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Moeller ps4-201-mm1, Hardware And Engineering

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About the PS4-200 
Compact PLC

14

04/

99 AW

B

 27-

1184 G

B

, 

Operating mode selector switch/
reset button

You can select the “Halt” (stop), “Run” and 
“Run M-Reset” modes with the operating mode 
selector switch. The selected mode is activated 
when you press the Reset button. The operating 
states are described in detail in the chapter 
“Operation”.

Plug connector for local expansion module

The plug connector provides the interface for 
connecting the LE4-... local expansion modules

Real-time clock
The PLC is equipped with a battery-backed, real-
time clock. It facilitates the time-controlled switching 
of machines and equipment. You can change 
between summer and winter time in the user 
program. A function block in the user program can be 
used to address and scan the real-time clock.

Summary of Contents for ps4-201-mm1

Page 1: ...B 1st published 1994 edition 04 94 2nd published 1995 edition 04 94 3rd published 1997 edition 06 97 4th published 1999 edition 04 99 See modifications list on page II Moeller GmbH Bonn Author Werner...

Page 2: ...ons of the mains voltage from the rated value must not exceed the tolerance limits given in the specifications otherwise this may cause malfunction and dangerous operation Emergency stop devices compl...

Page 3: ...84 GB Edition date Page Description New Modifica tion Omitted 04 99 gen Sucosoft S 30 S4 Sucosoft S 4 S 40 AWB 27 1185 1186 AWB 27 1280 D AWB 2700 1305 D AWB 27 1281 D AWB 2700 1306 D 14 Legend 41 Sla...

Page 4: ...II 04 99 AWB 27 1184 GB...

Page 5: ...conet K interface 22 Setting the bus terminating resistors 23 Local expansion 23 Arrangement of the control cabinet 24 Power supply 25 Avoiding interference 30 3 Mounting 35 Mounting on a top hat rail...

Page 6: ...our 61 Program transfer 63 Starting the PLC with a program stored in the memory module 65 Programming via Suconet K 65 7 Testing Commissioning Diagnostics 67 Status LEDs 67 Diagnostics 68 Message byte...

Page 7: ...and tells you how to alter the settings The configuration and setting of PLC parameters is carried out in the topology configurator of the programming software This is described in the chapter Softwar...

Page 8: ...the Sucosoft S 40 software Symbols The symbols in this manual have the following meaning Indicates handling instructions Draws your attention to interesting tips and additional information Warning War...

Page 9: ...least 16 Mbyte RAM 3 5 disk drive 1 44 MByte and CD ROM drive Hard disk with at least 40 MByte free capacity the temporary directory C _S40_ TMP is created during the installation and deleted again T...

Page 10: ...2 4V DC 6 digital outputs 24 V DC 2 analog inputs 1 analog output Setup Figure 1 provides an overview of the operating and display elements of the programmable controller as well as the device connec...

Page 11: ...6 digital outputs 24 V DC 0 5 A short circuit and overload proof 2 analog inputs U0 U1 0 to 10 V 1 analog output U10 0 to 10 V Suconet K interface Setpoint potentiometers P1 P2 Switch S1 for bus term...

Page 12: ...h a pulse pause ratio of 1 A function block is provided in the programming software for the high speed counter Alarm input The digital input I 0 1 enables you to respond to events quickly irrespective...

Page 13: ...the CPU and protected against short circuits and overloads Up to four outputs can be connected in parallel Analog inputs outputs The controller has two analog inputs and one analog output The signal...

Page 14: ...ualization etc Data for process control must not be exchanged here Programming networks for several PLCs via a PC see section Programming with Suconet K in the Operation chapter Setpoint potentiometer...

Page 15: ...e manual Language Elements of the PS4 150 200 300 and PS416 in AWB2700 1306GB chapter 6 Memory modules The PS4 200 has an internal battery backed 32 kByte RAM The memory is subdivided into a data memo...

Page 16: ...for example The 160 Kbyte combination module integrates all the features of the other two memory modules Figure 2 Dynamic memory allocation Status LEDs for the PLC The PLC states are indicated by mea...

