Moeller PS 416-CPU-400, PS 416-POW-400, PS 416-POW-410, PS 416-BGT-4 Series, PS 416-POW-420 Hardware And Engineering

Hardware and Engineering

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PS 416-CPU-x00
Central Unit

PS 416-POW-4x0
Power Supply Card

PS 416-BGT-4xx
Rack

02/98 AWB 27-1208 GB

3rd edition 02/98

© Moeller GmbH, Bonn

Author: Werner Albrecht
Editor: Thomas Kracht
Translator: Terence Osborn

Caution!

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Dangerous electrical voltage!

Before commencing the installation

● Disconnect the power supply of the

device.

● Ensure that the device 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 may

work on this device/system.

● Before installation and before touching

the device ensure that you are free of
electrostatic charge.

● Connecting cables and signal lines

should be installed so that inductive or
capacitive interference do 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 60 364-4-41 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 60 204-1 must be effective in all
operating modes of the automation
devices. Unlatching the emergency-stop
devices must not cause uncontrolled
operation or 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.

● 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,
emergency-stop devices should be
implemented.

IBM is a registered trademark of International
Business Machines Corporation.

All other brand and product names are
trademarks or registered trademarks of the
owner concerned.

All rights reserved, including those of the
translation.

No part of this manual may be reproduced in
any form (printed, photocopy, microfilm or
any otherprocess) or processed, duplicated
or distributed by means of electronic
systems without written permission of
Moeller GmbH, Bonn.

Subject to alterations without notice.

List of revisions to AWB 27-1208-GB

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Edition Page Revision new Rev. n. a.

02/98 PS 416-CPU-200/-300 ҂

II

02/98 AWB 27-1208-GB

Contents

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About the manual

PS 416 system

PS 416-BGT-4.. racks

PS 416-POW-400/410/420
Power supply cards

PS 416-CPU-200/-300/-400 Central unit

3

PS 416 system PS 416-POW-4x0PS 416-BGT-4.. AppendixPS 416-CPU-200/-300/-400

5

21

35

57

Appendix

Index

02/98 AWB 27-1208-GB

129

141

1

2

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02/98 AWB 27-1208-GB

About This Manual

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The rack, power supply card and the central
processing unit form the basis of the PS 416 system.
Their tasks and functions are described in this
manual.

There are various cards which you can integrate in
the modular system, depending on the requirements.
The functions of these cards are described in
separate manuals.

The communication between the stations in a
networked system is carried out via network cards.
These are the PS 416-CPU-300/-400 or the Suconet
K PS 416-NET-400 card if the stations are linked via
Suconet K. These cards manage the access to local
or remote input/output cards. This function is
explained in the “Suconet K Interface” manual
(AWB 27-1210-GB).

The Sucosoft S 40 programming software is used for
programming and configuration and is also
described in a separate documentation.

02/98 AWB 27-1208-GB

3

4

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02/98 AWB 27-1208-GB

PS 416 System

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Contents

PS 416 system

1 System Description

Setup 7
Hardware/software requirements 7
Components 8

2 Configuration

Master 12
Slaves for remote I/O expansion 13
Intelligent slaves 15

3 Engineering

Electromagnetic compatibility (EMC) 17
Reaction times 17
Interference immunity 17

7

11

17

02/98 AWB 27-1208-GB

5

6

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02/98 AWB 27-1208-GB

1 System Description

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Setup

Hardware/software
requirements

The PS 416 is a modular programmable controller.
The rack with an internal bus system for signal
transfer and slots for the connections of cards form
the basic unit. Interference-free supply cards supply
the system with a stabilised voltage. A central
processing unit with universal functions manages the
access to local and/or remote input/output cards or
enables an application process to be run separately
in the same rack. Various cards can be used for
detecting digital, analog and counter signals.

Networking and communication are implemented via
standard interfaces or standard bus protocols. The
Moeller Suconet K bus protocol is used as a system
bus for connecting remote inputs/outputs or an
expander rack. The Sucosoft S 40 software package
forms the user interface for user-friendly
programming, testing and commissioning.

