Modular I/O System LONWORKS ,

Transcription

1 Modular I/O System , Manual Technical description, installation and configuration Version 2.1.1

2 ii General Copyright 2007 by WAGO Kontakttechnik GmbH & Co. KG All rights reserved. WAGO Kontakttechnik GmbH & Co. KG Hansastraße 27 D Minden Germany Tel.: +49 (0) 571/ Fax: +49 (0) 571/ info@wago.com Web: Support: Tel.: +49 (0) 571/ Fax: +49 (0) 571/ teba@wago.com Web: Every conceivable measure has been taken to ensure the correctness and completeness of this documentation. However, as errors can never be fully excluded we would appreciate any information or ideas at any time. We wish to point out that the software and hardware terms as well as the trademarks of companies used and/or mentioned in the present manual are generally trademark or patent protected. LON, LONMARK, and Echelon are registered trademarks of Echelon Corporation. LNS TM is a trademark of Echelon Corporation. TOPLON is a registered trademark of WAGO Kontakttechnik GmbH.

3 Table of Contents iii Table of Contents 1 Important Notes Legal Principles Copyright Personnel Qualification Conforming Use of Series Technical Condition of the Devices Standards and Regulations for Operating the 750 Series Symbols Safety Information Font Conventions Number Notation The WAGO-I/O-SYSTEM System Description Technical Data Manufacturing Number Component Update Storage, Assembly and Transport Mechanical Setup Installation Position Total Expansion Assembly onto Carrier Rail Carrier rail properties WAGO DIN Rail Spacing Plugging and Removal of the Components Assembly Sequence Internal Bus/Data Contacts Power Contacts Wire connection Power Supply Isolation System Supply Connection Alignment Field Supply Connection Fusing Supplementary power supply regulations Supply example Power Supply Unit Grounding Grounding the DIN Rail Framework Assembly Insulated Assembly Grounding Function Grounding Protection...42 Modular I/O System

4 iv Table of Contents 2.9 Shielding (Screening) General Bus Conductors Signal Conductors WAGO Shield (Screen) Connecting System Assembly Guidelines/Standards Fieldbus coupler/controller Fieldbus coupler Description Software for the coupler Hardware View Device supply Fieldbus connection Display elements Configuration interface Hardware address Operating system Data exchange Starting-up LON fieldbus nodes LED display Blink code Fieldbus status Node status Fault message via the blink code of the I/O LED Supply voltage status Fault behavior Fieldbus failure Internal bus fault Technical Data Fieldbus controller Description Software for the controller Hardware View Device supply Fieldbus connection Display elements Configuration and programming interface Operating mode switch Hardware address Operating system Start-up PLC cycle Process image Data exchange Memory areas Addressing Starting-up LON fieldbus nodes...78

5 Table of Contents v Programming the PFC with WAGO-I/O-PRO LON library elements for WAGO-I/O-PRO IEC Program transfer LED display Blink code Fieldbus status Node status Fault message via the blink code of the I/O LED Supply voltage status Fault behavior Fieldbus failure Internal bus fault Technical Data LON General Safty Information! Information on the network architecture Network architecture Principles and Regulations Transmision media Topology Transceiver Recommended bus and cable lengths Bus shaped wiring Free Wiring Cable specifications Network installation Addressing Configuration Binding Network communication Data exchange via network variables Standard types of network variables Protocol Channel access method I/O Modules Overview Digital Input Modules Digital Output Modules Analog Intput Modules Analog Output Modules Special Modules System Modules TOPLON supported I/O modules Use in Hazardous Environments Foreword Protective measures Classification meeting CENELEC and IEC Divisions Modular I/O System

6 vi Table of Contents Explosion protection group Unit categories Temperature classes Types of ignition protection Classifications meeting the NEC Divisions Explosion protection groups Temperature classes Identification For Europe For America Installation regulations Glossary Literature list Index...144

7 Important Notes 7 Legal Principles 1 Important Notes 1.1 Legal Principles Copyright This section provides only a summary of the most important safety requirements and notes which will be mentioned in the individual sections. To protect your health and prevent damage to the devices, it is essential to read and carefully follow the safety guidelines. This manual including all figures and illustrations contained therein is subject to copyright. Any use of this manual which infringes the copyright provisions stipulated herein, is not permitted. Reproduction, translation and electronic and phototechnical archiving and amendments require the written consent of WAGO Kontakttechnik GmbH & Co. KG, Minden. Non-observance will entail the right of claims for damages. WAGO Kontakttechnik GmbH & Co. KG reserves the right of changes serving technical progress. All rights developing from the issue of a patent or the legal protection of utility patents are reserved to WAGO Kontakttechnik GmbH & Co. KG. Thirdparty products are always indicated without any notes concerning patent rights. Thus, the existence of such rights must not be excluded Personnel Qualification The use of the product described in this manual requires special qualifications, as shown in the following table: Activity Electrical specialist Instructed personnel*) Assembly X X Specialists**) having qualifications in PLC programming Commissioning X X Programming Maintenance X X Troubleshooting Disassembly X X X *) Instructed persons have been trained by qualified personnel or electrical specialists. **) A specialist is someone who, through technical training, knowledge and experience, demonstrates the ability to meet the relevant specifications and identify potential dangers in the mentioned field of activity. All personnel must be familiar with the applicable standards. WAGO Kontakttechnik GmbH & Co. KG declines any liability resulting from X Modular I/O System

8 8 Important Notes Standards and Regulations for Operating the 750 Series improper action and damage to WAGO products and third party products due to non-observance of the information contained in this manual Conforming Use of Series 750 The couplers and controllers of the modular I/O System 750 receive digital and analog signals from the I/O modules and sensors and transmit them to the actuators or higher level control systems. Using the WAGO controllers, the signals can also be (pre-)processed. The device is designed for IP20 protection class. It is protected against finger touch and solid impurities up to 12.5mm diameter, but not against water penetration. Unless otherwise specified, the device must not be operated in wet and dusty environments Technical Condition of the Devices For each individual application, the components are supplied from the factory with a dedicated hardware and software configuration. Changes in hardware, software and firmware are only admitted within the framework of the possibilities documented in the manuals. All changes to the hardware or software and the non-conforming use of the components entail the exclusion of liability on the part of WAGO Kontakttechnik GmbH & Co. KG. Please direct any requirements pertaining to a modified and/or new hardware or software configuration directly to WAGO Kontakttechnik GmbH & Co. KG. 1.2 Standards and Regulations for Operating the 750 Series Please observe the standards and regulations that are relevant to your installation: The data and power lines must be connected and installed in compliance with the standards to avoid failures on your installation and eliminate any danger to personnel. For installation, startup, maintenance and repair, please observe the accident prevention regulations of your machine (e.g. BGV A 3, "Electrical Installations and Equipment"). Emergency stop functions and equipment must not be made ineffective. See relevant standards (e.g. DIN EN 418). Your installation must be equipped in accordance to the EMC guidelines so that electromagnetic interferences can be eliminated. Operating 750 Series components in home applications without further measures is only permitted if they meet the emission limits (emissions of interference) according to EN You will find the relevant information in the section on "WAGO-I/O-SYSTEM 750" "System Description" "Technical Data".

9 Important Notes 9 Symbols 1.3 Symbols Please observe the safety measures against electrostatic discharge according to DIN EN /-3. When handling the modules, ensure that the environment (persons, workplace and packing) is well grounded. The relevant valid and applicable standards and guidelines concerning the installation of switch cabinets are to be observed. Danger Always observe this information to protect persons from injury. Warning Always observe this information to prevent damage to the device. Attention Marginal conditions that must always be observed to ensure smooth and efficient operation. ESD (Electrostatic Discharge) Warning of damage to the components through electrostatic discharge. Observe the precautionary measure for handling components at risk of electrostatic discharge. Note Make important notes that are to be complied with so that a trouble-free and efficient device operation can be guaranteed. Additional Information References to additional literature, manuals, data sheets and INTERNET pages. Modular I/O System

10 10 Important Notes Safety Information 1.4 Safety Information When connecting the device to your installation and during operation, the following safety notes must be observed: Danger The WAGO-I/O-SYSTEM 750 and its components are an open system. It must only be assembled in housings, cabinets or in electrical operation rooms. Access is only permitted via a key or tool to authorized qualified personnel. Danger All power sources to the device must always be switched off before carrying out any installation, repair or maintenance work. Warning Replace defective or damaged device/module (e.g. in the event of deformed contacts), as the functionality of fieldbus station in question can no longer be ensured on a long-term basis. Warning The components are not resistant against materials having seeping and insulating properties. Belonging to this group of materials is: e.g. aerosols, silicones, triglycerides (found in some hand creams). If it cannot be ruled out that these materials appear in the component environment, then the components must be installed in an enclosure that is resistant against the above mentioned materials. Clean tools and materials are generally required to operate the device/module. Warning Soiled contacts must be cleaned using oil-free compressed air or with ethyl alcohol and leather cloths. Warning Do not use contact sprays, which could possibly impair the functioning of the contact area. Warning Avoid reverse polarity of data and power lines, as this may damage the devices. ESD (Electrostatic Discharge) The devices are equipped with electronic components that may be destroyed by electrostatic discharge when touched.

11 Important Notes 11 Font Conventions 1.5 Font Conventions italic italic Names of paths and files are marked in italic. e.g.: C:\Programs\WAGO-IO-CHECK Menu items are marked in bold italic. e.g.: Save \ A backslash between two names characterizes the selection of a menu point from a menu. e.g.: File \ New END Press buttons are marked as bold with small capitals e.g.: ENTER < > Keys are marked bold within angle brackets e.g.: <F5> Courier The print font for program codes is Courier. e.g.: END_VAR 1.6 Number Notation Number code Example Note Decimal 100 Normal notation Hexadecimal 0x64 C notation Binary '100' ' ' Within ', Nibble separated with dots Modular I/O System

12 12 The WAGO-I/O-SYSTEM 750 System Description 2 The WAGO-I/O-SYSTEM System Description The WAGO-I/O-SYSTEM 750 is a modular, fieldbus independent I/O system. It is comprised of a fieldbus coupler/controller (1) and connected fieldbus modules (2) for any type of signal. Together, these make up the fieldbus node. The end module (3) completes the node. Fig. 2-1: Fieldbus node g0xxx00x Couplers/controllers for fieldbus systems such as PROFIBUS, INTERBUS, ETHERNET TCP/IP, CAN (CANopen, DeviceNet, CAL), MODBUS, LON and others are available. The coupler/controller contains the fieldbus interface, electronics and a power supply terminal. The fieldbus interface forms the physical interface to the relevant fieldbus. The electronics process the data of the bus modules and make it available for the fieldbus communication. The 24 V system supply and the 24 V field supply are fed in via the integrated power supply terminal. The fieldbus coupler communicates via the relevant fieldbus. The programmable fieldbus controller (PFC) enables the implementation of additional PLC functions. Programming is done with the WAGO-I/O-PRO 32 in accordance with IEC Bus modules for diverse digital and analog I/O functions as well as special functions can be connected to the coupler/controller. The communication between the coupler/controller and the bus modules is carried out via an internal bus. The WAGO-I/O-SYSTEM 750 has a clear port level with LEDs for status indication, insertable mini WSB markers and pullout group marker carriers. The 3-wire technology supplemented by a ground wire connection allows for direct sensor/actuator wiring.