Page 17: ...set button Plug connector for local expansion modules Operating mode selector switch Back up battery The battery backs up the internal RAM and the real time clock Reset 1 Halt Diag 2 Run 3 Run M Reset...

Page 18: ...s are described in detail in the chapter Operation Plug connector for local expansion module The plug connector provides the interface for connecting the LE4 local expansion modules Real time clock Th...

Page 19: ...signal cables Route screened data and signal cables on the left and the right of the device along the shortest possible distance and connect the screen braid to the ground terminal using a low impedan...

Page 20: ...Engineering 16 04 99 AWB 27 1184 GB Figure 4 Screen connection to reference potential surface M 4 4 E PS 0 V V 24 M4...

Page 21: ...2 5 mm2 Solid 0 22 2 5 mm2 Plug in screw terminal Terminal cross sections Flexible with ferrule 0 22 to 1 5 mm2 Solid 0 22 to 2 5 mm2 Plug connector for local expansion modules LE4 Suconet K interface...

Page 22: ...ramming device connector PRG left hand socket top view The housing of the socket is connected to the ground terminal of the power supply for the PS4 200 via a capacitor only applies to version 03 and...

Page 23: ...tentials cannot be achieved either connect the PC to the mains supply via an isolating transformer or use a laptop powered by an internal battery PS4 201 MM1 PRG interface 8 pole DIN pin connector PC...

Page 24: ...ta cable Suconet K TB RB PIN 2 Assigned internally PIN 3 Assigned internally PIN 4 RS 485 data cable Suconet K TA RA PIN 5 Assigned internally Connecting to the Suconet K field bus Use the bus cable K...

Page 25: ...4 200 can be expanded locally The local expansion modules LE4 modules are connected to the local bus connector of the PS4 200 using a local bus ribbon cable Up to six LEs can be connected locally All...

Page 26: ...er supply units In order to effectively eliminate electromagnetic interference we recommend subdividing the control cabinet into sections according to the different power and interference levels Simpl...

Page 27: ...for grounded operation Figure 12 Common power supply for the PS4 200 and the digital inputs outputs wired for non grounded floating ground operation PS 4 201 MM1 When you use the PS4 200 together with...

Page 28: ...om version 04 Connect top hat rail to mounting plate galvanized sheet steel with a low impedance connection over a large surface and with protection against corrosion Maintain a clearance of at least...

Page 29: ...5 04 99 AWB 27 1184 GB Figure 11 Common power supply wired for grounded operation I I I 24 V 0 V 24 V 0 V 24 V 0 V L1 L2 L3 N PE 24 V 0 V 0 1 7 0 V 2 3 4 5 6 0 1 0 V 2 3 4 5 U 0 U 1 U 10 PS 4 201 MM1...

Page 30: ...th PE connection no longer required from version 04 Connect top hat rail to mounting plate galvanized sheet steel with a low impedance connection over a large surface and with protection against corro...

Page 31: ...27 1184 GB Figure 12 Common power supply wired for non grounded operation I I K1 24 V 0 V 24 V 0 V K1 P1 P1 K1 24 V 0 V C1 C1 I L1 L2 L3 N PE 24 V 0 V 0 1 7 0 V 2 3 4 5 6 0 1 0 V 2 3 4 5 U 0 U 1 U 10...

Page 32: ...nt power ratings Always lay AC cables separately from DC cables Observe the following minimum clearances At least 10 cm 4 between power cables and signal cables At least 30 cm 12 between power cables...

Page 33: ...terference 29 04 99 AWB 27 1184 GB Figure 13 Using separate ducts for power and signal cables Cover Communication cables Cable duct Measuring cables analog cables Control cables Power cables Continuou...

Page 34: ...ace PRG and the Suconet K interface of the PS4 200 General rule the lower the coupling impedance the better the screening effect The screen is then able to carry high interference currents Suppressor...

Page 35: ...the point at which they enter the building or at the latest at the control cabinet Internal lightning protection Internal lightning protection includes all measures that reduce the effects of the ligh...

Page 36: ...32 04 99 AWB 27 1184 GB...

