Klockner-Moeller, Div of Eaton Corp. easy800 Users Manual
easy800
Control Relay
User Manual
08/04 AWB2528-1423GB
All brand and product names are trademarks or registered
trademarks of the owner concerned.
st
published 2002, edition date 05/02
1
nd
edition 11/2002
2
rd
edition 06/2003
3
th
edition 08/2004
4
See revision protocol in the “About this manual“ chapter
© Moeller GmbH, 53105 Bonn
Author: Dieter Bauerfeind
Editor: Heidrun Riege
Translator: Terence Osborn, David Long
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form
(printed, photocopy, microfilm or any other process) or
processed, duplicated or distributed by means of electronic
systems without written permission of Moeller GmbH, Bonn.
Subject to alteration without notice.
Warning!
Dangerous electrical voltage!
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally
restarted.
• Verify isolation from the supply.
• Earth and short circuit.
• Cover or enclose neighbouring units that
are live.
• Follow the engineering instructions (AWA)
of the device concerned.
• Only suitably qualified personnel in
accordance with EN 50110-1/-2
(VDE 0105 Part 100) may work on this
device/system.
• Before installation and before touching
the device ensure that you are free of
electrostatic charge.
• The functional earth (FE) must be
connected to the protective earth (PE) or
to the potential equalisation. The system
installer is responsible for implementing
this connection.
• Connecting cables and signal lines should
be installed so that inductive or capacitive
interference does not impair the
automation functions.
• Install automation devices and related
operating elements in such a way that they
are well protected against unintentional
operation.
• Suitable safety hardware and software
measures should be implemented for the
I/O interface so that a line or wire breakage
on the signal side does not result in
undefined states in the automation
devices.
• Ensure a reliable electrical isolation of the
low voltage for the 24 volt supply. Only
use power supply units complying with
IEC 60364-4-41 (VDE 0100 Part 410) or
HD 384.4.41 S2.
• Deviations of the mains voltage from the
rated value must not exceed the tolerance
limits given in the specifications, otherwise
this may cause malfunction and dangerous
operation.
•Emergency stop devices complying with
IEC/EN 60204-1 must be effective in all
operating modes of the automation
devices. Unlatching the emergency-stop
devices must not cause restart.
• Devices that are designed for mounting in
housings or control cabinets must only be
operated and controlled after they have
been installed with the housing closed.
Desktop or portable units must only be
operated and controlled in enclosed
housings.
Moeller GmbH
Safety instructions
• Measures should be taken to ensure the
proper restart of programs interrupted
after a voltage dip or failure. This should
not cause dangerous operating states even
for a short time. If necessary, emergencystop devices should be implemented.
• Wherever faults in the automation system
may cause damage to persons or property,
external measures must be implemented to
ensure a safe operating state in the event
of a fault or malfunction (for example, by
means of separate limit switches,
mechanical interlocks etc.).
08/04 AWB2528-1423GB
Contents
About This Manual 9
Device designation 9
Reading conventions 10
List of revisions 11
1easy800 15
Target readership 15
Proper use 15
– Improper use 15
Overview 16
Device overview 18
– easy basic units at a glance 18
– easy800 type references 19
easy operation 20
–Buttons 20
– Moving through menus and choosing values 20
– Selecting main and system menu 21
– easy800 status display 21
– Status display for local expansion 22
– easy800 advanced Status display 22
– easy800 LED display 23
–Menu structure 24
– Selecting or toggling between menu items 29
– Cursor display 30
– Setting values 30
2 Installation 31
Mounting 31
Connecting the expansion device 34
Terminals 35
–Tools 35
