 Modular PLC

Type overview Type Signal voltage Connection points Semi-conductor inputs On-delay, normally Off-delay, normally 3.0 ms 3.0 ms 0.2 ms 0.3 ms PS416-INP.. -400 24 V DC 16 -401 24 V DC 16

Engineering a Page 04/022 Accessories a Page 04/035 Documentation a Page 04/038

Application The PS416-INP-400 and PS416-INP-401 digital input cards detect local signals for medium-sized and large machine and plant controls. Features Space requirement: 1 slot Addresses are set separately via coding switches on the card Configuring by means of the S40 Topology Configurator 16 inputs 16 LEDs for displaying input status Potential isolation of all inputs via optocoupler Labelling field for individual designation of inputs Plug-in screw terminals; making it possible to prewire the plug connectors Integrated RC circuit for interference suppression Usable in basic unit and expander racks of the PS416 Provides input information on the local bit bus

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Description PS416-OUT-... Digital Output Cards

Type overview

Engineering The output power requires an external power supply of 24 V DC connected to the card DC contactors F 12 W can be actuated directly. However, this is not possible in DC operation in an economy circuit due to the high inrush current. Short-circuit behaviour of the PS416-OUT-400 Mode 1: Short-circuit/overload protection with manual reset. In the event of a short circuit, all outputs on the card are switched off until the short-circuit is rectified and is acknowledged with a manual Reset. An LED indicates short-circuit. The latter is available as a separate open collector output (ZAA). Mode 2: Short-circuit/overload protection without manual reset. In the event of a short-circuit the affected output will be switched off, and the separate open-collector short-circuit output (ZAA) is switched. After a few milliseconds, the card will automatically try to switch the output back on again. The short-circuit indicator is lit until the short-circuit is rectified and is acknowledged manually by pressing the Reset button. Short-circuit behaviour of the PS416-OUT-410 In the event of a short circuit, all outputs on the card are switched off until the short-circuit is rectified and is acknowledged with a manual Reset. An LED indicates short-circuit. The latter is available as a separate open collector output (ZAA). a Page 04/023 Accessories a Page 04/035 Documentation a Page 04/038

Type Signal voltage Connection points Outputs Rated operational current

PS416-OUT.. -400 24 V DC 16 Semiconductor 0.5 A -410 24 V DC 8 Semiconductor 2A

Application The PS416-OUT-400 and PS416-OUT-410 digital output card provide command and output signals for medium-sized and large machine and system controls. Features PS416-OUT-... Space requirement: 1 slot Addresses are set separately via coding switches on the card Configuring by means of the S40 Topology Configurator All outputs can be simultaneously loaded with the rated operational current Potential isolation of all outputs via optocoupler Labelling field for individual designation of outputs Plug-in screw terminals; making it possible to prewire the plug connectors Integrated suppressor for the semiconductor outputs against inductive overvoltage Usable in basic unit and expander racks of the PS416 Selection of behaviour in the event of a short-circuit via operating mode selector switch Central LED short-circuit indication as central message Short-circuit indication as ZAA signal low active Non-destructive electronic short-circuit protection of outputs Short reaction time via the local bit bus PS416-OUT-400 16 outputs with 0.5 A rated operational current per card 16 LEDs for displaying output status Parallel connection of up to 4 outputs per card possible PS416-OUT-410 8 outputs with 2 A rated operational current per card 8 LEDs for displaying output status Mode setting using the selector switch on the card

PS416 Modular PLC

04/010 Description PS416-AIN-400/PS416-AIO-400 Analog Input/Output Cards

Moeller HPL0213-2001/2002

PS416 Modular PLC

Type overview

Engineering Engineering notes The setting of the measuring ranges (configuration), output ranges, resolution and scan times is carried out in the Sucosoft S40 Topology Configurator. Only use screened twisted pair cable with an external diameter of max. 10 mm. Recommended cable: Metrofunk Kabel-Union, Berlin Type 08, e.g. 8 x 2-08 (8 x two-wire, each 0.08 mm) Messrs. HPM, Ditzingen Type Paartronic CY; e.g. 8 x 2 x 0.14 mm (8 x two-wire, each 0.14 mm) Recommended measurement probes: Messrs. Hirschmann Type Prof1, Article no. 931 376-100 (black) or 931 376-101 (red) Messrs. Brklin Article no. 35F114 (black) or 35F115 (red) a Page 04/024

Type

PS416-AIN.. -400 Channel 0 3

PS416-AIO.. -400 Input/output voltage 0 .. 10 V G 10 V 0 .. 5 V G5V Input/output current 0(4) .. 20 mA 4 inputs 4 outputs 12-bit max.