Page 37: ...at rail so that the top edge of the rail latches into the groove Insert a screwdriver into the slot of the sliding clip and lever the clip down Press the module onto the top hat rail Release the slidi...

Page 38: ...t Proceed as follows to mount the PLC on feet Press in the feet so that they snap into position Check that they are correctly in position The lug must latch in the hole Fasten the feet to the mounting...

Page 39: ...Master PLC with local expansion modules for the inputs outputs Network stations slaves for expanding the remote I O or intelligent slaves Local expansion modules LE4 Figure 16 Components of a topology...

Page 40: ...dules are numbered consecutively The master is module number 0 and the local expansion modules are numbered 1 to 6 Configuration of the master with remote expansion modules The master s configuration...

Page 41: ...e always 0 The modules are numbered consecutively LE 4 e g PS 4 201 MM1 e g PS 4 201 MM1 e g EM 4 201 DX2 Station 1 Station 2 Line 0 Station 0 Module 0 Module 0 Module 1 Line 1 If intelligent Suconet...

Page 42: ...must perform Master Intelligent slave SCO from PLC firmware version 05 The table below shows how the various types of station can be configured depending on their functions The fields which are not se...

Page 43: ...elow Master Intelligent slave SCO from ver 05 m s Line 0 1 0 Station 0 1 to 8 0 Module 0 0 0 Master Intelligent slave SCO from ver 05 m s Bus status Master Slave SCO Baud rate kBaud 187 375 0 3 to 19...

Page 44: ...e if only Suconet K stations are connected to the Suconet K line The internal plausibility checks of Sucosoft S 40 will automatically set the baud rate of the line to 187 5 kBaud if the line includes...

Page 45: ...mode selector switch of the intelligent slave must not be set to Halt stop Input data master a Number of bytes which the master must receive from the intelligent slave This number must be identical to...

Page 46: ...ou can specify the number of send and receive bytes yourself However the following maximum values must not be exceeded Table 4 Maximumvalues for send and receive bytes for the PS4 200 For certain conf...

Page 47: ...utput data parameter Now decide how many bytes the master is to send to the intelligent slave and specify this number as the Output data parameter in the master s configuration When you later define t...

Page 48: ...Configuration example Master Device A Intelligent slaves Devices B and C Slave for expanding the remote I O D Note that intelligent slaves are configured twice once in the master s configuration and o...

Page 49: ...example are configured as follows Configuration of device A Figure 20 Configuration of device A PS 4 201 MM1 PS 4 151 MM1 PS 4 201 MM1 EM 4 201 DX2 LE 4 LE 4 LE 4 LE 4 LE 4 LE 4 Line 1 Device A Device...

Page 50: ...s status master Baud rate 375 kBaud CRC status for slaves 1 to 3 OFF B PS4 201 MM1 1 1 0 Input data 20 Output data 10 C PS4 151 MM1 1 2 0 Input data 40 Output data 38 D EM4 201 DX2 1 3 0 1st LE4 1 3 1...

Page 51: ...figuration of device C Figure 22 Configuration of device C Table 8 Configuration of device C PS 4 151 MM1 Device Type Line Station Module Parameter C PS4 151 MM1 0 0 0 Bus status slave Slave address 3...

Page 52: ...48 04 99 AWB 27 1184 GB...

Page 53: ...tomatically addresses the relevant data ranges in your application You can thus access remote input output operands just as easily as local operands Table 9 Operand addressing of slaves for expanding...

Page 54: ...t Example You wish to scan the inputs of slaves 1 and 2 marked in the diagram below Figure 23 Configuration example for scanning the inputs of remote slaves You can derive the syntax for scanning the...

Page 55: ...which are available when the PS4 200 master PLC is operated with intelligent slaves Table 11 Operand addressing of intelligent slaves RD Receive Data defined receive data SD Send Data defined send da...

Page 56: ...rs in the Sucosoft S 40 Topology Configurator see chapter 4 Software Configuration Figure 24 Configurationexamplefor sendingandreceiving communication data to from an intelligent slave If the PS4 200...