– Cable cross-sections 35
Network cables and plug 35
Connecting the power supply 35
– DC basic units 38
– Cable protection 39
Contents
08/04 AWB2528-1423GB
Connecting the inputs 39
– Connecting the AC inputs 39
– Connecting the easy-DC 44
Connecting the outputs 50
Connecting relay outputs 51
– EASY8....-RC.. 51
– EASY6..-..RE.. 52
–EASY2..-RE 52
Connecting transistor outputs 53
– EASY8..-DC-TC, EASY6..-DC-TE 53
Connecting analog outputs 55
– Connecting servo valves 55
– Setpoint entry for a drive 56
Connecting the NET network 56
– Accessories 56
– Cable length and cross-sections 58
– Plugging and unplugging network cables 60
Expanding inputs/outputs 62
– Local expansion 63
– Remote expansion 64
3 Commissioning 65
Switching on 65
Setting the menu language 65
easy operating modes 66
Creating your first circuit diagram 67
– Starting point Status display 69
– Circuit diagram display 70
– From the first contact to the output coil 71
– Wiring 72
– Testing the circuit diagram 74
– Deleting the circuit diagram 77
– Fast circuit diagram entry 77
Configuring an easy-NET network 78
– Entering the network station number 79
– Entering network stations 80
– Configuring an easy-NET network 81
– Changing the easy-NET network configuration 82
– Displaying the Status display of other stations 83
08/04 AWB2528-1423GB
Contents
4 Wiring with easy800 85
easy800 operation 85
– Buttons for drawing circuit diagrams and
function block usage 85
– Operation 86
– Usable relays and function blocks (coils) 94
– Markers, analog operands 97
– Number formats 99
– Circuit diagram display 100
– Saving and loading programs 101
Working with contacts and relays 103
– Creating and modifying connections 106
– Inserting and deleting a circuit connection 108
– Saving circuit diagrams 109
– Aborting circuit diagram entry 109
– Searching for contacts and coils 109
– “Go to” a circuit connection 110
– Deleting the rung 110
– Switching via the cursor buttons 111
– Checking the circuit diagram 112
– Function block editor 113
– Checking function blocks 117
– Coil functions 118
Function blocks 123
– Analog value comparator/
threshold value switch 125
– Arithmetic function block 128
– Data block comparator 132
– Data block transfer 139
– Boolean operation 150
– Counters 153
– High-speed counters 159
– Frequency counter 160
– High-speed counters 164
– High-speed incremental encoder counters 170
– Comparators 175
– Text output function block 177
– Data function block 181
– PID controller 183
– Signal smoothing filter 189
Contents
08/04 AWB2528-1423GB
– GET, fetch a value from the network 192
– Seven-day time switch 194
– Year time switch 200
– Value scaling 204
– Jumps 208
– Master reset 211
– Numerical converters 212
– Operating hours counter 218
– PUT, send a value onto the network 219
– Pulse width modulation 221
– Setting date/time 224
– Set cycle time 226
– Timing relay 228
– Value limitation 241
– Example with timing relay and
counter function block 243
5 easy-NET network 247
Introduction to easy-NET 247
easy-NET network topologies, addressing and
functions 248
– Loop through the unit wiring method 248
– T connector and spur line 248
– Topology and addressing examples 249
– Position and addressing of the operands
via easy-NET 250
– Functions of the stations in the network 252
– Possible write and read authorisation in
the network 252
Configuration of the easy-NET network 253
– Station number 253
– Transmission speed 253
– Pause time, changing the write repetition rate
manually 254
– Send each change on the inputs/outputs
(SEND IO) 255
– Automatic change of the RUN and STOP mode 255
– Input/output device (REMOTE IO) configuration 256
– Displaying the Status display of other stations 257
– Station message types 258
08/04 AWB2528-1423GB
Contents
– Transfer behaviour 258
– Signs of life of the individual stations and
diagnostics 259
– Network transmission security 262
6easy Settings 263
Password protection 263
– Password setup 264
– Selecting the scope of the password 265