13 The WAGO-I/O-SYSTEM Technical Data 2.2 Technical Data Mechanic Material Polycarbonate, Polyamide 6.6 Dimensions W x H* x L * from upper edge of DIN 35 rail - Coupler/Controller (Standard) - Coupler/Controller (ECO) - Coupler/Controller (FireWire) - I/O module, single - I/O module, double - I/O module, fourfold Installation modular by Mounting position - 51 mm x 65 mm x 100 mm - 50 mm x 65 mm x 100 mm - 62 mm x 65 mm x 100 mm - 12 mm x 64 mm x 100 mm - 24 mm x 64 mm x 100 mm - 48 mm x 64 mm x 100 mm on DIN 35 with interlock double featherkey-dovetail any position Marking marking label type 247 and 248 paper marking label 8 x 47 mm Connection Connection type CAGE CLAMP Wire range 0.08 mm² mm², AWG Stripped length Contacts Power jumpers contacts Current via power contacts max Voltage drop at I max Data contacts Climatic environmental conditions Operating temperature 8 9 mm, 9 10 mm for components with pluggable wiring (753-xxx) blade/spring contact self-cleaning 10 A < 1 V/64 modules slide contact, hard gold plated 1.5 µm, self-cleaning Storage temperature -20 C C Relative humidity 0 C C, -20 C +60 C for components with extended temperature range (750-xxx/025-xxx) 5 % to 95 % without condensation Resistance to harmful substances acc. to IEC and IEC Maximum pollutant concentration at relative humidity < 75% Special conditions SO 2 25 ppm H 2 S 10 ppm Ensure that additional measures for components are taken, which are used in an environment involving: dust, caustic vapors or gasses ionization radiation. Modular I/O System

14 14 The WAGO-I/O-SYSTEM 750 Technical Data Safe electrical isolation Air and creepage distance acc. to IEC Degree of pollution acc. To IEC Degree of protection Degree of protection IP 20 Electromagnetic compatibility 2 Immunity to interference for industrial areas acc. to EN (2001) Test specification Test values Strength class EN ESD 4 kv/8 kv (contact/air) 2/3 B EN electromagnetic fields 10 V/m 80 MHz... 1 GHz 3 A EN burst 1 kv/2 kv (data/supply) 2/3 B EN surge EN RF disturbances Data: DC supply: AC supply: -/- (line/line) 1 kv (line/earth) kv (line/line) kv (line/earth) 1 1 kv (line/line) 2 2 kv (line/earth) 3 10 V/m 80 % AM ( MHz) Evaluation criteria B B B 3 A Emission of interference for industrial areas acc. to EN (2001) Test specification Limit values/[qp]*) Frequency range Distance EN (AC supply, conducted) EN (radiated) 79 db (µv) 150 khz khz 73 db (µv) 500 khz MHz 40 db (µv/m) 30 MHz MHz 10 m 47 db (µv/m) 230 MHz... 1 GHz 10 m Emission of interference for residential areas acc. to EN (2001) Test specification Limit values/[qp]*) Frequency range Distance EN (AC supply, conducted) EN (DC supply/data, conducted) EN (radiated) db (µv) 150 khz khz 56 db (µv) 500 khz... 5 MHz 60 db (µv) 5 MHz MHz db (µa) 150 khz khz 30 db (µa) 500 khz MHz 30 db (µv/m) 30 MHz MHz 10 m 37 db (µv/m) 230 MHz... 1 GHz 10 m

15 The WAGO-I/O-SYSTEM Technical Data Mechanical strength acc. to IEC Test specification Frequency range Limit value IEC vibration IEC shock IEC free fall *) QP: Quasi Peak 5 Hz f < 9 Hz 1.75 mm amplitude (permanent) 3.5 mm amplitude (short term) 9 Hz f < 150 Hz 0.5 g (permanent) 1 g (short term) Note on vibration test: a) Frequency change: max. 1 octave/minute b) Vibration direction: 3 axes 15 g Note on shock test: a) Type of shock: half sine b) Shock duration: 11 ms c) Shock direction: 3x in positive and 3x in negative direction for each of the three mutually perpendicular axes of the test specimen 1 m (module in original packing) Note: If the technical data of components differ from the values described here, the technical data shown in the manuals of the respective components shall be valid. Modular I/O System

16 16 The WAGO-I/O-SYSTEM 750 Technical Data For Products of the WAGO-I/O-SYSTEM 750 with ship specific approvals, supplementary guidelines are valid: Electromagnetic compatibility Immunity to interference acc. to Germanischer Lloyd (2003) Test specification Test values Strength class IEC ESD 6 kv/8 kv (contact/air) 3/3 B IEC electromagnetic fields 10 V/m 80 MHz... 2 GHz 3 A IEC burst 1 kv/2 kv (data/supply) 2/3 A IEC surge IEC RF disturances Type test AF disturbances (harmonic waves) Type test high voltage AC/DC Supply: 0.5 kv (line/line) 1 1 kv (line/earth) 2 10 V/m 80 % AM ( MHz) Evaluation criteria A 3 A 3 V, 2 W - A 755 V DC 1500 V AC Emission of interference acc. to Germanischer Lloyd (2003) - - Test specification Limit values Frequency range Distance Type test (EMC1, conducted) allows for ship bridge control applications db (µv) 10 khz khz db (µv) 150 khz khz 50 db (µv) 350 khz MHz Type test db (µv/m) 150 khz khz 3 m (EMC1, radiated) allows for ship bridge control db (µv/m) 300 khz MHz 3 m applications 54 db (µv/m) 30 MHz... 2 GHz 3 m außer für: 24 db (µv/m) 156 MHz MHz 3 m Mechanical strength acc. to Germanischer Lloyd (2003) Test specification Frequency range Limit value IEC vibration (category A D) 2 Hz f < 25 Hz ± 1.6 mm amplitude (permanent) 25 Hz f < 100 Hz 4 g (permanent) Note on vibration test: a) Frequency change: max. 1 octave/minute b) Vibration direction: 3 axes

17 The WAGO-I/O-SYSTEM Technical Data Range of application Required specification emission of interference Required specification immunity to interference Industrial areas EN (2001) EN (2001) Residential areas EN (2001)*) EN (2001) *) The system meets the requirements on emission of interference in residential areas with the fieldbus coupler/controller for: ETHERNET /-841/-842/-860 LonWorks CANopen DeviceNet MODBUS / / / /-314/ -315/ /-814/ -815/ -816 With a special permit, the system can also be implemented with other fieldbus couplers/controllers in residential areas (housing, commercial and business areas, small-scale enterprises). The special permit can be obtained from an authority or inspection office. In Germany, the Federal Office for Post and Telecommunications and its branch offices issues the permit. It is possible to use other field bus couplers/controllers under certain boundary conditions. Please contact WAGO Kontakttechnik GmbH & Co. KG. Maximum power dissipation of the components Bus modules Fieldbus coupler/controller 0.8 W / bus terminal (total power dissipation, system/field) 2.0 W / coupler/controller Warning The power dissipation of all installed components must not exceed the maximum conductible power of the housing (cabinet). When dimensioning the housing, care is to be taken that even under high external temperatures, the temperature inside the housing does not exceed the permissible ambient temperature of 55 C. Modular I/O System

18 18 The WAGO-I/O-SYSTEM 750 Technical Data Dimensions A B 24V 0V C D A B C D A B C D A B C D A B C D Side view Dimensions in mm Fig. 2-2: Dimensions g01xx05e Note: The illustration shows a standard coupler. For detailed dimensions, please refer to the technical data of the respective coupler/controller.

19 The WAGO-I/O-SYSTEM Manufacturing Number 2.3 Manufacturing Number The manufacturing number indicates the delivery status directly after production. This number is part of the lateral marking on the component. In addition, starting from calender week 43/2000 the manufacturing number is also printed on the cover of the configuration and programming interface of the fieldbus coupler or controller. PROFIBUS WAGO - I/O - SYSTEM V DC AWG C max ambient LISTED 22ZA AND 22XM B B GL NO DS SW HW FWL Hansastr. 27 D Minden ITEM-NO.: PROFIBUS DP 12 MBd /DPV1 - Power Supply Field + 24 V 0V Power Supply Electronic PATENTS PENDING II 3 GD DEMKO 02 ATEX X EEx na II T B Calendar week Manufacturing Number Year Software version - B Hardware version Firmware Loader version Internal Number Fig. 2-3: Example: Manufacturing Number of a PROFIBUS fieldbus coupler g01xx15e The manufacturing number consists of the production week and year, the software version (if available), the hardware version of the component, the firmware loader (if available) and further internal information for WAGO Kontakttechnik GmbH. Modular I/O System

20 20 The WAGO-I/O-SYSTEM 750 Component Update 2.4 Component Update For the case of an Update of one component, the lateral marking on each component contains a prepared matrix. This matrix makes columns available for altogether three updates to the entry of the current update data, like production order number (NO; starting from calendar week 13/2004), update date (DS), software version (SW), hardware version (HW) and the firmware loader version (FWL, if available). Update Matrix Current Version data for: Production Order NO Number Datestamp DS Software index Hardware index SW HW Firmware loader index FWL 1. Update 2. Update 3. Update Only starting from calendar week 13/2004 Only for coupler/ controller If the update of a component took place, the current version data are registered into the columns of the matrix. Additionally with the update of a fieldbus coupler or controller also the cover of the configuration and programming interface of the coupler or controller is printed on with the current manufacturing and production order number. The original manufacturing data on the housing of the component remain thereby. 2.5 Storage, Assembly and Transport Wherever possible, the components are to be stored in their original packaging. Likewise, the original packaging provides optimal protection during transport. When assembling or repacking the components, the contacts must not be soiled or damaged. The components must be stored and transported in appropriate containers/packaging. Thereby, the ESD information is to be regarded. Statically shielded transport bags with metal coatings are to be used for the transport of open components for which soiling with amine, amide and silicone has been ruled out, e.g. 3M 1900E.

