Bosch CL200 User Manual

RGB ELEKTRONIKA AGACIAK CIACIEK

SPÓŁKA JAWNA

Jana Dlugosza 2-6 Street

51-162 Wrocław

Poland

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www.rgbelektronika.pl

OTHER SYMBOLS:

CL-E2-24V

CLE224V, CLE2 24V, CLE2-24V, CL E224V, CL E2 24V, CL E2-24V, CL-E224V, CL-E2 24V, CL-E2-24V

BOSCH REXROTH

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Antriebs- und Steuerungstechnik

CL200
Manual

CL200

102

Edition

CL200

CL200
Manual

1070 072 145-102 (01.07) GB

E 1995 – 2001

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 20.– DM

Contents

V

1070 072 145-102 (01.07) GB

Contents

Page

1 Safety Instructions 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Intended use 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Qualified personnel 1–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Safety markings on components 1–3 . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Safety instructions in this manual 1–4 . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Safety instructions for the described product 1–5 . . . . . . . . . . . . . . . .

1.6 Documentation, software release and trademarks 1–7 . . . . . . . . . . .

2 System Introduction 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Features and Functions 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 UL-Certification 2–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Programming 2–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 CL200 Specifications 2–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Module slots 2–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Module Racks 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Overview 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Assembly 3–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Basic Unit 3–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Expansion Unit 3–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Expansion Structure 3–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 NT200 Power Supply Module 4–1 . . . . . . . . . . . . . . . . . .

4.1 Features and Functions 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Display and Control Elements 4–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Memory Backup Battery 4–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Specifications 4–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Central Processing Unit 5–1 . . . . . . . . . . . . . . . . . . . . . . .

5.1 Features and Functions 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Display and Control Elements 5–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 MemoryCard 5–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Interfaces 5–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Interface Connections 5–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 X71 Interrupt and High-speed Counter Inputs 5–11 . . . . . . . . . . . . . . .

5.4.3 X72 Analog Inputs and Outputs 5–15 . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.4 X31 Interface for PG Programming Unit 5–19 . . . . . . . . . . . . . . . . . . . .

5.4.5 X32 Second Serial Interface 5–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.6 X73 PROFIBUS-DP Interface 5–24 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Operating modes 5–27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Reloading the Firmware 5–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Specifications 5–29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 E 24 V– Digital Input Modules 6–1 . . . . . . . . . . . . . . . . . .

6.1 Features and Functions 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Connection 6–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Specifications 6–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

VI

1070 072 145-102 (01.07) GB

7 Digital Output Modules 7–1 . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Features and Functions 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Connections and Settings 7–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 A 24 V– Output Module / 0.5 A (16-way and 32-way) 7–5 . . . . . . . . .

7.4 A 24 V– / 2 A Output Module 7–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 AR/2A Relay Output module 7–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 Specifications 7–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Digital Input/Output Modules 8–1 . . . . . . . . . . . . . . . . . .

8.1 Functions and Features 8–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Addressing 8–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Connection 8–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1 X10 Power Terminals 8–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.2 X21A, X22A Inputs 8–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.3 X11B, X12B Outputs 8–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Specifications 8–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 DP-EA4 Peripheral Bus Station Module 9–1 . . . . . . . . .

9.1 Features and Functions 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Display and Control Elements, Connections and Settings 9–3 . . . . .

9.3 Specifications 9–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 AG/S Expansion Module 10–1 . . . . . . . . . . . . . . . . . . . . . . .

10.1 Features and Functions 10–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Specifications 10–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 R200, R200P, COM2-E Communication Modules 11–1 .

11.1 Functions and Features 11–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1.1.1 R200 Communication Module 11–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1.1.2 R200P Communication Module 11–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1.1.3 COM2-E Communication Module 1 1–4 . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 Specifications 11–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3 Advanced Documentation 11–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Analog Input Modules 12–1 . . . . . . . . . . . . . . . . . . . . . . . . .