Page 57: ...onfiguration Table 12 Syntax for addressing intelligent slaves data type word IL program in Data flow Ope rand Data type Line Sta tion Module Byte word Bit Syntax Master Master Slave Master Slave RDW...

Page 58: ...54 04 99 AWB 27 1184 GB...

Page 59: ...he test is successful these LEDs light up briefly when the power supply is switched on if not they blink The PLC s status depends on how the operating mode selector switch is set see Table 13 Shut dow...

Page 60: ...ector switch is set to Halt After the power supply is switched on if the operating mode selector switch is set to Halt By means of the programming software on the PC In slave mode if the master switch...

Page 61: ...s not run in Not Ready status The PLC is switched to the Not Ready status If there is no program loaded in the PLC As a result of a hardware error As a result of a serious error in the user program e...

Page 62: ...y after remaining cycle processed1 Ready Ready1 Not Ready Not Ready DSW diagnostic DSW error 2 Run Run DSW acknowledged Ready Run depends on system parameter setup 1 2 Not Ready Via Ready to Run depen...

Page 63: ...by switching on the power supply by pressing the Reset button or by means of the PC the backup program is compared with the program in the RAM If the programs are not the same the program in the memo...

Page 64: ...program has been transferred to the PLC Warm start A warm start causes the user program to be continued from the point at which it was interrupted to the end of the cycle The outputs and the communic...

Page 65: ...status Program transfer If the user program does not contain any syntax errors the compiler in the programming device PC translates it into a code that can be understood and executed by the CPU You m...

Page 66: ...Ready and Not Ready will light up while the program is being transferred together with the LED for input I 0 0 They confirm that the data transfer between the PS4 200 and the PC is progressing succes...

Page 67: ...ding to the configured startup conditions Programming via Suconet K It is possible to program several networked stations and to run test and startup functions from a single programming device attached...

Page 68: ...64 04 99 AWB 27 1184 GB Figure 25 Programming via Suconet K Programming on the PS4 201 MM1 is possible with Version 05 or higher PS 4 141 MM1 PS 4 201 MM1 LE 4 501 BS1 PS 4 151 MM1 PS 4 151 MM1 PLC p...

Page 69: ...3 seconds Suconet K error Run Off Program in Halt stop status On yellow User program is running Not Ready Off No errors in CPU and user program On red No user program or user program incorrect CPU err...

Page 70: ...egory E error bits 8 15 The diagnostics bits in category D have an indication function They can become set while the PLC is still in the Run or Ready status The diagnostics bits in category E cause th...

Page 71: ...byte for each of the stations DDK Diagnostics Remote Configuration Error in the configuration of the remote expansion devices Possible causes Less Suconet stations than the number defined in the Topo...

Page 72: ...ntive marker reset This error appears if you have selected the option Halt under Start after Not Ready in the PS4 200 configuration and have tried to carry out a warm start after a category E error ha...

Page 73: ...ndits meaningaredescribed in the manuals for the respective Suconet stations and local expansion modules Message byte The message byte contains information about the status of the PLC image data relat...

Page 74: ...70 04 99 AWB 27 1184 GB...

Page 75: ...e in this way the 128 byte COB can be used alternately for 128 bytes of send data and 128 bytes of receive data If there is not sufficient free memory when the master receives data froma slave valid d...

Page 76: ...ster and slaves Incorrect station address assignment Slave A station 1 Slave B station 2 Slave C station 3 The subdivision of the communication buffer COB in the master is then as follows Master Slave...

Page 77: ...er receives 50 bytes from slave A Free COB memory at this stage 0 bytes 3 Master sends 30 bytes to slave B Free COB memory at this stage 30 bytes 4 Master receives 40 bytes from slave B Overlapping of...

Page 78: ...of the COB with functionally correct station address assignment No overlapping takes place in this case After polling the first station the master has sent 48 bytes but only received 38 bytes Includi...

Page 79: ...ion module Hinged cover ZB4 101 GZ1 Hinged cover with space for labelling inputs outputs PS4 EM4 LE4 Feet ZB4 101 GF1 Feet for screwing the PS4 onto a mounting plate Backup battery ZB4 600 BT1 Battery...