21 The WAGO-I/O-SYSTEM Mechanical Setup 2.6 Mechanical Setup Installation Position Along with horizontal and vertical installation, all other installation positions are allowed. Attention In the case of vertical assembly, an end stop has to be mounted as an additional safeguard against slipping. WAGO item End stop for DIN 35 rail, 6 mm wide WAGO item End stop for DIN 35 rail, 10 mm wide Total Expansion The length of the module assembly (including one end module of 12mm width) that can be connected to the coupler/controller is 780mm. When assembled, the I/O modules have a maximum length of 768mm. Examples: 64 I/O modules of 12mm width can be connected to one coupler/controller. 32 I/O modules of 24mm width can be connected to one coupler/controller. Exception: The number of connected I/O modules also depends on which type of coupler/controller is used. For example, the maximum number of I/O modules that can be connected to a Profibus coupler/controller is 63 without end module.the maximum total expansion of a node is calculated as follows: Warning The maximum total length of a node without coupler/controller must not exceed 780mm. Furthermore, restrictions made on certain types of couplers/controllers must be observed (e.g. for Profibus). Modular I/O System

22 22 The WAGO-I/O-SYSTEM 750 Mechanical Setup Assembly onto Carrier Rail Carrier rail properties All system components can be snapped directly onto a carrier rail in accordance with the European standard EN (DIN 35). Warning WAGO supplies standardized carrier rails that are optimal for use with the I/O system. If other carrier rails are used, then a technical inspection and approval of the rail by WAGO Kontakttechnik GmbH should take place. Carrier rails have different mechanical and electrical properties. For the optimal system setup on a carrier rail, certain guidelines must be observed: The material must be non-corrosive. Most components have a contact to the carrier rail to ground electromagnetic disturbances. In order to avoid corrosion, this tin-plated carrier rail contact must not form a galvanic cell with the material of the carrier rail which generates a differential voltage above 0.5 V (saline solution of 0.3% at 20 C). The carrier rail must optimally support the EMC measures integrated into the system and the shielding of the bus module connections. A sufficiently stable carrier rail should be selected and, if necessary, several mounting points (every 20 cm) should be used in order to prevent bending and twisting (torsion). The geometry of the carrier rail must not be altered in order to secure the safe hold of the components. In particular, when shortening or mounting the carrier rail, it must not be crushed or bent. The base of the I/O components extends into the profile of the carrier rail. For carrier rails with a height of 7.5 mm, mounting points are to be riveted under the node in the carrier rail (slotted head captive screws or blind rivets).

23 The WAGO-I/O-SYSTEM Mechanical Setup WAGO DIN Rail WAGO carrier rails meet the electrical and mechanical requirements. Item Number Description / x 7.5; 1 mm; steel yellow chromated; slotted/unslotted / x 15; 1.5 mm; steel yellow chromated; slotted/unslotted x 15; 2.3 mm; steel yellow chromated; unslotted x 15; 2.3 mm; copper; unslotted x 7.5; 1 mm; aluminum; unslotted Spacing The spacing between adjacent components, cable conduits, casing and frame sides must be maintained for the complete field bus node. Fig. 2-4: Spacing g01xx13x The spacing creates room for heat transfer, installation or wiring. The spacing to cable conduits also prevents conducted electromagnetic interferences from influencing the operation. Modular I/O System

24 24 The WAGO-I/O-SYSTEM 750 Mechanical Setup Plugging and Removal of the Components Warning Before work is done on the components, the voltage supply must be turned off. In order to safeguard the coupler/controller from jamming, it should be fixed onto the carrier rail with the locking disc To do so, push on the upper groove of the locking disc using a screwdriver. To pull out the fieldbus coupler/controller, release the locking disc by pressing on the bottom groove with a screwdriver and then pulling the orange colored unlocking lug. Fig. 2-5: Coupler/Controller and unlocking lug g01xx12e It is also possible to release an individual I/O module from the unit by pulling an unlocking lug. Fig. 2-6: removing bus terminal p0xxx01x Danger Ensure that an interruption of the PE will not result in a condition which could endanger a person or equipment! For planning the ring feeding of the ground wire, please see chapter

25 The WAGO-I/O-SYSTEM Mechanical Setup Assembly Sequence All system components can be snapped directly on a carrier rail in accordance with the European standard EN (DIN 35). The reliable positioning and connection is made using a tongue and groove system. Due to the automatic locking, the individual components are securely seated on the rail after installing. Starting with the coupler/controller, the bus modules are assembled adjacent to each other according to the project planning. Errors in the planning of the node in terms of the potential groups (connection via the power contacts) are recognized, as the bus modules with power contacts (male contacts) cannot be linked to bus modules with fewer power contacts. Attention Always link the bus modules with the coupler/controller, and always plug from above. Warning Never plug bus modules from the direction of the end terminal. A ground wire power contact, which is inserted into a terminal without contacts, e.g. a 4-channel digital input module, has a decreased air and creepage distance to the neighboring contact in the example DI4. Always terminate the fieldbus node with an end module ( ). Modular I/O System

26 26 The WAGO-I/O-SYSTEM 750 Mechanical Setup Internal Bus/Data Contacts Communication between the coupler/controller and the bus modules as well as the system supply of the bus modules is carried out via the internal bus. It is comprised of 6 data contacts, which are available as self-cleaning gold spring contacts. Fig. 2-7: Data contacts p0xxx07x Warning Do not touch the gold spring contacts on the I/O modules in order to avoid soiling or scratching! ESD (Electrostatic Discharge) The modules are equipped with electronic components that may be destroyed by electrostatic discharge. When handling the modules, ensure that the environment (persons, workplace and packing) is well grounded. Avoid touching conductive components, e.g. gold contacts.

27 The WAGO-I/O-SYSTEM Mechanical Setup Power Contacts Self-cleaning power contacts, are situated on the side of the components which further conduct the supply voltage for the field side. These contacts come as touchproof spring contacts on the right side of the coupler/controller and the bus module. As fitting counterparts the module has male contacts on the left side. Danger The power contacts are sharp-edged. Handle the module carefully to prevent injury. Attention Please take into consideration that some bus modules have no or only a few power jumper contacts. The design of some modules does not allow them to be physically assembled in rows, as the grooves for the male contacts are closed at the top. Fig. 2-8: Example for the arrangement of power contacts g0xxx05e Recommendation With the WAGO ProServe Software smartdesigner, the assembly of a fieldbus node can be configured. The configuration can be tested via the integrated accuracy check. Modular I/O System

28 28 The WAGO-I/O-SYSTEM 750 Mechanical Setup Wire connection All components have CAGE CLAMP connections. The WAGO CAGE CLAMP connection is appropriate for solid, stranded and fine stranded conductors. Each clamping unit accommodates one conductor. Fig. 2-9: CAGE CLAMP Connection g0xxx08x The operating tool is inserted into the opening above the connection. This opens the CAGE CLAMP. Subsequently the conductor can be inserted into the opening. After removing the operating tool, the conductor is safely clamped. More than one conductor per connection is not permissible. If several conductors have to be made at one connection point, then they should be made away from the connection point using WAGO Terminal Blocks. The terminal blocks may be jumpered together and a single wire brought back to the I/O module connection point. Attention If it is unavoidable to jointly connect 2 conductors, then a ferrule must be used to join the wires together. Ferrule: Length 8 mm Nominal cross section max. 1 mm 2 for 2 conductors with 0.5 mm 2 each WAGO Product or products with comparable properties

29 The WAGO-I/O-SYSTEM Power Supply 2.7 Power Supply Isolation Within the fieldbus node, there are three electrically isolated potentials. Operational voltage for the fieldbus interface. Electronics of the couplers/controllers and the bus modules (internal bus). All bus modules have an electrical isolation between the electronics (internal bus, logic) and the field electronics. Some digital and analog input modules have each channel electrically isolated, please see catalog. Fig. 2-10: Isolation g0xxx01e Attention The ground wire connection must be present in each group. In order that all protective conductor functions are maintained under all circumstances, it is recommended that a ground wire be connected at the beginning and end of a potential group. (ring format, please see chapter "2.8.3"). Thus, if a bus module comes loose from a composite during servicing, then the protective conductor connection is still guaranteed for all connected field devices. When using a joint power supply unit for the 24 V system supply and the 24 V field supply, the electrical isolation between the internal bus and the field level is eliminated for the potential group. Modular I/O System

30 30 The WAGO-I/O-SYSTEM 750 Power Supply System Supply Connection The WAGO-I/O-SYSTEM 750 requires a 24 V direct current system supply (-15% or +20 %). The power supply is provided via the coupler/controller and, if necessary, in addition via the internal system supply modules ( ). The voltage supply is reverse voltage protected. Attention The use of an incorrect supply voltage or frequency can cause severe damage to the component. Fig. 2-11: System Supply g0xxx02e The direct current supplies all internal system components, e.g. coupler/controller electronics, fieldbus interface and bus modules via the internal bus (5 V system voltage). The 5 V system voltage is electrically connected to the 24 V system supply. Fig. 2-12: System Voltage g0xxx06e

31 The WAGO-I/O-SYSTEM Power Supply Attention Resetting the system by switching on and off the system supply, must take place simultaneously for all supply modules (coupler/controller and ) Alignment Recommendation A stable network supply cannot be taken for granted always and everywhere. Therefore, regulated power supply units should be used in order to guarantee the quality of the supply voltage. The supply capacity of the coupler/controller or the internal system supply module ( ) can be taken from the technical data of the components. Internal current consumption*) Residual current for bus terminals*) *) cf. catalogue W4 Volume 3, manuals or Internet Current consumption via system voltage: 5 V for electronics of the bus modules and coupler/controller Available current for the bus modules. Provided by the bus power supply unit. See coupler/controller and internal system supply module ( ) Example Coupler : internal current consumption:350 ma at 5V residual current for bus modules : 1650 ma at 5V sum I(5V) total : 2000 ma at 5V The internal current consumption is indicated in the technical data for each bus terminal. In order to determine the overall requirement, add together the values of all bus modules in the node. Attention If the sum of the internal current consumption exceeds the residual current for bus modules, then an internal system supply module ( ) must be placed before the module where the permissible residual current was exceeded. Example: A node with a PROFIBUS Coupler consists of 20 relay modules ( ) and 10 digital input modules ( ). Current consumption: 20* 90 ma = 1800 ma 10* 2 ma = 20 ma Sum 1820 ma The coupler can provide 1650 ma for the bus modules. Consequently, an internal system supply module ( ), e.g. in the middle of the node, should be added. Modular I/O System

32 32 The WAGO-I/O-SYSTEM 750 Power Supply Recommendation With the WAGO ProServe Software smartdesigner, the assembly of a fieldbus node can be configured. The configuration can be tested via the integrated accuracy check. The maximum input current of the 24 V system supply is 500 ma. The exact electrical consumption (I (24 V) ) can be determined with the following formulas: Coupler/Controller I(5 V) total = Sum of all the internal current consumption of the connected bus modules + internal current consumption coupler/controller I(5 V) total = Sum of all the internal current consumption of the connected bus modules Input current I(24 V) = 5 V / 24 V * I(5 V) total / η η = 0.87 (at nominal load) Note If the electrical consumption of the power supply point for the 24 V-system supply exceeds 500 ma, then the cause may be an improperly aligned node or a defect. During the test, all outputs, in particular those of the relay modules, must be active.