A P S416 system has the following minimum
requirements:

PS 416 system

02/98 AWB 27-1208-GB

7

System Description

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Table 1: Hardware and software requirements

Sucosoft
for PS 416-CPU-223

for PS 416-CPU-200/-300:

for PS 416-CPU 400:

Rack PS 416-BGT-400/410/420 or 421 with

Power supply units PS 416-POW-400/410/420
Central processing unit PS 416-CPU-200/300/400

Programming cable or
interface converter

1) Hardware and engineering of the
PS 416-CPU-223 see AWB 27-1243-GB

1)

:

Operating system from version 1.32
S 30-S 316-D/-GB/-F from
version 2.31
Operating system from version 2.0
S 40-D/-GB/-F from version 2.0
Operating system from version 1.0
S 40-D/-GB/-F from version 1.0

potential equalisation bar
PS 416-ZBX-401/402/403

PS 416-CPU-223
PS 416-ZBK-210 (PRG/RS 232)

UM 1.5 (PRG/RS 485)

1

The central unit is supplied without an operating
system. Sucosoft S 40 is required for loading the
operating system or a bootable memory card with a
loaded operating system. The prrogramming, test
and commissioning of the P S416 are described in
the relevant Sucosoft S 40 manuals.

Components

The PS 416 automation system consists of the
following components:

Basic elements

PS 416-BGT-4...rack

PS 416-POW-4x0 power supply card

PS 416-CPU-200/-300/-400/-223 central pro­cessing unit

8

02/98 AWB 27-1208-GB

Components

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Standard cards

Digital input/output cards
PS 416-INP-400/401
PS 416-OUT-400/410

Analogue input/output cards
PS 416-AIO-400/PS 416-AIN-400

PS 416-CNT-200 counter card

Networking/communications cards

PS 416-NET-210 Suconet K card
(only with PS 416-CPU-223 central unit)

PS 416-NET-400 Suconet K card

PS 416-NET-230 PROFIBUS card

PS 416-NET-220 Interbus S card

PS 416-COM-200 Communications card

PS 416-COM-200 Communications card

The basic elements, such as rack, power supply and
the central unit are described in this manual.

The hardware and programming of the
PS 416-CPU-223 are described in the
AWB 27-1243-GB.

PS 416 system

power supply

230 V AC

power

PS 416

POW-400

processing unit

not ready

change

run

ready

error

CPU-400

analog I/O

4xI, 4xQ, 12Bit

AIO-400

digital in

I

I

INP-400

digital out

Reset

Q

Q

OUT-400

network

16x0,5A

SUCOnet K

active
ready

ZAA

.0

error

.1
.2
.3
.4
.5
.6
.7
.0
.1
.2
.3
.4
.5
.6
.7

NET-400

16x0,3ms

.0
.1
.2
.3
.4
.5
.6
.7
.0
.1
.2
.3
.4
.5
.6
.7

COUNTER

14

1

GND

CH0

15

2

GND

CH0

16

3

GND

CH1

17

4

GND

CH1

18

5

GND

CH2

19

6
CH2

GND

7

20

CH3

5V

8

21

CH3

5V

9

22

CH4

5V

10

23

CH4

24V

11

24

CH5

24V

12

25

CH5

24V

13

CNT-200

network

PROFIBUS

NET-230

Bus
ERR

Figure 1: PS 416 automation system

02/98 AWB 27-1208-GB

network

InterBus-S

COM

NET-220

RxD/
TxD

ERR

C
F
G

S
U
C
O
n
e
t

S

COM­200

diag.-code

ready

clear
out

run

bsa

con
rb
lb

mod

9

10

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02/98 AWB 27-1208-GB

2 Configuration

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Networks for different applications can be created
with the Suconet K system bus. The network stations
are configured according to their functions. The
following functions are possible:

PS 416 system

AIN

POW

PS 416-CPU-x00

INP

AIN

AIO

OUT

EM 4-201-DX2

POW

NET 400

LE 4­116-DX1

AIN

Master

햲

Slaves for the expansion of the remote inputs/
outputs:

Expander rack

Expansion module

Intelligent slaves

햲

LE 4-

햴

116-XD1

INP

AIO

OUT

햳

햴

햵

INP

AIN

AIO

POW

NET 400 (E)

햵

OUT

햳

PS 416-CPU-400

*

Figure 2: Device configuration with Suconet K

*) This network line is not possible with the

PS 416-CPU-200.

