RECO Inline PROFIBUS DP. Application Manual SYSTEM200 DOK-CONTRL-R-IL*PBSSYS-AW02-EN-P

Transcription

1 RECO Inline PROFIBUS DP Application Manual SYSTEM200

2 About this Documentation PROFIBUS DP Title Type of Documentation RECO Inline PROFIBUS DP Application Manual Document Typecode Internal File Reference Document Number, B346-02/EN Purpose of Documentation This documentation serves as a general application manual of the RECO Inline modules in combination with INTERBUS-S applications, as project planning assistance of building a RECO Inline station, as reference book. Record of Revisions Description Release Date Notes B346-02/EN 05/01 First issue Copyright 2001 Rexroth Indramat GmbH Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. 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 (DIN 34-1). Validity All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Rexroth Indramat GmbH Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone 09352/40-0 Tx Fax 09352/ Dept. ECH1 (UK/CV) Note This document has been printed on chlorine-free bleached paper.

3 PROFIBUS DP Contents I Contents 1 Integration of the PROFIBUS DP Fieldbus Coupler PROFIBUS System PROFIBUS DP Fieldbus Coupler Important directions for use Appropriate use Introduction Areas of use and application Inappropriate use Safety Instructions for Electric Servo Drives and Controls Introduction Explanations Hazards by inappropriate use General Information Protection against contact with electrical parts Protection by protective low voltage (PELV) against electrical shock Protection against dangerous movements Protection against magnetic and electromagnetic fields during operations and mounting Protection against contact with hot parts Protection during handling and installation Battery safety Protection against pressurized Systems Structure of the RECO Inline Terminals Basic Structure of Terminals of the Low Signal Level Electronic Socket Connector Identification of Function and Labelling Housing Dimensions of the Modules of the Low Signal Level Electrical Voltage and Data Routing Electric Circuits and Voltage Supply Within a RECO Inline Station Supply of the PROFIBUS DP fieldbus coupler Logic circuit Analog circuit Main circuit Segment circuit Voltage Concept

4 II Contents PROFIBUS DP 4.9 Diagnostic and Status Indicators Indicators on the PROFIBUS DP fieldbus coupler Indicators on the supply terminals Indicators on the input/output modules Indicators on other Inline modules PROFIBUS DP Fieldbus Coupler and Permissible RECO Inline Modules PROFIBUS DP Fieldbus Coupler Supply Terminals Power terminal Segment terminal Input/Output Modules General information on modules for analog and digital signals Special information on modules for analog signals Mounting and Dismounting Modules and Connecting Lines Mounting Instructions Mounting and Dismounting RECO Inline Modules Mounting Dismounting Fuse replacement Grounding a RECO Inline Station Shielding a RECO Inline Station Shielding the PROFIBUS line Connecting Lines Connecting unshielded lines Connecting shielded lines via the shield connector Connecting Supply Voltages Supply at the PROFIBUS DP fieldbus coupler Supply at the power terminals Providing the segment voltage at power terminals Requirements for the supply voltages Connecting the PROFIBUS Line Connecting Sensors and Actuators Connection methods for sensors and actuators Typical connector pin assignments with digital input and output modules From Projecting to Startup Projecting the RECO Inline Station Describing and defining the task Selecting the RECO Inline modules required Taking the system limits into consideration Selecting the supply voltages Selecting the PROFIBUS line Installing and Connecting a RECO Inline Station Safety instructions and warnings

5 PROFIBUS DP Contents III Setting up a RECO Inline station Latching on the electronic socket Fitting the connector Removing the connector Removing the electronic socket General tips and instructions on how to set up the RECO Inline station Clamping the lines Connecting the PROFIBUS Connecting the additional ground Connecting RECO Inline modules Configuration and Startup of the Inline station at the PROFIBUS Configuring the hardware Network termination resistors Configuration and startup with SYSTEM 200 control units What to Do in Case of Failures On-Site Diagnostics PROFIBUS DP fieldbus coupler RECO Inline modules Diagnostics at the PROFIBUS Master Technical Data and Ordering Information Technical Data General data System data Interfaces Main supply U M V segment supply U s LED states Ambient conditions Compliance with the EMC Guideline 89/336/EEC Ordering Information Ordering information on the permissible RECO Inline modules Ordering information on the connectors Ordering information on the documentation Glossary 10-1 Explanation of Abbreviations and Symbols List of Figures Index 12-1

6 IV Contents PROFIBUS DP 13 Service & Support Helpdesk Service-Hotline Internet World Wide Web Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities

