AMKAMAC Product description AIO AMK I/O system

Transcription

1 AMKAMAC Product description AIO AMK I/O system Version: Part-no.: 2015/xx Translation of the "Original Dokumentation" - Preliminary description -

2 Imprint Name: PDK_205571_AIO_Handbuch_en Version: Version: Change Letter symbol 2015/xx New document STL Previous version: - Product version: Product AMK part no. Firmware Version (AMK part no.) Hardware Version (AMK part no.) Copyright notice: Reservation: Publisher: AMK Arnold Müller GmbH & Co. KG Any transfer or reproduction of this document, as well as utilisation or communication of its contents, requires express consent. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design. We reserve the right to modify the content of the documentation as well as the delivery options for the product. AMK Arnold Müller GmbH & Co. KG Gaußstraße D Kirchheim/Teck Germany Phone: 0049/(0)7021/ Fax: 0049/(0)7021/ info@amk-antriebe.de Personally liable shareholder: AMK Verwaltungsgesellschaft mbh, Kirchheim/Teck Managing directors: Dr. Thomas Lützenrath, Jochen Breßmer, Dr. Ulrich Viethen Registration court: Stuttgart HRB ; HRA Service: Phone: 0049/(0)7021/ , Fax -193 Internet address: For fast and reliable troubleshooting, you can help us by informing our Customer Service about the following: Type plate data for each unit Software version Device configuration and application Type of fault/problem and suspected cause Diagnostic messages (error messages) service@amk-antriebe.de 2 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

3 Content Imprint 2 1 About this documentation Keeping this document Target group Purpose Display conventions Appendant documents 6 2 For your safety Basic notes Presenting safety messages Class of hazard Safety alert symbols used Intended use CE mark Requirements for the personnel and their qualification 8 3 Product overview Description of the fieldbus coupler Description of I/O modules I/O module components Connector Mechanical fixing elements Type plate 14 4 Datasheets Fieldbus coupler Datasheet fieldbus coupler AIO-FBC-EC Active I/O modules Digital inputs Datasheet digital inputs AIO-4DI-P-TS Datasheet digital inputs AIO-8DI-P-3W Digital outputs Datasheet digital outputs AIO-4DO-P Datasheet digital outputs AIO-4DO-P-2A Datasheet digital outputs AIO-8DO-P Analogue inputs Datasheet analogue inputs AIO-4AI-RTD-DIAG Datasheet analogue inputs AIO-4AI-UI Analogue outputs Datasheet analogue outputs AIO-4AO-UI Passive I/O modules Datasheet power-feed AIO-PF-O 77 5 Projecting Arrangement of the modules Installation position Horizontal installation position Vertical installation position Installation distances Installation distances horizontally Installation distances vertically Current demand Derating Interpretation 85 PDK_205571_AIO_Handbuch / Version 2015/xx 3 / 127

4 5.4.1 Example calculation for the power supply Calculation of current demand for the input current Calculation of current demand for the output current Example calculation Calculation of power loss Feedback energy in DO modules 89 6 Assembly Preparations for assembly Assembling the AIO system Attaching the marker Coding the module Wiring 96 7 Startup Configuring modular device I/O access External I/O terminal (asynchronous) External I/O terminal (cyclical) Service Replacing components Removing / replacing the plug-in unit Replacing the electronic unit Replacing an I/O module Removing / replacing connectors Removing / replacing cables LED indicators and troubleshooting Fieldbus coupler Active I/O modules Passive I/O modules Disassembly and disposal Disassembly Disposal Appendix Examples of module position coding 124 Your opinion is important! / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

5 1 About this documentation 1.1 Keeping this document This document must permanently be available and readable at the place where the product is in use. If the product is used at another place or changed the owner, the document must be passed on. 1.2 Target group Any person who is entitled and intends to carry out one of the following works must read, understand, and observe this document. Transportation and storage Unpacking and installation Projecting Connection Parameterization Startup Testing and maintenance Service and repair Decommissioning and disposal Replacement Programming 1.3 Purpose This document is addressed to any person who handles the product. It gives information about the following topics: Safety messages which are absolutely necessary to take care of during handling the product Product identification Projecting, planning and dimensioning of the application Environmental conditions for storage, transportation and operation Assembly Electrical connections Startup and operation Maintenance Repair Replacement Diagnosis Decommissioning and disposal Technical data Conformity with standards 1.4 Display conventions Display Meaning This symbol points to parts of the text to which particular attention should be paid! 'Names' See 'chapter name' on page x e. g.: Calling up the function 'delete PLC program' Parameter names, e. g.: ID2 'SERCOS cycle time' Variable names, e. g.: The variable 'udaccel' contains the acceleration value. Diagnostic message, e. g.: 1042 'Mains phase fault' Safety parameters, e. g.: Prm67 'SMS safe maximum speed' Executable cross-reference in electronic output media PDK_205571_AIO_Handbuch / Version 2015/xx 5 / 127

6 1.5 Appendant documents Standards and directives Name EN (standard parts in accordance with the requirement EN ) DIN EN DIN EN UL 94 UL 508 Title EMC Protection class PLC Flammability class culus Device descriptions AMK part-no. Title Device description Servo drives KE/KW Device description Controllers A-series Functional documentations AMK part-no. Title Software description AIPEX PRO V3 6 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

7 2 For your safety 2.1 Basic notes At electrical drive systems, hazards are present in principle that can result in death or fatal injuries: o o o Electrical hazard (e. g. electric shock due to touch on electrical connections) Mechanical hazard (e. g. crush, retract due to the rotation of the motor shaft) Thermal hazard (e. g. burns due to touch on hot surfaces) These hazards are present while starting up and operating the unit, and also during servicing or maintenance work. Safety instructions in the documentation and on the product warn about the hazards. Personnel must have read and understood the safety instructions before installing and operating the product. In the documentation about the product the usage warnings pertain to direct hazards and must therefore be followed directly when operating or handling the product by the operator. AMK products must be kept in their original order, that means it is not allowed to do a significant constructional change on hardware side and software is not allowed to be decompiled and change the source code. Damaged or faulty products are not allowed to be integrated or put into operation. Do not start the system in which the AMK products are installed (begin of intended use) until you can determine that all relevant standards, laws, and directives have been complied with, e. g. low voltage directive, EMC directive, and the machinery directive, and possible further product standards. The plant manufacturer is responsible for the compliance with the laws, directives, and standards. 2.2 Presenting safety messages Any safety information is configured as follows: SIGNAL WORD Type and source of risk Consequence(s) of non-observance Steps to prevent: Class of hazard Safety and warning messages are graduated into classes of hazard (according to ANSI Z535). The class of hazard defines the risk if the safety message is not heeded and is defined by the signal word. The signal word is followed by a safety alert symbol (ISO 3864, DIN ). In accordance with ANSI Z535, the following signal words are used to define the class of hazard. Safety alert symbol and signal word DANGER Class of hazard and its meaning DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury WARNING CAUTION NOTICE WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury NOTICE is used to address preventions to avoid material damage, but not related to personal injury. PDK_205571_AIO_Handbuch / Version 2015/xx 7 / 127

8 2.4 Safety alert symbols used Safety symbol Meaning Generic warning! 2.5 Intended use The products of the AIO series are intended for use in industrial automation. A AIO system with a fieldbus coupler and connected modules is intended for the decentralised control of systems or sub-systems. Every station module in a field-bus structure is integrated via the fieldbus coupler and connected with the superordinate control unit. AIO products meet the requirements of protection class IP 20 (as per DIN EN 60529). The observance of the documentation is part of the intended use. 2.6 CE mark AMK products have been constructed using the "State of the Art" and are safe to operate. AMK issues an EC declaration of conformity for each of its products in which the standards and guidelines relevant for the product are listed. AMK also designates the products with the CE mark which signifies conformity to the standards. 2.7 Requirements for the personnel and their qualification Only authorized and qualified personnel may work on and with the AMK drive systems. Specialised personnel must: Perform mechanical and electrical work that is described in this documentation, such as mounting and connecting Observe all information in the documentation accompanying the product in order to work with the product safely and in an error-free manner Understand and know hazards that occur when handling the product Know connections and functions of the system Be familiar with the control concept in order to operate the drive system Be authorized to switch circuits and devices on and off, earth and label them Observe local specific safety requirements 8 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

9 3 Product overview The modular AIO system supports the EtherCAT fieldbus system and conforms to IEC A station consists of a fieldbus coupler and the connected modules. Each station is assigned a bus address in the fieldbus structure. Only the coupler is fieldbus-specific; the I/O modules are independent of the fieldbus. Up to 64 active I/O modules can be combined in a station. The largest expansion possible depends on the maximum amount of data transmitted by the selected fieldbus, in particular the configuration, parameter, or process data for the module types provided. The following components belong to the AIO product series: Fieldbus coupler (Gateway): Head station for converting the respective fieldbus protocol on the AIO system bus Active I/O modules: Digital input modules (DI) with 4 or 8 channels Digital output modules (DO) with 4 or 8 channels Analogue input modules (AI) with 4 channels Analogue output modules (AO) with 4 channels Passive I/O modules (no fieldbus communication): 24 V power-feed modules (PF) for output current Mechanical fixing elements: End bracket End plate Dimensions: Height H in mm Width W in mm Depth D in mm Fieldbus coupler I/O module End plate End bracket PDK_205571_AIO_Handbuch / Version 2015/xx 9 / 127

10 Double-click assembly: The station modules can be installed quickly and simply. When attaching the module to the DIN rail, a clear clicking noise can be heard, which means that the module has clicked into place. In the second step, which involves pushing the module being installed together with the neighbouring module, a further clicking noise indicates that the modules have been correctly connected to each other. Earthing: (functional earth FE) Each I/O module is fitted with an FE spring on the underside which creates an electrical connection to the DIN rail. In order to establish a secure connection, the assembly must be carried out carefully in accordance with the instructions. See 'Assembling the AIO system' on page 91. The module is earthed by connecting the DIN rail to the protective earth via the earth terminal. 3.1 Description of the fieldbus coupler A fieldbus coupler is used to connect the station I/O modules to the fieldbus. All of the data traffic with the programmable logic controller including the diagnostic messages is exchanged via the coupler. The integrated power supply provides the coupler and all connected modules with power. Detailed description of the coupler. See 'Datasheet fieldbus coupler AIO-FBC-EC' on page Catch lever for securing the DIN rail 5 Type designation 2 EtherCAT IN 6 LED power supply coupler 3 EtherCAT OUT 7 Status LEDs fieldbus coupler 4 Type designation 8 Power supply connector for the system and input modules 9 Power supply connector for output modules 10 Service flap 11 Latching hook for latching onto module sides 12 System bus 13 System current path 14 DIN rail foot 15 Input current path 16 Type plate with block diagram 17 Output current path 18 Latching hook for latching onto module sides 10 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