02/98 AWB 27-1208-GB

11

Configuration

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Master

The master manages the access to the remote input/
output cards. A master is any card that manages a
network line. In a PS 416 system the
PS 416-CPU-300/-400 and/or PS 416-NET-400 can
be implemented as master. Both cards have a
Suconet K interface. The configuration of the
operating mode and the stations is carried out in the
Sucosoft S 40 Topology Configurator.

A PS 416-CPU-300/-400 central unit can manage up
to nine bus lines. One line is integrated on the card,
whilst other lines can be formed using the
PS 416-NET-400 card.

A P S416-CPU-200 central unit can manage up to
eight bus lines, using the PS 416-NET-400 network
card to connect each line.

The current requirements must be calculated in all
cases for the number of bus lines to be used.

Up to 30 stations can be connected to each line. The
number depends on the memory requirements of
each station in the communication memory of the
master.

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02/98 AWB 27-1208-GB

Slaves for remote I/O

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expansion

NET 400

NET 400

NET 400

1...30

1...30

NET 400

NET 400

1...30

1...30

1...30

NET 400

NET 400

NET 400

PS 416-CPU-x00

PS 416-POW-4x0

햲

123456789

햳

12345678

햴

1...30

1...30

1...30

1...30

Figure 3: Maximum expansion

햲 Lines with PS 416-CPU-300/-400

Lines with

햳
햴 Stations

PS 416-CPU-200

PS 416 system

Slaves for remote I/O
expansion

Slaves for remote I/O expansion have no individual
central unit. They provide the master their data if
requested but cannot communicate with the master.
The number of data bytes which the slaves occupy in
the communication memory of the master is
predefined. This therefore does not have to be
specified in the configuration.

The slaves are addressed in a 5-point notation based
on the spatial configuration of the stations. The
stations are configured in the Topology Configurator
of Sucosoft S 40. Expander racks or expansion
modules are used as slaves for the remote expansion
of the inputs/outputs.

02/98 AWB 27-1208-GB

13

Configuration

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Expander racks

The remote expansion of the inputs/outputs in a
PS 416 system is implemented with racks which do
not have a CPU (expander racks). The required
configuration parameters of the local inputs/outputs
of these racks are sent to the PS 416-NET-400 card
via the master.

The address set on the card must comply with the
address set in the Sucosoft Topology Configurator.
You will find detailed information on the
PS 416-NET-400 card in the Suconet K Interface
manual, AWB 27-1210-GB.

The PS 416 automation system can process up to
30 expander racks on one line. Up to nine/eight lines
(depending on the CPU) can be managed on each
basic unit. The total permissible number of cards
that can be used on the rack depends on the total
current consumption of the individual cards and the
power supply card used (current consumption
calculation). The standard cards can be used as
components of the expander rack. The
communication is carried out via Suconet K. The
following settings are possible depending on the
application at hand:

Table 2: Application criteria

Baud rate
(Kbaud)

187.5 no 600 m good

187.5 yes 600 m very good

375 no 300 m good
375 yes 300 m very good

1) These bus lengths can only be implemented with the

CRC16 check max. bus

cable listed under Accessories in the appendix.

length

1)

Data saving

14

02/98 AWB 27-1208-GB

Intelligent slaves

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784 bytes of memory are available for the
communication with all connected stations of a line
on the PS 416-CPU-300/-400. The following table
shows the memory assignment of the cards to be
used.