12.1 Features and Functions 12–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.1.1 E ana Analog Input Module 12–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.1.2 E20 ana Analog Input Module 12–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.2 Specifications 12–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.3 Advanced Documentation 12–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Analog Output Modules 13–1 . . . . . . . . . . . . . . . . . . . . . . .

13.1 Features and Functions 13–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.1.1 A ana Analog Output Module 13–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.1.2 A10 ana Analog Output Module 13–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.1.3 A20 ana Analog Output Module 13–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.2 Specifications 13–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.3 Advanced Documentation 13–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

VII

1070 072 145-102 (01.07) GB

14 Positioning Modules 14–1 . . . . . . . . . . . . . . . . . . . . . . . . . .

14.1 Features and Function 14–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.1.1 POS-SA1 and POS-SA2 counting / positioning modules 14–2 . . . . . .

14.1.2 POS-LR1 and POS-LR2 positioning modules 14–3 . . . . . . . . . . . . . . .

14.2 Specifications 14–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.3 Advanced Documentation 14–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 BM2-ASI Bus Master 15–1 . . . . . . . . . . . . . . . . . . . . . . . . . .

15.1 Features and Functions 15–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.2 Specifications 15–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.3 Advanced Documentation 15–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RM2-DP12 Module 16–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.1 Features and Functions 16–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.2 Connecting to PROFIBUS-DP 16–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.3 Display and Control Elements 16–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.4 Specifications 16–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.5 Advanced Documentation 16–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 Installation 17–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.1 External Power Supply 17–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.2 24 V Power Supply 17–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.2.1 Hardware Configuration w/o Electrical Isolation 17–2 . . . . . . . . . . . . .

17.2.2 Hardware Configuration w/ Electrical Isolation 17–3 . . . . . . . . . . . . . .

17.2.3 Reference Conductor Connected to Protective Earth 17–4 . . . . . . . . .

17.2.4 Reference Conductor Not Connected to PE Conductor 17–5 . . . . . . .

17.2.5 Programming Unit and Earthing 17–5 . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.2.6 Capacitive Load in Power Supply Network 17–6 . . . . . . . . . . . . . . . . . .

17.2.7 Dimensioning Power Cables 17–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.2.8 Master Switch 17–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.2.9 Fuses 17–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.2.10 Earthing 17–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.3 Electromagnetic Compatibility (EMC) 17–10 . . . . . . . . . . . . . . . . . . . . . .

17.3.1 Interference 17–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.3.2 Signal-to-Noise Ratio 17–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.3.3 EMC Directive and CE Label 17–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.3.4 EMC Characteristics of the CL200 17–11 . . . . . . . . . . . . . . . . . . . . . . . .

17.3.5 Installation Procedures Ensuring Interference Resistance 17–13 . . . .

A Appendix A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Index A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

VIII

1070 072 145-102 (01.07) GB

Notes:

Safety Instructions

1–1

1070 072 145-102 (01.07) GB

1 Safety Instructions

Before you start working with the CL200 Controller, we recommend that you
thoroughly familiarize yourself with the contents of this manual. Keep this
manual in a place where it is always accessible to all users.

1.1 Intended use

This instruction manual presents a comprehensive set of instructions and in-
formation required for the standard operation of the described products.

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 emis-

sions). The following restrictions apply:
D No direct connection to the public low-voltage power supply is permit-

ted.

D Connection to the medium and/or high-voltage system must be provi-

ded via transformer .

The following applies for application within a personal residence, in busi-
ness areas, on retail premises or in a small-industry setting:

D Installation in a control cabinet or housing with high shield attenua-

tion.

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.

. 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.

Safety Instructions

1–2

1070 072 145-102 (01.07) GB

1.2 Qualified personnel

This instruction manual is designed for specially trained personnel. The rele-
vant 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 instruction manual addresses specially trained personnel possessing
in-depth knowledge of Programmable Logic Controllers.