11 3.2 Description of I/O modules 1 Catch lever for securing the DIN rail 7 Connector frame unlocking device 2 System bus 8 Module status LED (collective message) 3 System current path 9 Connector 4 Input current path 10 Channel status LEDs 5 Output current path 11 Latching hook for latching onto module sides 6 Type designation 12 DIN rail foot 13 Type plate with block diagram 14 Latching hook for latching onto module sides PDK_205571_AIO_Handbuch / Version 2015/xx 11 / 127

12 3.2.1 I/O module components 1 Basic module 2 Electronic unit 3 Removal lever for electronic unit 4 Connector frame 5 Connector 6 Plug-in unit 12 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

13 3.2.2 Connector The connection frame can take up to four connectors, and four conductors can be connected to each connector. PUSH IN technology allows for fine-wired conductors with crimped wire-end ferrules or ultrasonically welded conductors, each with a maximum cross-section of 1.5 mm 2, to be inserted easily through the opening in the clamping terminal without having to use tools. To insert fine-wired conductors without wire-end ferrules, the pusher must be pressed in with a screwdriver. See 'Wiring' on page 96. conductor cross-section 0.14 to 1.5 mm 2 (AWG 26-16) max. ampacity: 10 A 4 pin The pushers are color-coded for the following connections: Color grey blue red green Signal Signal GND 24 VDC Functional earth (FE) PDK_205571_AIO_Handbuch / Version 2015/xx 13 / 127

14 3.3 Mechanical fixing elements The station is fixed in the installation position by an end bracket at either side. The last I/O module is protected against dust by a cover plate, into which the second end bracket is inserted and screwed to the mounting rail. Every AIO coupler is supplied with a termination kit. 1 End bracket (left end, on the coupler side) 2 End plate and end bracket (right end) 3.4 Type plate Each fieldbus coupler and each module features a type plate, which includes identification information, the key technical specifications and a block diagram. In addition, a QR code allows for direct online access to the associated documentation. The software for reading the QR code must support inverted QR codes. 1 Product number 2 Serial number 3 Manufacturing code 4 QR code 14 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

15 4 Datasheets 4.1 Fieldbus coupler Datasheet fieldbus coupler AIO-FBC-EC AMK I/O fieldbus coupler, Ethernet, EtherCAT Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis The power supply for the coupler supplies the connected modules Product name and ordering data Product name AIO-FBC-EC Order number E1202 PDK_205571_AIO_Handbuch / Version 2015/xx 15 / 127

16 Description The AIO-FBC-EC fieldbus coupler is an EtherCAT slave participant, which is certified by the EtherCAT Technology Group. It is the front module for the system bus, onto which up to 64 active I/O modules can be connected. It has two Ethernet ports. The integrated switch supports a linear network structure. The supply for the coupler and all connected modules is integrated into the coupler. It is supplied by two 4-pin connectors which are separated depending on the input and output current path. Interfaces and status LEDs Coupler status LED: Voltage supply Module LED Green: Supply voltage >18 VDC Red: At least one current path <18 VDC 16 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

17 LED status display: Coupler PWR Power LED Green: Supply voltage on SF Group error Red: Configuration error, error in the coupler, error in a module, or there is a new diagnostic message Flashes red: Station is in force mode BF Bus error Red: No connection to fieldbus; Flashes red: Configuration error, no connection to controller, or error in parameter set MT Maintenance Yellow: Error on system bus L/A IN Connection / activity Green: Connection established between port 1 of the coupler and an additional field device; Flashes green: Data exchange at port 1 L/A OUT Connection / activity Green: Connection established between port 2 of the coupler and an additional field device; Flashes green: Data exchange at port 2 RUN Coupler status Off: INIT; Flashes green: PRE-OPERATIONAL; Briefly lights up green: SAFE-OPERATIONAL; Green: OPERATIONAL ERROR Internal error Red: Critical error in coupler; Briefly lights up red: Error in the coupler application; Briefly lights up red twice: SyncManager Watchdog output lapsed; Flashes red: Configuration error LED status display: Supply connection for system U SYS and input modules U IN 3.1 Green: Supply voltage for input current path U IN >18 VDC 3.2 Red: Supply voltage for input current path <18 VDC 3.4 Red: Internal fuse defective LED status display: Supply connection for output modules U OUT 4.1 Green: Supply voltage for output current path U OUT >18 VDC 4.2 Red: Supply voltage for output current path <18 VDC 4.4 Red: Internal fuse defective PDK_205571_AIO_Handbuch / Version 2015/xx 17 / 127

18 Simplified diagram Technical data Formal data Type of module Fieldbus coupler with EtherCAT interface Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Mechanical data Width Height (with release lever) Depth Weight 52 mm 120 (128) mm 76 mm 227 g 18 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

19 Ambient conditions Temperature Operation (horizontal installation): C (supply 2 x 8 A) C (supply 2 x 10 A) Operation (vertical installation): C (supply 2 x 6 A) C (supply 2 x 8 A) Storage and transport C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sine wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) X1 X2 "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Material Damage! EtherCAT IN NOTICE EtherCAT OUT (transmission to next participant) At a maximum current of >8 A and a maximum temperature of > +55 C, all four contacts must be connected with 1.5 mm². Supply Supply voltage for system, inputs, and outputs Max. supply current at input modules Max. supply current at output modules Current consumption (internal), typical 24 VDC +20 % / -15 % 10 A 10 A 130 ma PDK_205571_AIO_Handbuch / Version 2015/xx 19 / 127

20 System data Connection Real-time protocol 2 x RJ45 EtherCAT Process image Process data: max bytes Parameter data: Diagnosis data: max. 64 x 64 = 4 Kbytes max. 64 x 50 bytes Data format Number of modules Transfer rate Intel Max. 64 active Ethernet, EtherCAT, max. 100 Mbit/s Internal system bus, max. 48 Mbit/s Module configuration Overview of the adjustable parameters Parameter Possible values Default setting Process alarm Deactivated / activated Deactivated Diagnosis Deactivated / activated Deactivated Output behavior in the event of fieldbus error Module behavior in the event of hot swap All outputs off / activate replacement values / retain last value Continue data exchange / behave as in event of fieldbus error Data format Motorola / Intel Intel Coupler controller Reserved Off All outputs off Continue data exchange Device status To reach diagnostic and status messages quickly and directly via the controller, status bytes are available as additional process input data for the coupler and the modules. Status bits of coupler AIO-FBC-EC Bit Name Meaning 0 Summarized module diagnosis Module diagnosis is available. A diagnosis is available for at least one module with diagnosis function. Module status messages can be read via object 0x10F3: Status value 0x0 0x1 0x80 0x81 1 Error bit 1 Reserved 2 Error bit 2 Reserved Meaning Slot is undefined Slot = module OK Slot empty, module has been removed Incorrect module connected 20 diagnoses are saved in a circular buffer; the most recent diagnosis overwrites the oldest (subindex 06 to 19) 3 System bus error Error on system bus. Communication with the connected modules has been interrupted. 4 Error bit 4 Reserved 5 Error bit 5 Reserved 20 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

21 Bit Name Meaning 6 I/O configuration error Abnormal configuration. The module list has changed. The list of configured modules (Configured Module Ident List 0xF030) deviates from the list of modules detected by the coupler (Detected Module Ident List 0xF050). 7 Master configuration error Master configuration error. The list of configured modules (Configured Module Ident List 0xF030) deviates significantly from the list of modules detected by the coupler (Detected Module Ident List 0xF050). A process data exchange with the modules cannot take place. The station switches to PRE-OPERATIONAL status. 8 Error bit 8 Reserved 9 Error bit 9 Reserved 10 Reserved Reserved 11 Error bit 11 Reserved 12 Error bit 12 Reserved 13 Voltage U OUT error Output voltage supply error 14 Voltage U IN error System and input voltage supply error 15 Error bit 15 Reserved PDK_205571_AIO_Handbuch / Version 2015/xx 21 / 127

22 4.2 Active I/O modules Digital inputs Datasheet digital inputs AIO-4DI-P-TS AMK I/O module, 4 digital inputs with time stamp function Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire or 3-wire connection technology Reverse polarity protection Product name and ordering data Product name AIO-4DI-P-TS Order number O / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

23 Description AIO-4DI-P-TS digital input modules with time stamp function are used to receive binary control signals and provide them with a time stamp (resolution 1 μs). Each module has 4 inputs. One sensor can be connected to each connector using 2-wire, 3-wire or 3-wire + FE technology. A status LED is assigned to each channel. The inputs are fully compliant with IEC and can be connected to type 1 and 3 sensors on the input side in accordance with the standard. Depending on the configuration of the module, up to 5 or 15 time stamp entries can be evaluated. The module electronics supply the connected sensors with current from the input current path (U IN ) of the coupler. Interfaces and status LEDs LED status display: Digital inputs Module LED Green: Communication via the system bus active Red: Error indication 1.1 Yellow: Input 0 active 2.1 Yellow: Input 1 active 3.1 Yellow: Input 2 active 4.1 Yellow: Input 3 active PDK_205571_AIO_Handbuch / Version 2015/xx 23 / 127

24 Simplified diagram Technical data Type of module Digital inputs Approvals and standarts culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Inputs Number of inputs 4 Input type (IEC ) Type 1 and Type 3 Input filter Filter time adjustable up to 40 ms Input voltage low <5 VDC Input voltage high >11 VDC Max. input current per channel 3 ma Sensor supply Yes Sensor connection 2-wire, 3-wire, 3-wire +FE Reverse polarity protection Yes Module diagnosis Yes Individual channel diagnosis No Time stamp data width 16 bits Time stamp resolution 1 μs Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible 24 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

25 Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Vibration resistance (IEC ) Shock resistance (IEC ) Storage and transport: 700 hpa (height 3000 m) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from input current path I IN Current consumption from system current path I SYS <10 ma + sensor supply 8 ma System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s PDK_205571_AIO_Handbuch / Version 2015/xx 25 / 127

26 Module configuration Overview of the adjustable parameters Channel Designation Options (value) Default settings Input delay (0) None 3 ms (1) 0.3 ms (2) 3 ms (3) 10 ms (4) 20 ms (5) 40 ms Time stamp at Edge 0-1 disabled (0) / enabled (1) Time stamp at Edge 1-0 disabled (0) / enabled (1) disabled disabled Process data Data format of the coupler is valid (Intel). Byte Format Name Remark IB0 Byte Input image 1 Bit 0 = DI0... Bit 3 = DI3, Bit reserved IB1 Byte Running number rotating IB2 Word Time stamp μs rotating IB3 IB4 Byte Input image 2 IB5 Byte Running number 2 IB6 Word Time stamp 2 IB7 IB8 Byte Input image 3 IB9 Byte Running number 3 IB10 Word Time stamp 3 IB IB56 Byte Input image 15 IB57 Byte Running number 15 IB58 Word Time stamp 15 IB59 26 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