Input voltage

0 .. 10 V G 10 V 0 .. 5 V G5V Channel 4 7 0 .. 1 V Channel 0 7

Input current Connection points Resolution

0(4) .. 20 mA 8 inputs 12-bit max.

Accessories a Page 04/035 Documentation

Application The PS416-AIN-400 and PS416-AIO-400 analog cards detect analog measured values. The PS416-AIO-400 also provides analog output values for the process to be controlled. Features Space requirement: 1 slot Potential isolation to PS416 internal bus Plug-in screw terminals; making it possible to prewire the plug connectors Resolution max. 12-bit or 4096 increments Preselection of different resolutions for optimum matching to the process to be controlled Signal measuring points for measurements with external measuring devices The measured values are available either in the user program as normalized values (mV, mA) or as non-scaled values (0 to 4095) Can be used in basic units and expander racks of the PS416 No external power supply for the card Inputs are protected from excessive voltages and currents Total error of voltage and current I/O (0 to +55 C) normally 0.4 %; deviations due to interference max. 10 % (interference class B)

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Description PS416-CNT-200 Digital Counter Card

Type overview

Engineering The PS416-ZBX-405 ferrite ring should be used to suppress interference on counter signals a Page 04/025 Engineering notes The power supply of the PS416-CNT-200 must be isolated from the power supply of the other cards. The PS416-CNT-200 can only sense input signals when an external power supply is applied If required the CM62.x modules can be operated with interference masking (differential measurement) The encoder cables are connected via a 25-pole D-SUB plug The FIL-DC1.1 filter is used to eliminate interference of the 24 V DC supply voltage A mode selector switch allows three operating modes to be selected Accessories a Page 04/035 Documentation a Page 04/038

Type Input voltage Connection channels Counter frequency Counter direction

PS416-CNT-200 5/24 V Up to 6 0 50 kHz Up or up/down

Application The PS416-CNT-200 digital counter card is designed for detecting incremental and digital counter pulses. Features Space requirement: 2 slots Recording of the counter pulses on the card does not mean any additional burden on CPU cycle time The type of counter functions (up or down counter) is determined by the modules fitted Suitable for input voltages of +24 V DC and +5 V DC Counter modules for up and down counters with direction discriminator Up to 6 counter channels can be operated regardless of the modules fitted Usable in basic unit and expander racks of the PS416 Up to 6 slots available for counter modules per card, depending on the modules fitted The card can be inserted in any slot

PS416 Modular PLC

04/012 Description PS416-NET-220 INTERBUS Card

Moeller HPL0213-2001/2002

PS416 Modular PLC

Type overview

Engineering The PS416-ZBX-405 ferrite ring should be used to suppress interference on bus signals The INTERBUS card is configured during commissioning with the CFG-CMD Configurator. Communication between the PC and the card is via the RS232C interface. The data created (topology and bitmapped command sequences) are saved in the cards EEPROM. a Page 04/026 Technical data Messrs. Austerlitz electronik GmbH, Nuremberg Li2y + Cy AWG 24 DUE 4403 Zp24-9910 7.0 mm Messrs. Berkenhoff & Drebes, Alar Messrs. Helu Kabel GmbH, Hemmingen Messrs. LAPP Kabel GmbH, Stuttgart

PS416-NET-220 Interface for INTERBUS networks

Application The PS416-NET-220 INTERBUS card enables communication with all remote devices which support the INTERBUS protocol in accordance with EN 50 254. Features Space requirement: 2 slots Up to 4 cards can be inserted in the basic unit; note the total current required Intelligent card with its own processor and ASIC. Protocol processing does not mean any additional burden on the cycle time of the PS416 Master station on the INTERBUS network Data is addressed either physically or logically Up to 4096 I/O points, distributed on max. 256 stations can be addressed Exchange of 1024 I/O points in 3.7 ms Bitmapped command sequences Straightforward diagnostics via LED and 7 segment display RS 422 two-wire interface to INTERBUS; isolated RS 232C interface to CFG-CMD Configurator Configurator CFG-CMD a Page 08/013

Type Article no. External diameter Core Weight

LI (z) 2Y (PiMF) LI YCY (F) 3 2 0.6 3 2 0.5 See type 7.05 mm 21035 6.9 mm

LI YCY 3 2 0.5 0035801 7.1 mm

0.23 mm 61 kg/km

0.22 mm 61 kg/km 60 pF/m 20 to +70 C

0.25 mm 32 kg/km 150 pF/m 20 to +80 C

0.25 mm 66 kg/km 100 pF/m 20 to +80 C

Operational 45 pF/m (800 Hz) capacity Temperature range 40 to +80 C

Accessories a Page 04/035 Documentation a Page 04/038