Manual. Rack-135U. Order no.: HB32E Rev. 00/19. Subject to change to cater for technical progress

Transcription

1 Manual Rack-135U Order no.: HB32E Rev. 00/19 Subject to change to cater for technical progress

2 Lerrzeichen

3 VIPA Rack-135U Manual VIPA does not assume any liability for the information contained in this manual. The information is subject to change without notice. Copyright 2000 VIPA, Gesellschaft für Visualisierung und Prozeßautomatisierung mbh, Ohmstraße 4, D Herzogenaurach Tel.: +49 (91 32) Fax.: +49 (91 32) Hotline: +49 (91 32) All rights reserved Disclaimer of liability The contents of this manual was verified with respect to the hard- and software. However, we assume no responsibility for any discrepancies or errors. The information in this manual is verified on a regular basis and any required corrections will be included in subsequent editions. Suggestions for improvement are always welcome. Trademarks VIPA is a registered trademark of VIPA company for visualisation and process automation Ltd. SIMATIC is a registered trademark of Siemens AG. STEP5 is a registered trademark of Siemens AG. Any other trade marks referred to in the text are the trade marks of the respective owner and we acknowledge their registration. Subject to change to cater for technical progress.

4 About this manual VIPA Rack-135U Manual About this manual This manual describes the operation of the Rack-135U and the respective power supply unit. The combination of the rack with the power supply unit and a VIPA CPU provides a powerful programmable logic controller. The compact rack is provided with 7 plug-in locations witch are sufficient for many uses. Outline Chapter 1: Principles This introduction contains some notes on the handling of electrostatically sensitive modules and information on applications for the Rack-135U. In addition to the performance characteristics this part also contains an overview of the modules that may be installed in the Rack-135U. Chapter 2: Rack-135U This chapter contains specific information on the Rack. The rack forms the framework for your Rack-135U programmable logic controller (PLC). This chapter contains all the information required for the installation of the process control system using the Rack, i.e. dimensions, installation, commissioning etc. Chapter 3: Power supply unit Chapter 3 of the manual contains a description of the power supply unit that is currently available from VIPA. The text describes the construction, installation, wiring and commissioning of the power supply. This chapter also contains details on how the backup battery and the internal fuse for the primary circuit should be replaced. Chapter 4: Fan subassembly Part 4 deals with the fan subassembly witch is optionally available from VIPA. The construction, mounting, wiring, start-up are discribed as well as the changing of fuses. Chapter 5: Installation guidelines This chapter is intended to assist you with the design of a reliable process control system. The chapter starts with a list of the possible sources of disturbance or interference and the respective coupling mechanisms followed by the basic rules and regulations to safeguard EMC. You are also provided with certain specifications on the proper installation and wiring to achieve EMC. The chapter concludes with a description of various grounding-concepts and an overview of the different switch boards and cubicles. Subject to change to cater for technical progress.

5 VIPA Rack-135U Manual Contents Contents User Considerations...1 Safety Information...2 Chapter 1 Principles Safety information for users General Applications Performance Characteristics Chapter 2 Rack-135U Construction Rack-135U Installation Commissioning Troubleshooting guidelines Technical Data Chapter 3 Power Supply Unit Construction of the power supply unit Operating and indicator elements Light emitting diodes Connections Installation/removal Wiring Commissioning of power supply Backup power for CPU-RAM Replacing the internal fuse Technical data Chapter4 Fan subassembly Construction of the fan subassembly Control and display elements Mounting dimensions Mounting-/Dismounting Wiring Start-up of the fan subassembly Changing internal fuse Technical Data Chapter 5 Installation guidelines Basic techniques for EMC compliant installation of systems EMC compliant installation of controllers EMC-compliant wiring of the controller Special precautions providing high noise immunity Checklist for the EMC-compliant installation of controllers Power supply for controllers and peripheral equipment Noise immunity of decentralised links Selection and assembly of cubicles using VIPA-modules A Appendix... A-1 Index... A-1 Rev. 00/19 i

6 Contents VIPA Rack-135U Manual ii Rev. 00/19

7 VIPA Rack-135U Manual User Considerations User Considerations Purpose and contents This manual contains a description of the programmable logic controller Rack-135U. The description includes the construction, project design and application. The Rack-135U belongs to the family of programmable controllers. These support all the PLC-components available from VIPA. The device supports single-processor as well as multi-processor operation with a maximum of 2 CPUs. Target audience The manual is intended for users with a basic knowledge of automation technology and PLC programming. Structure of the manual The manual is divided into 4 chapters. Each chapter contains a comprehensive description of a specific topic in no more than 30 pages. Guide to the document The following guides are available in the manual: a complete table of contents at the beginning of the manual a summary of the topics at the beginning of each chapter cross-reference index at the end of the manual Availability The manual is available as follows: in printed form as an electronic document in a PDF-file (Adobe Acrobat Reader) Icons and announcements The following icons and announcements indicate important sections of text: Danger! Immediate or implied danger. Personnel may be endangered. Attention! Material damage may result if these recommendations are not observed. Note! Additional information and useful tips. Rev. 00/19 1