27 Diagnosis data Name Byte Bit Description Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 0 4 Error 5 Reserved 0 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x0F Reserved 0 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnosis FIFO full Reserved 0 Channel type Channel type 0x70 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 0 Number of channels 6 Number of the same channels per module 4 Channel error Reserved 0 Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) Time stamp function: With time stamp function (ETS-function, ETS=edge time stamp) enabled, at every corresponding edge the time value of the timer is stored in the process image as an ETS entry together with the status of the inputs and a running number. The module does not use any bytes in the output image. It uses 60 Bytes in the input image for 15 ETS entries each with 4 bytes. Structure of an ETS entry Input map PII Running number RN Time stamp ETS_US After the edge transition, the status of the inputs is stored here. The input byte has the following bit assignments: Bit 0: Bit 1: Bit 2: Bit 3: DI0 DI1 DI2 DI3 Bit 4...7: reserved (0) The RN (running number) is a consecutive number from 0 to 127. It describes the chronological sequence of the edges. The 16-bit timer ( μs) in the AIO module is started as soon as the power supply is switched on and after (2 16-1) μs restarts at 0. PDK_205571_AIO_Handbuch / Version 2015/xx 27 / 127

28 Example for the mode of operation The following example shows the sequence in which ETS entries are stored. The input channels are predefined as follows: DI0 and DI1: time stamp at edge 0-1 enabled DI2 and DI3: time stamp at edge 0-1 disabled DI0 and DI1: time stamp at edge 1-0 enabled DI2 and DI3: time stamp at edge 1-0 disabled The ETS entries available at time (t) are designated by the green area in the diagram. ETS entries that are not (or no longer) available have a grey background New ETS entries are always entered starting at address +0 and already existing ETS entries are each shifted by 4 bytes. Process image is empty at t 0 Address PII RN ETS_US st ETS entry at t 1 A rising 0-1 edge on DI0 causes the 1st ETS entry at address +0. Address PII RN ETS_US nd ETS entry at t 2 A rising 0-1 edge on DI1 causes the 2nd ETS entry at address +0. The 1st ETS entry is shifted by 4 bytes. Address PII RN ETS_US / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

29 3rd ETS entry at t 3 A falling 1-0 edge on DI0 causes the 3rd ETS entry. Address PII RN ETS_US th to 14th. ETS entry... 15th ETS entry at t 15 A rising 0-1 edge on DI0 causes the 15th ETS entry. Address PII RN ETS_US th ETS entry at t 16 A rising 0-1 edge on DI1 causes the 16th ETS entry. The 1st ETS entry is deleted and not available anymore. Address PII RN ETS_US PDK_205571_AIO_Handbuch / Version 2015/xx 29 / 127

30 17th ETS entry at t 17 A falling 1-0 edge on DI1 causes the 17th ETS entry. The 2nd ETS entry is deleted ant not available anymore. Address PII RN ETS_US / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

31 Datasheet digital inputs AIO-8DI-P-3W AMK I/O module, 8 digital inputs Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire or 3-wire connection technology Reverse polarity protection Product name and ordering data Product name AIO-8DI-P-3W Order number O926 Description AIO-8DI-P-3W digital input modules are used to receive binary control signals from sensors, encoders, switches, or proximity switches. Each module has 8 inputs. Two sensors can be connected to each connector using 2-wire or 3-wire technology. A status LED is assigned to each channel. The inputs are fully compliant with IEC and can be connected to type 1 and 3 sensors PDK_205571_AIO_Handbuch / Version 2015/xx 31 / 127

32 on the input side in accordance with the standard. The module electronics supply the connected sensors with current from the input current path (U IN ) of the coupler. Interfaces and status LEDs LED status display: Digital inputs Module LED Green: Communication via the system bus active Red: Error indication 1.1 Yellow: Input 0 active 1.4 Yellow: Input 1 active 2.1 Yellow: Input 2 active 2.4 Yellow: Input 3 active 3.1 Yellow: Input 4 active 3.4 Yellow: Input 5 active 4.1 Yellow: Input 6 active 4.4 Yellow: Input 7 active 32 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

33 Simplified diagram Technical data Formal data Type of module Digital inputs Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Inputs Number of inputs 8 Input type (IEC ) Type 1 and type 3 Input filter Filter time adjustable up to 40 ms Input voltage low <5 VDC Input voltage high >11 VDC Sensor supply Max. 2 A per connector, total max. 8 A Sensor connection 2-wire, 3-wire Reverse polarity protection Yes Module diagnosis Yes Individual channel diagnosis No Max. frequency 1 khz Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible PDK_205571_AIO_Handbuch / Version 2015/xx 33 / 127

34 Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from input current path I IN <22 ma + sensor supply Current consumption from system current path I SYS 8 ma System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s Module configuration Overview of the adjustable parameters Channel Designation Possible values Default setting 0 7 Switch-on delay 0 None 3 ms ms 2 3 ms 3 10 ms 4 20 ms 5 40 ms 34 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

35 Process data Data format of the coupler is valid (Intel). Byte Bit Description IB0 IX0.0 DI0 IX0.1 DI1 IX0.2 DI2 IX0.3 DI3 IX0.4 DI4 IX0.5 DI5 IX0.6 DI6 IX0.7 DI7 Diagnosis data Name Byte Bit Description Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 0 4 Error 5 Reserved 0 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x0F Reserved 0 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnosis FIFO full Reserved 0 Channel type Channel type 0x70 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 0 Number of channels 6 Number of the same channels per module 8 Channel error Reserved 0 Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) PDK_205571_AIO_Handbuch / Version 2015/xx 35 / 127

36 4.2.2 Digital outputs Datasheet digital outputs AIO-4DO-P AMK I/O module, 4 digital outputs Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire or 3-wire connection technology Short-circuit proof Product name and ordering data Product name AIO-4DO-P Order number O934 Description AIO-4DO-P digital output modules are used to link peripheral actuators. Each module has 4 outputs which are designed to connect DC-13 actuators in accordance with EN and the IEC specification. Actuators can be connected to each connector using 2-wire, 3-wire or 3-wire + FE technology. A status 36 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

37 LED is assigned to each channel. The module electronics supply the connected actuators with current (max. 0.5 A per channel) from the output current path (U OUT ) of the coupler. Interfaces and status LEDs LED status display: Digital outputs Module LED Green: Communication via the system bus active Red: Error indication 1.1 Yellow: Output 0 active 2.1 Yellow: Output 1 active 3.1 Yellow: Output 2 active 4.1 Yellow: Output 3 active PDK_205571_AIO_Handbuch / Version 2015/xx 37 / 127

38 Simplified diagram Technical data Formal data Type of module Digital outputs Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Outputs Number of outputs 4 Load type Resistive, inductive, lamp load Response time Max. 100 µs high; max. 250 µs low Max. output current 0.5 A per channel 2 A per channel Breaking energy (inductive) 150 mj Switching frequency Resistive load (min. 47 ohms): 1 khz Inductive load (DC 13): Lamp load (12 W): 2 Hz 1 khz Actuator connection 2-wire, 3-wire, 3-wire +FE Short-circuit proof Yes Protective circuit Constant current with thermal cut-off and automatic restart Current limiter response time <100 µs Module diagnosis Yes Individual channel diagnosis No Nonreactive Yes 38 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

39 Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from output current path I OUT 10 ma + load Current consumption from system current path I SYS 8 ma System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s PDK_205571_AIO_Handbuch / Version 2015/xx 39 / 127

40 Module configuration Overview of the adjustable parameters Channel Designation Options (value) Default setting Error replacement value 0 Off Off 1 On Process data Data format of the coupler is valid (Intel). Byte Bit Description QB0 QX0.0 DO0 QX0.1 DO1 QX0.2 DO2 QX0.3 DO3 QX0.4 reserved QX0.5 reserved QX0.6 reserved QX0.7 reserved Diagnosis data Name Byte Bit Description Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 0 4 Error 5 Reserved 0 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x0F Reserved 0 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnosis FIFO full Reserved 0 Channel type Channel type 0x72 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 0 Number of channels 6 Number of the same channels per module 4 Channel error Reserved 0 Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) 40 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

41 Datasheet digital outputs AIO-4DO-P-2A AMK I/O module, 4 digital outputs Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire or 3-wire connection technology Short-circuit proof Product name and ordering data Product name AIO-4DO-P-2A Order number O935 Description AIO-4DO-P digital output modules are used to link peripheral actuators. Each module has 4 outputs which are designed to connect DC-13 actuators in accordance with EN and the IEC specification. Actuators can be connected to each connector using 2-wire, 3-wire or 3-wire +FE technology. A status LED is assigned to each channel. The module electronics supply the connected actuators with current (max. 2 A per channel) from the output current path (U OUT ) of the coupler. PDK_205571_AIO_Handbuch / Version 2015/xx 41 / 127

42 Interfaces and status LEDs LED status display: Digital outputs Module LED Green: Communivation via the system bus active Red: Error indication 1.1 Yellow: Output 0 active 2.1 Yellow: Output 1 active 3.1 Yellow: Output 2 active 4.1 Yellow: Output 3 active Simplified diagram 42 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

43 Technical data Formal data Type of module Digital outputs Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Outputs Number of outputs 4 Load type Resistive, inductive, lamp load Response time Max. 100 µs high; max. 250 µs low Max. output current 2 A per channel 8 A per channel Breaking energy (inductive) 150 mj Switching frequency Resistive load (min. 47 ohms): 1 khz Inductive load (DC 13): Lamp load (12 W): 2 Hz 1 khz Actuator connection 2-wire, 3-wire, 3-wire +FE Short-circuit proof Yes Protective circuit Constant current with thermal cut-off and automatic restart Current limiter response time <100 µs Module diagnosis Yes Individual channel diagnosis No Nonreactive Yes Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave PDK_205571_AIO_Handbuch / Version 2015/xx 43 / 127

44 Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from output current path I OUT 10 ma + load Current consumption from system current path I SYS 8 ma System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s Module configuration Overview of the adjustable parameters Channel Designation Options (value) Default setting Error replacement value 0 Off Off 1 On Process data Data format of the coupler is valid (Intel). Byte Bit Description QB0 QX0.0 DO0 QX0.1 DO1 QX0.2 DO2 QX0.3 DO3 QX0.4 reserved QX0.5 reserved QX0.6 reserved QX0.7 reserved 44 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

45 Diagnosis data Name Byte Bit Description Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 0 4 Error 5 Reserved 0 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x0F Reserved 0 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnosis FIFO full Reserved 0 Channel type Channel type 0x72 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 0 Number of channels 6 Number of the same channels per module 4 Channel error Reserved 0 Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) PDK_205571_AIO_Handbuch / Version 2015/xx 45 / 127

46 Datasheet digital outputs AIO-8DO-P AMK I/O module, 8 digital outputs Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire connection technology Short-circuit proof Product name and ordering data Product name AIO-8DO-P Order number O925 Description AIO-8DO-P digital output modules are used to link peripheral actuators. Each module has 8 outputs which are designed to connect DC-13 actuators in accordance with EN and the IEC specification. Actuators can be connected to each connector using 2-wire technology. A status LED is assigned to each channel. The module electronics supply the connected actuators with current (max. 0.5 A per channel) from the output current path (U OUT ) of the coupler. 46 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