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 techni-
cal 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 compre-
hensive training program. The professional staff at our training centre will be
pleased to provide detailed information. You may contact the centre by tele-
phone at ([phone].

Safety Instructions

1–3

1070 072 145-102 (01.07) GB

1.3 Safety markings on components

DANGER! High voltage!

DANGER! Corrosive battery acid!

CAUTION! Electrostatically sensitive devices (ESD)!

Disconnect mains power before opening!

Lug for connecting PE conductor only!

Functional earthing or low-noise earth only!
Screened conductor only!

Safety Instructions

1–4

1070 072 145-102 (01.07) GB

1.4 Safety instructions in this manual

DANGEROUS ELECTRICAL VOLTAGE

This symbol warns of the presence of a dangerous electrical voltage. In-
sufficient of lacking compliance with this warning can result in personal

injury.

DANGER

This symbol is used wherever insufficient or lacking observance of this in-
struction can result in personal injury.

CAUTION

This symbol is used wherever insufficient or lacking observance of instruc-
tions 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.

Safety Instructions

1–5

1070 072 145-102 (01.07) GB

1.5 Safety instructions for the described product

DANGER
Fatal injury hazard through ineffective Emergency-STOP devices!
Emergency-STOP safety devices must remain effective and accessi-
ble during all operating modes of the system. The release of functio-
nal locks imposed by Emergency-STOP devices must never be allo-
wed to cause an uncontrolled system restart! Before restoring power
to the system, test the Emergency-STOP 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 pro-
ducts 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 manufac-
turers will require express approval by Bosch.

DANGEROUS ELECTRICAL VOL TAGE
Unless described otherwise, maintenance procedures must always
be carried out only while the system is isolated from the power sup-
ply. 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
Danger to the module!
Do not insert or remove the module while the controller is switched
ON! This may destroy the module. Prior to inserting or removing the
module, switch OFF or remove the power supply module of the con-
troller, external power supply and signal voltage!

CAUTION
Only Bosch-approved spare parts may be used!

Safety Instructions

1–6

1070 072 145-102 (01.07) GB

CAUTION
Danger to the module!
All ESD protection measures must be observed when using the mo-
dule! Prevent electrostatic discharges!

Observe the following protective measures for electrostatically sensitive de-
vices (ESD)!

D The personnel responsible for storage, transport and handling must be

trained in ESD protection.

D ESDs must be stored and transported in dedicated protective packaging.
D Out of principle, ESDs may be handled only at special ESD workstations

equipped for this particular purpose.

D Personnel, work surfaces and all devices and tools that could come into

contact with ESDs 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 ESDs may under no circumstances come into contact with objects su-

sceptible to accumulating an electrostatic charge. Most items made of
plastic belong to this category.

D When installing ESDs in or removing them from an electronic device, the

power supply of the device must be switched OFF.

Safety Instructions

1–7

1070 072 145-102 (01.07) GB

1.6 Documentation, software release and trademarks

Relevant documentation

The present manual provides comprehensive information about the CL200
Controller and its accessories.
Programming information is not included in the manual.

Overview of available manuals:

Overview of available documentation

Order no.
German English French Spanish

Die Welt der SPS 1070 072 407 – – –
Manual 1070 072 091 1070 072 145 1070 072 213 1070 072 336
Operations List 1070 072 090 1070 072 151 1070 072 214 1070 072 337
SFC Sequence Function Chart 1070 072 402 1070 072 186 – 1070 072 342
KETTE200 1070 072 092 1070 072 150 1070 072 218 1070 072 338
BT-MADAP 1070 072 096 1070 072 163 – –
R200 1070 072 400 1070 072 157 – –
R200P 1070 072 401 1070 072 162 – –
BM2-ASI 1070 072 442 1070 072 194 – –
E ana, E20 ana 1070 072 408 1070 072 164 – –
A ana, A10 ana 1070 072 409 1070 072 165 – –
POS-SA1, POS-SA2 1070 072 405 1070 072 169 – –
POS-LR1, POS-LR2 1070 072 424 1070 072 191 – –
BT20-Bedienoberfläche für POS-LR 1070 072 429 – – –
RM2-DP12 1070 072 448 1070 072 449 – –
Control Terminal BT2 / BT5N / BT20N 1070 083 628 1070 083 630 – –

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 permis-
sion of the respective manufacturer or copyright owner.