8 Safety Information VIPA Rack-135U Manual Safety Information Appropriate utilisation The Rack-135U was constructed and manufactured for all VIPA PLC components communications and process control general control and automation applications industrial applications operation within the environmental limitations specified in the technical data installation in switchboards mounted in cubicles Danger! This device is not certified for applications in an explosive environment (EX-zone) Documentation Manual must be available to all staff members concerned with Project design Installation Commissioning Operation The following must be noted and understood before the components described in this manual are commissioned or placed into operation: Modifications to the automation system must never be carried out when the system is connected to the power supply! Connections and modifications should only be carried out by fully qualified electrical technicians The national rules and regulations that are in force in the respective country must be satisfied (installation, safety, EMC...) Disposal You must comply with applicable national rules and regulations when disposing of the equipment! 2 Rev. 00/19

9 VIPA Rack-135U Manual Chapter 1 Principles Chapter 1 Principles Outline This chapter presents recommendations for handling electrostatically sensitive modules and information on the utilisation and applications for the VIPA Rack-135U. The chapter concludes with a table containing various installation options. Below follows a description of: Safety information for users Typical applications and examples Performance characteristics and installation options Contents Topic Page Chapter 1 Principles Safety information for users General Applications Performance Characteristics Ordering details - overview Type Order number Description Rack VIPA 188-3UA00 Rack-135U with 7 plug-in locations incl. Power supply unit Power VIPA 188-3UA00-1 Power supply unit (replacement part) supply Fan VIPA 188-3UA00-2 Fan module for the Rack Rev. 00/19 1-1

10 Chapter 1 Principles VIPA Rack-135U Manual Safety information for users Handling of electrostatically sensitive modules VIPA-modules make use of highly integrated components in MOStechnology. These components are extremely sensitive to over-voltages that can occur during electrostatic discharges. Electrostatically sensitive module! This symbol is attached to modules that can be destroyed by electrostatic discharges: The symbol is located on the module, the module rack or on packing material and it indicates the presence of electrostatically sensitive equipment. Background It is possible that electrostatically sensitive equipment is destroyed by energies and voltages that are far less than the human threshold of perception. These voltages can occur where persons do not discharge themselves before handling electrostatically sensitive modules and they can damage components thereby causing the module to become inoperable or unusable. Behaviour of damaged modules Modules that have been damaged by electrostatic discharge are usually not detected immediately. The respective failure can only become apparent after a period of operation. Components damaged by electrostatic discharges can fail after a temperature change, mechanical shock or changes in the electrical load. Precautions Only the consistent implementation of protective devices and meticulous attention to the applicable rules and regulations for handling the respective equipment can prevent failures of electrostatically sensitive modules. 1-2 Rev. 00/19

11 VIPA Rack-135U Manual Chapter 1 Principles Shipping of electrostatically sensitive modules Modules must be shipped in the original packing material. You can provide additional protection by wrapping the modules in conductive bags before they are shipped. Conductive material is manufactured from antistatic foil or metallized plastic containers. Attention! If the module that must be shipped contains a battery you must make sure that the conductive packing material does not come into contact with or short out the battery connections. Measurements and alterations on electrostatically sensitive modules When you are conducting measurements on electrostatically sensitive modules you should take the following precautions: Floating instruments must be discharged before use. Instruments must be grounded. You should only use soldering irons with grounded tips when you are making modifications on electrostatically sensitive modules. Attention! People, tools and instruments should be grounded when working on electrostatically sensitive modules. Rev. 00/19 1-3

12 Chapter 1 Principles VIPA Rack-135U Manual General Compact construction for mobile applications The construction of the Rack-135U supplied by VIPA is very compact. Due to the weight of 2,3kg and the dimensions of 269x266x215 (WxHxD in mm) the PLC is ideal for mobile applications. No fan required for currents less than 8A This PLC does not require a fan if the total current does not exceed 8A. A fan-module is essential for higher currents (10A max.). 7 plug-in locations In spite of the compact construction the PLC's rack has provision for 7 plug-in locations: 1 co-ordinator or I/O upto2cpus up to 4 CPs / IM-modules upto3pcs Applications The VIPA Rack-135U is the basic unit for process automation applications. It can accommodate all the PLC components supplied by VIPA. In contrast to many other similar units the design of this system is very compact. In conjunction with a CPU and various I/O modules you can design a centralised process control system. You can interface the system to a network by means of the CP143 TCP/IP or the H1 module. If you install a BG4xD module you can communicate in serial mode with other components like sensors, CP, etc. The IM308 module can be used to design a decentralised system based on Profibus. This system can then be used to connect to the powerful System 200V supplied by VIPA. It is also possible to install up to 3 PC modules in the rack that can be used for programming purposes or processing of process data. 1-4 Rev. 00/19

13 VIPA Rack-135U Manual Chapter 1 Principles Sample applications The following section contains samples of a few typical applications that to highlight some of the many different tasks that the system can solve for you. Decentralised operation CPU CPP IM 308 CPU CPP mit IM Master-Slavecommunication Commander Compact System 200V Serial links Scale CPU CPP BG43D CPU BG43D Drive STX-ETX/ASCII/3964(R)/RK512 System 200V Barcode reader CP240 CPU BG43D Rev. 00/19 1-5