7 PROFIBUS DP Integration of the PROFIBUS DP Fieldbus Coupler Integration of the PROFIBUS DP Fieldbus Coupler 1.1 PROFIBUS System 1.2 PROFIBUS DP Fieldbus Coupler PROFIBUS is a serial bus system for data exchange between control systems and spatially distributed input and output modules, to which the sensors and actuators are connected. The PROFIBUS has a star-tree structure. In the PROFIBUS topology, the individual bus devices are differentiated by their addressing. The way the devices transfer their data serially via the bus is defined in the communication profiles. Apart from PROFIBUS FMS (Fieldbus Message Specification) and PROFIBUS PA (Process Automation), PROFIBUS DP (Decentralized Peripherals) is the communication profile used most frequently. The typical PROFIBUS DP is a single-master system, i.e. all devices of a PROFIBUS DP are controlled by one master. It has been optimized for simple transfer of input and output data and has, in particular, been designed for communication between automation systems and the decentralized peripheral equipment. The PROFIBUS DP fieldbus coupler (in short: coupler) constitutes the link between the PROFIBUS DP and the RECO Inline installation system. Using the PROFIBUS DP fieldbus coupler, RECO Inline modules can be connected to an existing PROFIBUS DP, and therefore all the advantages of an installation system set up with these modules can also be used for PROFIBUS DP. The PROFIBUS DP fieldbus coupler has the following features: A maximum of 63 RECO Inline I/O modules can be connected to the PROFIBUS DP by simply latching them to each other via the coupler. The total of input and output data should not exceed 192 bytes per station. For instance, 16 bits are allocated to an analog channel. The coupler can be used on a PROFIBUS DP at a baud rate of 9.6 kbit/s with an overall extension of no more than 1200 m or, at a baud rate of 12 Mbit/s, of no more than 100 m. The working voltage of the coupler is 24 V DC; the range of operating temperature is 0 C to 55 C. Diagnosis is implemented locally via LEDs both on the coupler and on the RECO Inline modules. Moreover, the PROFIBUS is also used to transmit the diagnosis information to the PROFIBUS master.

8 1-2 Integration of the PROFIBUS DP Fieldbus Coupler PROFIBUS DP Because of the sophisticated wiring technology of the RECO Inline modules, the stations can be set up easily and quickly because, for instance, the extensive wiring for supplying the modules with voltage is not applicable any longer. Normally, only the power supply units integrated in the PROFIBUS DP fieldbus coupler must be supplied with 24 V DC voltage on their input side. They generate the operating voltages required for the PROFIBUS DP fieldbus coupler and the connected RECO Inline I/O modules. Fig. 1-1: Typical PROFIBUS DP fieldbus coupler station 6138a005.eps

9 PROFIBUS DP Important directions for use Important directions for use 2.1 Appropriate use Introduction Rexroth Indramat products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel. Note: Rexroth Indramat, as manufacturer, is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Rexroth Indramat products, make sure that all the prerequisites for appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the product takes the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation.

10 2-2 Important directions for use PROFIBUS DP Areas of use and application The RECO Inline system is a decentralized modular field-bus-coupled input and output system. The RECO Inline system by Rexroth Indramat is intended for the cases of use listed below. Machine tools Transfer systems General automation Note: The RECO Inline system may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant function descriptions. 2.2 Inappropriate use The typical fields of application of RECO Inline modules are as follows: Turning machines Milling machines Machining centers General automation The RECO Inline system may only be operated under the assembly, installation and ambient conditions as described here (temperature, system of protection, humidity, EMC requirements, etc.) and in the position specified. Using the RECO Inline system outside of the above-referenced areas of application or under operating conditions other than described in the document and the technical data specified is defined as inappropriate use". The RECO Inline system may not be used if they are subject to operating conditions that do not meet the above specified ambient conditions. This includes, for example, operation under water, in the case of extreme temperature fluctuations or extreme maximum temperatures or if Rexroth Indramat has not specifically released them for that intended purpose. Please note the specifications outlined in the general Safety Instructions!

11 PROFIBUS DP Safety Instructions for Electric Servo Drives and Controls Safety Instructions for Electric Servo Drives and Controls 3.1 Introduction Read these instructions before the equipment is used and eliminate the risk of personal injury or property damage. Follow these safety instructions at all times. Do not attempt to install, use or service this equipment without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment contact your local Rexroth Indramat representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the product is resold, rented or transferred or passed on to others, then these safety instructions must be delivered with the product. WARNING Inappropriate use of this equipment, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in product damage, personal injury, severe electrical shock or death! 3.2 Explanations The safety warnings in this documentation describe individual degrees of hazard seriousness in compliance with ANSI: Warning symbol with signal word Degree of hazard seriousness The degree of hazard seriousness describes the consequences resulting from non-compliance with the safety guidelines. Bodily harm or product damage will occur. DANGER Death or severe bodily harm may occur. WARNING Death or severe bodily harm may occur. CAUTION Fig. 3-1: Classes of danger with ANSI