47 Interfaces and status LEDs LED status display: Digital outputs Module LED Green: Communication via the system bus active Red: Error indication 1.1 Yellow: Output 0 active 1.3 Yellow: Output 1 active 2.1 Yellow: Output 2 active 2.3 Yellow: Output 3 active 3.1 Yellow: Output 4 active 3.3 Yellow: Output 5 active 4.1 Yellow: Output 6 active 4.3 Yellow: Output 7 active PDK_205571_AIO_Handbuch / Version 2015/xx 47 / 127

48 Simplified diagram Technical data Formal data Type of module Digital outputs Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Outputs Number of outputs 8 Load type Resistive, inductive, lamp load Response time Max. 100 µs high; max. 250 µs low Max. output current 0.5 A per channel 4 A per module Breaking energy (inductive) 150 mj Switching frequency Resistive load (min. 47 ohms): 1 khz Inductive load (DC 13): Lamp load (12 W): 2 Hz 1 khz Actuator connection 2-wire Short-circuit proof Yes Protective circuit Constant current with thermal cut-off and automatic restart Current limiter response time <100 µs Module diagnosis Yes Individual channel diagnosis No Nonreactive Yes 48 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

49 Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from output current path I OUT 15 ma + load Current consumption from system current path I SYS 8 ma System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s PDK_205571_AIO_Handbuch / Version 2015/xx 49 / 127

50 Module configuration Overview of the adjustable parameters Channel Designation Possible values Default setting 0 7 Error replacement value 0 Off Off 1 On Process data Data format of the coupler is valid (Intel). Byte Bit Description QB0 QX0.0 DO0 QX0.1 DO1 QX0.2 DO2 QX0.3 DO3 QX0.4 DO4 QX0.5 DO5 QX0.6 DO6 QX0.7 DO7 Diagnosis data Name Byte Bit Description Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 0 4 Error 5 Reserved 0 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x0F Reserved 0 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnosis FIFO full Reserved 0 Channel type Channel type 0x72 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 0 Number of channels 6 Number of the same channels per module 8 Channel error Reserved 0 Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) 50 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

51 4.2.3 Analogue inputs Datasheet analogue inputs AIO-4AI-RTD-DIAG AMK I/O module, 4 analogue inputs, temperature, RTD Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire, 3-wire or 4-wire connection technology Reverse polarity protection Product name and ordering data Product name AIO-4AI-RTD-DIAG Order number O930 Description AIO-4AI-RTD-DIAG analogue input modules are used to collect thermocouple and resistance temperature sensors. Each module has 4 inputs and are suited for all common thermocouple elements and resistance temperature sensors. One sensor can be connected to each connector using 2-wire, 3-wire or 4-wire technology. Sensor type and temperature range PDK_205571_AIO_Handbuch / Version 2015/xx 51 / 127

52 are set using parameterisation. A status LED is assigned to each channel. The module electronics supply the connected sensors with current from the input current path (U IN ) of the coupler. Interfaces and status LEDs LED status display: Analogue inputs Module LED Green: Communication via the system bus active Red: Error indication 1.1 Red: Signal at input 0 outside the permissible range, line break or short-circuit 2.1 Red: Signal at input 1 outside the permissible range, line break or short-circuit 3.1 Red: Signal at input 2 outside the permissible range, line break or short-circuit 4.1 Red: Signal at input 3 outside the permissible range, line break or short-circuit 52 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

53 Simplified diagram Technical data Formal data Type of module Analogue inputs Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Inputs Number of inputs 4 Input type Resolution Accuracy Sensor connection Max. wire resistance / measurement range Temperature coefficient Pt100, Pt200, Pt500, Pt1000, Ni100, Ni120, Ni200, Ni500, Ni1000, Cu10, 40 Ω, 80 Ω, 150 Ω, 300 Ω, 500 Ω, 1000 Ω, 2000 Ω, 4000 Ω 16 bit max. 0.2% FSR / 0.3% FSR for Ni sensors / 0.6% FSR for Cu10 2-wire, 3-wire, 4-wire 2.5 Ω / 40 Ω, 5 Ω / 80 Ω, 10 Ω / 150 Ω Cu10: 25 Ω in all other measuring ranges ±50 ppm / K max. Temperature range C Conversion time Common mode input voltage range Reverse polarity protection Module diagnosis Individual channel diagnosis ms, adjustable Channel to channel: max. ±2 V Channel to voltage supply: max. ±50 V Yes Yes Yes PDK_205571_AIO_Handbuch / Version 2015/xx 53 / 127

54 Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from input current path I IN 20 ma Current consumption from system current path I SYS 8 ma System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s 54 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

55 Module configuration Overview of the adjustable parameters Channel Designation Options (value) Default settings Temperature unit Degree Celsius (0) Degree Fahrenheit (1) Kelvin (2) Measurement range (0) PT C (1) PT C (2) PT C (3) PT C (4) NI C (5) NI C (6) NI C (7) NI C (8) NI C (9) Cu C (10) Resistance 40 Ω (11) Resistance 80 Ω (12) Resistance 150 Ω (13) Resistance 300 Ω (14) Resistance 500 Ω (15) Resistance 1000 Ω (16) Resistance 2000 Ω (17) Resistance 4000 Ω (18) disabled Degree Celsius disabled Connection type 2-wire (0) / 3-wire (1) / 4-wire (2) 2-wire Conversion time 240 ms (0) / 130 ms (1) / 80 ms (2) / 55 ms (3) / 43 ms (4) / 36 ms (5) 80 ms Channel diagnostics disabled (0) / enabled (1) disabled Limit value monitoring disabled (0) / enabled (1) disabled High limit value Low limit value Process data Data format of the coupler is valid (Intel). Byte Format Description IB0 Word RTD0 IB1 IB2 Word RTD1 IB3 IB4 Word RTD2 IB5 IB6 Word RTD3 IB7 PDK_205571_AIO_Handbuch / Version 2015/xx 55 / 127

56 Process alarm Name Number of Function bytes High alarm 1 Bit 0: Upper limit exceeded channel 0 Bit 1: Upper limit exceeded channel 1 Bit 2: Upper limit exceeded channel 2 Bit 3: Upper limit exceeded channel 3 Bit 4...7: Reserved Low alarm 1 Bit 0: Lower limit underrun channel 0 Bit 1: Lower limit underrun channel 1 Bit 2: Lower limit underrun channel 2 Bit 3: Lower limit underrun channel 3 Bit 4...7: Reserved Time stamp 2 The two least significant bytes of the internal 32 bit timer Diagnosis data Name Byte Bit Description Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 4 Error 5 Power supply fault 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x Channel information available 1 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnosis FIFO full 4 Power supply fault 5 Reserved 0 6 Process alarm lost 7 Reserved 0 Channel type Channel type 0x71 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 8 Number of channels 6 Number of the same channels per module 4 56 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

57 Name Byte Bit Description Default Channel error 7 0 Error at channel 0 1 Error at channel 1 2 Error at channel 2 3 Error at channel Reserved 0 Channel error Reserved Channel error Reserved Channel error Reserved Channel 0 error 11 0 Parameter error 1 Reserved 0 2 Reserved 0 3 Reserved 0 4 Line break 5 Process alarm lost 6 Lower limit exceeded 7 Upper limit exceeded Channel 1 error 12 0 Parameter error 1 Reserved 0 2 Reserved 0 3 Reserved 0 4 Line break 5 Process alarm lost 6 Lower limit exceeded 7 Upper limit exceeded Channel 2 error 13 0 Parameter error 1 Reserved 0 2 Reserved 0 3 Reserved 0 4 Line break 5 Process alarm lost 6 Lower limit exceeded 7 Upper limit exceeded Channel 3 error 14 0 Parameter error 1 Reserved 0 2 Reserved 0 3 Reserved 0 4 Line break 5 Process alarm lost 6 Lower limit exceeded 7 Upper limit exceeded Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) PDK_205571_AIO_Handbuch / Version 2015/xx 57 / 127

58 Measurement ranges Resistance Measurement range Resistance Decimal Hexadecimal Range 40 Ω >47.04 Ω x7FFF Overloading or line break Ω x7EFF Overloading 40 Ω x6C00 Nominal range 0 0 0x Ω >94.07 Ω x7FFF Overloading or line break Ω x7EFF Overloading 80 Ω x6C00 Nominal range 0 0 0x Ω >176.4 Ω x7FFF Overloading or line break Ω x7EFF Overloading 150 Ω x6C00 Nominal range 0 0 0x Ω > Ω x7FFF Overloading or line break Ω x7EFF Overloading 300 Ω x6C00 Nominal range 0 0 0x Ω >598.7 Ω x7FFF Overloading or line break Ω x7EFF Overloading 500 Ω x6C00 Nominal range 0 0 0x Ω >1177 Ω x7FFF Overloading or line break 1177 Ω x7EFF Overloading 1000 Ω x6C00 Nominal range 0 0 0x Ω >2352 Ω x7FFF Overloading or line break 2352 Ω x7EFF Overloading 2000 Ω x6C00 Nominal range 0 0 0x Ω >4703 Ω x7FFF Overloading or line break 4703 Ω x7EFF Overloading 4000 Ω x6C00 Nominal range 0 0 0x / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

59 Temperature Measurement range Value in C Value in F Value in K Range 0.1 resolution 0.1 / digit 0.1 / digit Pt C C Underloading Overloading Line break Pt C C Underloading Overloading Line break Pt C C Underloading Overloading Line break Pt C C Underloading Overloading Line break Ni C C Underloading Overloading Line break Ni C C Underloading Overloading Line break Ni C C Underloading Overloading Line break Ni C C Underloading Overloading Line break Ni C C Underloading Overloading Line break Cu C C Underloading Overloading Line break PDK_205571_AIO_Handbuch / Version 2015/xx 59 / 127

60 Datasheet analogue inputs AIO-4AI-UI-16 AMK I/O module, 4 analogue inputs Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire or 3-wire connection technology Short-circuit proof Reverse polarity protection Product name and ordering data Product name AIO-4AI-UI-16 Order number O931 Description AIO-4AI-UI-16 analogue input modules are used to receive analogue signals from sensors. Each module has 4 inputs and can record analogue sensors with following ranges: Ranges: ±10 V / ±5 V / V / V / V / V / ma / ma 60 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

61 One sensor can be connected to each connector using 2-wire, 3-wire or 3-wire +FE technology. The measurement range from each channel is defined using parameterisation. A status LED is assigned to each channel. The module electronics supply the connected sensors with current from the input current path (U IN ) of the coupler. Interfaces and status LEDs LED status display: Analogue inputs Module LED Green: Communication via the system bus active Red: Error indication 1.1 Red: Channel error 2.1 Red: Channel error 3.1 Red: Channel error 4.1 Red: Channel error PDK_205571_AIO_Handbuch / Version 2015/xx 61 / 127