– Activating the password 266
– Unlocking easy 267
– Changing or deleting the password range 268
Changing the menu language 270
Changing parameters 271
– Adjustable parameters for function blocks 272
Setting date, time and daylight saving time 273
Changing between winter/summer time (DST) 274
– Selecting DST 275
Activating input delay (debounce) 276
– Deactivating debounce (input delay) 276
Activating and deactivating the P buttons 277
– Activating the P buttons 277
– Deactivating the P buttons 278
Startup behaviour 278
– Setting the startup behaviour 278
– Behaviour when the circuit diagram is deleted 279
– Behaviour during upload/download to
card or PC 279
– Possible faults 280
– Card startup behaviour 280
Setting LCD contrast and backlight 281
Retention 283
– Requirements 284
– Setting retentive behaviour 284
– Deleting ranges 285
– Deleting retentive actual values of markers and
function blocks 285
– Transferring retentive behaviour 286
Displaying device information 287
Contents
08/04 AWB2528-1423GB
7 Inside easy 289
easy Program cycle 289
– How easy evaluates the high-speed counters
CF, CH and CI 292
Delay times for inputs and outputs 292
– Delay times with easy-DC basic units 293
– Delay time with easy AC basic units 294
– Behaviour with and without delay time 295
Monitoring of short-circuit/overload with
EASY..-D.-T.. 297
Expanding easy800 299
– How is an expansion unit recognised? 299
– Transfer behaviour 300
– Function monitoring of expansion units 300
QA analog output 302
– Behaviour with assignment of values
exceeding 1023 302
Loading and saving programs 303
– EASY…-..-..XMFD without display and keypad 303
– Program compatibility of the hardware 303
– Interface 304
– COM connection 304
– Terminal mode 304
– Memory card 305
– EASY-SOFT (-PRO) 308
Compatibility of different easy800 versions. 310
– Device compatibility 310
Device version 311
08/04 AWB2528-1423GB
Contents
Appendix 313
Technical data 313
– General 313
– Power supply 318
– Inputs 319
– Relay outputs 324
– Transistor outputs 326
– Analog output 329
– easy-NET Network 330
List of the function blocks 332
– Function blocks 332
– Function block coils 333
– Function block contacts 334
– Function block inputs (constants, operands) 335
– Function block output (operands) 336
– Other operands 336
Memory space requirement 337
– Optimization of the memory space requirement 338
Index 339
08/04 AWB2528-1423GB
08/04 AWB2528-1423GB
About This Manual
This manual describes the installation, commissioning and
programming (circuit-diagram generation) of the easy800
control relay.
A specialist knowledge of electrical engineering is needed
for commissioning and creating circuit diagrams. When
active components such as motors or pressure cylinders are
controlled, parts of the system can be damaged and persons
put at risk if easy is connected or programmed incorrectly.
Device designation This manual uses the following abbreviated designations for
different easy models:
• easy800 for
– EASY819-..,
– EASY820-..,
– EASY821-..,
– EASY822-..
• easy412 for
– EASY412-AC-…,
– EASY412-D.-…
• easy600 for
– EASY6..-AC-RC(X)
– EASY..-DC-.C(X)
About This Manual
•easy-AC for
– EASY8..-AC-…
– EASY412-AC-..
– EASY6..-AC-RC(X)
•easy-DC for
– EASY8..-.DC-…
– EASY12-DC-..
– EASY620/621-DC-.C(X)
• easy-DA for
EASY412-DA-RC
Reading conventions Symbols used in this manual have the following meanings:
X Indicates actions to be taken.
Attention!
h
Warns of the possibility of light damage.
08/04 AWB2528-1423GB
i
j
h
Caution!
Warns of the possibility of serious damage and slight
injury.
Warning!
Warns of the possibility of substantial damage, serious
injury or death.
Indicates interesting tips and additional information
For greater clarity, the name of the current chapter is shown
in the header of the left-hand page and the name of the
current section in the header of the right-hand page. Pages
at the start of a chapter and empty pages at the end of a
chapter are exceptions.