14 Chapter 1 Principles VIPA Rack-135U Manual Performance Characteristics PLC rack light-weight and compact construction with an optional fan-module 7 plug-in locations multi-processor operation for up to 2 CPUs by means of a co-ordinator low weight of 2,3kg dimensions 269x266x215 (WxHxD in mm) Power supply easily replaceable power supply microcontroller based signal generation for power-on and power-off phase. voltage monitoring by means of an LED 5V and 24V. a fan is not required where total current does not exceed 8A. Above 8A up to a max. of 10A the optional fan module must be installed Installation options The following table shows which modules can be installed into which plugin locations. Location-no. Type of module * 7* power supply co-ordinator CPU 922 CPU 928B/C, CPU 948 CPP, BG4xD, CP 143, CP 5xx digital and analogue I/O IP 241USW, IP 244, IP 246, IP 247, IP 252 IP 240, IP 241, IP 242, IP 242A, IP 242B, IP 243, IP 281 IP 254, IP 257 IP 260, IP 261 IM 308V, IM 304 IM *) no 24V DC supply via back panel bus electrical connection mechanical width 1-6 Rev. 00/19

15 VIPA Rack-135U Manual Chapter 2 Rack-135U Chapter 2 Rack-135U Outline This chapter contains information on the PLC rack which is designed to accommodate a power supply and up to 7 PLC modules. A short summary on the construction and the operation is followed by details on optional modules, the installation and commissioning. Installation dimensions are depicted by a drawing. The chapter concludes with the technical data. Below follows a description of: mechanical construction optional modules and an overview of the types of modules installation and commissioning installation dimensions technical data Contents Topic Page Chapter 2 Rack-135U Construction Rack-135U Installation Commissioning Troubleshooting guidelines Technical Data Ordering details Type Order number Description Rack VIPA 188-3UA00 Rack-135U rack with 7 plug-in locations incl. Power supply unit Power VIPA 188-3UA00-1 Power supply unit (replacement part) supply Fan VIPA 188-3UA00-2 Fan module for PLC rack Rev. 00/19 2-1

16 Chapter 2 Rack-135U VIPA Rack-135U Manual Construction Rack-135U 2-2 Rev. 00/19

17 VIPA Rack-135U Manual Chapter 2 Rack-135U Mechanical description The Rack-135U rack consists of an enclosure with a back panel bus that can accommodate the different PLC modules and the power supply. A fan module can be installed on the bottom of the enclosure. The order-no. of the fan module is 188-3UA00-2. Drawing of the PLC rack The following drawing shows the most important items of the PLC rack: [1] Compact enclosure with 7 plug-in locations [2] Locking rail for all the modules [3] Back panel bus [4] Upper and lower guides for the power supply unit (plug-in location 0) [5] Upper and lower guides for the different modules (plug-in location ) [6] Upper and lower vent-holes Enclosure The enclosure consists of anodised aluminium profiles held together by means of screws. The sides of the enclosure are closed. The top and the bottom are provided with vent holes to ensure adequate ventilation. The enclosure contains the main board with the bus that provides the electrical and logical connection between the different modules. Every plug-in location has an upper and a lower guide for the modules. This ensures that plugs and contact strips are in the correct position. A locking rail located at the top prevents ensures that modules can not move out of the rack by themselves. Modules with individual locking mechanisms are locked into their location by means of the lower rail. Rev. 00/19 2-3

18 Chapter 2 Rack-135U VIPA Rack-135U Manual Power supply unit The power supply unit must always be inserted into the left-most location (plug-in location 0). The power supply unit provides 5V and 24V and it can be connected to a supply voltage between V AC ( Hz). Limit values: 5V: max. 8A without fan max. 10A with fan module 24V: max. 3,5A without fan max. 4,5A with fan module Installation options The following table shows which modules can be installed into the different plug-in locations. Location-no. Type of module * 7* power supply unit co-ordinator CPU 922 CPU 928B/C, CPU 948 CPP, BG4xD, CP 143, CP 5xx digital and analogue I/O IP 241USW, IP 244, IP 246, IP 247, IP 252 IP 240, IP 241, IP 242, IP 242A, IP 242B, IP 243, IP 281 IP 254, IP 257 IP 260, IP 261 IM 308V, IM 304 IM *) no 24V DC supply via back panel bus electrical connection mechanical width Attention! Do not install any module into a location that is not intended for the respective module, you could damage the respective module or other modules permanently! 2-4 Rev. 00/19

19 VIPA Rack-135U Manual Chapter 2 Rack-135U Type of modules Due to the modular construction of the PLC rack this can accommodate various different modules and it can therefore be adapted to process control applications as required. The different modules perform the following functions: Power supply unit The power supply unit can only be installed into the left-most location (plug-in location 0). The power supply is short-circuit proof and provides output voltages of 5V and 24V. The 24V output is also available via the front panel. Co-ordinator When you install the co-ordinator you can use the Rack-135U as multiprocessor device with up to 2 different combinations of CPU to cater for specific applications. These CPUs operate independently. CPU The CPU processes input signals to the PLC in accordance with application program and issues the results as output signals. The following CPUs may be installed: CPU 928B CPU 928C CPU 948 CPU 922 CP-modules CP-modules provide facilities for ethernet connections or serial links which are used for data communications between the modules and the PLC or between PLC's. digital and analogue I/O-modules The interface to the process is provided by digital and analogue input/output modules. These modules can also be installed into the location for the co-ordinator (plug-in location 1). IP-module IP-modules are intelligent peripheral modules that reduce the load on the CPU. They provide independent computational regulation, positioning and counting functions. IM-modules IM-modules are coupler modules. These you can use to link your system to other systems, for example the System 200V supplied by VIPA. Rev. 00/19 2-5