MS-DOSr and Windowst are registered trademarks of Microsoft Corpo-
ration.

PROFIBUSr is a registered trademark of the PROFIBUS Nutzerorganisa-
tion e.V. (user organization).

MOBYr is a registered trademark of Siemens AG.
AS-Ir is a registered trademark of AS-International Association.
INTERBUS-Sr is a registered trademark of Phoenix Contact.
DeviceNetr is a registered trademark (TM) of ODVA (Open DeviceNet Ven-

dor Association, Inc.).

Safety Instructions

1–8

1070 072 145-102 (01.07) GB

The UL Mark is a registered certification mark of Underwriters Laboratories,
Inc., an independent, not-for-profit product safety testing and certification or-
ganization.

System Introduction

2–1

1070 072 145-102 (01.07) GB

2 System Introduction

2.1 Features and Functions

The CL200 is a powerful controller system of compact and modular design.

Application areas

In its minimum configuration, the CL200 facilitates cost efficient deployment
even in the smallest machine compounds. When fully configured with all
available options or deployed as a decentralized controller in a networked
situation, it can handle partial tasks in transfer lines.

Thanks to its networking option and extensive command repertoire, the
CL200 is also capable of assuming controller tasks of the medium perfor-
mance category.

D Packaging machines
D Conveyor technology
D Building automation
D Bottling equipment and racking plants
D Heating, climate control, ventilation and environmental technologies
D Subsections of transfer line construction
D assembly and handling technologies
D Food processing industry
D General applications in mechanical engineering

System Introduction

2–2

1070 072 145-102 (01.07) GB

Performance range

With 7 di f ferent central processing units, the CL200 allows accurate fine–tu-
ning of the controller performance to task related requirements.

D ZE200

Cost effective variant for small and high-speed controller tasks.

D 2 high-speed 32-bit counters
D 3 interrupt inputs
D Centralized system clock
D Function modules for sequential control and diagnostics

D ZE200A

Similar to ZE200, plus

D 4 analog inputs
D 1 analog output

D ZE200M

Similar to ZE200, plus

D MemoryCard

D ZE200AM

Range of functions as on ZE200A and ZE200M

D ZE201

Similar to ZE200, plus

D Second serial interface (COM port)

D ZE200-DP

Similar to ZE200, plus

D Bus master for COMNET-DP

D ZE200A-DP

Range of functions as on ZE200-DP and ZE200A

Hardware configuration

The minimum configuration of the CL200 consists of the following:

D One GG3 or GG3-K module rack
D One NT200 power supply module
D One central processing unit

Functional extension is possible by inserting additional peripheral modules
(intelligent modules or I/O modules).
In the event that more peripheral modules are required, additional modules
can be installed in expansion units.

System Introduction

2–3

1070 072 145-102 (01.07) GB

2.1.1 UL-Certification

The CL200 hardware modules are Underwriters Laboratories (UL) certified
for operation in the United States and Canada. The modules are listed in the

“Product Identity 17YB”.