08/04 AWB2528-1423GB
List of revisions
List of revisions
Edition Page Description New Modifi-
cation
08/04 48 Section “20 A sensor” j
97 Table 6 j
97 Section “Composition of the markers” j
168 Figure 76, “Signal diagram of high-
speed counter”
194 Section “Function of the GET function
block”
202 Section “Function of the year time
switch function block”
219 Section “Accuracy” j
223 Section “Function of the pulse width
modulation function block”
230 Section “Time range”, table j
231 Section “Variable setpoint values”,
example
234 Figure 106 j
235,
236
269 Section “Password incorrect or no
305 Section “Memory card” j
308 Section “EASY-SOFT (-PRO)” j
315 Electromagnetic compatibility (EMC),
316 Dielectric strength
Figure 107 and Figure 108 j
longer known”
radio interference suppression
j
j
j
j
j
j
j
Omitted
About This Manual
08/04 AWB2528-1423GB
Edition Page Description New Modifi-
cation
06/03 58 Cable length and cross-sections j
59 Section “Calculating the cable length
with known cable resistance”
197 Section “Memory requirement of the 7-
day time switch”
202 Section “Memory requirement for the
year time switch”
220 Coils j
242 Coil j
248 Note: length of spur line j
332 List of the function blocks j
337 HW, HY: space requirement at the
function block output
05/03 132 Data block comparator j
139 Data block transfer j
153 NOT Boolean sequence j
180 Entering setpoint values j
183 PID controller j
189 Signal smoothing filter j
195 Warning switching behaviour j
204 Value scaling j
212 Numerical converters j
221 Pulse width modulation j
226 Set cycle time j
257 Note on Status display j
266 Activating the password j
274 Note on DST time change j
j
j
j
j
Omitted
08/04 AWB2528-1423GB
List of revisions
Edition Page Description New Modifi-
cation
11/02 302 QA analog output, Value range j
336 Function block output (operands) j
15 Target readership j
15 Proper use j
21/21 Menu displays j
24 Operating buttons j
26 Operating buttons j
46 Number of circuits j
58 Surge impedance j
61 Fig. 36, Station number j
78 Fig. 49, Station number j
89 Short-circuit/overload with expansion j
108 Number of circuit connections j
115 Notation for >I1 and QV> j
117 Notation for >I1 and QV> j
117 Notation for >I1 and QV> j
122 Useful coil functions j
129 Notation for QV> j
151 Notation for QV> j
163 Notation for I1 and I4 j
177 Memory requirement 160 Bytes j
197 Memory requirement 68 Bytes j
202 Memory requirement 68 Bytes j
218 Fig. 98, last line j
228 Notation for parameter display j
232 Memory requirement 48 Bytes j
240 Pulse and pause time j
250 Point to point connection j
Omitted
About This Manual
08/04 AWB2528-1423GB
Edition Page Description New Modifi-
cation
11/02 253 125 KB factory default setting j
290 Processing function blocks j
294/
295
302 QA analog output j
303 Saving and loading circuit diagrams j
318 List of the function blocks j
318 Memory requirement j
Off-delay I7 and I8 j
Omitted
08/04 AWB2528-1423GB
1easy800
Target readership easy must only be installed and wired up by trained
electricians or other persons familiar with the installation of
electrical equipment.
A specialist knowledge of electrical engineering is needed
for commissioning and creating circuit diagrams. When
controlling active components such as motors or pressure
cylinders, parts of the system can be damaged and persons
put at risk if easy is connected or programmed incorrectly.
Proper use easy is a programmable switching and control device and is
used as a replacement for relay and contactor control
circuits. easy must be properly installed before use.
easy is designed to be installed in an enclosure, switch
cabinet or distribution board. Both the power feed and the
signal terminals must be laid and covered so as to prevent
accidental contact.
The installation must conform to regulations for
electromagnetic compatibility (EMC).
The power up of the easy must not cause any hazards arising
from activated devices, such as unexpected motor startups
or power ups.
Improper use
easy should not be used as a substitute for safety-related
controls such as burner or crane controls, emergency-stop or
two-hand safety controls.
easy800
08/04 AWB2528-1423GB
Overview easy800 is an electronic control relay with:
• Logic functions,
• Timing relay and counter functions,
• Time switch functions
• Arithmetic functions
• PID controllers
• Operator and display functions
easy800 is a control and input device rolled into one. With
easy800 you can create solutions for domestic applications
as well as for tasks in machine and plant construction.
The integral easy-NET network enables the connection of up
to eight easy-NET stations to form a single control system.
Each easy-NET station can contain an individual circuit
diagram. This allows the design of systems using fast
controllers with decentralised intelligence.
Circuit diagrams are connected up using ladder diagrams,
and each element is entered directly via the easy display. For
example, you can:
• connect make and break contacts in series and in parallel
• switch output relays and auxiliary contacts,
• define outputs as coils, impulse relays, rising or falling
edge-triggered relays or as latching relays,
• select timing relays with different functions:
– on-delayed,
– on-delayed with random switching,
– off-delayed,
– off-delayed with random switching,
– on and off delayed,
– on and off delayed with random switching,
– single pulse,
– synchronous flashing,
– asynchronous flashing.
