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User´s Guide Power Rail Booster

Version 12/2005

6ES7 972-4AA02-0XA0

Page 1 of 49

Power Rail Booster

User’s Guide

Version 12/2005

Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Summary of Contents for 6ES7 972-4AA02-0XA0

Page 1: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

Page 2: ...Version 12 2005 Copyright Siemens AG 2005 All rights reserved 6ES7 972 4AA02 0XA0 Page 1 of 49 Power Rail Booster User s Guide Version 12 2005 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 3: ... and any necessary corrections included in subsequent editions Suggestions for improvement are welcomed Copyright Copyright Siemens AG 2005 All rights reserved The reproduction transmission or use of this document or its content is not permitted without express written authority Offenders will be liable for damages All rights including rights created by patent grant or registration of a utility mo...

Page 4: ...el Comparison with the previous version The previous version of this manual was revised and supplemented to create this latest version General Remarks revised and Table Overview of Compatibility with Previous Versions supplemented Chapter 2 Introduction revised Chapter 3 2 3 LED Test on Activating the Voltage Supply added Chapter 3 3 Mode dependent Functions added Chapter 4 3 1 Cascading revised C...

Page 5: ...m 90x132x75 90x165x75 90x132x75 90x165x75 120x110x135 120x170x135 Terminal connectors Power Rail DC24 SF signalling contact Pluggable Max cross section 2 5 sqmm max cross section 2 5 sqmm max cross section 2 5 sqmm Pluggable Max cross section 2 5 sqmm Max cross section 2 5 sqmm Max cross section 2 5 sqmm Integrated Max cross section 2 5 sqmm Max cross section 2 5 sqmm Max cross section 4 0 sqmm Hy...

Page 6: ...OPOLOGY 16 4 3 4 STAR TOPOLOGY 16 4 3 5 CLOSED RING CIRCUITS 17 4 4 RAIL SECTIONS 18 5 CONFIGURATION 19 5 1 PROCEDURE 19 5 2 CONFIGURATION WITH THE PRB CHECKER 21 5 3 CONFIGURATION OF THE BUS PARAMETERS 23 5 3 1 CONFIGURING THE PARAMETER NUMBER OF OLMS 23 5 3 2 ADAPTING THE RETRY LIMIT PARAMETER 24 5 4 CONFIGURING THE CONTACT RAILS AND SLIDING CONTACTS 24 5 4 1 INTRODUCTION 24 5 4 2 CONTACT RAIL C...

Page 7: ...BLE SLIDING CONTACTS 33 7 LED DISPLAY AND TROUBLESHOOTING 34 7 1 DIAGNOSTIC DISPLAYS FOR THE POWER RAIL BOOSTER 34 7 2 DIAGNOSTICS MESSAGE FRAME 35 7 2 1 MESSAGE FRAME STRUCTURE 35 7 2 2 CONTENTS OF THE MESSAGE FRAME 35 7 2 3 TIMING 36 7 3 FAULT SCENARIOS IN A DP MASTER SYSTEM WITH PRBS 36 8 TECHNICAL SPECIFICATIONS 37 9 APPENDIX 39 9 1 ADDITIONAL HARDWARE AND SOFTWARE FOR PRB APPLICATIONS 39 9 1 ...

Page 8: ...ious injury or substantial material damage will occur if the prescribed precautionary measures are not taken U Warning This means that death serious injury or substantial material damage may occur if the prescribed precautionary measures are not taken U Caution This means that minor injuries or light material may occur if the prescribed precautionary measures are not taken Note Provides important ...

Page 9: ...t rooms The device may not be opened U Warning The configuring engineer is always responsible for ensuring that data transmission errors cannot produce a dangerous situation In the case of systems connected by contact conductors it is not possible to exclude brief interruptions to communication due to the mechanical link of the electrical transfer paths The control software must take this into acc...

Page 10: ...w you to achieve higher limit values Every PRB has two independent isolated interfaces each in turn consisting of a transmitter component and a receiver component The primary channel is designated as 9 pin D subminiature female socket connector An RS 485 bus segment to PROFIBUS Standard EN 50170 can be connected to this channel The secondary channel is run to a terminal strip There are two pins fo...