12 3-2 Safety Instructions for Electric Servo Drives and Controls PROFIBUS DP 3.3 Hazards by inappropriate use DANGER High voltage and high discharge current! Danger to life, risk of severe electrical shock and risk of injury! DANGER Dangerous movements! Danger to life and risk of injury or equipment damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life, severe electrical shock and severe bodily injury! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to inappropriate handling! Bodily injury caused by crushing, shearing, cutting and mechanical shock or improper handling of pressurized systems! Risk of injury due to inappropriate handling of batteries! CAUTION

13 PROFIBUS DP Safety Instructions for Electric Servo Drives and Controls General Information Rexroth Indramat GmbH is not liable for damages resulting from failure to observe the warnings given in these documentation. Order operating, maintenance and safety instructions in your language before starting up the machine. If you find that due to a translation error you can not completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Trained and qualified personnel in electrical equipment: Only trained and qualified personnel may work on this equipment or within its proximity. Personnel are qualified if they have sufficient knowledge of the assembly, installation and operation of the product as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they should be trained, instructed and qualified to switch electrical circuits and equipment on and off, to ground them and to mark them according to the requirements of safe work practices and common sense. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation on commercial machinery. European countries: see directive 89/392/EEC (machine guideline). The ambient conditions given in the product documentation must be observed. Use only safety features that are clearly and explicitly approved in the Project Planning manual. For example, the following areas of use are not allowed: Construction cranes, Elevators used for people or freight, Devices and vehicles to transport people, Medical applications, Refinery plants, the transport of hazardous goods, Radioactive or nuclear applications, Applications sensitive to high frequency, mining, food processing, Control of protection equipment (also in a machine). Start-up is only permitted once it is sure that the machine, in which the product is installed, complies with the requirements of national safety regulations and safety specifications of the application. Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the INDRAMAT document "EMC in Drive and Control Systems. The machine builder is responsible for compliance with the limiting values as prescribed in the national regulations and specific EMC regulations for the application. European countries: see Directive 89/336/EEC (EMC Guideline). U.S.A.: See National Electrical Codes (NEC), National Electrical Manufacturers Association (NEMA), and local building codes. The user of this equipment must consult the above noted items at all times. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

14 3-4 Safety Instructions for Electric Servo Drives and Controls PROFIBUS DP 3.5 Protection against contact with electrical parts Note: This section refers to equipment with voltages above 50 Volts. Making contact with parts conducting voltages above 50 Volts could be dangerous to personnel and cause an electrical shock. When operating electrical equipment, it is unavoidable that some parts of the unit conduct dangerous voltages. DANGER High electrical voltage! Danger to life, severe electrical shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on electrical installations. Before switching on power the ground wire must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time if the ground wire is not permanently connected, even for brief measurements or tests. Before working with electrical parts with voltage potentials higher than 50 V, the equipment must be disconnected from the mains voltage or power supply. The following should be observed with electrical drives, power supplies, and filter components: Wait five (5) minutes after switching off power to allow capacitors to discharge before beginning work. Measure the voltage on the capacitors before beginning work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (r.c.d.) must not be used on an electric drive! Indirect contact must be prevented by other means, for example, by an overcurrent protective device. Equipment that is built into machines must be secured against direct contact. Use appropriate housings, for example a control cabinet. European countries: according to EN 50178/1998, section U.S.A: See National Electrical Codes (NEC), National Electrical Manufacturers Association (NEMA) and local building codes. The user of this equipment must observe the above noted instructions at all times.

15 PROFIBUS DP Safety Instructions for Electric Servo Drives and Controls 3-5 To be observed with electrical drives, power supplies, and filter components: DANGER High electrical voltage! High leakage current! Danger to life, danger of injury and bodily harm from electrical shock! Before switching on power for electrical units, all housings and motors must be permanently grounded according to the connection diagram. This applies even for brief tests. Leakage current exceeds 3.5 ma. Therefore the electrical equipment and units must always be firmly connected to the supply network. Use a copper conductor with at least 10 mm² cross section over its entire course for this protective connection! Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. High voltage levels can occur on the housing that could lead to severe electrical shock and personal injury. European countries: EN 50178/1998, section USA: See National Electrical Codes (NEC), National Electrical Manufacturers Association (NEMA), and local building codes. The user of this equipment must maintain the above noted instructions at all times.