Page 80: ...0 IABx y 0 1 Bit Byte PS4 1x1 active RDBx y 0 0 RDBx y 0 1 RDBx y 0 2 RDBx y 0 6 Bit byte PS4 141 MM1 RDBx y 0 0 RDBx y 0 1 RDBx y 0 2 RDBx y 0 77 Bit byte word PS4 151 MM1 RDBx y 0 0 RDBx y 0 1 RDBx...

Page 81: ...0 RDBx y 0 1 RDBx y 0 2 RDBx y 0 17 Byte word ZB4 501 UM2 RDBx y 0 0 RDBx y 0 1 RDBx y 0 2 RDBx y 0 23 Bit byte word RMQ16I IBx y 0 0 IBx y 0 1 Bit byte RBI1 1 RDBx y 0 0 RDBx y 0 1 RDBx y 0 2 RDBx y...

Page 82: ...Bx y 0 0 Bit Byte PS3 AC QBx y 0 0 QBx y 0 1 QABx y 0 0 QABx y 0 0 Bit Byte PS3 8 QBx y 0 0 QBx y 0 1 Bit byte LE4 501 BS1 SDBx y 0 0 SDBx y 0 1 SDBx y 0 2 SDBx y 0 77 Bit byte word CM 501 FS1 QBx y 0...

Page 83: ...Transfer rate 187 5 kBit s to 375 kBit s Operating mode Master slave Degree of protection IP 20 Rated insulation voltage Ui 600 V AC Real time clock Yes Accuracy of real time clock 6 1 min year batter...

Page 84: ...Bridging of voltage dips Duration of dip 10 ms Repetition rate 1 s Error indication Yes LEDs Protection class 1 Galvanic isolation Yes Terminals Plug in screw terminals Conductor cross section Flexibl...

Page 85: ...r input I0 0 Clock frequency 3 kHz Pulse shape Square Pulse duration 50 Edge duration 3 Alarm input I0 1 Analog inputs No 2 Signal range 0 V to 10 V Total error Normally 0 8 of full scale No of conver...

Page 86: ...onnection of outputs No of outputs max 4 Total maximum current 2 A Total minimum current 250 mA Residual current with 0 signal Approx 140 A Short circuit protection Yes without set Max short circuit r...

Page 87: ...pe Two wire connection General specifications on electromagnetic compatibility EMC of automation equipment Emission EN 55 011 22 Class A Immunity to interference ESD EN 61 000 4 2 Contact discharge ai...

Page 88: ...84 04 99 AWB 27 1184 GB...

Page 89: ...75 Cabling 28 Clock real time 14 Cold start 59 Combination memory module 160 Kbyte 12 Commissioning 65 Communication with PC 56 Configuration 38 Intelligent slaves 37 Local expansion 36 Master with re...

Page 90: ...stations 68 Diagnostics status word 66 Digital inputs 8 Status LEDs 9 Digital outputs 9 DST 14 Dynamic memory allocation 12 E Elements PS 4 200 8 EMC regulations 15 Engineering instructions 15 F Fast...

Page 91: ...12 160 Kbyte combination module 12 32 Kbyte RAM module 11 Backup 12 Recipe data 12 Memory allocation dynamic 12 Memory capacity 11 Memory module 11 75 Memory test 55 Message byte for Suconet K station...

Page 92: ...arrangements 23 Power supply unit 8 Power up behaviour 55 Program transfer LEDs 62 Program transfer to PLC 61 Programming cable 5 19 75 Programming device interface PRG 11 Pin assignments 18 Programmi...

Page 93: ...or 75 Slave address 41 Slave addressing 49 76 Slaves for expanding the remote I O 35 Software requirements for programming 5 Start up behaviour 59 Station 40 Status LEDs 65 Digital inputs 9 Outputs 9...

Page 94: ...WB 27 1184 GB Summer winter 14 Topology configuration procedure 36 Transfer 61 Transfer of program to PLC 61 Twin level terminal block 75 U Up counter 8 User program test 55 V Ventilation 22 W Warm st...

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