33 The WAGO-I/O-SYSTEM Power Supply Field Supply Connection Sensors and actuators can be directly connected to the relevant channel of the bus module in 1-/4 conductor connection technology. The bus module supplies power to the sensors and actuators. The input and output drivers of some bus modules require the field side supply voltage. The coupler/controller provides field side power (DC 24V). In this case it is a passive power supply without protection equipment. Power supply modules are available for other potentials, e.g. AC 230 V. Likewise, with the aid of the power supply modules, various potentials can be set up. The connections are linked in pairs with a power contact. Fig. 2-13: Field Supply (Sensor/Actuator) g0xxx03e The supply voltage for the field side is automatically passed to the next module via the power jumper contacts when assembling the bus modules. The current load of the power contacts must not exceed 10 A on a continual basis. The current load capacity between two connection terminals is identical to the load capacity of the connection wires. By inserting an additional power supply module, the field supply via the power contacts is disrupted. From there a new power supply occurs which may also contain a new voltage potential. Modular I/O System

34 34 The WAGO-I/O-SYSTEM 750 Power Supply Fusing Attention Some bus modules have no or very few power contacts (depending on the I/O function). Due to this, the passing through of the relevant potential is disrupted. If a field supply is required for subsequent bus modules, then a power supply module must be used. Note the data sheets of the bus modules. In the case of a node setup with different potentials, e.g. the alteration from DC 24 V to AC 230V, a spacer module should be used. The optical separation of the potentials acts as a warning to heed caution in the case of wiring and maintenance works. Thus, the results of wiring errors can be prevented. Internal fusing of the field supply is possible for various field voltages via an appropriate power supply module V DC, Supply/Fuse V AC, Supply/Fuse V AC, Supply/Fuse V DC, Supply/Fuse/Diagnosis V AC, Supply/Fuse/Diagnosis Fig. 2-14: Supply module with fuse carrier (Example ) g0xxx09x

35 The WAGO-I/O-SYSTEM Power Supply Warning In the case of power supply modules with fuse holders, only fuses with a maximum dissipation of 1.6 W (IEC 127) must be used. For UL approved systems only use UL approved fuses. In order to insert or change a fuse, or to switch off the voltage in succeeding bus modules, the fuse holder may be pulled out. In order to do this, use a screwdriver for example, to reach into one of the slits (one on both sides) and pull out the holder. Fig. 2-15: Removing the fuse carrier p0xxx05x Lifting the cover to the side opens the fuse carrier. Fig. 2-16: Opening the fuse carrier p0xxx03x Fig. 2-17: Change fuse p0xxx04x After changing the fuse, the fuse carrier is pushed back into its original position. Modular I/O System

36 36 The WAGO-I/O-SYSTEM 750 Power Supply Alternatively, fusing can be done externally. The fuse modules of the WAGO series 281 and 282 are suitable for this purpose. Fig. 2-18: Fuse modules for automotive fuses, Series 282 pf66800x Fig. 2-19: Fuse modules with pivotable fuse carrier, Series 281 pe61100x Fig. 2-20: Fuse modules, Series 282 pf12400x

37 2.7.4 Supplementary power supply regulations The WAGO-I/O-SYSTEM Power Supply The WAGO-I/O-SYSTEM 750 can also be used in shipbuilding or offshore and onshore areas of work (e.g. working platforms, loading plants). This is demonstrated by complying with the standards of influential classification companies such as Germanischer Lloyd and Lloyds Register. Filter modules for 24-volt supply are required for the certified operation of the system. Item No. Name Description Supply filter Filter module for system supply and field supply (24 V, 0 V), i.e. for field bus coupler/controller and bus power supply ( ) Supply filter Filter module for the 24 V- field supply ( , , ) Therefore, the following power supply concept must be absolutely complied with. Fig. 2-21: Power supply concept g01xx11e Note Another potential power terminal /602/610 must only be used behind the filter terminal if the protective earth conductor is needed on the lower power contact or if a fuse protection is required. Modular I/O System

38 38 The WAGO-I/O-SYSTEM 750 Power Supply Supply example Note The system supply and the field supply should be separated in order to ensure bus operation in the event of a short-circuit on the actuator side. L1 L2 L3 N PE a) b) 1) 1) c) d) ) 2) Shield (screen) bus Main ground bus System Supply 10 A 230V 24V Field Supply 230V 24V Field Supply Fig. 2-22: Supply example 10 A 1) Separation module recommended 2) Ring-feeding recommended a) Power Supply on coupler / controller via external Supply Module b) Internal System Supply Module c) Supply Module passive d) Supply Module with fuse carrier/ diagnostics g0xxx04e

39 The WAGO-I/O-SYSTEM Power Supply Power Supply Unit The WAGO-I/O-SYSTEM 750 requires a 24 V direct current system supply with a maximum deviation of -15% or +20 %. Recommendation A stable network supply cannot be taken for granted always and everywhere. Therefore, regulated power supply units should be used in order to guarantee the quality of the supply voltage. A buffer (200 µf per 1 A current load) should be provided for brief voltage dips. The I/O system buffers for approx 1 ms. The electrical requirement for the field supply is to be determined individually for each power supply point. Thereby all loads through the field devices and bus modules should be considered. The field supply as well influences the bus modules, as the inputs and outputs of some bus modules require the voltage of the field supply. Note The system supply and the field supply should be isolated from the power supplies in order to ensure bus operation in the event of short circuits on the actuator side. WAGO products Article No. Description Primary switched - mode, DC 24 V, 5 A wide input voltage range AC V PFC (Power Factor Correction) Primary switched - mode, DC 24 V, 10 A wide input voltage range AC V PFC (Power Factor Correction) Primary switched - mode, DC 24 V, 2 A wide input voltage range AC V PFC (Power Factor Correction) Rail-mounted modules with universal mounting carrier AC 115 V / DC 24 V; 0,5 A AC 230 V / DC 24 V; 0,5 A AC 230 V / DC 24 V; 2 A AC 115 V / DC 24 V; 2 A Modular I/O System

40 40 The WAGO-I/O-SYSTEM 750 Grounding 2.8 Grounding Grounding the DIN Rail Framework Assembly Insulated Assembly When setting up the framework, the carrier rail must be screwed together with the electrically conducting cabinet or housing frame. The framework or the housing must be grounded. The electronic connection is established via the screw. Thus, the carrier rail is grounded. Attention Care must be taken to ensure the flawless electrical connection between the carrier rail and the frame or housing in order to guarantee sufficient grounding. Insulated assembly has been achieved when there is constructively no direct conduction connection between the cabinet frame or machine parts and the carrier rail. Here the earth must be set up via an electrical conductor. The connected grounding conductor should have a cross section of at least 4 mm 2. Recommendation The optimal insulated setup is a metallic assembly plate with grounding connection with an electrical conductive link with the carrier rail. The separate grounding of the carrier rail can be easily set up with the aid of the WAGO ground wire terminals. Article No. Description Single-conductor ground (earth) terminal block make an automatic contact to the carrier rail; conductor cross section: mm2 Note: Also order the end and intermediate plate ( )

41 The WAGO-I/O-SYSTEM Grounding Grounding Function The grounding function increases the resistance against disturbances from electro-magnetic interferences. Some components in the I/O system have a carrier rail contact that dissipates electro-magnetic disturbances to the carrier rail. Fig. 2-23: Carrier rail contact g0xxx10e Attention Care must be taken to ensure the direct electrical connection between the carrier rail contact and the carrier rail. The carrier rail must be grounded. For information on carrier rail properties, please see chapter Modular I/O System

42 42 The WAGO-I/O-SYSTEM 750 Grounding Grounding Protection For the field side, the ground wire is connected to the lowest connection terminals of the power supply module. The ground connection is then connected to the next module via the Power Jumper Contact (PJC). If the bus module has the lower power jumper contact, then the ground wire connection of the field devices can be directly connected to the lower connection terminals of the bus module. Attention Should the ground conductor connection of the power jumper contacts within the node become disrupted, e.g. due to a 4-channel bus terminal, the ground connection will need to be re-established. The ring feeding of the grounding potential will increase the system safety. When one bus module is removed from the group, the grounding connection will remain intact. The ring feeding method has the grounding conductor connected to the beginning and end of each potential group. Fig. 2-24: Ring-feeding g0xxx07e Attention The regulations relating to the place of assembly as well as the national regulations for maintenance and inspection of the grounding protection must be observed.

43 The WAGO-I/O-SYSTEM Shielding (Screening) 2.9 Shielding (Screening) General The shielding of the data and signal conductors reduces electromagnetic interferences thereby increasing the signal quality. Measurement errors, data transmission errors and even disturbances caused by overvoltage can be avoided. Attention Constant shielding is absolutely required in order to ensure the technical specifications in terms of the measurement accuracy. The data and signal conductors should be separated from all high-voltage cables. The cable shield should be potential. With this, incoming disturbances can be easily diverted. The shielding should be placed over the entrance of the cabinet or housing in order to already repel disturbances at the entrance Bus Conductors The shielding of the bus conductor is described in the relevant assembly guidelines and standards of the bus system Signal Conductors Bus modules for most analog signals along with many of the interface bus modules include a connection for the shield. Note For better shield performance, the shield should have previously been placed over a large area. The WAGO shield connection system is suggested for such an application. This suggestion is especially applicable when the equipment can have even current or high impulse formed currents running through it (for example through atmospheric end loading). Modular I/O System

44 44 The WAGO-I/O-SYSTEM 750 Assembly Guidelines/Standards WAGO Shield (Screen) Connecting System The WAGO Shield Connecting system includes a shield clamping saddle, a collection of rails and a variety of mounting feet. Together these allow many dfferent possibilities. See catalog W4 volume 3 chapter 10. Fig. 2-25: WAGO Shield (Screen) Connecting System p0xxx08x, p0xxx09x, and p0xxx10x Fig. 2-26: Application of the WAGO Shield (Screen) Connecting System p0xxx11x 2.10 Assembly Guidelines/Standards DIN 60204, DIN EN EN Electrical equipping of machines Equipping of high-voltage systems with electronic components (replacement for VDE 0160) Low voltage switch box combinations

45 Fieldbus coupler/controller 45 Fieldbus coupler Fieldbus coupler/controller 3.1 Fieldbus coupler This chapter includes: Description Software for the coupler Hardware View Device supply Fieldbus connection Display elements Configuration interface Hardware address Operating system Data exchange Starting-up LON fieldbus nodes LED display Blink code Fieldbus status Node status Fault message via the blink code of the I/O LED Supply voltage status Fault behavior Fieldbus failure Internal bus fault Technical Data...59 Modular I/O System

46 46 Fieldbus coupler/controller Fieldbus coupler Description This buscoupler allows connection of the WAGO-I/O-SYSTEM 750 as a slave via FTT (Free Topology Transceiver) to the LON fieldbus. All input signals of the sensors are consolidated in the coupler/controller and transfered via fieldbus to the superior control system (PC with Network Management Tool Software). In the superior control system the linkage of the process data can take place. Afterwards the resulted data will be exported via fieldbus and network node to the actuators. The data is transmitted with network variables. In the initialization phase the fieldbus controller determines the physical structure of the node and creates a process image from this with all inputs and outputs. This could involve a mixed arrangement of analog (word by word data exchange) and digital (byte by byte data exchange) modules. The local process image is subdivided into an input and output data area. The data of the analog modules are mapped into the PDOs according to the order of their position downstream of the bus coupler. The bits of the digital modules are compiled to form bytes and also mapped into PDOs. Should the number of digital I/Os exceed 8 bits, the coupler automatically starts another byte Software for the coupler The LNS-based plug-in TOPLON IF (Item-No.: / ) includes ready made, freely combinable applications such as stairwell light, touch dimmers and sunblind controls for the fieldbus coupler The abbreviation IF stands for "Installation Functions". The LNS-based plug-in TOPLON PRIO (Item-No.: / ) is used to connect the fieldbus coupler directly to the LON network. The fieldbus coupler is provided with the RIO-function which is the remote operating mode of TOPLON PRIO. With the RIO-function the I/O data can be directly assigned from the fieldbus node to the network variables. The abbreviation RIO stands for "Remote I/O".