16 3-6 Safety Instructions for Electric Servo Drives and Controls PROFIBUS DP 3.6 Protection by protective low voltage (PELV) against electrical shock All connections and terminals with voltages between 5 and 50 Volts on INDRAMAT products are protective low voltages designed in accordance with the following standards on contact safety: International: IEC EU countries: see EN 50178/1998, section WARNING High electrical voltage due to wrong connections! Danger to life, severe electrical shock and severe bodily injury! Only equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) may be connected to all terminals and clamps with 0 to 50 Volts. Only safely isolated voltages and electrical circuits may be connected. Safe isolation is achieved, for example, with an isolating transformer, an optoelectronic coupler or when battery-operated. 3.7 Protection against dangerous movements Dangerous movements can be caused by faulty control or the connected motors. These causes are be various such as: unclean or wrong wiring of cable connections inappropriate or wrong operation of equipment malfunction of sensors, encoders and monitoring circuits defective components software errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. The monitors in the drive components make faulty operation almost impossible. Regarding personnel safety, especially the danger of bodily harm and property damage, this alone should not be relied upon to ensure complete safety. Until the built-in monitors become active and effective, it must be assumed in any case that some faulty drive movements will occur. The extent of these faulty drive movements depends upon the type of control and the state of operation.

17 PROFIBUS DP Safety Instructions for Electric Servo Drives and Controls 3-7 DANGER Dangerous movements! Danger to life and risk of injury or equipment damage! Personnel protection must be secured for the above listed reason by means of superordinate monitors or measures. These are instituted in accordance with the specific situation of the facility and a danger and fault analysis conducted by the manufacturer of the facility. All the safety regulations that apply to this facility are included therein. By switching off, circumventing or if safety devices have simply not been activated, then random machine movements or other types of faults can occur. Avoiding accidents, injury or property damage: Keep free and clear of the machine s range of motion and moving parts. Prevent people from accidentally entering the machine s range of movement: - use protective fences - use protective railings - install protective coverings - install light curtains or light barriers Fences must be strong enough to withstand maximum possible momentum. Mount the emergency stop switch (E-stop) in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a start-inhibit system to prevent unintentional start-up. Make sure that the drives are brought to standstill before accessing or entering the danger zone. Secure vertical axes against falling or slipping after switching off the motor power by, for example: - Mechanically securing the vertical axes - Adding an external brake / clamping mechanism - Balancing and thus compensating for the vertical axes mass and the gravitational force The standard equipment motor brake or an external brake controlled directly by the servo drive are not sufficient to guarantee the safety of personnel!

18 3-8 Safety Instructions for Electric Servo Drives and Controls PROFIBUS DP Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: - maintenance and repair work - cleaning of equipment - long periods of discontinued equipment use Avoid operating high-frequency, remote control and radio equipment near electronics circuits and supply leads. If use of such equipment cannot be avoided, verify the system and the plant for possible malfunctions at all possible positions of normal use before the first start-up. If necessary, perform a special electromagnetic compatibility (EMC) test on the plant. 3.8 Protection against magnetic and electromagnetic fields during operations and mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with pacemakers, metal implants and hearing aids are not permitted to enter following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a pacemaker to enter such an area, then a physician must be consulted prior to doing so. Pacemaker, that are already implanted or will be implanted in the future, have a considerable deviation in their resistance to interference. Due to the unpredictable behavior there are no rules with general validity. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise health hazards will occur.

19 PROFIBUS DP Safety Instructions for Electric Servo Drives and Controls Protection against contact with hot parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch surfaces near the source of heat! Danger of burns! Wait ten (10) minutes before you access any hot unit. Allow the unit to cool down. Do not touch hot parts of the equipment, such as housings, heatsinks or resistors. Danger of burns! 3.10 Protection during handling and installation Under certain conditions unappropriate handling and installation of parts and components may cause injuries. CAUTION Risk of injury through incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general instructions and safety regulations during handling installation. Use only appropriate lifting or moving equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. Wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stay under suspended loads. Clean up liquids from the floor immediately to prevent personnel from slipping.

20 3-10 Safety Instructions for Electric Servo Drives and Controls PROFIBUS DP 3.11 Battery safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or equipment damage. CAUTION Risk of injury through incorrect handling! Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and corrosion). Never charge batteries (danger from leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Handle with care. Incorrect extraction or installation of a battery can damage equipment. Note: Environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose batteries separately from other refuse. Observe the legal requirements given in the country of installation Protection against pressurized Systems Certain Motors (ADS, ADM, 1MB etc.) and drives, corresponding to the information in the Project Planning manual, must be provided with and remain under a forced load such as compressed air, hydraulic oil, cooling fluid or coolant. In these cases, improper handling of the supply of the pressurized systems or connections of the fluid or air under pressure can lead to injuries or accidents. CAUTION Danger of injury when pressurized systems are handled by untrained personnel! Do not attempt to disassemble, to open or to cut a pressurized system. Observe the operation restrictions of the respective manufacturer. Before the disassembly of pressurized systems, lower pressure and drain off the fluid or gas. Use suitable protective clothing (for example protective eyewear, safety shoes and gloves) Remove any fluid that has leaked out onto the floor immediately. Note: Environmental protection and disposal! The fluids used in the operation of the pressurized system equipment is not environmentally compatible. Fluid that is damaging to the environment must be disposed of separate from normal waste. Observe the national specifications of the country of installation.