Designation Order no. Described in

Input module
E 24 V– 16-way

w/ spring loa-
ded terminals

1070 083 383

Chapter 6

Input module
E 24 V– 32-way

w/ spring loa-
ded terminals

1070 083 384

Input module, analog
E20 ana

w/ spring loa-
ded terminals

1070 079 455 Chapter 12

and separate
manual (see
page 1–7)

Output module
A 24 V– / 2 A, 8-way

w/ spring loa-
ded terminals

1070 083 385

Chapter 7

Output module
A 24 V– / 0.5 A, 16-way

w/ spring loa-
ded terminals

1070 083 386

Output module
A 24 V– / 0.5 A, 32-way

w/ spring loa-
ded terminals

1070 083 387

I/O module
E16/A16-0.5 A

w/ spring loa-
ded terminals

1070 079 452 Chapter 8

Output module, analog
A10 ana (4 channels)

w/ spring loa-
ded terminals

1070 079 454

Chapter 13
and separate

Output module, analog
A10 ana (8 Channels)

w/ spring loa-
ded terminals

1070 079 453

manual (see
page 1–7)

BM2-ASI, AS interface bus master 1070 078 284 Chapter 15

and separate
manual (see
page 1–7)

RM2-DP12, remote module 1070 075 814 Chapter 16

and separate
manual (see
page 1–7)

. As a prerequisite for UL approved application, the following connec-

ting cables are required:

D Copper cables rated up to 60/75 _C
D Only Class 1 or similar cables

System Introduction

2–4

1070 072 145-102 (01.07) GB

2.2 Programming

The CL200 is programmed with the aid of a PC via the serial COM port.
With the use of the PC, the PLC program can also be written without requi-
ring the physical presence of the controller.

The CL200 provides the following options for storing the PLC program:

D Battery backed RAM memory
D Flash EPROM memory
D MemoryCard

Program Structure

The PLC program is subdivided into clearly defined and technologically allo-
cated program modules.

Programming

The PLC program is produced with the use of the Bosch proprietary WinSPS
software application.

The PLC program can be produced in the form of

D IL instruction list
D LD ladder diagram
D FUD function diagram
D SFC sequential function chart

with optional use of symbolic or absolute operands.
The programming language is based on DIN 19239.

PLC program documentation

The clearly structured and easily understood PLC program documentation
providing cross-reference lists supports the user in the case of quick system
startup, system troubleshooting, or when adapting the controller to new ap-
plications.

Both in the form of the screen display of the programming unit and as hard-
copy, the PLC program documentation provides a substantial rate of com-
ments.

System Introduction

2–5

1070 072 145-102 (01.07) GB

2.3 CL200 Specifications

. The Specifications as stated below apply to operation without the Me-

moryCard. Operating with the MemoryCard requires additional obser-
vation of the operating conditions issued by the manufacturer.

. The CL200 controller is a Class A device. It is designated for deploy-

ment in an industrial setting. When operated in private residences, in
business or small-industry settings, the CL200 may cause radio inter-
ference. In such case, the user will be required to introduce suitable
preventive radio interference countermeasures. Such measures inc-
lude the introduction of additional screening and filters. The user will
be required to obtain a single operating license issued by the appro-
priate national authority or approval body.

Specifications CL200

Complies w/ applicable laws/standards D EMC Directive of 9.11.1992

D EN 50081-2
D EN 61131-2
D EN 60204-1
D EN 50178
D EN 60529

Power supply NT200 power supply module, 24 VDC,

(19.2 thru 30 V)

Bridging capability, input power inter-
mittents on NT200 power supply mo-
dule, as per EN 61131-2

Class PS2
v 10 ms, repetition rate w 1 s

Current draw, from 24-V power supply

D Nominal current 1.8 A
D Minimum HW configuration:

NT200, ZE200A, 16 inputs, 16 out-
puts

typ. 220 mA

Interference emission when properly
installed in module rack

D Housing, radio interference sup-

pression as per EN 50081–2

Class A
D Frequency 30 thru 230 MHz;

imit. value 30 dB (mV/m) at 30 m

D Frequency 230 thru 1000 MHz;

limit value 37 dB (mV/m) at 30 m

Interference resistance when properly
installed in module rack

D high-frequency electromagnetic

fields, as per EN 61131-2

Test field strength 10 V/m
Frequency range 27 thru 500 MHz
Sweep rate 0.0015 Dec/s