Page 11: ...mens AG 2005 All rights reserved 6ES7 972 4AA02 0XA0 Page 10 of 49 The following illustration shows a sample application Fig 1 Sample application of the Power Rail Booster Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 12: ... PROFIBUS networks It is a pure transformer and is largely transparent as PROFIBUS device It has no PROFIBUS address Messages are checked for syntax but the data are not checked for correctness as regards their content The Power Rail Booster supports mono and multi master systems PROFIBUS DP FMS as well as FDL and MPI are transferred as protocols U Warning If there are active stations on both side...

Page 13: ... output has cooled down the PRB automatically restarts data transmission Critical states are signalled as described in Chapter 7 LED Display and Troubleshooting 3 2 7 Commissioning Aids At least one active station is required to test the Power Rail connection during installation That station is usually the PROFIBUS master on the stationary side of the Power Rail This station serves as message sour...

Page 14: ...nal If the structure of the Power Rail network is a point to point connection as described in Chapter 4 3 2 you must set DIP switches DIP 7 and DIP 8 to ON on both the stationary and travelling PRB 3 3 3 Diagnostic Message Using DIP switch DIP 6 users can choose between two diagnostics modes DIP 6 Æ OFF The electronic signalling contact maps the behaviour of the SF LED as described in the Table in...

Page 15: ...r segment Normally a contact rail system consists of only one DP master segment If there are multiple DP master segments care must be taken to see that no electrical connection short circuit can be established between DP master segments via the double collector This can be done using rail sections see Chapter 4 4 Rail sections PRB Segment As a rule more than one stationary Power Rail Booster is re...

Page 16: ...th PROFIBUS cable 4 3 Examples of Topologies 4 3 1 Cascading The PRB regenerates the signal waveshape of the data received making it possible to cascade as many as 10 PRBs You must consider the increased signal throughput time 6 T bits per PRB when configuring in STEP 7 see Chapter 5 3 1 Fig 4 Example of cascading 4 3 2 Point to point Connection This configuration is distinguished by the fact that...

Page 17: ...e PRBs are installed on the moving side Fig 6 Example of line topology 4 3 4 Star Topology This configuration is distinguished by the fact that multiple contact rail segments are cabled in a star structure and that more than one PRB is installed on the moving side The star structure is permissible on no more than two levels paths and branches Fig 7 Example of star topology Artisan Technology Group...

Page 18: ...17 of 49 4 3 5 Closed Ring Circuits When using systems with closed loops it is recommended to establish a low resistance connection to ground with the steel construction parallel to the contact rail Fig 8 Example of a closed loop Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 19: ...parated by a non conductive section In this case the plant controller and the vehicle cannot communicate during the transition Fig 10 Example of an isolating rail section The isolating rail section can be created by isolating the contact rail with a suitable isolator In addition to isolating properties it is also necessary to take into account mechanical properties particularly those relating to a...

Page 20: ...ee whether there is a need to divide the number of DP master segments specified in Step 1 into multiple PRB segments This step must be performed separately for each DP master segment specified in Step 1 Prerequisites Results from Step 1 PRB Checker configuring tool Layout of the plant with dimensions Number of slaves in the relevant DP master segment Number of vehicles in the relevant PRB segment ...

Page 21: ...B segments 8Æ Continue with Step 3 configuration of the PRB segments 4 Adjusting the bus parameters for the DP master segments Prerequisites All PRB segments in the relevant DP master segment configured Result Have the bus parameters in all DP master segments been adjusted 4Æ Configuration completed 8Æ Continue with Step 4 configuration of the bus parameters 5 Additional procedures for ensuring th...

Page 22: ... must also be taken into account The applications engineer has at his her disposal free of cost the PRB Checker software tool for easy fast and reliable calculation of the lengths of the individual PRB segments This tool can be obtained through Siemens Customer Support under the ID 13884116 for downloading over the Internet Installation is not necessary following downloading All files must be copi...