47 Fieldbus coupler/controller 47 Fieldbus coupler Hardware View Fieldbus connection Series 231 (MCS) LonWorks SERVICE STATUS ICOM I/O A B V 0V + + C D Status voltage supply -Power jumper contacts -System Data contacts Supply 24V 0V Supply via power jumper contacts 24V Address Address V Configuration interface SERVICE Fig. 3-1: Fieldbus coupler LON The fieldbus coupler comprises of: Power jumper contacts g031900e Supply module with Internal system supply module for the system supply as well as power jumper contacts for the field supply via I/O module assemblies. Fieldbus interface with the bus connection Display elements (LED's) for status display of the operation, the bus communication, the operating voltages as well as for fault messages and diagnosis Encoder switch for logical node address Service-Pin Configuration interface Electronics for communication with the I/O modules (internal bus) and the fieldbus interface Modular I/O System

48 48 Fieldbus coupler/controller Fieldbus coupler Device supply The supply is made via terminal bocks with CAGE CLAMP connection. The device supply is intended both for the system and the field units. 24V V/0V 10nF DC DC I/O MODULES 0V FiELDBUS INTERFACE ELECTRONIC V 0V 24V 0V 10nF ELECTRONIC FiELDBUS INTERFACE Fieldbus connection Fig. 3-2: Device supply g031901d The integrated internal system supply module generates the necessary voltage to supply the electronics and the connected I/O modules. For the field bus connection, the LON interface is equipped with a 2 pole header, series 231 (MCS). The scope of delivery includes the plug connector Bus cable connection is made isolated from the system. The data decoding method makes it independent of the polarity. Fig. 3-1: Fieldbus connection, series 231 (MCS) g012735x The connection point is mechanically lowered allowing the installation in a 80 mm deep switch box once the plug is connected. The connecting cable Twisted Pair is recommended for the FTT-10- Tranceiver (Free-Topology Transceiver) in the LON coupler. i More information You can find detailled information on more cable types in Chapter Cable specification.

49 Fieldbus coupler/controller 49 Fieldbus coupler Display elements The operating condition of the fieldbus coupler or node is signalled via light diodes (LED). LonWorks SERVICE STATUS ICOM A B V 0V C D C A I/O + + Fig. 3-3: Display elements g031902x LED Color Meaning SERVICE green The 'SERVICE'-LED indicates the status of the Neuron application. STATUS red The 'STATUS'-LED visualizes error states and wink tasks. ICOM green The 'ICOM'-LED indicates the internal communication between Neuron-Chip and µc 165. IO red /green / orange The I/O -LED indicates the operation of the node and signals faults encountered. A green Status of the operating voltage system C green Status of the operating voltage power jumper contacts Configuration interface The configuration interface used for the communication with WAGO-I/O-CHECK or for firmware transfer is located behind the cover flap. Configuration interface Fig. 3-4: Configuration interface g01xx06e The communication cable ( ) is connected to the 4 pole header. Warning The communication cable must not be connected or disconnected while the coupler/controller is powered on! Modular I/O System

50 50 Fieldbus coupler/controller Fieldbus coupler Hardware address Each Neuron-Chip in a WAGO LON fieldbus coupler is provided from the factory with a unique and unambiguous physical address, the Neuron-ID. This address is to be found on the rear of the coupler and on an adhesive tear-off label on the side of the coupler. By a press on the Service-Pin at the beginning of network configuration a special network management telegram will be send out. With this telegram the node informs the network management tool about his Neuron-ID, a unique 48-bit number. During the starting up, the Network Management Tool Software uses the Neuron-ID for the unequivocal addressing of the node. For network communication the NMT software assignes automatically in the standard applications WAGO TOPLON IF and WAGO TOPLON PRIO for each node a logical address. Thereby the encoder switches are without function. i Assigning a logical address via the encoder switch on the buscoupler is only relevant when an independent application is written in Neuron-C, the address can be freely assigned within the program, or in an application involving a data exchange coupler (peer-to-peer). More information Please find information about the LON data exchange coupler (peer-to-peer) in the catalogue information and the expanded data sheet under: The address is adjustable in the range of 0x00 and 0xFF and is used to create the node address. The value of the switch at the bottom is the most significant value of the address (upper Nibble). The value of the switch at the top is the least significant value of the address (lower Nibble). Example: For the logical address 0x63 the switch at the top is set to 3 and the switch at the bottom is set to 6. During the initialization the chosen address is read. If the address is changed during the running mode, the change has no effect until power is cycled ACE ACE SERVICE Fig. 3-2: Encoder switches for logical address and Service-Pin g9123a0x

51 Fieldbus coupler/controller 51 Fieldbus coupler Operating system Following is the configuration of the master activation and the electrical installation of the fieldbus station. After switching on the supply voltage, the coupler performs a self test of all functions of its devices, the I/O module and the fieldbus interface. Following this the I/O modules and the present configuration is determined, whereby an external not visible list is generated. In the event of a fault the coupler changes to the "Stop" condition. The "I/O" LED flashes red. After clearing the fault and cycling power, the coupler changes to the "Fieldbus start" status and the "I/O" LED lights up green. Switching on the supply voltage Initialization, Determination of the I/O modules and the configuration, I/O LED is blinking red Test o.k.? No Yes Fieldbus coupler is in operating mode I/O LED is shining green Fig. 3-5: Operating system Stop red I/O LED indicates blink code g012920e Modular I/O System

52 52 Fieldbus coupler/controller Fieldbus coupler Data exchange With LON, the transmission and exchange of data is made using objects network variables. A network variable (NV) is a type based variable in the Neuron-C programming language for the realisation of logical communication channels between LON - nodes. If data is transferred from a node to the network, this is made using the network output variable (nvo), if data is transferred from the network to a node this is made using the network input variable (nvi). For the exchange of I/O data the coupler provides an assigned value of network input and output variables. This number depends on the selected Neuron-C application (TOPLON IF or TOPLON PRIO), respectively on the network interface of the Neuron-C application. For data access a hardware configuration in WAGO TOPLON IF and in the RIO (Remote I/O)-function of TOPLON PRIO will be done. Thereby the I/O module constellation will be automatically dertermined and entered in the particular plug-in. i Subsequent to this all existing digital and analog inputs and outputs are available for further processing in the software configuration. More information Please find a detailled description on Hard- and Software configuration handling in the corresponding manual to the plug-in WAGO TOPLON IF and WAGO TOPLON PRIO (Item no.: / part 4 (IF) respectively part 5 (PRIO)). If you want futhermore program special own Neuron-C applications, you can use a set of ready functions of the TOPLON -I/O Library. These functions provide important basic-functions for operation with a controll system, as reading of digital and analog inputs and writing on digital and analog outputs. i More information You can download the functions of the I/O library for TOPLON excempt from charges from the Internet under:

53 Fieldbus coupler/controller 53 Fieldbus coupler Starting-up LON fieldbus nodes i The general procedure for starting up a WAGO LON fieldbus node with the buscoupler is described step-by-step for TOPLON IF and for the Remote I/O (RIO) -function of TOPLON PRIO in the brief instructions WAGO TOPLON (Quickstart, Item no.: / part 7). These should form a guideline for further projects. More information The brief instructions WAGO TOPLON (Quickstart, Item no.: / part 7) can be found in the Internet under: Attention This description is given as an example and is limited to the execution of a local start-up of an individual LON fieldbus node with TOPLON IF or with the Remote I/O function of TOPLON PRIO. Modular I/O System

54 54 Fieldbus coupler/controller Fieldbus coupler LED display The coupler possesses several LEDs for on site display of the coupler operating status or the complete node. LonWorks SERVICE STATUS ICOM A B V 0V C D C A I/O + + Fig. 3-6: Display elements g031902x A differentiation between two LED groups is made. The first group = fieldbus contains the solid color LEDs having the designation SERVICE (green), STATUS (red) und ICOM (green) indicating the operating status of the communication via LON. The second group = internal bus consists of the three-color I/O LED (red/green/orange). This LED is used to display the status of the internal bus and software exception handling, i. e. the status of the fieldbus node. LEDs located on the right-hand side in the coupler power supply section show the status of the supply voltage Blink code Detailed fault messages are displayed with the aid of a blink code. A fault is cyclically displayed with up to 3 blink sequences. The first blink sequence (approx. 10 Hz) starts the fault display. The second blink sequence (approx. 1 Hz) following a pause. The number of blink pulses indicates the fault code. The third blink sequence (approx. 1 Hz) follows after a further pause. The number of blink pulses indicates the fault argument.