20 Chapter 2 Rack-135U VIPA Rack-135U Manual Installation Installation Rack The PLC rack is designed to be installed into cubicles, on frames and for mounting on walls. Connections and maintenance only require that the rack is accessible from the front. You can use the mounting bracket attached to the PLC's frame to install it into cubicles, on frames and for mounting on walls. You should use M6 screws for this purpose, or for mounting on walls you should use screws of the respective gauge. 1-Man installation The PLC rack can be installed by a single person due to the light-weight construction and the small dimensions. Note! During the installation of the PLC rack you must observe the specifications presented in the chapter on "Installation guidelines"! Installation dimensions 6,42 269cm 251 This diagram shows all dimensions required for the installation. 7,5 All dimensions are in mm , Rev. 00/19

21 VIPA Rack-135U Manual Chapter 2 Rack-135U Installation of the power supply unit You can only install power supplies manufactured by VIPA into this Rack. The power supply must be installed into plug-in location 0! Installation of modules: Checklist The modules for the Rack-135U have a double Euro-card format, 233,4x160 (HxD in mm) Remove the supply voltage from the PLC Remove the cover from the upper locking rail by removing the 2 retaining screws. If your module has a latch on the lower front rotate this into a horizontal position. Change the jumper settings on your module as required Grip the module by the front plate and insert the module into the lower and the upper guide, then push it into the rack. The plugs located on the rear end of the module click into the sockets located on the back panel bus and the latch on the module is changed to a horizontal position. If your module is provided with a locking latch you must push this latch down and rotate it through 90 degrees. Replace the cover of the upper locking rail and fasten the 2 retaining screws. Connect the wiring from the module to the located plug on the front of the module. Attention! Take care that you align the correct plug with the respective module to avoid damaging the modules! Rev. 00/19 2-7

22 Chapter 2 Rack-135U VIPA Rack-135U Manual Commissioning The commissioning of the PLC should occur in the sequence shown below. This procedure applies up to the point where you conduct the first test run withacpu. The following steps are required for commissioning: Install the PLC such that the airflow is not impaired in any way. Insert the power supply into plug-in location 0 and connect the supply power. (See also Chapter 3 "Commissioning of the power supply unit") Insert the CPU into plug-in location 2 and place the operating mode switch in the STOP position Turn the power supply unit on Reaction: - LEDs 5V DC and 24V DC are turned on - operating voltages are connected to back panel bus and module Reset your CPU if your CPU requests a reset. Place your CPU into the RUN condition At this stage the PLC has been installed and it can operate using a single CPU. Battery low LED is turned on When the "Battery Low" LED is on battery power is not available. The battery could be discharged or it could be missing from the unit. The battery consists of a 3,6V lithium battery. You can replace the battery while the PLC is operational. Once the battery has been replaced the "Battery Low" LED will be extinguished. Battery replacement and QUIT-key When you replace the battery while the PLC is operational the "Battery Low" LED is turned on and the BAU signal (battery fail) is set. This signal will remain active even after the battery has been replaced. The BAU signal can be reset by means of the QUIT-key located on the front of the power supply unit. Please refer to chapter 3 "Battery power for CPU-RAM" for details on the replacement of the backup. 2-8 Rev. 00/19

23 VIPA Rack-135U Manual Chapter 2 Rack-135U Troubleshooting guidelines You must observe the general safety regulations if you need to perform measuring or testing operations on an operational device. You must use tools that are suitable and have been approved for work on electrical equipment. The equipment must always be disconnected from the main power supply before it is opened. Wait at least 2 minutes before you remove the power supply unit and before opening it. Only the VIPA customer service staff or suitably qualified personnel may perform repairs to process control equipment. The 230V supply fuse located in the power supply must always be replaced with a fuse of the same rating. Danger! Unauthorised access and improper repairs can cause for fatalities or severe bodily injury as well as very expensive material damage! Rev. 00/19 2-9

24 Chapter 2 Rack-135U VIPA Rack-135U Manual Technical Data VIPA Rack data VIPA 188-3UA00 Plug-in locations 7 -COR 1 -CPU 2 - CP / IM308 4 Enclosure - Material Aluminium profiles, anodised - Locking mechanism Upper locking rail, strip for individual locks located at the bottom Ventilation - Enclosure Top and bottom vent holes - Fan module optional Order-no.: VIPA 188-3UA00-2 Dimensions and weight Dimensions (WxHxD) Weight 269x266x215mm 2,3kg 2-10 Rev. 00/19

25 VIPA Rack-135U Manual Chapter 3 Power Supply Unit Chapter 3 Power Supply Unit Outline This chapter describes the construction and the application of the power supply unit. The power supply unit is only suitable for use in the VIPA PLC rack. Below follows a description of: Components of the power supply unit Operating and indicator elements Wiring connections and commissioning Backup battery and replacement of the internal fuse Technical data Contents Topic Page Chapter 3 Power Supply Unit Construction of the power supply unit Operating and indicator elements Light emitting diodes Connections Installation/removal Wiring Commissioning of power supply Backup power for CPU-RAM Replacing the internal fuse Technical data Ordering information Type Order number Description Power supply VIPA 188-3UA00-1 Power supply unit (replacement part) Backup battery VN Backup battery type AA, 3,6V / 1,9Ah Rev. 00/19 3-1