21 PROFIBUS DP Structure of the RECO Inline Terminals Structure of the RECO Inline Terminals 4.1 Basic Structure of Terminals of the Low Signal Level Independently of the function and the overall width, a RECO Inline module of the low signal level consists of the electronic socket (in short: socket) and the plug-in connector (in short: connector). ZBFM labeling field for connectors Rear connector shaft latch Transparent field Labeling field slot ZBFM labeling field for signal 1/2 Signal terminals 1/2 Diagnostic and status indicators Colored function coding Rear release mechanism ZBFM labeling field for module identification Potential terminals FE or signal terminals 3/4 ZBFM labeling field for signal 3/4 Connector Front connector shaft latch Electronic socket Data routing Slot coding Voltage routing Front release mechanism Latch on mounting rail Feather key of the keyway/feather key connection 5520a033.eps Fig. 4-1: Basic structure of a RECO Inline module The most important components shown in Fig. 4-1: Basic structure of a RECO Inline module are described in the chapter entitled Electronic Socket on page 4-2 and in the chapter entitled Connector on page 4-2. ZBFM: Zack marker strips, flat (also see the chapter entitled Identification of Function and Labeling on page 4-5).

22 4-2 Structure of the RECO Inline Terminals PROFIBUS DP 4.2 Electronic Socket Overall widths All the electronic parts of the RECO Inline module as well as the voltage and data jumper are situated in the electronic socket. As a standard, the electronic sockets for terminals of the low signal level are available in standard widths of 8 terminal points (8-slot connector) and 2 terminal points (2-slot connector). Any other dimensions are combinations of the two above mentioned basic terminal widths (also refer to the chapter entitled Housing Dimensions of the Modules of the Low Signal Level on page 4-7). 4.3 Connector Advantages Connector width Connector types The connection of the peripheral equipment or the supply voltages is provided in the form of a connector that can be disconnected from the electronic socket. This pluggable connection has the following advantages: Easy replacement of electronic module parts for servicing. The wiring does not have to be removed. For different requirements, different connectors can be plugged on an electronic socket. Independent of the width of the electronic socket, the connectors have a width of two terminal points. Accordingly, you must plug 1 connector on a 2-slot socket, 2 connectors on a 4-slot socket and 4 connectors on a 8- slot socket. The following connector types are available: eps Fig. 4-2: RECO Inline connector types

23 PROFIBUS DP Structure of the RECO Inline Terminals 4-3 Connector identification All connectors are available with color print. If connectors are provided with color print, the terminal points are color-coded according to their functions. The signals of the terminal points are coded by the following colors: 1 Standard connector The gray standard connector is used for connecting two signals in 4-wire technology (e.g. digital input/output signals). The black standard connector is used for supply terminals. Its neighboring contacts are internally jumpered (see Fig. 4-4 on Page 4-3 ). 2 Shield connector This gray connector is used for signals connected via shielded lines (e.g. analog input/output signals). The FE and/or shielding connection is not provided through terminal points but through a shield clip. 3 Expanded double-signal connector This gray connector is used for connecting four signals in 3- wire technology (e.g. digital input/output signals). Color Signal at the terminal point Red + Blue - Green / yellow Functional earth ground Fig. 4-3: Color-coding of the terminal points Interior design of the connectors ) * +,!!!!!!!! " " " " " " " " # # $ $ # # )! 5520a032.eps Fig. 4-4: Interior design of the connectors A B C D Gray connector for peripheral connection Black connector for supply terminals Shield connector for analog terminals Large gray connector for peripheral connection

24 4-4 Structure of the RECO Inline Terminals PROFIBUS DP Connectors with integrated jumpering of terminal points are shown in Fig The shield connector is jumpered by the shield connection. All other connectors are jumpered by a connection of the terminal points. Note: To avoid malfunctions, only latch the connector onto the terminal it is intended for. Refer to the specific data sheet of each module to select the appropriate connector. The black connector may not be latched onto a terminal that is intended for a double signal connector. Any reversal would lead to a short-circuit between the two signal terminal points ( ). Important:Place only black connectors on supply terminals! The terminal point jumpering ensures that the potential is transmitted (if this feature is provided) via the jumpering in the connector and not via the module board. Connector coding It is possible to prevent the mismatching of connectors by coding socket and connector eps Fig. 4-5: Connector coding For this purpose, put a coding profile into the coding keyway in the socket (1) and pull it off the small plate (2) by rotation (Fig. 4-5, Fig. A). Use nippers to cut the respective coding tab off the connector (Fig. 4-5, Fig. B) Now, only socket and connector with the same coding fit together (Fig. 4-5, Fig. C).