Table 3: Memory assignment of the cards of an expander
rack

Card Input byte Output byte

PS 416-INP-400/401 2 –
PS 416-OUT-400/410 – 2/1
PS 416-AIN-400 16 –
PS 416-AIO-400 8 8
PS 416-CNT-200 12 –

Expansion modules

Expansion modules of the EM... compact series are
usually used for the expansion of remote inputs/
outputs. They do not have their own central unit.

PS 416 system

Intelligent slaves

Intelligent slaves have their own central unit and are
thus able to process their own user program. The
communication between the master and intelligent
slaves is carried out in both directions. The number
of send and receive data bytes for intelligent slaves
must be defined in the Sucosoft S 40 Topology
Configurator. The memory size depends on the type
of slave.

The following components can be used as intelligent
slaves:

02/98 AWB 27-1208-GB

15

Table 4: Data exchange memory of intelligent slaves

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Components Usable memory

PS 416-CPU-300/-400 784 bytes
PS 416-NET-400 1492 bytes
PS 4-101-DD1

PS 4-111-DR1/DR5
PS 4-201-MM1

PS 4-141-MM1
PS 4-151-MM1

PS 4-401-MM2 168 bytes

1) The available memory size depends on the number of
connected slaves on a line. The values stated in the
table apply with the maximum utilization of the line.

6 bytes Master 씮 Slave
7 bytes Slave 씮 Master

Total I/O 78 bytes

1)

The station is addressed by the user program in bit,
byte, word or double word format depending on the
station. The operations with the possible operands
and function blocks are described in the
Sucosoft S 40 programming software.

16

02/98 AWB 27-1208-GB

3 Engineering

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Electromagnetic
compatibility (EMC)

Reaction times

Interference immunity

Observe the engineering instructions in the manual
“EMC Engineering Guidelines for Automation
Systems” (AWB 27-1287-GB)

The shortest reaction time can be implemented with
local cards that are addressed by the central unit via
the internal bus. Only the program cycle time and the
input/output delays of the cards determine the
reaction time.

If remote stations are connected via Suconet K, the
reaction time depends on the number of stations on
the line, the data volume and the data transfer rate.

Further information on the calculation of the reaction
time is given in the Appendix.

The PS 416 system is designed for industrial
applications.

Provide the supply cable of the power supply card
with a ferrite ring. Mounting should be carried out as
close to the card as possible. No further connections
to other devices may be implemented beyond this
point.

PS 416 system

The ferrite ring is not delivered with the cards.



02/98 AWB 27-1208-GB

Please order separately:
Type PS 416-ZBX-405

The following figure shows the use of the ferrite ring,
using the PS 416-POW-400 as an example:

17

Engineering

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PS 416

POW-400

Ferrite ring

230 V AC

3

Ensure that all signal cables of communications and
analog cards are laid separately from power and
control cables in order to prevent interference.

Radiated interference

Interference is either caused by radiation or via
electromagentic fields or by static discharges.

Interference signals coming from

fields

can affect signal cables. This can be prevented
by screening these cables. The screen braid here
intercepts the interference potential. The screen
discharge to earth is implemented via high-frequency,
low-impedance connections.

electromagnetic

The screen earth should
be located as close as possible to the most sensitive
location of the system, e. g. on the inputs of the
cards. A potential equalisation bar can therefore be
fitted on the racks of the PS 416 system (see
Appendix). The screen must not be interrupted so
that the conductive plugs and mounting components
which do not belong to the signal circuit on the card
are connected with the screen. They are earthed via
the protective conductor on the rack which is
connected with the central reference point.
Installation notes, see chapter “Racks”.

18

02/98 AWB 27-1208-GB

Interference immunity

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Static discharges

may cause a system fault via
conductive components which do not belong to the
operating circuit (e. g. plugs, switches, mounting
components). All freely accessible components
which are not covered by a flap or covering are
electrically connected to the rack. The guide rails of
the card are provided with contact springs. Ensure
that these contact elements function correctly.

Note

Ensure that you are free of electrostatic charge
when working with operating elements and
components that are covered. This especially
applies to the battery, the memory card and the
operating switches of the CPU.