D electrostatic discharge on exposed

housing components,
w/o MemoryCard

EMI resistance 4 for moisture class
RH-2

D as per EN 61131-2 D Air gap discharge 15 kV

D Contact discharge 4 kV

System Introduction

2–6

1070 072 145-102 (01.07) GB

Specifications CL200

D Line transient interference

D Rapid burst pulses, symm.,

as per EN 61131-2

D 2 kV for power supply module and

digital inputs/outputs

D 1 kV for analog inputs / outputs,

counter and interrupt inputs, serial
interfaces

D Dampened sinewave 1 MHz,

symm., as per EN 61131-2

1 kV for

D NT200 power supply module
D Digital inputs / outputs
D All power supply connections on

modules

Insulation test voltage, as per
EN 61131-2

D 350 V, AC voltage
D 500 V, DC voltage
D 500 V Pulse, 1.2 / 50 ms

Shock and vibration resistance
D Sinewave-shaped oscillations on

X, Y and Z axes, to EN 61131-2

D 10 thru 57 Hz

D 0.0375 mm amplitude, contin.
D 0.075 mm amplitude, occas.

D 57 thru 150 Hz

D 0.5 g, continuous
D 1 g, occasional

D Shock loads on X, Y, and Z axes,

as per EN 61131-2

11 ms semi-sinewave 15 g

Corrosion, chemical resistance

The ambient air must be free of eleva-
ted concentrations of acids, alkali, cor-
rosives, salts, metallic vapours, or
other electrically conductive pollutants.

Pollution level, as per VDE 0110 Part1 2

The ambient air must be dust–free.
Housing and installation environments
accommodating the module rack must

comply with IP 54.
Protection category, as per EN 60529 IP 20
Safety class, as per EN 50178 Class Ι
Humidity rating, as per EN 61131-2 RH-2, 5 through 95 %, condensation

not permitted
Operating temperature range, as per

EN 61131-2, w/o battery and
MemoryCard*)

D Horizontal

installation

D 5 to +55 _C

D Vertical

installation

D 5 to +40 _C

Storage temperature range, as per
EN 61131-2

–25 to +70 _C, w/o battery and

MemoryCard*)
Atmospheric pressure, as per

EN 61131-2

Operation up to 2000 m above sea

level
Transportability, as per EN 61131-2 Drop height, in package 1 m

System Introduction

2–7

1070 072 145-102 (01.07) GB

Specifications CL200

Weight, GG3 module rack D Net weight, 1kg

D Fully populated, approx. 3 kg

Weight, GG3-K module rack D Net weight, 0.58 kg

D Fully populated, approx. 1.8 kg

Dimensions, GG3 , w/ population
in mm (B x H x T)

224 x 184 x 126

Dimensions, GG3-K, w/ population
in mm (B x H x T)

132 x 184 x 126

*) Battery and MemoryCard are subject to the specification of the respective
manufacturer.

. The backplane must always be in a vertical position.

2.4 Module slots

The module descriptions list the usable module slots for the module racks of
both basic unit and expansion unit. Usable module slots are shown in grey in
the diagram below.

1234567

Basic unit

GG3

1234567

Expansion unit

GG3

GG3-K

GG3-K

System Introduction

2–8

1070 072 145-102 (01.07) GB

Notes:

Module Racks

3–1

1070 072 145-102 (01.07) GB

3 Module Racks

3.1 Overview

For the basic and expansion units, the following module racks are available:

D GG3 w/ 7 module slots
D GG3-K w/ 4 module slots

Both module racks consist of a metal housing.

The modules are inserted into the slot guide rails inside the module rack and
then pressed home until properly seated.
The tight contact between module and module rack thus achieved provides
for a high degree of mechanical stiffness while at the same time ensuring
increased resistance against external electrical interference.