26 Chapter 3 Power Supply Unit VIPA Rack-135U Manual Construction of the power supply unit 3-2 Rev. 00/19

27 VIPA Rack-135U Manual Chapter 3 Power Supply Unit Components The power supply unit is only suitable for installation in the Rack-135U and it contains the following components: 230V AC power supply with 5V DC and 24V DC outputs Input voltage: V AC ( Hz) Current capacity: 5V: 8A (10A with fan) 24V: 3,5A (4,5A with fan) External 24V connection via front panel Short-circuit proof outputs Voltage monitoring by means of LED indicator Fuse for supply voltage (5A / 250V) Controller for power-on and power-off phase Backup battery using a lithium battery 3,6V / 1,9Ah External battery supply Monitoring of the condition of the battery Operating and indicator elements The front panel carries the following operating and indicator elements: On/off switch (POWER) LEDs for voltage monitoring 5V and 24V LED for battery condition (BATTERY LOW) Connector for input voltage (INPUT) Connector for output voltage 24V (OUTPUT) Connector for external battery supply (EXT. BATT 3,4...9V) Strain relief for input and output wiring Cover for the 3,6V lithium battery Quit-key for acknowledgement of the replacement of the battery while the system is operational Rev. 00/19 3-3

28 Chapter 3 Power Supply Unit VIPA Rack-135U Manual Operating and indicator elements Front view power supply unit L1 N + - BATTERY LOW QUITT EXT BATT V 5V DC 24V DC OUTPUT 24V DC INPUT V AC PS 8A POWER Caution! Disconnect before removing power supply! [1] LED (red), battery monitor [2] Quit-key for replacement battery [3] Connection for external battery supply [4] LED (green), 5V DC monitor [5] LED (green), 24V DC monitor [6] On/off switch [7] Connector for 24V output [8] Strain relief 24V connector [9] Connector 230V input [10] Strain relief 230V input [11] Cover for backup battery [12] Individual lock with retaining screw ! Rev. 00/19

29 VIPA Rack-135U Manual Chapter 3 Power Supply Unit Light emitting diodes Battery monitor BATTERY LOW (red LED) The LED monitoring the status of the backup battery is turned on when the battery voltage or the voltage from the external battery connector falls below 2,6V. The LED is extinguished when the battery has been replaced. A description of the procedure to replace the battery is located in this chapter under the heading "Backup power CPU-RAM". Voltage monitoring 5V DC (green LED) This LED indicates the presence of the 5V-supply voltage. This LED as well as the LED for the 24V supply is extinguished by a shortcircuit. Voltage monitoring 24V DC (green LED) This LED indicates the presence of the 24V-supply voltage. As mentioned above, this LED as well as the LED for the 5V supply is extinguished if a short-circuit should occur. Danger! Before you start to work on the power cable or the power supply you must remove the main supply power (remove the plug from the socket or the respective fuse where the unit is permanently wired to the supply)! Note! When one or both voltage monitoring LEDs (5V and 24V) are off and this is not caused by a short-circuit the following could be the reason: the internal fuse is open (both LEDs are off). see also the chapter "Replacing the internal fuse" power supply unit is defective you should contact VIPA customer service. the 230V power cable is damaged check and replace the cable Rev. 00/19 3-5

30 Chapter 3 Power Supply Unit VIPA Rack-135U Manual Connections Input voltage INPUT V AC The input socket of the power supply unit must be connected to a source of AC. An internal fuse protects the input from overloads. Input voltage: V AC ( Hz) Output voltage OUTPUT 24V DC Here you can connect peripheral equipment that requires 24V DC. Similar to the 5V output from the back panel bus this output is also protected against short circuits. Current capacity: 3,5A (4,5A with fan) Please note that the 24V supply is also available from the back panel bus. External battery connection EXT BATT V In addition to the lithium battery that sustains the contents of the RAM of your CPU the power supply unit is equipped with a connector for an external battery. When the voltage of the external power supply exceeds 3,6V DC the internal lithium battery is turned off. Terminals for EXT BATT 12 2 Please use the spade terminals shown alongside to connect the external battery. (dimensions in mm) 3-6 Rev. 00/19

31 VIPA Rack-135U Manual Chapter 3 Power Supply Unit Installation/removal Installation power supply checklist Disconnect the power supply unit from mains power Undo the 2 retaining screws to remove the covering strip from the upper locking rail of the Rack-135U. The lower edge of the front of the power supply carries a latch. Rotate this latch into a horizontal direction. Hold the power supply unit by the front plate and insert it into the lower and upper guide of plug-in location 0 and push it as far back as possible. The plugs on the rear of the module click into the sockets located on the back panel bus and the latch on the front jumps into a horizontal position. Push the latch on your power supply down and rotate it by 90 degrees. Replace the covering strip of the upper locking rail and tighten the retaining screws. Connect the necessary wiring to the front of your power supply. Removal power supply checklist Disconnect the power supply unit from mains power Undo the 2 retaining screws to remove the covering strip from the upper locking rail of the Rack-135U. The lower edge of the front of the power supply carries a latch. Rotate this latch into a horizontal direction. Push the latch on the front of your power supply down The power supply is removed from the sockets on the back panel and it is pushed from the Rack-135U. Remove the power supply unit from the Rack-135U. Danger! The power supply unit must always be disconnected from mains power when you remove or install the power supply unit you intend to open the power supply unit Rev. 00/19 3-7