25 PROFIBUS DP Structure of the RECO Inline Terminals Identification of Function and Labelling For optical identification of their function, the modules are color-coded (1 in Fig. 4-6). # # ) % # 5520a075.eps Fig. 4-6: Identification of function The various functions are identified by the following colors: Color Module function Light-blue Digital input, 24 V range Pink Digital output, 24 V range Blue Digital input, 120/230 V range Red Digital output, 120/230 V range Green Analog input Yellow Analog output Orange Field bus coupler, function modules *) Black Power terminal / segment terminal Fig. 4-7: Color-coding of modules Connector identification Labeling/numbering of terminal points *) All accepted function modules are illustrated in Fig. 7-1 on page 7.2. The color-coding of the terminal points is described above (on this page). The numbering of the terminal points is illustrated by means of a 8-slot module.

26 4-6 Structure of the RECO Inline Terminals PROFIBUS DP! "!!!!! " " " " : ;! "!! " "!! " "!! " "! " " # # )! # 5520a035.eps Fig. 4-8: Numbering of terminal points Slot/connector Terminal point Additional labeling The slots (connectors) on a socket are numbered consecutively (1 in Fig. 4-8). These numbers are not specified on the module. On each connector, the terminal points are identified by X.Y. X is the number of the terminal point rows on the connector and is indicated on the top of the respective terminal point row (2 in Fig. 4-8). Y is the number of the terminal point in a row and is indicated directly at the terminal point (3 in Fig. 4-8). Thus, the position of the slot and terminal point can be exactly determined. For instance, the gray connection (4 in Fig. 4-8) is numbered as follows: slot 3, terminal point 2.3. In addition to the above labeling of the module, you can label the slots, terminal points and connections with zack marker strips (ZBFMs) and labeling fields.

27 PROFIBUS DP Structure of the RECO Inline Terminals 4-7! " # # # )! $ Fig. 4-9: Labeling of modules 5520a036.eps There are various possibilities to label the slots and terminal points: 1 You can label each connector individually with zack marker strips. 2 / 3 As an option, you can use a large labeling field. This labeling field is available in two widths, either as labeling field covering only one connector (2) or as labeling field covering four connectors (3). Thus, you can label each channel individually with continuous text. In the upper connector head, there is a keyway to attach the labeling field on the connector/s. The labeling field can be moved up and down. A small catch at both end positions allows the labeling field to keep its position. 4 / 5 You can label each signal with zack marker strips. With double signal connectors, the upper keyway (4) is provided for labeling the signals 1/2, and the bottom keyway (5) for the signals 3/4. 6 The electronic socket offers the possibility to label each slot individually with zack marker strips. If the connector is latched onto the socket, this labeling is hidden. You can clearly assign connector and slot by using the labeling fields at the connector and on the electronic socket.

28 4-8 Structure of the RECO Inline Terminals PROFIBUS DP 4.5 Housing Dimensions of the Modules of the Low Signal Level 2-slot housing Today, small I/O stations are often used in 80 mm standard control boxes. The RECO Inline modules have been designed for the use in this type of control box. The housing dimensions of a module are defined by the dimensions of the electronic socket and the connector. The electronic sockets of the modules of the low signal level are available in three overall widths (12.2 mm; 24.4 mm; and 48.8 mm). One, two or four connectors of a width of 12.2 mm are plugged on these sockets. With connector, each module has a depth of 71.5 mm. The height of the module depends on the connector used. The connectors are available in three versions (see Fig. 4-13). % # & # " % " " & # #! eps Fig. 4-10: Dimensions of the electronic sockets (2-slot housing)

29 PROFIBUS DP Structure of the RECO Inline Terminals slot housing % # & # " % " " & # #! eps Fig. 4-11: Dimensions of the electronic sockets (4-slot housing) 8-slot housing % # & # " % " " & & ' # # " eps Fig. 4-12: Dimensions of the electronic socket (8-slot housing)

30 4-10 Structure of the RECO Inline Terminals PROFIBUS DP Connector ) * + " " " #! "! "! # ' %! "! "! % #! ' "! "! " " & " & # $ # $ " & # # # & L: A Standard connector B Shield connector C Extended double-signal connector Fig. 4-13: Connector dimensions eps The connector depth is irrelevant as it has no effect on the overall module depth.