62 Simplified diagram Technische Daten Formal data Type of module Analogue inputs Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Inputs Number of inputs 4 Input levels 1. Voltage V, ±5 V, V, ±10 V, V, V Resolution Accuracy Sensor supply Sensor connection Conversion time Internal resistance Reverse polarity protection Short-circuit proof Response time of the protective circuit Module diagnosis Individual channel diagnosis 2. Current ma, ma 16 bit 0.1 % FSR max. 50 ppm / K max. Max. -10 mv / A at 25 C Temperature coefficient Additional inaccuracy in the voltage mode due to sensor power supply current Max. 2 A per connector, total max. 8 A 2-wire, 3-wire, 3-wire +FE 1 ms U: 100 kω; I:41.2 Ω Yes Yes <50 ms Yes No 62 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

63 Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from input current path I IN 25 ma + sensor supply Current consumption from system current path I SYS 8 ma System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s PDK_205571_AIO_Handbuch / Version 2015/xx 63 / 127

64 Module configuration Overview of the adjustable parameters Channel Designation Options (value) Default settings Frequency suppression disabled (0) 50 Hz (1) 60 Hz (2) Average over 16 values (3) Data format S5 Data format (0) S7 Data format (1) Measurement range (0) 0 ma ma (1) 4 ma ma (2) 0 V V (3) -10 V V (4) 0 V... 5 V (5) -5 V V (6) 1 V... 5 V (7) 2 V V (8) disabled disabled S7 Data format disabled Process data Data format of the coupler is valid (Intel). Byte Format Description IB0 Word AI0 IB1 IB2 Word AI1 IB3 IB4 Word AI2 IB5 IB6 Word AI3 IB7 64 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

65 Diagnosis data Name Byte Bit Description Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 0 4 Error 5 Reserved 0 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x Reserved 0 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnosis FIFO full 4 Power supply fault 5 Reserved 0 6 Reserved 0 7 Reserved 0 Channel type Channel type 0x74 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 0 Number of channels 6 Number of the same channels per module 4 Channel error Reserved 0 Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) PDK_205571_AIO_Handbuch / Version 2015/xx 65 / 127

66 Measurement range Current Measurement range Current (I) Decimal (D) ma S7 format ma S5 format ma S7 format ma S5 format Voltage Hexadecimal Range Conversion ma x7EFF Overloading 20 ma x6C00 10 ma x ma 0 0x0000 Nominal range ma x4B44 Overloading 20 ma x ma x ma 0 0x0000 Nominal range ma x7EFF Overloading 20 ma x6C00 12 ma x ma 0 0x0000 Nominal range 1.19 ma xED00 Underloading ma x4B44 Overloading 20 ma x ma x ma 0 0x0000 Measurement range Voltage (U) Decimal (D) V S7 format V S5 format ±10 V S7 format ±10 V S5 format Nominal range 0.8 ma xF333 Underloading D = x I / 20 I = D x 20 / D = x I / 20 I = D x 20 / D = x (I - 4) / 16 I = D x 16 / D = x (I - 4) / 16 I = D x 16 / Hexadecimal Range Conversion V x7EFF Overloading 10 V x6C00 5 V x V 0 0x0000 Nominal range V x4B44 Overloading 10 V x V x V 0 0x0000 Nominal range V x7EFF Overloading 10 V x6C00 5 V x V 0 0x V xCA00-10 V x9400 Nominal range V x8100 Underloading V x4B44 Overloading 10 V x V x V 0 0x V xE V xC000 Nominal range V xB4BC Underloading D = x U / 10 U = D x 10 / D = x U / 10 U = D x 10 / D = x U / 10 U = D x 10 / D = x U / 10 U = D x 10 / / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

67 Measurement range Voltage (U) Decimal (D) V S7 format V S5 format V S7 format V S5 format V S7 format V S5 format ±5 V S7 format ±5 V S5 format The following applies for all S7 ranges: input value > overload range = 0x7FFF input value < underload range = 0x8000 Hexadecimal Range Conversion V x7EFF Overloading 10 V x6C00 6 V x V 0 0x0000 Nominal range 0.59 V xED00 Underloading V x4B44 Overloading 10 V x V x V 0 0x0000 Nominal range 0.40 V xF333 Underloading 5.7 V x7EFF Overloading 5 V x6C00 3 V x V 0 0x0000 Nominal range 0.30 V xED00 Underloading 5.7 V x4B44 Overloading 5 V x V x V 0 0x0000 Nominal range 0.20 V xF333 Underloading 5.88 V x7EFF Overloading 5 V x6C V x V 0 0x0000 Nominal range 5.88 V x4B44 Overloading 5 V x V x V 0 0x0000 Nominal range 5.88 V x7EFF Overloading 5 V x6C V x V 0 0x V xCA00-5 V x9400 Nominal range V x8100 Underloading 5.88 V x4B44 Overloading 5 V x V x V 0 0x V xE000-5 V xC000 Nominal range V xB4BC Underloading D = x (U -2) / 8 U = D x 8 / D = x (U -2) / 8 U = D x 8 / D = x (U -1) / 4 U = D x 4 / D = x (U -1) / 4 U = D x 4 / D = x U / 5 U = D x 5 / D = x U / 5 U = D x 5 / D = x U / 5 U = D x 5 / D = x U / 5 U = D x 5 / Additional status bits are set for S5. PDK_205571_AIO_Handbuch / Version 2015/xx 67 / 127

68 Digital measured value representation in S5 format Data bit Byte 0 (high byte) Byte 1 (low byte) A F O A: 0 = not active 1 = active F: 0 = no line break 1 = line break O: 0 = 0 to 4095 units 1 = ±4096 units (overflow) Representation in two s complement 2 12 = VZ in representation as amount and signs Example: Conversion from digital measured value representation to decimal (D), hexadecimal and voltage (U). Measurement range V Data bit Byte 0 (high byte) Byte 1 (low byte) Calculation decimal: D = D = D = 2457 Hexadecimal = 0x0999 Calculation voltage: U = D x 5 / U = 2457 x 5 / U = ~0.75 V Byte 1 bit 2 = active Byte 1 bit 1 = no line break Byte 1 bit 0 = 0 to 4095 units 68 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

69 4.2.4 Analogue outputs Datasheet analogue outputs AIO-4AO-UI-16 AMK I/O module, 4 analogue outputs Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Module supply from fieldbus coupler AIO-FBC-EC 2-wire or 4-wire connection technology Short-circuit proof Product name and ordering data Product name AIO-4AO-UI-16 Order number O932 Description AIO-4AO-UI-16 analogue output modules are used to link peripheral actuators Each module has 4 outputs and can control analogue actuators with following ranges: Ranges: ±10 V / ±5 V / V / V / V / V / ma / ma PDK_205571_AIO_Handbuch / Version 2015/xx 69 / 127

70 Actuators can be connected to each connector using 2-wire or 4-wire technology, the internal switching is carried out automatically. The output range is defined using parameterisation. A status LED is assigned to each channel. The module electronics supply the connected actuators with current (max. 0.5 A per channel) from the output current path (U OUT ) of the coupler. Interfaces and status LEDs Material Damage! Risk of material damage! NOTICE The outputs as well as the sense-lines of the modules must not be used as power outputs LED status display: Analogue outputs Module LED Green: Communication via the system bus active Red: Error indication 1.2 Red:Channel 0 at voltage output: overload or short circuit. Channel 0 at current output: shunt resistance to high or line break detected. 2.2 Red: Channel 1 at voltage output: overload or short circuit. Channel 1 at current output: shunt resistance to high or line break detected. 3.2 Red: Channel 2 at voltage output: overload or short circuit. Channel 2 at current output: shunt resistance to high or line break detected. 70 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

71 4.2 Red: Channel 3 at voltage output: overload or short circuit. Channel 3 at current output: shunt resistance to high or line break detected. Simplified diagram Technical data Formal data Type of module Analogue outputs Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Outputs Number of outputs 4 Output levels 1. Voltage V, ±5 V, V, ±10 V, V, V Response time Resolution Accuracy Temperature coefficient Max. error between T min and T max Monotony Crosstalk between the channels Repeat accuracy 2. Current ma, ma 1 ms for 4 channels 16 bit ±0.1 % FSR max., 0.05 % FSR typ. 20 ppm voltage / 31 ppm current measurement / K ±220 ppm FSR Yes ±0.001 % FSR max. < ±1 mv eff. Output ripple max % Voltage output load resistance Current output load resistance 1000 Ω (at >50 C max. ambient temperature, total sensor current of 25 ma and 10 ma per channel) 600 Ω PDK_205571_AIO_Handbuch / Version 2015/xx 71 / 127

72 Actuator connection Short-circuit proof Module diagnosis Individual channel diagnosis Error replacement value 2-wire (current and voltage) 4-wire (voltage), (2-wire: automatic detection) Yes Yes No Yes Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG 26 AWG 16) Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from output current path I OUT 85 ma Current consumption from system current path I SYS 8 ma 72 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

73 System data Data Interface Transfer rate Dependent on coupler Internal system bus Internal system bus, max. 48 Mbit/s Module configuration Overview of the adjustable parameters Channel Designation Options (value) Default settings Data format S5 Data format (0) S7 Data format (1) S7 Data format Output range (0) 0 ma ma disabled (1) 4 ma ma (2) 0 V V (3) -10 V V (4) 0 V... 5 V (5) -5 V V (6) 1 V... 5 V (7) 2 V V (8) disabled Error replacement value Depending on the channels data format (S5 / S7), see table 'Value range' 0 Process data Data format of the coupler is valid (Intel). Byte Format Description QB0 Word AO0 QB1 QB2 Word AO1 QB3 QB4 Word AO2 QB5 QB6 Word AO3 QB7 PDK_205571_AIO_Handbuch / Version 2015/xx 73 / 127

74 Diagnosis data Name Byte Bit Beschreibung Default Error indicator 0 0 Module error 1 Internal error 2 External error 3 Channel error 0 4 Error 5 Reserved 0 6 Reserved 0 7 Parameter error Module type 1 0 Module type 0x Reserved 0 5 Reserved 0 6 Reserved 0 7 Reserved 0 Error byte Reserved 0 Error byte Reserved 0 3 Internal diagnostic FIFO full 4 Power supply fault 5 Reserved 0 6 Reserved 0 7 Reserved 0 Channel type Channel type 0x73 Diagnostic bits per channel 7 Reserved 0 5 Number of diagnostic bits per channel 0 Number of channels 6 Number of the same channels per module 4 Channel error Reserved 0 Error channel Reserved 0 Time stamp Time stamp [µs] (32 bit) 74 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