32 Chapter 3 Power Supply Unit VIPA Rack-135U Manual Wiring Connections to the power supply unit are provided by WAGO spring-clips. These spring-clips make the wiring process simple and quick. In contrast to wiring using screw-terminals this type of connection is vibration-proof. You can install conductors with a cross section of between 0,08mm 2 and 2,5mm 2. The insulation must be stripped from the wires for app. 8mm. Connections by means of springclip technology You connect cables to the spring-clip connectors as follows: Rectangular opening for screwdriver Round opening for conductors Use a suitable screwdriver to push the spring-clip into the rear of the rectangular opening and keep it pressed. Insert the hook-up wire all the way into the round opening of the spring-clip that you have pressed down Remove the screwdriver. The wire is gripped by the spring-clip which provides a secure contact. Strain relief Youcanfastenthewiretothefrontbymeansofthe2strainreliefclamps. 3-8 Rev. 00/19

33 VIPA Rack-135U Manual Chapter 3 Power Supply Unit Commissioning of power supply Checklist for commissioning Install the power supply unit Connect the supply voltage Turn the power supply unit on Start-up When the mains supply is connected to the power supply unit and it is turned on the LEDs 5V and 24Vlocated on the front panel will also be turned on. These LEDs indicate that these 2 voltages are available. At the same time certain signals are transmitted via the back panel bus. These ensure that the PLC modules commence proper operation. Indication of faults Under the following conditions the two LEDs will not be turned on: the voltage is not available or the power supply unit has not been turned on the internal fuse is blown (see chapter "Replacing the internal fuse" later on) A short-circuit has occurred on the 5V supply (back panel bus) or the 24V supply (front and back panel bus). This is also discernible by an audible hum from the power supply unit. Note! If a single LED is off the power supply unit could be faulty. In this case you must please contact the VIPA-hotline. Connecting the periphery Turn off the mains power to the power supply unit and insert the PLC modules and also connect any periphery to the 24V output on the front panel. Turn the power supply back on. The power supply unit should start properly. The remaining operations required by the commissioning procedure for your Rack-135U are available from chapter 2 "Commissioning" Rev. 00/19 3-9

34 Chapter 3 Power Supply Unit VIPA Rack-135U Manual Backup power for CPU-RAM The power supply unit contains a lithium battery that is used to sustain the RAM of your CPU(s) when a power failure occurs or when the power supply is turned off. A full battery will maintain the contents of the RAM for up to 1 year. You can also connect a DC supply (3,4... 9V) to the front of the unit. The respective current consumption is 0,2mA. The lithium battery is turned off when the external voltage exceeds 3,7V. When the battery voltage falls below 2,6V the "BATTERY LOW" LED is turned on when the unit is turned on and the respective signals are transmitted via the back panel bus. Should you replace the battery on an operational unit you must depress the Quit-key to reset the "BATTERY LOW"-LED and the signal at the back panel bus. The battery is protected by a cover with the label BATTERY which is located on the front of the power supply unit. Backup battery replacement - + Use a large screwdriver or a coin to open the cover. rotate the cover by 90 degrees in a counter clockwise direction. The cover will pop open. Replace the battery with the positive terminal facing the cover. Replace the cover by placing pressure on it and rotate it in a clockwise direction until it is in its original position. Lithium backup battery The following batteries can be used: Lithium battery VIPA order-no.: VN Voltage: 3,6V Capacity: 1,9Ah Size: AA (Mignon) Disposal! Please note that used batteries are classified as toxic waste. Drained batteries must be sent to the local collection point for toxic waste! 3-10 Rev. 00/19

35 VIPA Rack-135U Manual Chapter 3 Power Supply Unit Replacing the internal fuse Indication of failures When both the 5V and the 24V LEDs are off and this is not caused by a short-circuit the following could be the reason: the internal fuse was been blown s by an overvoltage condition power supply unit is defective you should contact VIPA customer service. Attention! The fuse must be replaced with a fuse of exactly the same type, else the guarantee becomes null and void and your equipment could be damaged by excessive currents. Type of fuse: G-fuse 5A, 250V, slow (type T) Replacing the fuse The fuse for the input voltage is located behind the front cover. The drawing indicates the retaining screws for the front panel by means of arrows. Remove the screws and move the front plate to one side. The fuse is located on the power supply board directly behind the front cover. Danger! The power supply unit must always be disconnected from the main power source if you remove or install the power supply unit intend to open the power supply unit Rev. 00/

36 Chapter 3 Power Supply Unit VIPA Rack-135U Manual Technical data Electrical data VIPA 188-3UA00-1 Input voltage V AC ( Hz) Power consumption (RMS power) 160W max. Output voltages - without fan 5V DC, max. 8A 24V DC, max. 3,5A - with fan module 5V DC, max. 10A DC24V,max.4,5A Inrush current max. 35A for 230V AC Power dropout protection 20ms Backup battery Li-battery 3,6V / 1,9Ah Backup capacity 1 year at 0,2mA, 25 C, continuous operation. Short-circuit protection electronic Fault indication 5V- and 24V-LED Primary fuse G-fuse: 5A / 250V Protection class Class 1 Isolation yes RF suppression level EN55022 Level A Power dissipation 50W max. Dimensions and weight Dimensions (WxHxD) Weight 70x254x205mm 1,5kg 3-12 Rev. 00/19