31 PROFIBUS DP Structure of the RECO Inline Terminals Electrical Voltage and Data Routing An essential feature of the RECO Inline product family and the PROFIBUS DP fieldbus coupler is the internal voltage routing system. The electrical connection between the individual station devices is established automatically when the station is set up. When the individual station devices are latched to each other, a power rail is created for the respective electric circuit. Mechanically, this contact is realized by the blade and feather key contacts of the neighboring modules latching into each other. Using a special segment circuit, the user does not have to establish the additional external potential transmission to the neighboring modules. In one station, two independent electric circuits have been realized: the logic circuit and the circuit of the peripheral equipment.! " # $ % = >? Fig. 4-14: Voltage and data routing & ' # # # % eps No. Function Description V U L+ Supply of module electronics 2 24 V U ANA Peripheral supply voltage for analog modules 3 GND U L+ Ground of the logic supply voltage and the peripheral supply voltage for analog modules 4 24 V U S Supply of the segment circuit (if necessary protected against overload) This voltage jumper does not exist at voltage levels from 120 V to 230 V V U M Supply of the main circuit (if necessary protected against overload) 6 GND GND Ground of segment and main supply (neutral conductor) 7 FE FE Functional earth ground (9) (FE spring) FE contact to the mounting rail (with the PROFIBUS DP fieldbus coupler as well as the power and segment terminals) Fig. 4-15: Voltage jumper (see Fig. 4-14)

32 4-12 Structure of the RECO Inline Terminals PROFIBUS DP Important:The GND voltage jumper carries the total current of the main and the segment circuits. It may not exceed the maximum load capacity of the voltage jumpers of 8 A. If, during projecting, the limit of 8 A is reached at one of the U S, U M and GND voltage jumpers, a new power terminal must be used! Note: The FE voltage jumper must be connected to a ground terminal at the PROFIBUS DP fieldbus coupler via the terminal point 1.4 or 2.4 (see Fig. 4-8). In addition, it must be connected to the grounded mounting rail at each supply terminal via the FE spring and routed through all of the modules. No. Function Description 8a DI1 Local bus signal (Data In) 8b DO1 Local bus signal (Data Out) 8c DCLK Clock signal, local bus Fig. 4-16: Data jumper (see Fig. 4-14) 4.7 Electric Circuits and Voltage Supply Within a RECO Inline Station There are several electric circuits within a RECO Inline station. These circuits are set up automatically when the modules are latched to each other. The voltages of the different electric circuits are supplied to the connected modules via the voltage jumpers. Note: Please refer to the module-specific data sheet for further information about the electric circuit to which the peripheral circuit of a specific module has to be connected. Load capacity of the jumper contacts The maximum load capacity of the lateral jumper contacts must be observed for each electric circuit. The load capacities for all voltage jumpers are specified in the sections below. The arrangement of the voltage jumpers is illustrated in the chapter entitled Voltage and Data Routing on page The connection of the supply voltages is described in the chapter entitled Connecting Supply Voltages on page For information on the connection of voltages, please refer to the notes in the module-specific data sheets.

33 PROFIBUS DP Structure of the RECO Inline Terminals 4-13 Supply of the PROFIBUS DP fieldbus coupler The main voltage U M and the segment voltage U S must be connected to the PROFIBUS DP fieldbus coupler. The main voltage is used internally to generate the voltages for the logic circuit U L and the module supply voltage for analog signals U ANA. The segment voltage is used to supply the sensors and actuators (see Fig. 4-17). Logic circuit Analog circuit Function Voltage Generation of U L Load capacity Function Voltage Generation of U ANA Load capacity The logic circuit with the logic voltage U L starts at the PROFIBUS DP fieldbus coupler and is routed through all modules of a station; it cannot be re-supplied via an additional supply terminal. Logic voltage is supplied from the logic circuits to all modules of the station. The voltage in this circuit is 7.5 V. The logic voltage is generated from the main voltage U M of the PROFIBUS DP fieldbus coupler. The maximum load capacity of U L is 2 A. The logic voltage is not galvanically isolated from the 24 V input voltage of the PROFIBUS DP fieldbus coupler. The analog circuit with the supply voltage for the analog modules (also called analog voltage in the following) U ANA starts at the PROFIBUS DP fieldbus coupler and is routed through all modules of a RECO Inline station. The peripheral equipment of the modules for analog signals is supplied from the analog circuit. The voltage in this circuit is 24 V. The analog voltage U ANA is generated from the main voltage of the PROFIBUS DP fieldbus coupler. The maximum load capacity of U ANA is 0.5 A. 1 2 * * /. 7 7 ) ) /, L: R-IL PB BK PROFIBUS DP fieldbus coupler R-IL 24 PWR IN Power terminal R-IL 24 SEG/F Segment terminal with fuse Fig. 4-17: Logic and analog circuits $! & ) 6138a002.eps