55 Fieldbus coupler/controller 55 Fieldbus coupler Fieldbus status The operating status of the communication via LON is signalled via the top LED group (SERVICE, STATUS and ICOM). The SERVICE LED is directly connected to the Service Pin of the Neuron Chip and indicates the state of the Neuron-C application. SERVICE- LED green (lights up for half a second and then remains off) green blinks (1 second on, 1 second off) green blinks (1 second on, 2 seconds off then remains on) green blinks cyclically Meaning Configuration successfully completed. Adress assigned and Neuron-C application is active. No configuration, no addressing of the Network Management Tool (domain, subnet, node), Neuron-C application is not activated yet. No Neuron-C application loaded on the node. Watchdog Timer, Neuron-C application error Trouble shooting Press the Service-Pin of the coupler and check the Neuron-C application. Load the Neuron-C application from your network management tool software into the node. Check the Neuron-C application, if necessary restart the application. The STATUS LED indicates that a coupler is activated. This is the case when a wink task is sent and when the communication of both network manager and DPRAM interface fails. STATUS- LED red blinks (0,5 Hz) red blinks (2 Hz) Meaning 5 times within the WINK task (fault messages basically have a greater priority than the WINK task. DPRAM interface communication fault (has priority) Trouble shouting Reset fieldbus coupler hardware by switching off the supply voltage of the coupler for about 3 seconds. Change the fieldbus coupler if necessary. The ICOM-LED indicates a communication and data exchange between Neuron Chip and µc165. ICOM-LED Meaning Trouble shooting green Data exchange off No data exchange Check bus system integrity Modular I/O System

56 56 Fieldbus coupler/controller Fieldbus coupler Node status LED Color Meaning IO red /green / orange The 'I/O' LED indicates the node operation and signals faults occurring. The coupler starts after switching on the supply voltage. The "I/O" LED flashes red. Following an error free start up the "I/O" LED changes to green steady light. In the case of a fault the "I/O" LED continues blinking red. The fault is cyclically displayed with the blink code. Fig. 3-7: Signalling the LED's node status g012111e After overcoming a fault, restart the coupler by cycling the power. I/O-LED Meaning Trouble shooting green Data cycle on the internal bus off No data cycle on the internal bus red Coupler hardware defective Change the coupler red blinks a) When starting: internal bus is initialized b) During operation: general internal bus fault Evaluate the fault signal (fault code and fault argument) red blinks cyclically Fault message during internal bus reset and internal fault. Evaluate the fault signal (fault code and fault argument)

57 Fieldbus coupler/controller 57 Fieldbus coupler Fault message via the blink code of the I/O LED Fault argument Fault description Trouble shooting Fault code 1: Hardware and configuration fault 0 EEPROM check sum fault / check sum Change the fieldbus coupler fault in parameter area of the flash memory 1 Overflow of the internal buffer memory Change the fieldbus coupler for the inline code 2 Unknown data type Change the fieldbus coupler 3 Module type of the flash program Change the fieldbus coupler memory could not be determined / is incorrect 4 Fault during writing in the flash memory Change the fieldbus coupler 5 Fault when deleting the FLASH memory Change the fieldbus coupler 6 Changed I/O module configuration Change the fieldbus coupler found after AUTORESET 7 Fault when writing in the serial EEPROM 8 Invalid firmware 9 Checksum error serial EPROM 10 Initial error serial EPROM 11 Read error serial EPROM 12 Timeout error serial EPROM Fault code 2: Fault in programmed configuration n* (n<0, n>65) Incorrect table entry Change the entry in the configuration for I/O module n. Fault code 3: Internal bus command fault 0 I/O module(s) has (have) identified internal bus command as incorrect. Fault code 4: Internal bus data fault Determine where the module bus has been interrupted by removing the fieldbus cable. Plug the end module in the middle of the node. Switch the coupler off and on again. If the I/O LED keeps blinking, displace the end module anew. If there is only one module left which is connected to the coupler and if the I/O LED lights up, either the module or the coupler is defective. Change the defective component. n* (n<0, n>65) Interruption after the nth module Replace the nth module within the node Fault code 5: Register communication fault n* (n<0, n>65) Module bus fault during register communication Fault code 6: Fieldbus specific fault 0 Fault code 6 is not implemented Fault code 7: I/O module not supported Fault code 8: unused n* I/O module not supported at position n 0 Fault code 8 is not used. Fault code 9: CPU TRAP error 1 Illegal Opcode 2 Stack overflow 3 Stack underflow 4 NMI Replace the nth module within the node * The number of blink pulses (n) indicates the position of the I/O module. I/O modules without data are not counted (i.e. supply module without diagnosis) Modular I/O System

58 58 Fieldbus coupler/controller Fieldbus coupler Example: the 13 th I/O module is removed. 1. The "I/O" LED generates a fault display with the first blink sequence (approx. 10 Hz). 2. The first pause is followed by the second blink sequence (approx. 1 Hz). The "I/O" LED blinks four times and thus signals the fault code 4 (internal bus data fault). 3. The third blink sequence follows the second pause. The "I/O" LED blinks twelve times. The fault argument 12 means that the internal bus is interrupted after the 12th I/O module Supply voltage status There are two green LEDs in the coupler supply section to display the supply voltage. The left LED (A) indicates the 24 V supply for the coupler. The right hand LED (C) signals the supply to the field side, i.e. the power jumper contacts. LED Color Meaning A green Status of the operating voltage system C green Status of the operating voltage power jumper contacts Fault behavior Fieldbus failure Internal bus fault A fieldbus failure is given i. e. when the network manager (PC with Network Management Tool Software) cuts-out or the bus cable is interrupted. A fault in the network manager can also lead to a fieldbus failure. For the LON fieldbus coupler the fault code and the fault argument are transfered by network variables or explicite messages. An internal bus fault is created, for example, if an I/O module is removed. If this fault occurs during operation, the output modules behave in the same manner as an I/O module stop. The "I/O" LED blinks red. The coupler generates a fault message (fault code and fault argument). Once the internal bus fault is fixed, the controller starts up following power being cycled as during a normal start-up. The transfer of the process data is then resumed and the node outputs are correspondingly set.

59 Fieldbus coupler/controller 59 Fieldbus coupler Technical Data System data No. of nodes Transmission medium Max. length of fieldbus segment Topology Baud rate Buscoupler connection Standards and approvals 64 without repeater, 127 with repeater Twisted Pair - FTT free topology 500 m,bus topology 2700 m in accordance with LON specification 78 kbps UL E175199, UL 508 Conformity marking Technical data Max. number of I/O modules digital signals analog signals Config. possibility 2-pole male connector, series 231 (MCS) female connector ( ) is included CE 62 per node max. 248 (Inputs and Outputs) max. 124 (Inputs and Outputs) via PC with LON interface Voltage supply DC 24 V (-15 % / + 20 %) Input current max Efficiency of the power supply 87 % Internal current consumption Total current for I/O modules Isolation 500 ma at 24 V 300 ma at 5 V 1700 ma at 5 V 500 V system/supply Voltage via power jumper contacts DC 24 V (-15 % / + 20 %) Current via power jumper contact max DC 10 A Transceiver Dimensions (mm) W x H x L Weight FTT 10 A 51 x 65* x 100 (*from top edge of mounting rail) ca. 180 g EMC Immunity to interference acc. EN (96) EMC Emission of interference acc. EN (93) Modular I/O System

60 60 Fieldbus coupler/controller Fieldbus controller Fieldbus controller This chapter includes: Description Software for the controller Hardware View Device supply Fieldbus connection Display elements Configuration and programming interface Operating mode switch Hardware address Operating system Start-up PLC cycle Process image Data exchange Memory areas Addressing Starting-up LON fieldbus nodes Programming the PFC with WAGO-I/O-PRO LON library elements for WAGO-I/O-PRO IEC Program transfer LED display Blink code Fieldbus status Node status Fault message via the blink code of the I/O LED Supply voltage status Fault behavior Fieldbus failure Internal bus fault Technical Data Description The programmable fieldbus controller (short: PFC) combines the LON interface connection with that of a programmable logic control (PLC). The application program is created with WAGO-I/O-PRO 32 in accordance with IEC According to the IEC programming, data processing occurs locally in the PFC. The link results created in this manner can be put out directly to the actuators or transmitted to the higher ranking control system via the bus. The data is transmitted with network variables.

61 Fieldbus coupler/controller 61 Review In the initialization phase the fieldbus controller determines the physical structure of the node and creates a process image from this with all inputs and outputs. This could involve a mixed arrangement of analog (word by word data exchange) and digital (byte by byte data exchange) modules. The local process image is subdivided into an input and output data area. The data of the analog modules are mapped into the PDOs according to the order of their position downstream of the bus coupler. The bits of the digital modules are compiled to form bytes and also mapped into PDOs. Should the number of digital I/Os exceed 8 bits, the coupler automatically starts another byte. The programmer has access to all fieldbus and I/O data. Attention An application program meeting IEC standards is necessary for the fieldbus controller to operate. The bus module data must be copyed on the PFC variables (fieldbus variables) via the IEC application program, in order to be read Software for the controller PLC applications on the programmable fieldbus controller can be a- chieved with the programming and visualization tool WAGO-I/O-PRO 32 (Item-No.: / ) meeting IEC standards. The LNS-based Plug-In TOPLON PRIO (Item-No.: / ) is used to connect the LON network with the programmable fieldbus controller. TOPLON PRIO is used to link the programming tool WAGO-I/O-PRO 32 and to assign the IEC variables to the network variables. The abbreviation "PRIO" means "Programmable Remote I/O". Modular I/O System

62 62 Fieldbus coupler/controller Review Hardware View Fieldbus connection Series 231 (MCS) LonWorks SERVICE STATUS ICOM I/O USR A B V 0V + + C D Status voltage supply -Power jumper contacts -System Data contacts Supply 24V 0V Supply via power jumper contacts 24V Address V Address Configuration and programming interface Fig. 3-8: Fieldbus controller LON The fieldbus coupler comprises of: Power jumper contacts g081900e Supply module with Internal system supply module for the system supply as well as power jumper contacts for the field supply via I/O module assemblies. Fieldbus interface with the bus connection Display elements (LED's) for status display of the operation, the bus communication, the operating voltages as well as for fault messages and diagnosis Encoder switch for logical node address Service-Pin Configuration and programming interface and operating mode switch Electronics for communication with the I/O modules (internal bus) and the fieldbus interface

63 Fieldbus coupler/controller 63 Review Device supply The supply is via fed in terminal blocks with CAGE CLAMP connection. Device supply is intended for system supply and field side supply. 24V V/0V 10nF DC DC I/O MODULES 0V FiELDBUS INTERFACE ELECTRONIC V 0V 24V 0V 10nF ELECTRONIC FiELDBUS INTERFACE Fieldbus connection Fig. 3-9: Device supply g081901e The integrated internal system supply module generates the necessary voltage to supply the electronics and the connected I/O modules. For the field bus connection, the LON interface is equipped with a 2 pole header, series 231 (MCS). The scope of delivery includes the plug connector Bus cable connection is made isolated from the system. The data decoding method makes it independent of the polarity. Fig. 3-3: Fieldbus connection, series 231 (MCS) g012735x The connection point is mechanically lowered allowing the installation in a 80 mm deep switch box once the plug is connected. The connecting cable Twisted Pair is recommended for the FTT-10- Tranceiver (Free-Topology Transceiver) in the LON coupler. i More information You can find detailled information on more cable types in Chapter Cable specification. Modular I/O System

64 64 Fieldbus coupler/controller Review Display elements The operating condition of the fieldbus coupler or node is signalled via light diodes (LED). LonWorks SERVICE STATUS ICOM A B V 0V C D C A I/O USR + + Fig. 3-10: Display elements g081902x LED Color Meaning SERVICE green The 'SERVICE'-LED indicates the status of the Neuron application. STATUS red The 'STATUS'-LED visualizes error states and wink tasks. ICOM green The 'ICOM'-LED indicates the internal communication between Neuron-Chip and µc 165. IO red /green / orange The I/O -LED indicates the operation of the node and signals faults encountered. USR red /green / orange The 'USR' LED can be selected by a user program in a programmable fieldbus controller. A green Status of the operating voltage system C green Status of the operating voltage power jumper contacts Configuration and programming interface The configuration and programming interface is located behind the cover flap. This is used to communicate with WAGO-I/O-CHECK and WAGO-I/O-PRO 32 as well as for firmware transfer. open flap Configuration and programming interface Fig. 3-11: Configuration and programming interface g01xx07e The communication cable ( ) is connected to the 4 pole header.