08/04 AWB2528-1423GB
Overview
• use up and down counters,
• count high-speed signals:
– up and down counters with upper and lower limit
values,
– preset,
– frequency counters,
– high-speed counters,
– count incremental encoder values.
• compare values,
• display any texts with variables, enter setpoints
• process analog input and output values (DC units),
• process additional inputs and outputs,
• use 7-day and year time switches,
• count operating hours (operating hours counter),
• communicate via the integrated easy-NET network,
• provide closed-loop control with P, PI and PID controllers,
• scale arithmetic values,
• output manipulated variables as pulse-width modulated
signals,
• run arithmetic functions:
–add,
–subtract,
–multiply,
– divide.
• track the flow of current in the circuit diagram
• load, save and password-protect circuit diagrams
If you prefer to wire up easy800 from a PC, then use
EASY-SOFT or EASY-SOFT-PRO. EASY-SOFT or
EASY-SOFT-PRO allow you to create and test your circuit
diagram on the PC. EASY-SOFT (-PRO) enables you to print
out your circuit diagram in DIN, ANSI or easy format.
easy800
Device overview easy basic units at a glance
08/04 AWB2528-1423GB
ab
c
d
h
e
f
g
Figure 1: Device overview
a Power supply
b Inputs
c easy-NET connections
d Operating status LEDs
e Interface socket for memory card or PC connection
f Buttons
g Outputs
h Display
08/04 AWB2528-1423GB
Device overview
easy800 type references
easy-x xx -xx-x x x
LCD display: X = No display
Time switch: C = Available; E = Expansion
Output type:
R = Relay
T = Transistor
Supply voltage, device and inputs
AC = AC voltage
DC = DC voltage
Number of inputs/outputs (+ expansion)
19 = 12 I/6 O + expansion
20 = 12 I/7 O + expansion
21 = 12 I/8 O + expansion
22 = 12 I/9 O + expansion
Performance class 8 (= 8 easy-NET network stations)
easy control relay
easy800
easy operation Buttons
DEL: Delete object in circuit diagram
DEL
ALT
ALT: Special functions in circuit-diagram, Status display
Cursor buttons
Move cursor
Select menu items
ESC
Set contact numbers, contacts and values
OK
OK: Next menu level, Save your entry
ESC: Previous menu level, Cancel
Moving through menus and choosing values
and Show System menu
DEL
ALT
Go to next menu level
OK
Select menu item
Activate, modify, save your entry
Return to last menu level
ESC
Cancel your entry since the last OK
Í Ú
Change menu item
Change value
ú í
Change place
Function of P buttons:
ú
Input P1,
í
Input P3,
úíÍ Ú:
Í
Ú
08/04 AWB2528-1423GB
Input P2
Input P4
08/04 AWB2528-1423GB
easy operation
Selecting main and system menu
Status display
Current selection
flashes in
the easy menu
I .2..5.......
R.2
MO 02:00
RS
Q..34 . STOP
MO
S .2 6..
P-
OK
PROGRAM...
STOPå RUN
PARAMETERS
SET CLOCK
st
menu level
1
Main menu
Date display
I .2..5.......
MO 11:50
Q..34.... STOP
P-
easy800 status display
DEL
and
No
ESCESC
SECURITY...
SYSTEM...
MENU LANGUAGE
CONFIGURATOR...
password
1st menu level
System menu
ALT
I .2..5.......
MO 01.04.2002
Q..34.... STOP
ALT
P-
Inputs
Weekday/Time or Weekday/Date
Outputs RUN/STOP/BUSY mode
I 12..........
PMO 02:00
Q..34.... STOP
On: 1, 2, 3, 4/Off:…
easy800
08/04 AWB2528-1423GB
Status display for local expansion
Inputs AC expansion ok/P buttons
Expansion or Weekday/Date
Weekday/Time
Outputs
R 1.........12
RS AC PMO 10:42
S 1......8 STOP
On: 1, 2, 3, 4/Off:…
RS = Expansion functioning correctly
easy800 advanced Status display
I 12...6.89..12
Retention/debounce/
easy-NET station
: Retention switched on
RE
: Debounce switched on
I
: easy-NET station with station address
NT1
: AC expansion functioning correctly
AC
: DC expansion functioning correctly
DC
: Bus coupling module detected
GW
GW flashes: Only easy200-easy detected. I/O expansion not be detected.