Line-conducted interference

Line-conducted interference may be due to galvanic,
capacitive and inductive coupling. All cards of the
PS 416 system have appropriate suppressor
elements which ensure the correct functioning of the
cards according to the relevant interference class.
The engineering of the system should not involve any
switchgear with higher interference levels.
Interference sources of this kind must be eliminated
via an appropriate installation or suppressor
elements.

PS 416 system

02/98 AWB 27-1208-GB

19

20

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02/98 AWB 27-1208-GB

PS 416-BGT-4.. Racks

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Contents

1 Racks

Task 23
System description 23
Setup 24

2 Engineering

Coupling the racks 27
Assignment of the rack 27

3 Installation

Fixing the potential equalisation bar 29
Connecting the protective earth 29
Fitting/removing cards 29

4Operation

Monitoring 33

23

PS 416-BGT-4..

27

29

33

02/98 AWB 27-1208-GB

21

22

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1 Racks

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Task

System description

The PS 416-BGT-4.. racks are used for the assembly
of PS 416 programmable controllers.

The racks house mechanically and electrically house
the individual cards. They provide protection against
mechanical and electromagnetic interference. An
internal bus is used for the power supply and the
signal exchange between the cards. An integrated
monitoring element monitors the 5 V system voltage
and the bus activity and generates an Enable signal
(ENA) for the cards.

Fully mounted devices for installation on a mounting
plate are available in three different sizes as well as a
rack for front installation. The following table shows
the mounting type and the number of the freely
available slots in the individual racks.

Table 5: Type overview of racks

Type Installation type Number of free slots

PS 416-BGT-400 Mounting plate 9
PS 416-BGT-410 Mounting plate 13
PS 416-BGT-420 Mounting plate 19
PS 416-BGT-421 Front mounting 19

PS 416-BGT-4..

02/98 AWB 27-1208-GB

23

Racks

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Setup

햲

햴

햴

햶

햵

햴

햳

햲

Figure 4: Setup of the racks for mounting plate installation
(left) and front mounting (right)

햲 Fixing holes for mounting/installation of the rack

햳 Protective earth connection (PE)
햴 Fixing holes for the potential equalisation bar
햵 Fast-release lock for fixing the card
햶 Rails for inserting the card

24

02/98 AWB 27-1208-GB

PS 416-BGT-4xx

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햲
햳

M4

8

´

Setup

Potential equalisation bar

A suitable potential equalisation bar is supplied with
each rack as an accessory. The bar is used for
connecting the cable screens to the protective earth.
Table 6 shows an overview of potential equalisation
bars for the individual racks.

Table 6: Type overview potential equalisation bars

Racks Potential equalisation bar

PS 416-BGT-400 PS 416-ZBX-403
PS 416-BGT-410 PS 416-ZBX-402
PS 416-BGT-420, PS 416-BGT-421 PS 416-ZBX-401

PS 416-ZBX-40x

M4

´

12

PS 416-BGT-4..

햴

PS 416-ZBX-404

Figure 5: Setup and mounting of the potential equalisation
bar

햲 Cable

햳 Screen
햴 Marking strip

02/98 AWB 27-1208-GB

25

26

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02/98 AWB 27-1208-GB

2 Engineering

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All racks can be used as a basic unit (with central
unit) or as an expander rack (without central unit).

Each rack must be fitted with a power supply card
which must always be fitted in the left "POW" slot.
The other slots can be used as required.

Coupling the racks

Assignment of the rack

The coupling between the basic unit and expander
rack is carried out via the Suconet K field bus. The
internal bus in the basic unit is operated by the
central unit, in the expander by the PS 416-NET-400
Suconet K card. You will find a detailed description
of coupling with PS 416-NET-400 in the “Suconet K
interface” manual AWB 27-1210-GB.

All card types can be used in a rack.

The PS 416-NET-400 card is used in the expander
rack for coupling to the basic unit and for controlling
the internal bus. Only standard cards must be used
in an expander rack:

Digital input/output cards

Analogue input/output cards

Counter card

PS 416-BGT-4..

02/98 AWB 27-1208-GB

27