75 Value range Current Value range 1) Current (I) Decimal (D) ma S7 format ma S5 format ma S7 format ma S5 format Hexadecimal Range Conversion ma x7EFF Overloading 20 ma x6C00 10 ma x ma 0 0x0000 Nominal range ma x4B44 Overloading 20 ma x ma x ma 0 0x0000 Nominal range ma x7EFF Overloading 20 ma x6C00 12 ma x ma 0 0x0000 Nominal range 1.19 ma xED00 Underloading ma x4B44 Overloading 20 ma x ma x ma 0 0x0000 Nominal range 0.8 ma xF333 Underloading D = x I / 20 I = D x 20 / D = x I / 20 I = D x 20 / D = x (I - 4) / 16 I = D x 16 / D = x (I - 4) / 16 I = D x 16 / ) If the process value is beyond the valid value range, the corresponding channel releases 0 ma respectively. Voltage Value range 1) Voltage (U) Decimal (D) V S7 format V S5 format ±10 V S7 format ±10 V S5 format Hexadecimal Range Conversion V x7EFF Overloading 10 V x6C00 5 V x V 0 0x0000 Nominal range V x4B44 Overloading 10 V x V x V 0 0x0000 Nominal range V x7EFF Overloading 10 V x6C00 5 V x V 0 0x V xCA00-10 V x9400 Nominal range V x8100 Underloading V x4B44 Overloading 10 V x V x V 0 0x V xE V xC000 Nominal range V xB4BC Underloading D = x U / 10 U = D x 10 / D = x U / 10 U = D x 10 / D = x U / 10 U = D x 10 / D = x U / 10 U = D x 10 / PDK_205571_AIO_Handbuch / Version 2015/xx 75 / 127

76 Value range 1) Voltage (U) Decimal (D) V S7 format V S5 format V S7 format V S5 format V S7 format V S5 format ±5 V S7 format ±5 V S5 format Hexadecimal Range Conversion V x7EFF Overloading 10 V x6C00 6 V x V 0 0x0000 Nominal range 0.59 V xED00 Underloading V x4B44 Overloading 10 V x V x V 0 0x0000 Nominal range 0.40 V xF333 Underloading 5.7 V x7EFF Overloading 5 V x6C00 3 V x V 0 0x0000 Nominal range 0.30 V xED00 Underloading 5.7 V x4B44 Overloading 5 V x V x V 0 0x0000 Nominal range 0.20 V xF333 Underloading 5.88 V x7EFF Overloading 5 V x6C V x V 0 0x0000 Nominal range 5.88 V x4B44 Overloading 5 V x V x V 0 0x0000 Nominal range 5.88 V x7EFF Overloading 5 V x6C V x V 0 0x V xCA00-5 V x9400 Nominal range V x8100 Underloading 5.88 V x4B44 Overloading 5 V x V x V 0 0x V xE000-5 V xC000 Nominal range V xB4BC Underloading D = x (U - 2) / 8 U = D x 8 / D = x (U - 2) / 8 U = D x 8 / D = x (U - 1) / 4 U = D x 4 / D = x (U - 1) / 4 U = D x 4 / D = x U / 5 U = D x 5 / D = x U / 5 U = D x 5 / D = x U / 5 U = D x 5 / D = x U / 5 U = D x 5 / ) If the process value is beyond the valid value range, the corresponding channel releases 0 V respectively. The following applies for all S5 and S7 ranges:: value > overload range = output deactivated value < underload range = output deactivated 76 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

77 4.3 Passive I/O modules Datasheet power-feed AIO-PF-O AMK I/O power-feed module Highlights Tool-free assembly Extremely space-saving Modular construction Status LEDs directly on the module for quick diagnosis Product name and ordering data Product name AIO-PF-O Order number O929 Description AIO-PF-O power-feed modules serve to refresh the current paths and isolate the power supply.the station's main power supply is fed in via the coupler. A power feed module must be connected if the current demand of the series of output modules is too large. The maximum feed-in current in the output current path via the 4-pole connector is 10 A. Details required to calculate current demand and power supply: See 'Example calculation for the power supply' on page 85. PDK_205571_AIO_Handbuch / Version 2015/xx 77 / 127

78 Power-feed modules are passive modules without fieldbus communication, therefore they are not considered during configuration. A maximum of three passive modules may be installed in succession, however the next module to be installed must be an active module! Interfaces and status LEDs LED status display: Power feed module Module LED Green: Voltage applied and is >18 VDC 4.1 Green: Supply voltage for output circuit >18 VDC 4.2 Red: Supply voltage for output circuit <18 VDC 4.4 Red: Internal fuse defective, replace module 78 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

79 Simplified diagram Technical data Formal data Type of module Power feed Approvals and standards culus UL 508 Protection class (EN 60529) EMC PLC EN IP20 Flammability rating UL94 V-0 eclass 6.2 classification EN (partial standards in acc. with requirement of EN ) Mechanical data Width Height (with release lever) Depth Weight Installation position 11.5 mm 120 (128) mm 76 mm 87 g Horizontal and vertical possible Ambient conditions Temperature Operation: -20 C +60 C Storage and transport: -40 C +85 C Relative humidity (IEC ) Operation, storage, and transport: 10 % to 95 %, non-condensing Air pressure (IEC ) Operation: 795 hpa (height 2000 m) Storage and transport: 700 hpa (height 3000 m) Vibration resistance (IEC ) Shock resistance (IEC ) 5 Hz f 8.4 Hz: 3.5 mm amplitude 8.4 Hz f 150 Hz: 1 g acceleration 15 g over 11 ms, half sinusoidal wave PDK_205571_AIO_Handbuch / Version 2015/xx 79 / 127

80 Electrical data Electrical isolation Test voltage: max VDC inside a channel 500 VDC field / system Degree of pollution: 2 Overvoltage category: II Connection technology Type of connection Conductor cross section (single wire or fine-strand) "PUSH IN" 0.14 mm mm 2 (AWG AWG 16) Material Damage! NOTICE In the case of a maximum power supply of >8 A and a maximum temperature of >55 C, all four contacts must be connected with 1.5 mm 2 wiring! Supply Supply voltage 24 VDC +20 % / -15 % Current consumption from output current path I OUT 10 ma Maximum feed-in current for output modules 10 A 80 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

81 5 Projecting 5.1 Arrangement of the modules The AIO system elements are designed to be installed on a profile rail according to EN ( mm), a steel strip in accordance with Appendix A of EN 60715, or a tin-plated steel strip. A I/O station may be built up to a maximum length of 1 m. Therefore at most 82 modules (including max. 64 active modules) can be aligned on a coupler. A maximum of three passive modules may be placed in successive positions. Then at least one active module must follow. A I/O station may only be installed in this sequence (starting from the left / bottom): End bracket Bus coupler Up to 82 modules (including max. 64 active modules) End plate and end bracket Installation position Horizontal installation position Installation position of the I/O station on horizontally positioned DIN rail. PDK_205571_AIO_Handbuch / Version 2015/xx 81 / 127

82 Vertical installation position Installation position of the I/O station on a vertically positioned DIN rail. When installation on vertically positioned DIN rails, the heat dissipation is reduced such that the derating values change See 'Derating' on page 85. In the case of vertical mounting, the fieldbus coupler must always be arranged as the first module at the bottom Installation distances In order to be able to carry out the installation and subsequent maintenance work and to ensure sufficient ventilation, the I/O station must be installed while observing the following minimum distances Depending on how the station shielding is implemented, the specified distances may have to be made larger, where necessary. The minimum permissible conductor bending radii must also be observed. Earth terminals already installed can be ignored when calculating the distance. Minimum distance for electrical cabinet door: 82 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

83 Installation distances horizontally Minimum distances for horizontal installation Calculation of space requirements: The space requirements for a I/O station with n modules (horizontal installation) is calculated as follows: Height: 120 mm module height + 2 x 40 mm distances at top and bottom = 200 mm Width: 8 mm end bracket + 52 mm bus coupler + n x 11.5 mm n modules mm end plate and end bracket + 2 x 20 mm distances to the sides = mm + n x 11.5 mm PDK_205571_AIO_Handbuch / Version 2015/xx 83 / 127

84 Installation distances vertically Minimum distances for vertical installation Calculation of space requirements: The space requirements for a I/O station with n modules (horizontal installation) is calculated as follows: Height: 12.5 mm end bracket + 52 mm bus coupler + n x 11.5 mm n modules mm end plate and end bracket + 2 x 20 mm distances at top and bottom = 114 mm + n x 11.5 mm Width: 120 mm module height + 2 x 40 mm distances to the sides = 200 mm 84 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

85 5.2 Current demand The AIO system uses three internal current paths: The I SYS system current path supplies the communication part of the I/O modules; it is fed from the coupler input supply and cannot be interrupted by any module. The maximum current-carrying capacity of I SYS allows a I/O station to be expanded with a maximum of 64 active modules without having to refresh the power. The I IN input current path supplies the input circuit of the input modules as well as the connected I S sensors. The I OUT output current path supplies the output circuit of the output modules with power, as well as the connected I L actuators. The current must be refreshed with the AIO-PF-O (power feed-out), as required. These AIO-PF-O modules isolate the output current path to the left (towards the coupler), and as a result start a new electricity segment to the right. The design of the power supply being used must take start-up peaks into account. Material Damage! NOTICE Equipment may become damaged by overcurrent! Auxiliary supplies as well as signal inputs and outputs may not be used for supplying the station. 5.3 Derating The power supply is restricted according to the temperature. The following values apply for the horizontal and vertical positioning of the station: Coupler power supply Power-feed module power supply horizontal 60 C / 2 x 8 A 55 C / 2 x 10 A vertical 55 C / 2 x 6 A 50 C / 2 x 8 A 60 C / 1 x 10 A 55 C / 1 x 8 A 5.4 Interpretation Example calculation for the power supply The power supply must be calculated individually for each station installation. Therefore the simultaneity factor g and the current demand of each module, as well as the devices to be connected must be established. In the example station, a AIO-FBC-EC fieldbus coupler is configured with four AIO-8DI-P-3W modules and eight AIO-8DO-P modules. The cumulative current demand for each module is now calculated to determine whether and at which point a AIO-PF-O power-feed module must be positioned to refresh the current path. A power-feed module must always be used where the current demand exceeds 10 A. The power refresh must be separately calculated for the input and output current paths. The system voltage need not be considered during this step. PDK_205571_AIO_Handbuch / Version 2015/xx 85 / 127

86 Calculation of current demand for the input current The current consumption of the fieldbus coupler must be considered for the main power supply, and the sum of consumption values is multiplied by the simultaneity factor g for each following module: I SYS coupler + ( ISYS + I IN ) + (I S x g) module 1 + (I SYS + I IN ) + (I S x g) module 2 + Σ((I SYS + I IN ) + (I S x g)) modules 3 to 4 = Cumulative current demand I SYS Current consumption from the system current path I IN Current consumption from the input current path I S Power supplies for the connected sensors In the case of an additional power supply (power refresh) with a AIO-PF-O power-feed module, only the sensor power supplies and the module current consumption have to be considered: ((I IN + I S module x) x g) + ((I IN + I S module y) x g) + Σ((I IN + I S ) x g) n modules = Cumulative current demand I IN Current consumption from the input current path I S Power supplies for the connected sensors Calculation of current demand for the output current The current consumption of each module and the current demand of the connected actuators must be considered for the output current. There is no difference in the calculation of the main power supply and power refresh: (I OUT + (I L x g)) module 1 + (I OUT + (I L x g)) module 2 + Σ(I OUT + (I L x g)) n modules = Cumulative current demand I OUT module current consumption from the output current path I L Current demand of the connected actuators Example calculation The values in the following table are used to calculate the current demand of the example station (cumulative for each module). The input current is: Module 1: I = A + (0.008 A A) + (0.06 A x 1) = A Module 2: I = A + (0.008 A A) + (0.06 A x 1) = A The values for the other modules are calculated accordingly. The result shows that the accumulated value for up to 12 modules remains under 10 A, and therefore a power-feed module need not be used for the input current path. Results for the output current path: 86 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