: When the power supply is switched on, easy switches to STOP mode
ST
RE I NT1 AC PMO 14:42 T
Q 12345678 RUN
AC expansion ok/P buttons
Startup behaviour
08/04 AWB2528-1423GB
easy operation
easy800 LED display
easy800 has two LEDs located on the front which indicate
the state of the power supply voltage (POW) as well as the
RUN or STOP modes (a Fig. 1, Page 18).
Table 1: LED power supply/RUN-STOP mode
LED OFF
LED continuously lit Power supply present, STOP mode
LED flashing Power supply present, RUN mode
Table 2: easy-NET LED (easy-NET)
LED OFF
LED continuously lit
LED flashing easy-NET operating fault-free
No power supply
easy-NET not operational, fault, in
configuration
easy-NET is initialised and no station has
been detected.
easy800
Main menu
08/04 AWB2528-1423GB
Menu structure
Main menu without password protection
X You access the main menu by pressing OK.
STOP: Circuit diagram display
RUN: Power flow display
PROGRAM...
STOP å RUN
PARAMETERS
SET CLOCK
PROGRAM...
DELETE PROGRAM
CARD
PROGRAM...
DELETE PROGRAM
CARD...
CIRCUIT DIAGRAM
FUNCTION RELAYS
Parameter
display
Parameters
CIRCUIT DIAGRAM
FUNCTION RELAYS
DELETE ?
Circuit diagram
SAVE Æ
CANCEL Æ
SEARCH Æ
æ
GO TO Æ
æ
æ
æ
Function block editor
Parameters
SAVE Æ
CANCEL æ
SEARCH Æ
æ
GO TO Æ
æ
æ
æ
08/04 AWB2528-1423GB
Main menu
PROGRAM...
STOP RUN å
PARAMETERS
SET CLOCK
PROGRAM...
STOP RUN å
PARAMETERS
SET CLOCK
PROGRAM...
DELETE PROGRAM
CARD...
Parameter display
Parameters
easy operation
DEVICE-CARD
CARD-DEVICE
DELETE CARD ?
DEVICE-CARD
CARD-DEVICE
DELETE CARD ?
DEVICE-CARD
CARD-DEVICE
DELETE CARD ?
REPLACE ?
REPLACE ?
DELETE ?
PROGRAM...
STOP RUN å
PARAMETERS
SET CLOCK
SET CLOCK
DST SETTING
SET CLOCK
DST SETTING
Only one selection is possible.
Display for date and time
setting
HH:MM --:-DD.MM --.-YEAR ____
NONE å
MANUAL å
EU å
GB å
US å
HH:MM 14:23
DD.MM 03.10
YEAR 2001
SUMMERTIME START
DD.MM : --.-SUMMER TIME END
DD.MM : --.--
easy800
08/04 AWB2528-1423GB
Main menu with password protection
Main menu
PASSWORD...
STOP RUN å
PARAMETERS
SET CLOCK
PASSWORD...
RUN
System menu
SECURITY...
SYSTEM...
MENU LANGUAGE
CONFIGURATOR...
Password
change/
delete
easy
Password
setup
PASSWORD...
RANGE...
ACTIVATE PW
CHANGE PW
Password entryUnlocking
(if enabled)
DELETE ALL?
Password
Correct
Four wrong entries
Status display
entry
easy800 System menu
X The System menu is accessed by simultaneously pressing
DEL and ALT.
Password entry
ENTER PASSWORD
------
ENTER PASSWORD
------
ACTIVATE PW
CHANGE PW
ACTIVATE PW
CHANGE PW
PASSWORD...
RANGE...
PROGRAM å Æ
PARAMETERS
TIME
OPERATING MODE æ
INTERFACE
DELETE FUNCTION
PROGRAM å Æ
PARAMETERS å
TIME å
OPERATING MODEåæ
INTERFACE å
DELETE FUNCTION
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