. Empty slots must be closed with dummy covers.

Ordering information

Designation Order no.

GG3 Module rack 1070 075 100
GG3-K Module rack 1070 079 961
Locking foot, for support rail assembly 1070 077 225

Module Racks

3–2

1070 072 145-102 (01.07) GB

3.2 Assembly

Hole for joining two module
racks w/ mounting screws

Hole for joining two module
racks w/ mounting screws

Locking foot

GG3 : 223.5

GG3K : 132

162.4

183.8

125.9

The module racks GG3 and GG3-K are suitable for installation in a control
cabinet meeting IP54 protection category requirements.

The GG3 and GG3-K module racks can be installed in two ways:

D horizontal rack installation
D vertical rack installation,

in which case the permissible operating temperature as per EN 61 131-2
is reduced to between 5 and 40 _C, and only 50% of the outputs may
have a HIGH signal applied at the same time.

Vertical rack installation

Horizontal rack installation

Module Racks

3–3

1070 072 145-102 (01.07) GB

Clear space

Clear space

45 + cable
channel

45 + cable
channel

Clear space

100 + cable
channel

100 + cable-

channel

100 + cable
channel

[Dimensions in mm]

Installation

The GG3 / GG3-K module rack can be secured in one of the following ways:

D Screw mounted surface installation
D Installation via locking foot, and insertion in 35 x 7.5 mm support rail, as

per EN 50022.

. The locking foot is not supplied as standard equipment with the mo-

dule racks, and must be ordered separately (refer to page 3–1).

Screw mounted surface installation, drilling template

GG3K : 58.6
GG3 : 150

36.75

( 183.8 )

( 10.7 )

( 162.4 )

96.5

( 10.7 )

Module Racks

3–4

1070 072 145-102 (01.07) GB

Installation using locking foot

Install locking foot w/ M4 x 8Z3
combination screws

Locking foot

( 135.7 )

Module Racks

3–5

1070 072 145-102 (01.07) GB

3.3 Basic Unit

In its minimum configuration, the basic unit consists of:

D GG3 or GG3-K module rack
D NT200 power supply module
D Central processing unit

The remaining module slots can be used for

D Digital input / output modules
D Analog modules
D Intelligent modules (R200, R200P, COM2E)
D Max. of 1 AG/S expansion module

. Empty slots must be closed with dummy covers.

Module Racks

3–6

1070 072 145-102 (01.07) GB

Ordering information

Designation Order no.

GG3 Module rack 1070 075 100
GG3-K Module rack 1070 079 961
Locking foot for support rail 1070 077 225
NT200 Power supply module 1070 075 096
Buffer / backup battery 1070 917 152
ZE200 Central processing unit 1070 075 169
ZE200A Central processing unit 1070 075 171
ZE200M Central processing unit 1070 075 175
ZE200AM Central processing unit 1070 075 176
ZE201 Central processing unit 1070 078 795
ZE200-DP Central processing unit 1070 078 883
ZE200A-DP Central processing unit 1070 081 448
Dummy cover 1070 075 174

3.4 Expansion Unit

. When planning an expansion, the maximum address range and the

current draw of the controller must always be observed.

The CL200 can be expanded very easily to accommodate additional modu-
les. The GG3 or GG3-K module rack is used as an expansion unit.

There are several structural options for expansion:

D Inline configuration with a maximum of 2 GG3 module racks.
D Dual inline configuration comprising one GG3 plus one GG3-K module

rack.

D Multi-row inline configuration comprising a maximum of three rows, inclu-

ding a maximum of two GG3 module racks.

D Multi-row inline configuration comprising three rows with one GG3 and

GG3-k module rack each.

The connection between two module racks is accomplished with the use of:

D Bus coupler, connecting two module racks in a row
D AG/S expansion module for interconnecting two inline rows

. Empty slots must be closed with dummy covers.