87 Module 5: I = A + (0.5 A x 2) = A Module 6: I = A + (0.015 A + (0.5 A x 4)) = 3.03 A Module 10: I = A + (0.015 A + (0.5 A x 4)) = 8.19 A Module 11 (without power refresh): I = 8.19 A + (0.015 A + (0.5 A x 4)) = A Therefore the available 10 A would be exceeded. As a result, a AIO-PF-O power-feed module must be positioned before the 11th module, which will supply anocalculation of current consumption is repeated for each power-feed module. Unused current values may not be included. Module 11 (with power refresh per AIO-PF-O): I = (0.015 A + (0.5 A x 4)) = A Module 12 (with power refresh per AIO-PF-O): I = A ( A + (0.5 A x 4)) = A Module no. Product I SYS I IN I OUT I S I L Simultaneity factor g Cumulative current demands of the input current path Cumulative current demand of the output power path coupler AIO-FBC-EC AIO-8DI-P-3W AIO-8DI-P-3W AIO-8DI-P-3W AIO-8DI-P-3W AIO-8DO-P AIO-8DO-P AIO-8DO-P AIO-8DO-P AIO-8DO-P AIO-8DO-P AIO-PF-O Cumulative current demand of the AIO-PF- O output power path 11 AIO-8DO-P AIO-8DO-P I SYS Current consumption from the system power supply I IN Power consumption from input current path I OUT Power consumption from output current path I S I L Current demand of the connected sensors Current demand of the connected actuators The current demand is just under 10 A! The output current path must therefore be refreshed before the 11th module. 10 A is supplied by the AIO-PF-O module. The A calculated as remaining after the 10th module must not be added to the 10 A after the AIO-PF-O module! PDK_205571_AIO_Handbuch / Version 2015/xx 87 / 127

88 5.4.2 Calculation of power loss The power loss of the fieldbus coupler is calculated als follows: P = P + N x P + I x U + I x U coupler 0 mod in in out out P 0 static power loss in the coupler 2.3 W N number of modules P mod power loss due to module supply from the system current path 0.02 W I in current fed in through the input current path ΔU in voltage drop across the contacts in the input current path 0.18 V I out current fed in through the output current path ΔU out voltage drop across the contacts in the output current path 0.18 V The power loss of a I/O station is calculated using the power loss of the coupler and the power loss of the individual modules. It depends on the current in both current paths. It is assumed that there is a maximum power loss of 2 watts for the module. Maximum values were assumed for these calculations. P = P + N x P station coupler modules 88 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

89 5.4.3 Feedback energy in DO modules With digital output modules, power is fed back through the channels during operation. The sum of the power fed back through all channels is the output module s feedback energy. It varies with the ambient temperature. If the maximum permissible feedback energy for a module is exceeded, the module shuts down temporarily. Feedback energy can be prevented by installing external freewheeling protection. With it, the same switching rate can be achieved with an inductive load as with a resistive load. Calculation of feedback energy The feedback energy for a digital output module can be calculated as follows: P= Σ 1 / 2n x L x I² all channels i i i P Feedback energy of the module n i Switching cycles of channel i in 1/seconds E i Feedback energy when shutting off Channel i during a shutdown procedure I i Current through the load connected to Channel i L i Inductance of the load connected to Channel i Once the maximum permissible feedback energy E max is reached, the module shuts down. The maximum feedback energy varies with the ambient temperature PDK_205571_AIO_Handbuch / Version 2015/xx 89 / 127

90 6 Assembly 6.1 Preparations for assembly WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! The I/O station is designed for installation in switch cabinets, terminals or switch boxes in decentralised systems. The fieldbus coupler and I/O modules conform to protection class IP20. Environmental conditions Make sure that the permitted environmental conditions for installation and operation are observed! DIN rail The AIO system products are intended for installation on a DIN rail in accordance with EN ( mm), steel strip in accordance with Appendix A of EN 60715, or tinplated steel strip. The DIN rail must be mounted prior to the installation of the I/O station. The DIN rail must be attached to the surface at least every 20 cm to protect it from vibration and impact. If the DIN rail is installed on earthed mounting plates, it does not have to be separately earthed. Stripping lengths The external dimensions of the crimped wire-end ferrules must conform with IEC See 'Wiring' on page 96. Unpacking the delivery Material Damage! NOTICE Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e. g. signal and power supply cable) must be avoided. Otherwise you can be damaged the components when touching by static discharge. Steps to prevent: Avoid touching electrical connections and contacts. During handling the electronic component discharge yourself by touching PE. Pay attention to the ESD-notes (electrostatic discharge). All of the elements that make up the I/O station are packaged individually for delivery. Please check the delivery for completeness and transport damage. Please report any transport damage immediately to the respective transport company. Unpack all parts and sort the modules into the installation sequence as per the instructions. Dispose of all packaging in accordance with the local disposal guidlines. The cardboard packaging from the modules and fieldbus couplers can be sent for paper recycling. 90 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

91 6.2 Assembling the AIO system WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! NOTICE Material Damage! Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e. g. signal and power supply cable) must be avoided. Otherwise you can be damaged the components when touching by static discharge. Steps to prevent: Avoid touching electrical connections and contacts. During handling the electronic component discharge yourself by touching PE. Pay attention to the ESD-notes (electrostatic discharge). When installing the AIO products, make sure that you listen for the double click: 1. When snapping onto the DIN rail 2. When pushing together with the neighboring module. The modules are in the correct position and the connection is made only when both snapping noises are heard. Material Damage! Material Damage! Improper installation may prevent earthing! The earthing of the modules and couplers is only ensured if the FE spring at the bottom is in contact with the DIN rail. During installation, make sure that both release levers on the bus coupler and all release levers on the modules are closed before snapping onto the DIN rail. PDK_205571_AIO_Handbuch / Version 2015/xx 91 / 127

92 Attaching the end bracket On the left side of the installation site, place an end bracket on the DIN rail with the exterior of the bracket facing left and screw it down tightly (using a 3-mm screwdriver). Attaching the fieldbus coupler to the DIN rail Place the fieldbus coupler (module side to the right) on the DIN rail so that it audibly clicks into place. Sliding the fieldbus coupler into position Slide the bus coupler to the left until it completely connects with the end bracket. At the same time, press the bus coupler as close as possible to the DIN rail so that the coupler is not tilted. 92 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

93 Sliding the module into position Place the first module on the DIN rail and press it down firmly. It must audibly click into place. Slide the module to the left until it audibly clicks into place on the bus coupler. At the same time, press the module as close as possible to the DIN rail so that the module is not tilted. Attach all of the other modules as described above. Sliding the end plate with end bracket into position and attaching Connect the second end bracket to the end plate as specified by the alignment pins. Place both parts on the DIN rail on the right-hand side of the station so that the end bracket faces outwards. Slide the end bracket and end plate to the left until it completely connects with the last module. Screw down the end bracket tightly (using a 3-mm screwdriver). Make sure that all release levers are in the locking position as standard. If this is not the case, click the open release lever into place. PDK_205571_AIO_Handbuch / Version 2015/xx 93 / 127

94 6.3 Attaching the marker Attaching the module marker Each module can be labelled at three points using the markers. This ensures clear allocation when replacing individual elements. Press the labelled marker into the corresponding fixture. Attaching connection marker Insert the labelled marker into the pusher for the connector. 6.4 Coding the module Position coding In order to prevent an electronic module being mismated, the modules can be coded by the customer. Coding is carried out by two small components: the coding socket and the coding pin. Three codings can be applied to each basic module. Suggestions for the appropriate coding: See 'Examples of module position coding' on page / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

95 Open the connection frame and remove the electronic unit. Place the coding sockets in the coding ports on the inside of the basic module. Each coding socket has one pointed and three rounded corners. The arrangement of the three sockets in the basic module allows for 4 3, i. e. 64, possible combinations. If necessary, you can rotate the inserted coding sockets into the required position using a 3-mm screwdriver. Insert a black coding pin to the stop in each coding socket. A small coloured corner will now be visible on each coding unit, which to be indicating the coding state. Put the electronic module back into position. The coding pin now engages securely in the electronic module. If the electronic unit has to be removed again, it can subsequently only be re-inserted back into the correspondingly coded basic module. If the electronic module is replaced by a new module, this must be fitted with new coding pins. PDK_205571_AIO_Handbuch / Version 2015/xx 95 / 127

96 Functional coding The I/O modules are mechanically coded using three cutouts in the circuit board. There are different function codes for: I/O modules Power-feed modules for the output current path (AIO-PF-O) 6.5 Wiring WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! Once the station has been mechanically installed, the wiring can be carried out in accordance with the wiring plan. Wiring of modules Wires with a cross section between 0.14 mm 2 and 1.5 mm 2 (AWG 26 16) can be connected. I/O modules and fieldbus couplers are equipped with the PUSH IN connector system. Single wire and fine-strand lines with wire-end ferrules can be inserted without the need for a tool. See 'Connector' on page 13. Each cable must be the optimal length so that the bending radii observe the manufacturer's specifications. Strip the insulation from the lines to a length of approx. 10 mm ±1 mm, even if you are using wire-end ferrules. If you use wire-end ferrules with plastic collars, strip the wires to 12 mm ±1 mm. Connect all lines according to wiring diagram. For the usage and handling of the PUSH-IN system: See 'Removing / replacing cables' on page / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

97 7 Startup For startup, use the AMK software AIPEX PRO 7.1 Configuring modular device The following example describes how to configure a 'modular device'. Prerequisite: The device description file of the bus coupler is imported. If the bus coupler or the I/O modules not integrated in AIPEX PRO, the device description files can be imported with the function 'Import description of external device'. See document Software description AIPEX PRO V3, AMK part no ) Start AIPEX PRO. Press 'Logon' PDK_205571_AIO_Handbuch / Version 2015/xx 97 / 127

98 Add the device data to your project. Press 'Accepted to the project complete' Select the'pdo options' in the 'Messages' 'Options' tab. 98 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

99 Select the 'Configure Slots...'. The first terminal corresponds physically to the first terminal block after the bus coupler (etc.) Assign the physically existing terminal blocks to the terminals. PDK_205571_AIO_Handbuch / Version 2015/xx 99 / 127