65 Fieldbus coupler/controller 65 Review Warning The communication cable must not be connected or disconnected while the coupler/controller is powered on! Operating mode switch The operating mode switch is located behind the cover flap beside the configuration and programming interface. open flap Configuration and interface programming interface Fig. 3-12: Operating mode switch Mode switch The switch is a push/slide switch with 3 settings and a hold-to-run function. Operating mode switch From middle to top position From top to middle position Lower position, bootstrap Push down (i.e.with a screwdriver) Function Activate program processing (RUN) Stop program processing (STOP) For original loading of firmware, not necessary for user g01xx08e Hardware reset All outputs are reset; variables are set to 0 or to FALSE or to an initial value. The hardware reset can be performed with STOP as well as RUN in any position of the operating mode switch! An operating mode is internally changed at the end of a PLC cycle. Attention If outputs are set when switching over the operating mode switch from RUN to STOP, they remain set! Switching off the software side i.e. by initiators, are ineffective, because the program is no longer processed. Note With "GET_STOP_VALUE" (library "System.lib") WAGO-I/O-PRO 32 provides a function which serves to recognize the last cycle prior to a program stop giving the user the possibility to program the behavior of the controller in case of a STOP. With the aid of this function the controller outputs can be switched to a safe condition. Modular I/O System

66 66 Fieldbus coupler/controller Review Hardware address Each Neuron-Chip in a WAGO LON fieldbus controller is provided from the factory with a unique and unambiguous physical address, the Neuron-ID. This address is to be found on the rear of the controller and on an adhesive tear-off label on the side of the controller. By a press on the Service-Pin at the beginning of network configuration a special network management telegram will be send out. With this telegram the node informs the network management tool about his Neuron-ID, a unique 48-bit number. During the starting up, the Network Management Tool Software uses the Neuron-ID for the unequivocal addressing of the node. For network communication the NMT software assignes automatically in the standard application WAGO TOPLON PRIO for each node a logical address. Thereby the encoder switches are without function. With the address setting via the encoder switches in WAGO TOPLON PRIO the first byte of the Location ID (information on the fieldbus node location) is generated. The address is adjustable in the range of 0x00 and 0xFF and is used to create the node address. The value of the switch at the bottom is the most significant value of the address (upper Nibble). The value of the switch at the top is the least significant value of the address (lower Nibble). Example: If the logical address 0x63 is set with the switch at the top to 3 and the switch at the bottom to 6, the first byte of Location ID is generated to During the initialization the chosen address is read. If the address is changed during the running mode, the change has no effect until power is cycled ACE ACE SERVICE Fig. 3-4: Encoder switches for logical address and Service-Pin g9123a0x

67 Fieldbus coupler/controller 67 Review Operating system Start-up The controller starts-up after switching on the supply voltage or after a hardware reset. The PLC program in the flash memory is transferred to the RAM. This is followed by the initialization of the system. The controller determines the I/O modules and the present configuration. The variables are set to 0 or to FALSE or to an initialization value given by the PLC program. The flags retain their status. The "I/O" LED blinks red during this phase. Attention PFC program variables that are linked with network input variables are also set to 0 or to FALSE after reset, even if they are defined in the retentive memory area or as a flag. Therefore, variables used for external configuration via LON fieldbus must be linked with CPs (Configuration Properties). i More information You can find detailled information on the Configuration Properties (CPs) in Chapter "Memory areas" and Chapter "Addressing the configuration variable". Following an error free start-up, the controller changes over to the "RUN" mode. The "I/O" LED lights up green. In the delivery state the flash memory is blank therefore no PFC program is included. Attention An application program in accordance with IEC is absolutely necessary for the fieldbus controller to operate. The data of the bus modules need to be copyed into the PFC variables (fieldbus variables) via the IEC application program, in order to be used. Modular I/O System

68 68 Fieldbus coupler/controller Review PLC cycle The PLC cycle starts following an error free start-up when the operating mode switch is in the top position or by a start command from the WAGO-I/O-PRO 32. The input and output data of the fieldbus and the I/O modules as well as the times are read. Subsequently the PLC program in the RAM is processed followed by the output data of the fieldbus and the I/O modules in the process image. Operating system functions, amongst others, for diagnosis and communication are performed and the times are updated at the end of the PLC cycle. The cycle starts again with the reading in of the input and output data and the times. The change of the operating mode (STOP/RUN) is made at the end of a PLC cycle. The cycle time is the time from the start of the PLC program to the next start. If a loop is programmed within a PLC program, the PLC running time and thus the PLC cycle are extended correspondingly. The inputs, outputs and times are not updated during the processing of the PLC program. This update occurs in a defined manner only at the end of the PLC program. For this reason it is not possible to wait for an event from the process or the elapse of a time within a loop.

69 Fieldbus coupler/controller 69 Review Switching on the supply voltage I/O LED is blinking orange Is a PLC program in the Flash memory? Yes PLC program transfer from the flash memory to RAM No Determination of the I/O modules and the configuration Determination of the I/O modules and the configuration I/O LED is blinking red Initialization of the system Test o.k.? No Variables are set to 0 or FALSE or to their initial value, flags remain in the same status. Stop No Test o.k.? PLC cycle Yes STOP Operating mode RUN Reading inputs, outputs and times operating mode switch is in the top position or start command in WAGO-IO-PRO 32: Online/Start or Online/Stop Fieldbus data, data of I/O modules Yes PLC program in the RAM is processed Fieldbus start behaviour as a coupler I/O LED is shining green Writing outputs Fieldbus data, data of I/O modules Operating system functions, updating times Operating mode RUN STOP operating mode switch is in the top position or start command in WAGO-IO-PRO 32: Online/Start or Online/Stop Fig. 3-13: Controller operating system g012941e Modular I/O System

70 70 Fieldbus coupler/controller Review Process image Attention The DPRAM of the fieldbus controller does not contain the process image but the PFC variables from the IEC program. The module data must be copyed on the PFC variables via the IEC application program, in order to be processed by the Neuron-Chip. After switching on, the controller recognizes all I/O modules plugged into the node which supply or wait for data (data width/bit width > 0). In nodes analog and digital I/O modules can be mixed. The data of the digital I/O modules is bit orientated, i.e. the data exchange is made bit for bit. The analog I/O modules are all byte orientated I/O modules, i.e. those where the data exchange is made byte for byte. These I/O modules include for example the counter modules, I/O modules for angle and path measurement as well as the communication modules. Data width = 1 Word / channel Analog input modules Analog output modules Input modules for thermal elements Input modules for resistance sensors Pulse width output modules Interface module Up/down counter I/O modules for angle and path measurement Data width = 1 Bit / channel Digital input modules Digital output modules Digital output modules with diagnosis (2 Bit / channel) Power supply modules with fuse holder / diagnosis Solid State power relay Relay output modules Tab. 3-1: I/O module data width The controller produces an internal process image from the data width and the type of I/O module as well as the position of the I/O modules in the node. It is divided into an input and an output data area. The data of the I/O modules is separated form the local input and output process image in the sequence of their position after the coupler in the individual process image. In the respective I/O area, first of all analog modules are mapped, then all digital modules, even if the order of the connected analog and digital modules does not comply with this order. The digital channels are grouped, each of these groups having a data width of 1 byte. Should the number of digital I/Os exceed 8 bits, the controller automatically starts another byte. Note For the number of input and output bits or bytes of the individually activated on I/O modules please refer to the corresponding I/O module description.

71 Fieldbus coupler/controller 71 Review Attention The I/O module data must be copyed into the PFC variables via the IEC application program, in order to be processed by the Neuron-Chip. Note A process image restructuring may result if a node is changed or extended. In this case the process data addresses also change in comparison with earlier ones. In the event of adding modules, take the process data of all previous modules into account Data exchange With LON, the transmission and exchange of data is made using objects network variables. A network variable (NV) is a type based variable in the Neuron-C programming language for the realisation of logical communication channels between LON - nodes. If data is transferred from a node to the network, this is made using the network output variable (nvo), if data is transferred from the network to a node this is made using the network input variable (nvi). For the exchange of I/O data the coupler provides an assigned value of network input and output variables. This number depends on the selected network interface of the Neuron-C application TOPLON PRIO. i For the access on the PFC variables data, in TOPLON PRIO a so-called Symbol-file (Sym-file) will be imported. This file contents all defined IEC variables and will be created in the programming software WAGO-I/O-PRO 32. After the import in WAGO TOPLON PRIO all defined boolean and other PFC input and output variables according IEC are automatically available in the plug-in for further processing. More information Please find a detailled description on handling of the IEC programming software WAGO-I/O-PRO 32 in the respective manual (Item no.: / ). The Software configuration handling in the plug-in WAGO TOPLON PRIO is extensive explained in the corresponding manual to this plug-in (Item no.: / part 5). Modular I/O System

72 72 Fieldbus coupler/controller Review Memory areas The controller uses a memory space of 256 words (word ) for the physical input and output data. Attention The physical I/O module data can only be read internal by the CPU. The data must be copyed into the PFC variables via the IEC program, in order to be processed by the Neuron-Chip and accessed from the fieldbus side. The controller is assigned an additional memory space for mapping the PFC variables defined according to IEC This extended memory space (word each) is used to map the PFC variables behind the physical process image. Programmable fieldbus controller fieldbus nvi nvo memory area memory area for input for I/O module variable data input data word 256 IEC word 0 program 11 PFC input variables word 511 memory area for output variable data word PFC output variables word 511 CPU input modules word 255 memory area for I/O module output data word 0 2 output modules word 255 I/O modules I O Fig. 3-5: Memory areas and data exchange for a fieldbus controller g012753e 1 The data of the input modules can only be read internal by the CPU. Via the IEC program they can be processed or directly copyed on PFC output variables. 2 In the same manner, writing to the output modules is only possible from the CPU. 3 Transferring data from the fieldbus side to the controller is made using network input variables (nivs). These are either processed in the Neuron-Chip via the Neuron-C application or directly transmitted and written to the memory area of the PFC input variables via the Dual-Port-RAM. Subsequently the data can be read by the CPU in order to be processed. 4 Once the data has been processed through the IEC program, the CPU writes the variable data to the memory area of the PFC output variables. The variables are transferred to the Neuron-Chip via the DPRAM and processed in the Neuron-C application. Subsequently the data can be accessed from the fieldbus side using network output variables (nvos).