37 VIPA Rack-135U Manual Chapter 4 Fan subassembly Chapter4 Fan subassembly Overview In this chapter the construction and the application of the fan subassembly is described. The fan subassembly is utilized in conjunction with the Rack-135U and makes a maximum permitted total current of 10A possible for the power supply.unit (PS 8A). The following is described: Components of the fan subassembly Control and display elements Connection and start-up Changing of the internal fuse Technical data Contents Topic Page Chapter4 Fan subassembly Construction of the fan subassembly Control and display elements Mounting dimensions Mounting-/Dismounting Wiring Start-up of the fan subassembly Changing internal fuse Technical Data Order data Module Order number Description Fan subassembly VIPA 188-1TA00 DC24V fan subassembly for Rack-135U Rev. 00/19 4-1

38 Chapter 4 Fan subassembly VIPA Rack-135U Manual Construction of the fan subassembly Components The fan subassembly which is screwed from underneath onto the Rack- 135U consists of the following components: Connection DC24V for the supply voltage Connection of error output incase of fan malfunction LEDs for display of operating voltage and fan malfunction Electronics for fan control and monitoring Fan with rotation monitoring Fuse for input voltage (T2L/250V). 4-2 Rev. 00/19

39 VIPA Rack-135U Manual Chapter 4 Fan subassembly Control and display elements Part of front view of the fan subassembly INPUT DC24V LED "DC24V" The fan subassembly is supplied with DC24V via the "Input DC24V"- connection. The green DC24V-LED glows when power supply is active. The input is safeguarded via a fuse. See below for full details. Please pay attention to the right polarity! FAN WARNING LED "Fault" In the fan subassembly a fan is utilized which is controlled by a relay. In the error-free state and with active power supply the relay is picked-up which means that contacts 1 and 2 are bridged. If a fault occurs with the fan then the relay is released (release state), the contacts 2 and 3 are bridged and the error will be displayed via the red "Fault"-LED. As soon as the fan impeller rotates normally then the relay picks up again. Please note that the max. relay contact load is 8A with DC24V! Connection with cage clamp technique The wiring is secured as follows on the cage clamp contacts. Rectangular opening for screwdriver Round opening for wires Display of a defect fuse If the LED DC24V does not glow when the power supply is active and if the there is no short circuit then an internal fuse maybe defect. Rev. 00/19 4-3

40 Chapter 4 Fan subassembly VIPA Rack-135U Manual Mounting dimensions Dimensions All the necessary dimensions of the fan subassembly can be found in the following diagram Minimum clearance Please keep a minimum clearance of 50mm on top and below! 4-4 Rev. 00/19

41 VIPA Rack-135U Manual Chapter 4 Fan subassembly Mounting-/Dismounting Mounting the fan subassembly Separate the power supply unit from the supply voltage. Place the fan subassembly from underneath onto the Rack-135U as shown in the sketch. Secure the fan subassembly with 4 screws Connect the DC24V-input with the DC24V-output of the power supply. Connect the relay output with the PLC for error evaluation. Dismounting the fan subassembly Separate the power supply unit from the supply voltage. Remove the wires connected to the fan subassembly. Remove the four screws which secure the fan subassembly to the Rack- 135U. Remove the fan subassembly from underneath. Hint! The fan subassembly is always to be separated from the power supply when: the fan subassembly is dismounted or mounted replacing the fuses in fan subassembly Rev. 00/19 4-5

42 Chapter 4 Fan subassembly VIPA Rack-135U Manual Wiring The cage clamp technique from the company WAGO is used for the wiring. Wiring with the cage clamp technique makes possible a fast connection of the supply line. In contrast to the screw connection this type of connection is vibration proof. Wires with a cross-section of 0,08mm 2 to 2,5mm 2 can be connected. The wires can be stripped to approx. 8mm. Connection with Cage clamp technique Secure the wiring as follows on the cage clamp contacts: Rectangular opening for screwdriver Round opening for wires Use a suitable screwdriver to push the cage clamp in the rectangular opening towards the back and hold it pressed. Insert the wire or litz wire as far as it will go into the round opening of the pressed cage clamp. Remove the screwdriver. The wire is held by the cage clamp and provides a reliable connection. 4-6 Rev. 00/19

43 VIPA Rack-135U Manual Chapter 4 Fan subassembly Start-up of the fan subassembly Checklist for the starting-up Mount the fan subassembly Connect the power supply Switch the power supply unit on Fan operation As soon as the system voltage is active and the power supply unit which is connected to the fan subassembly is switched on then the LED 24V on the front of the fan subassembly will light up. At the same time the fan will run and with constant speed it will blow air from underneath into the Rack-135U. Hint! For the optimal air exchange it should be observed that the upper-side of the rack is not covered. The air must be able to flow out again unobstructed. Please pay attention that the rack is closed, this means, that slots that are not used on the front are to be closed off with a cover. It is only through these two measures that a sufficient air exchange is guaranteed. Rev. 00/19 4-7

44 Chapter 4 Fan subassembly VIPA Rack-135U Manual Changing internal fuse Display of a defect fuse If the LED 24V does not light-up with active voltage and there is no short circuit then it could be the case that an internal fuse is defect. Attention! The fuse may only be replaced by a fuse of the same type or else the right to a claim on the guarantee is negated and the unit can be damaged because of a too high current. Fuse type: G-fuse 2A, 250V, slow fuse (Type T) Changing of the fuse The fuse for the input voltage is in the fan subassembly on the board directly behind the frontside. Mounted fan subassemblies must firstly be dismounted. Danger! If the fan subassembly is to mounted or dismounted then it must always be be separated from the power supply! 4-8 Rev. 00/19