100 Example of read and write I/O terminal with CODESYS. See 'External I/O terminal (asynchronous)' on page 100. See 'External I/O terminal (cyclical)' on page 104. As an alternative to manual input of occupied slots in 'modular device', the current configuration can be designed directly from the connected device. Prerequisite: Online mode active. 7.2 I/O access External I/O terminal (asynchronous) Integration of an external I/O terminal. The example shows an AIO-FBC-EC fieldbus coupler with three AIO-8DO-P and three AIO-8DI-P-3W modules. The fieldbus coupler is detected automatically by AIPEX PRO. The I/Os are read (at program start) and written (at program end) within one program cycle. 100 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

101 A global I/O variable must be set in CODESYS for each input and output block. In the example, an input byte by_i_plc1 and an output byte by_q_plc1 is created. PDK_205571_AIO_Handbuch / Version 2015/xx 101 / 127

102 Call 'Configuration create'. Assign the symbolic device names to the I/O interfaces in the AIPEX PRO device tree. 102 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

103 Testing The following options are available for updating the I/O variables in the PLC project: Link the symbolic device names with PLC variables Set the option 'Always update variable' (see illustration) PDK_205571_AIO_Handbuch / Version 2015/xx 103 / 127

104 Alternatively, you can activate the 'Update all variables in all devices' option. Call the 'Login' function (code is generated automatically). Start the application on the controller. Set binary inputs on the controller for testing External I/O terminal (cyclical) Integration of an external I/O terminal. The example shows an AIO-FBC-EC fieldbus coupler with three AIO-8DO-P and three AIO-8DI-P-3W modules. The fieldbus coupler is detected automatically by AIPEX PRO. The procedure is based on the 'Additional variable access' principle. See document Software description AIPEX PRO V3, AMK part no ) 104 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

105 The cyclical reading and writing of an I/O map is performed via the device interface. This is done by connecting an 'Interface' to your terminal and open the 'Additional variable access' window. PDK_205571_AIO_Handbuch / Version 2015/xx 105 / 127

106 The possible selection of connectable variables is stored in the corresponding devices XML file. Generate a 'Write' function block for the output module (AIO-8DO-P) in the same way 106 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

107 Add the device names to the PLC project. To do this, you can use the automatic 'Import device names' function. Alternatively, you can create the terminals manually in the PLC controller configuration (G_DEVICE (G_DEVICE) and then assign them to the 'Interface' icon. Open the CODESYS project. (Steuerung.project) PDK_205571_AIO_Handbuch / Version 2015/xx 107 / 127

108 In the real time level (FPLC_PRG), add one instance each of the generated modules 'GET_FDEV_READ_MODULE_4_AIO_ 8DI_P_3W_INPUT_DI1' and 'SET_FDEV_WRITE_MODULE_1_AIO_8DO_P_OUTPUT_DO1'. Connect each 'stdevice' variable with the corresponding symbolic device name. Testing Create the project: See document Software description AIPEX PRO V3, AMK part no ) 108 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

109 PDK_205571_AIO_Handbuch / Version 2015/xx 109 / 127

110 8 Service 8.1 Replacing components Removing / replacing the plug-in unit WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! NOTICE Material Damage! Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e. g. signal and power supply cable) must be avoided. Otherwise you can be damaged the components when touching by static discharge. Steps to prevent: Avoid touching electrical connections and contacts. During handling the electronic component discharge yourself by touching PE. Pay attention to the ESD-notes (electrostatic discharge). Unlocking the connector frame Unlock the connector frame. 110 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

111 Opening the connector frame and pulling out the plug-in unit Swivel the plug-in unit with the cabling towards the front by 90. The plug-in unit can only be removed in this 90 position! Remove the plug-in unit by pulling it out in a straight, downward motion Replacing the electronic unit WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! WARNING Operation of the machine / system can be disrupted! By removing or adding from connectors / cables or electronic units, the inputs and outputs of all modules can be put into an undefined state. Steps to prevent: Replacement can only be made once the machine / system is disconnected from the power! NOTICE Material Damage! Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e. g. signal and power supply cable) must be avoided. Otherwise you can be damaged the components when touching by static discharge. Steps to prevent: Avoid touching electrical connections and contacts. During handling the electronic component discharge yourself by touching PE. Pay attention to the ESD-notes (electrostatic discharge). Once an electronic unit is removed from a power-feed module, the inputs and outputs of the subsequent modules are no longer supplied with power. PDK_205571_AIO_Handbuch / Version 2015/xx 111 / 127

112 An electronic unit can be replaced while the system is powered up (no load) and in operation without having to disassemble the module. The station remains functional, and there is no need to disconnect and restart it. When replacing the electronic unit, the wiring remains intact. If the new electronic unit is to be coded by the customer, new coding pins will be required. Unlocking and opening the connector frame Unlock the connector frame and open it as far as possible (at least to an angle of 90 ). 112 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

113 Unlocking the electronic unit and opening the removal lever Lift the electronic unit removal lever and swivel it forwards by 90. PDK_205571_AIO_Handbuch / Version 2015/xx 113 / 127

114 Pulling out the electronic unit Using the removal lever, pull the electronic unit forwards and out. Inserting the new electronic unit If the existing electronic unit was coded, insert the new coding pins into the coding seats located in the base module. See 'Coding the module' on page 94. Hold the new electronic unit by the top and the bottom, and carefully slide it into the base module. The electronic units are functionally coded so that they can only be inserted into the appropriate base module. If it is not possible to insert a new electronic unit into the base module, check if the combination is correct and if there is a possible mix-up. Fold the connector frame back so that it closes and clicks into place. In case of replacement during operation: Pay attention to the collective error LED (SF) on the fieldbus coupler. Only when this doesn't light up any more, the new electronic unit has been recognised and the next electronic unit is able to be pulled out. 114 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

115 8.1.3 Replacing an I/O module WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! NOTICE Material Damage! Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e. g. signal and power supply cable) must be avoided. Otherwise you can be damaged the components when touching by static discharge. Steps to prevent: Avoid touching electrical connections and contacts. During handling the electronic component discharge yourself by touching PE. Pay attention to the ESD-notes (electrostatic discharge). To remove an individual module from the station, all modules to the right of it and the termination kit must be moved by approximately 5 cm. Unlocking the last I/O module Unfasten the mounting screw on the right-hand end bracket. Slide the end bracket and end plate approximately 5 cm to the right or remove both parts from the DIN rail. Open the release lever on the module furthest to the right. Slide the module on the DIN rail approximately 5 cm to the right, push it onto the DIN rail and click the release lever into place. Repeat the aforementioned step for all other modules which are located to the right of the module being replaced: release, slide to the right and click in once again. PDK_205571_AIO_Handbuch / Version 2015/xx 115 / 127

116 Unlocking the I/O module to be replaced Remove the plug-in unit of the module to be replaced. See 'Removing / replacing the plug-in unit' on page 110. Open the release lever for the module to be removed. Slide the module to the right and remove it from the DIN rail. Assembling I/O module Position the new module with its closed release lever on the DIN rail so that it clicks audibly into place. Slide the module to the left until it audibly clicks into place against the neighbouring module. Return the modules that were slid away back into their original position: slide the modules to the left so that they audibly click into place on the new module. After all the modules have been moved, make sure that they have all been clicked securely into place on the DIN rail! Reassemble the end plate and end bracket. See 'Assembling the AIO system' on page 91. Inserting the plug-in unit Place the plug-in unit in a 90 position from below into the guideway of the base module on the new module. The plug-in unit can only be inserted in this 90 position! Swivel the plug-in unit upwards until the connector frame clicks into place. 116 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

117 8.1.4 Removing / replacing connectors WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! WARNING Operation of the machine / system can be disrupted! By removing or adding from connectors / cables or electronic units, the inputs and outputs of all modules can be put into an undefined state. Steps to prevent: Replacement can only be made once the machine / system is disconnected from the power! Risk of contact fire! WARNING Material Damage! Steps to prevent: Remove connectors / cables only while they are load current free NOTICE Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e. g. signal and power supply cable) must be avoided. Otherwise you can be damaged the components when touching by static discharge. Steps to prevent: Avoid touching electrical connections and contacts. During handling the electronic component discharge yourself by touching PE. Pay attention to the ESD-notes (electrostatic discharge). Unlocking the connector frame Open the connector frame and flip the plug-in unit open so far that you can reach the connector. PDK_205571_AIO_Handbuch / Version 2015/xx 117 / 127

118 Removing / replacing connectors Press both sides of the connector together so that it can be slid off the frame. Remove the connector by pulling it off. Insert the new connector in the frame so that it audibly clicks into place. Swivel the plug-in unit upwards until the connector frame clicks into place Removing / replacing cables WARNING Dangerous contact voltage!! Electrical terminals and connectors carry voltages that cause injury when touched. Steps to prevent: Carry out assembly and wiring work only when the power supply is disconnected. Make sure that the place of installation has been disconnected from the power supply! WARNING Operation of the machine / system can be disrupted! By removing or adding from connectors / cables or electronic units, the inputs and outputs of all modules can be put into an undefined state. Steps to prevent: Replacement can only be made once the machine / system is disconnected from the power! Risk of contact fire! WARNING Material Damage! Steps to prevent: Remove connectors / cables only while they are load current free NOTICE Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e. g. signal and power supply cable) must be avoided. Otherwise you can be damaged the components when touching by static discharge. Steps to prevent: Avoid touching electrical connections and contacts. During handling the electronic component discharge yourself by touching PE. Pay attention to the ESD-notes (electrostatic discharge). 118 / 127 PDK_205571_AIO_Handbuch / Version 2015/xx

119 Pushing the pusher in with a screwdriver and removing cables Using a 3-mm screwdriver, push in the pusher adjacent to the cable to be removed and pull the wire out. Release the pusher. Insert the new wire into the opening. To do so, you do not need to push in the pusher. 8.2 LED indicators and troubleshooting In the event of a malfunction occurring on a AIO product, carry out the following recommended measures Fieldbus coupler LED status: AIO-FBC-EC coupler LED Indikator Status Recommended action PWR Power LED Green: Supply voltage SF Collective error Off and the status LED on the module is green: Defective coupler Off and the status LED on the module is off: Improper supply voltage Red: Configuration error, or error in the coupler, or error in a module, or there is a new diagnostic message Flashes red: Station in Force mode Replace the coupler. The internal fuse was triggered due to an overload. Check the supply voltage. Please contact AMK Service. Information AMK Service: Check that the XML configuration file is up-to-date. Check if the configured station setup matches the actual setup. Read the diagnostic message and determine which further actions to take. BF Bus failure Red: No connection to the fieldbus Check the fieldbus cable and the PLC configuration. Flashes red: Configuration error, no Please contact AMK Service. connection to the controller, or error in the parameter set Information AMK Service: Check the fieldbus parameters and the PLC configuration. Check that the XML configuration file is up-to-date. Check if the configured station setup matches the actual setup. MT Maintenance Yellow: Error on the system bus or fieldbus Check that the modules have been snapped into place properly. L/A IN Connection / active Off: No connection Green: Connection established between port 1 of the coupler and another field device Flashes green: Data being exchanged on port 1 Check the fieldbus cable. PDK_205571_AIO_Handbuch / Version 2015/xx 119 / 127