73 Fieldbus coupler/controller 73 Review In addition, the controller offers further memory spaces. A special memory space is reserved for the variables used for external configuration. The binding of the configuration variables with the so-called Configuration Properties (CPs) bind them permanently. CPs are variables comparable to nvis that are used for the external controller configuration via the LON network. As opposed to the nvis, the settings via CPs are stored in the LNS data base and in the EEPROM of the Neuron-Chip. Thus they are still available after a reset and they can be subsequently accessed when changing the node for example. The address range of the configuration variables spans 128 double words. The following memory spaces inside the controller cannot be accessed from the fieldbus side: RAM Retain The RAM memory is used to create variables not required for communication with the interfaces but for internal processing, such as computation of results. The retain memory is a non-volatile memory, i.e. all values are retained following a voltage failure. The memory management is automatic. In this memory area, flags for the IEC program are filed together with variables without memory space addressing or variables which are explicitly defined with "var retain". Note The automatic memory management can cause a data overlap. For this reason, we recommend not to use a mix of flags and retain variables. Code memory The IEC program is filed in the code memory. The code memory is a flash ROM. Once the supply voltage is applied, the program is transmitted from the flash to the RAM memory. After an error-free start-up, the PFC cycle starts when the operating mode switch is turned to its upper position or by a start command from WAGO-I/O-PRO 32. Modular I/O System

74 74 Fieldbus coupler/controller Review Addressing The data of I/O modules, PFC-variables and CPs are absolute adressed for processing internally in the controller through an IEC program. This application program for the PLC functionality (CPU) of the PFC is created with WAGO-I/O-PRO 32 in accordance with IEC The direct display of individual memory cells (absolute addresses) in accordance with IEC is made using special character strings in accordance with the following table: Position Character Nomination Comment 1 % Apply an absolute address 2 I Input Q M Output Flag 3 X* Single bit Data width B W D Byte (8 Bits) Word (16 Bits) 4 Address * The character 'X' for single bits can be deleted. Tab. 3-2: Absolute addresses Double word (32 Bits)

75 Fieldbus coupler/controller 75 Review Attention Enter the absolute address character strings without blanks! Fig. 3-6: Examples for absolute addresses g912203e Note For the number of input and output bits or bytes of the individual I/O modules please refer to the corresponding I/O module description. The data width of the PFC variables depends on the according data type Addressing the I/O modules Upon switching on the supply voltage, the data of the I/O modules are mapped into the process image. The PFC functions simular to that of a PLC s CPU enable the bus modules data and PFC variables to be processed within the IEC environment as internal applications, such as linking DIs with DOs. With absolute addresses, the CPU directly accesses the bus module data in the respective memory range (word 0 to 255). Following this, the linking results can be directly written in the output data via absolute addressing. Modular I/O System

76 76 Fieldbus coupler/controller Review Inputs I/O modules Outputs 750-4xx...6xx %IW0 %QW0 PII PIO %IW255 %QW255 Inputs Outputs PLC functionality (CPU) Programmable Fieldbus Controller PII = Process Input Image PIO = Process Output Image Fig. 3-7: Data exchange between PLC functionality (CPU) of the PFC and I/O modulesg012943d Note A process image restructuring may result if a node is changed or extended. In this case the process data addresses also change in comparison with earlier ones. In the event of adding a module, take the process data of all previous modules into account Addressing the PFC variables The PFC variables are to be found in the memory ranging from word 256 to 512. When programming an internal PLC application, the CPU accesses PFC variables via absolute addresses. However, depending on the data type used, the same physical address space is addressed differently. Byte addresses Word addresses Double word addresses Tab. 3-3: Utiliztation of the address range for PFC variables Bit Address Word address.0 to.15 Byte Address 1st byte: 2 x Word address 2nd byte: 2 x Word address + 1

77 Fieldbus coupler/controller 77 Review DWord Address lower section: Word address (even numbers) / 2 upper section: Word address (odd numbers) / 2, rounded off Attention To avoid address overlapping all the previous address assignments must be taken into account! Template Addressing becomes very complex when using a free memory organisation and mixing different data types. Therefore, the template (Template_750_819.pro) for the IEC programming tool WAGO-I/O-PRO 32 enables considerable work saving. The template predefines memory areas, so that address overlapping can generally be excluded. i More information You can find the file "Template_750_819.pro" in the Internet under: AUTOMATION /LON DOWNLOADS/PROGRAMMING and also on the CD ROM TOPLON (Item-No.: / ). After selecting "Open" and "Save as..." the file is used as template for a new project with the programming tool WAGO-I/O-PRO 32. The memory spaces of PFC variables are divided into data type areas. This results in the maximum number of predefined variables: PFC input variables (word 256 to 512) PFC output variables (word 256 to 512) 20 x double word 20 x double word 100 x word 100 x word 100 x Int 100 x Int 100 x byte 100 x byte 496 x bit 496 x bit Tab. 3-4: Maximum number of variables in the template file Template_ pro The following address ranges for input and output memory space (word 256 to 512) are preset within the template: PFC input variables (word 256 to 512) PFC output variables (word 256 to 512) 2 x double word %ID138 - %ID139 2 x double word %QD138 - %QD x word %IW320 - %IW x word %QW320 - %QW x Int %IW330 - %IW x Int %QW330 - %QW x byte %IB845 - %IB x byte %QB845 - %QB859 Modular I/O System

78 78 Fieldbus coupler/controller Review 20 x bit %IX475.0-%IX x bit %QX475.0-%QX476.3 Tab. 3-5: Presetting addresses in the template file Template_ pro This template can be upgraded and modified at any time. Once the IEC application programmed in WAGO-I/O-PRO 32 has been compiled, all declared variables can be stored in a Symbol-file (SYM-file). After downloading the SYM-file in the WAGO TOPLON PRIO plug-in, all variables are ready to be linked with network variables. Note Given that all variables are automatically imported from the template into the standard WAGO TOPLON PRIO application, unused variables should not be deleted from the template in order to achieve a better clarity Addressing the configuration variables Variables used for external configuration via the LON fieldbus are absolute addressed in double flag words. The address range begins with %MD1792 and has a capacity of 128 variables. After downloading the SYM-file into WAGO TOPLON PRIO, all defined configuration variables are ready to be linked with CPs (Configuration Properties) just like the PFC variables Starting-up LON fieldbus nodes i The general procedure for starting up a WAGO LON fieldbus node with the fieldbus controller is described step-by-step for TOPLON PRIO in the brief instructions WAGO TOPLON (Quickstart, Item no.: / part 7). These should form a guideline for further projects. More information The brief instructions WAGO TOPLON (Quickstart, Item no.: / part 7) can be found in the Internet under: Attention This description is given as an example and is limited to the execution of a local start-up of an individual LON fieldbus node with TOPLON PRIO Programming the PFC with WAGO-I/O-PRO 32 Due to the IEC programming of the LON fieldbus controller you have the option to use the functionality of a PLC.

79 Fieldbus coupler/controller 79 Review An application program according to IEC is created using the programming tool WAGO-I/O-PRO 32 (order No.: / ). i This manual, however, does not include a description of how to program with WAGO-I/O-PRO 32. In contrast, the following chapters are to describe the special modules for WAGO-I/O-PRO 32 for you to utilize explicitly for programming the LON fieldbus controller. The description also explains transmitting the IEC program into the controller and loading a suitable communication driver. More information For a detailed description of how to use the software, please refer to the WAGO-I/O-PRO 32 manual (order No.: / ). Modular I/O System

80 80 Fieldbus coupler/controller Review LON library elements for WAGO-I/O-PRO 32 You are offered various libraries for different IEC programming applications in WAGO-I/O-PRO 32. They contain modules for universal use and can, thereby, facilitate and speed up the creation of your program. As standard, the library 'standard.lib' is available to you. The library described in the following is specifically intended for LON projects in the building automation with WAGO-I/O-PRO 32. i These libraries include functional modules for building automation and they are loaded on the WAGO-I/O-PRO CD. Having integrated this library, you have access to its POUs, data types and global variables which can be used in the same manner as those defined by yourself. More information For a detailed description of the POUs and the software operation, please refer to the WAGO-I/O-PRO 32 manual (order No.: / ). i More information The function blocks of the LON libraries for WAGO-I/O-PRO 32 are being constantly upgraded. You can download the latest upgrade of the libraries from the Internet at: ions/index.htm.

81 Fieldbus coupler/controller 81 Review This page has been intentionally left blank, so that you can file the printed documentation of the last upgrade of the WAGO-I/O-PRO function blocks. Modular I/O System

82 82 Fieldbus coupler/controller Review IEC Program transfer Program transfer from the PC to the controller following programming of the desired IEC application can be made in two different ways: via the serial interface or via the fieldbus Transmission via the serial interface Use the WAGO communication cable to produce a physical connection via the serial interface. This is contained in the scope of delivery of the programming tool IEC , order No.: / , or can be purchased as an accessory under order No.: Connect the COMX port of your PC with the communication interface of your controller via the WAGO communication cable. Warning The communication cable must not be connected or disconnected while the coupler/controller is powered on! i A communication driver is required for serial data transmission. In WAGO- I/O-PRO 32, this driver and its parameters are entered in the "Communication parameters" dialog. More information Please find more information on the installation of the communication driver and the detailed description of software handling in the manual WAGO-I/O-PRO 32 (order no.: / ). 1. Start the WAGO-I/O-PRO 32 software via Start/Programs or by double clicking on the WAGO-I/O-PRO-32 symbol on your desk top. 2. In the "Online" menu click on the "Communication parameters" menu point. The dialog "Communication parameters" opens. The basic setting of this dialog has not yet any entries. 3. In the selection window mark the desired driver on the right-hand dialog side (i.e. "Serial (RS232)", to configure the serial connection between PC and the controller). 4. In the center window of the dialog, the following entries have to appear: - Parity: Even - Stop bits: 1 If necessary, change the entries accordingly. You can now commence testing the controller.

83 Fieldbus coupler/controller 83 Review Note To be able to access the controller, ensure that the operating mode switch of the controller is set to the center or the top position. 5. Under "Online" click on the "Log-on" menu point to log into the controller. (The WAGO-I/O-PRO 32 server is active during online operation. The communication parameters cannot be polled.) 6. If there is not a program in the controller, a window appears asking whether or not the program is to be loaded. Confirm with "Yes". Subsequently the current program will be loaded. 7. As soon as the program is loaded, you can start program via the "Online" menu, menu point "Start". At the right-hand end of the status bar, the system signals "ONLINE RUNNING"." gemeldet. 8. To terminate the online operation, return via the "Online" menu and click on the "Log-off" menu point Transmission via the fieldbus The field bus cable is the physical connection between the PC and the controller. In TOPLON PRIO the transfer of the IEC programm take place via Menue "WAGO-I/O-PRO\Download IEC Application". Fig. 3-8: Main view TOPLON PRIO g012377e Modular I/O System

84 84 Fieldbus coupler/controller Review 1. Start the Plug-In TOPLON PRIO in the NMT (Networkmanagement Tool Software). 2. Click on the menue "WAGO-I/O-PRO"/"Download IEC Applikation" in the main view of TOPLON PRIO. A dialog window "Selection of a IEC Application" appears. Fig. 3-9: Dialog window for selection of an IEC Application p9123a2e 3. Select the desired IEC application with the extension *.hex and click on the button "ÖFFNEN". The selection window is closed and the PLC-program, respectively the PLC-programm modifications are adopt into the controller.