34 4-14 Structure of the RECO Inline Terminals PROFIBUS DP Main circuit Function Voltage Load capacity The main circuit with the main voltage U M starts at the PROFIBUS DP fieldbus coupler or at a power terminal and is routed through all following modules to the next power terminal. At the next power terminal, a new circuit is started; its potential is isolated from the previous circuit. Several power terminals can be used within one station. Several independent segments can be created within the main circuit. The main circuit provides the main voltage for these segments. For instance, a separate supply system for the actuators can be set up. The voltage in this circuit must not exceed 250 V AC. The maximum load capacity is 8 A (total current with the segment circuit). If the limit for the voltage jumpers U M and U S has been reached (total current of U S and U M), a new power terminal must be used. 1 2 * * /. 7 7 ) ) /, L: R-IL PB BK PROFIBUS DP fieldbus coupler R-IL 24 PWR IN Power terminal R-IL 24 SEG/F Segment terminal with fuse Fig. 4-18: Main circuit $! & )! 6138a003.eps Generation of U M In the simplest case, the main voltage U M can be supplied at the PROFIBUS DP fieldbus coupler. The main voltage U M can also be supplied via a power terminal. A power terminal must be used in the following cases: 1 An electrical isolation is to be set up. 2 The maximum load capacity of a voltage jumper (U M, U S or GND, total current of U S and U M ) has been reached.

35 PROFIBUS DP Structure of the RECO Inline Terminals 4-15 Segment circuit Function Voltage Load capacity Generation of U S The segment circuit or auxiliary circuit with the segment voltage U S starts at the PROFIBUS DP fieldbus coupler or a supply terminal (power terminal or segment terminal) and is routed through all following modules up to the next supply terminal. You can use several segment terminals within one main circuit, and therefore segment the latter. The reference to ground is the same as that of the main circuit. Thus, you can realize within the station differently fused electric circuits without any external cross wiring. The voltage in this circuit must not exceed 24 V DC. The maximum load capacity is 8 A (total current with the main circuit). If the limit for a voltage jumper U M and U S has been reached (total current of U S and U M), a new power terminal must be used. The segment voltage U S can be provided in various ways: 1 You can feed in the segment voltage at the PROFIBUS DP fieldbus coupler or at a power terminal. 2 You can tap the segment voltage from the main voltage, either at the PROFIBUS DP fieldbus coupler or at a power terminal using a jumper or a switch. 3 You can use a segment terminal with fuse. In this terminal, the segment voltage is automatically tapped from the main voltage. Note: In the 120 V and 230 V voltage levels, it is not possible to set up segments. Here, only the main circuit is used. Special power terminals must be used. 1 2 * * /. 7 7 ) ) /, L: R-IL PB BK PROFIBUS DP fieldbus coupler R-IL 24 PWR IN Power terminal R-IL 24 SEG/F Segment terminal with fuse Fig. 4-19: Segment circuit $! & ) " 6138a004.eps

36 4-16 Structure of the RECO Inline Terminals PROFIBUS DP 4.8 Voltage Concept Electrical isolation: PROFIBUS DP Electrical isolation: Peripheral equipment The PROFIBUS DP fieldbus coupler and the RECO Inline system are based on a defined voltage and grounding concept. This prevents any undesired feedback of peripheral equipment to the logic section, suppresses the flow of any undesired circulating currents, and increases the immunity. The PROFIBUS interface is galvanically isolated from the field bus coupler logic. The shield of the PROFIBUS cable is directly connected to the functional earth ground spring (FE spring), which is positioned to the left directly under the SUB-D socket on the bottom side of the field bus coupler. In the module, this spring is not connected to the second FE spring, which is positioned to the right on the bottom side directly under the terminal points. The spring to the right is directly connected to the two terminal points of the power connector. When latched on, the two functional earth ground springs are in contact with the mounting rail; they are provided to discharge interferences and may not be used as protective ground. To ensure that interferences are properly discharged even with the mounting rail dirty, the functional earth ground must be connected directly to the terminal points 1.4 or 2.4. This also adequately grounds the RECO Inline station up to the first segment terminal. To prevent circulating currents possibly affecting the quality of data transfer from flowing, an adequately dimensioned equipotential bonding line must be connected in parallel with the PROFIBUS line. The field bus coupler does not have an electrical isolation for the logic voltage supply of the RECO Inline modules. U M (24 V), U L (7.5 V) and U ANA (24 V) are not galvanically isolated. Since they have the same reference to ground, both the main voltage U M and the peripheral voltage U S can only be fused separately, by feeding them in separately on the field bus coupler. If you wish to galvanically isolate the two voltages, you must fit a separate power terminal. Only then is it ensured that the galvanically isolating in the input and output modules is not jumpered by a joint reference to ground.