45 VIPA Rack-135U Manual Chapter 4 Fan subassembly Technical Data Electrical Data VIPA 188-1TA00 Input voltage DC24V Input current 0,25A Wattage 6W Relay-outgang max. load 8A with DC24V Short circuit protection electronic Disturbance display "Fault"-LED - and 24V-LED Fuse input voltage G-fuse: 2A / 250V slow fuse Measurements and weight Dimensions (WxHxD) Weight 226x64x206mm 526g Rev. 00/19 4-9

46 Chapter 4 Fan subassembly VIPA Rack-135U Manual 4-10 Rev. 00/19

47 VIPA Rack-135U Manual Chapter 5 Installation Guidelines Chapter 5 Installation guidelines Outline The chapter on installation guidelines provides information on the proper installation of programmable controllers in conjunction with the Rack-135U. This chapter describes how interference can enter your controller, how you can guarantee the electromagnetic compatibility (EMC) and how the required screening techniques. Below follows a description of: EMC and possible sources of interference The basic techniques required to achieve EMC EMC-compliant installation and wiring Guidelines for the power supply for the controller and peripherals Guidelines for setting up couplings Selection of a suitable switchboard/cubicle Contents Topic Page Chapter 5 Installation guidelines Basic techniques for EMC compliant installation of systems EMC compliant installation of controllers EMC-compliant wiring of the controller Special precautions providing high noise immunity Checklist for the EMC-compliant installation of controllers Power supply for controllers and peripheral equipment Noise immunity of decentralised links Selection and assembly of cubicles using VIPA-modules Rev. 00/19 5-1

48 Chapter 5 Installation Guidelines VIPA Rack-135U Manual Basic techniques for EMC compliant installation of systems What is EMC? The term electromagnetic compatibility (EMC) refers to the ability of electrical equipment to operate without failures within a specific electromagnetic environment without it being affected by or itself unnecessarily affecting the surroundings. The VIPA products have been developed for applications in rough industrial environments and they comply with stringent ENC requirements. In spite of this it is advisable that you plan your EMC strategy including all possible sources of interference before you install the controller. Outline of possible sources of interference Electromagnetic interference can be coupled into programmable controller in various ways: Depending no the medium of propagation (conductor based or without conductors) and the distance to the source of interference electromagnetic disturbance enters the programmable controller through many different coupling mechanisms. We can distinguish the following: galvanically coupled capacitively coupled inductively coupled radiation coupled 5-2 Rev. 00/19

49 VIPA Rack-135U Manual Chapter 5 Installation Guidelines Coupling mechanisms and sources of interference The following table shows the four different coupling mechanisms, their origin and possible sources of interference. Coupling mechanisms Origin Sources of interference Galvanic coupling The galvanic or metal-bound Switch-mode devices coupling occurs when two (power-based interference Source of circuits make use of a caused by inverters and interference common conductor foreign power supplies) Starting motors Automation System galvanic coupling Capacitive coupling Source of interference capacitive coupling Capacitive or electrical coupling occurs between conductors that are at different electrical levels. This coupling is proportional to therateofchangeofthe voltage. Different types of material for the enclosures of different components being supplied from the same power source Static discharges Interference enters via parallel signal cables Static discharge of the operator Contactors Automation System Inductive coupling Automation System Effective signal Radiation coupling Source of interference Source of interferenc inductive coupling Radiation coupling Inductive or magnetic coupling occurs between two looped conductors that are carrying currents. The magnetic flux caused by the currents induce interfering voltages. This coupling is proportional to the rate of change of the current. Radiation coupling occurs when an electromagnetic wave encounters a set of conductors. Currents and voltages are induced when the wave meets the conductor. Transformers, motors electrical welders Power cables in parallel Cables carrying currents that are being switched Signal cables carrying high frequency Disconnected coils Transmitter in close proximity (e.g. walkie-talkies) Spark gaps (spark plugs, collectors of electrical motors, welding equipment) Automation System Rev. 00/19 5-3

50 Chapter 5 Installation Guidelines VIPA Rack-135U Manual Basic techniques required to achieve EMC In many cases EMC can be achieved by ensuring that the respective structures comply with certain elementary rules. For this reason you must comply with the following basic rules when you assemble a controller. During the installation you must therefore verify that inactive metallic parts are grounded properly by means of large-surface contacts Interconnect all inactive metallic parts by means of large-surface lowimpedance conductors. Bolted connections between metallic components that have been varnished or anodised require special contact washers or you must remove the insulation surface. Install a central connection between ground and the earthing/neutral conductor system. Make sure that the conductors are routed properly when you are wiring the equipment Divide the wiring task amongst groups of conductors (high-power cables, power supply cables, signal lines, data lines). High-power cables and signal or data lines must always be installed in separate channels or bundles. Install signal and data lines in close proximity to grounded surfaces (e.g. frame members, metallic rails, covers of enclosures). Check that the screening of cables is grounded properly Data lines must be screened. Screens must be grounded at both ends Analogue lines must be screened. Where low-amplitude signals are concerned it may be of advantage to connect only one side of the cable to ground Attach the screening directly to the screening/neutral conductor rail at the point where the cable enters the cubicle. Use large-surface contacts and cable clamps. The screening conductor must be continued to the module without interruption, however, it must not be connected to the module. Ensure that the screening/neutral conductor rails are connected to the enclosure by means of low-impedance connections. Screened data lines should only use metallic or metallized covers for connectors. 5-4 Rev. 00/19