Page 23: ...ngth of the line the number of vehicles in the PRB segment or the number of vehicles in the DP master segment In this way you configure segment by segment as described in section 5 1 Procedure until you have structured the entire length of your contact rail including cabling in the DP master and PRB segments You can also add comments and store your configuration segment by segment The files can th...

Page 24: ...tics line The following applies One OLM is equivalent to one PRB The line length remains unchanged The configuration tools then check to see whether the Slot Time parameter in the selected communications profile can be left unchanged If the slot time were to be exceeded due to additional delays caused by Power Rail Boosters a warning message is issued and the parameters are modified accordingly Th...

Page 25: ...s on the contact rail systems Double collectors must be used in order to ensure continuous contact The maintenance instructions provided by the contact rail supplier must be observed to ensure long term compliance with the limit values 5 4 2 Contact Rail Capacitance The higher the capacitance of the contact rails the lower the distributable rail length per Power Booster segment The PRB Checker con...

Page 26: ...cleaning be sufficiently frequent so as not to endanger problem free data transmission through contaminated or oxidized contact rails sliding contacts or switching contacts 5 4 4 Preferred Arrangement of the Contact Conductors For optimizing immunity to interference it is advisable to arrange the contact conductors as follows Maximum distance between the contact conductors for Power Rail A B and t...

Page 27: ...A B are separated from the wires for power L1 L2 L3 by a shield Fig 16 Preferred arrangement of the wires in cables U Note To ensure reliable safe data transmission the use of mechanically independent double sliding contacts is mandatory These sliding contacts must be installed and set so that there is adequate surface pressure between sliding contacts and contact rails at all times The slider s f...

Page 28: ...ated operating current 6W These data only apply to resistive loads In the case of interconnection with inductive loads you must suppress interference using suitable protective circuits varistors or free wheeling diodes U Danger Never connect the Power Rail Booster to mains voltage U Select a location for installation which fulfils the ambient conditions and mechanical limit values shown in the tec...

Page 29: ...g steps must be taken to put the PRB into operation 1 Set all DIP switches to the position according the desired additional functions 2 Install the PRB 3 Connect the supply voltage and signalling contacts 4 Connect the Power Rail 5 Connect the RS 485 bus cable with preassembled bus connector Fig 17 Front view of the Power Rail Booster Artisan Technology Group Quality Instrumentation Guaranteed 888...

Page 30: ... and mechanical limit values shown in the technical specifications Æ Sufficient space to connect all lines and cables must be available at the chosen location In order to ensure sufficient heat dissipation a space of at least 15mm must separate the upper corner of the PRB from the housing Æ Install the PRB only on a low resistance and low reactance grounded mounting plate On removing a PRB from a ...

Page 31: ...for Power 24 V DC Power Rail A B SF OUT Usable wires cables Unshielded shielded solid flexible Unshielded shielded solid flexible Shield Not necessary Not necessary Wire routing No special requirement Carry functional ground parallel for example additional wire connected on both sides Preferably use of 3 5 wired cables No special requirement Connectable cross sections for solid wires 0 2 to 2 5 mm...

Page 32: ...type locking mechanism Bus lines A and B are galvanically isolated from the 24 V supply voltage and the Power Rail voltage The port is located on the front of the PRB Æ For the PROFIBUS DP side the installation guidelines contained in the SIMATIC NET PROFIBUS Networks manual apply Æ Connect the RS 485 bus segment using a PROFIBUS bus connector If the PRB is located at the beginning or end of a bus...

Page 33: ... 2 6 Connecting the signalling contacts An electronic semi conductor relay with potential free contacts is provided for signalling faults or the failure of the operating voltage The signalling contact can be connected to a controller s digital I 0 via the 15 pin terminal block on the front of the PRB Æ Be sure there is a sufficient tensile load and observe the cable s minimum bending radii Pin Nr ...

Page 34: ...eries resistances on individual double sliding contacts In order to measure the transfer resistances on a moving vehicle a pair of double sliding contacts can be used as substitute Fig 26 Measuring the series resistances on individual double sliding contacts The following applies to resistors R1 R2 measured via the two double sliding contacts Æ R1 R2 4 100 ohms 6 4 1 3 Measuring the serial resista...

Page 35: ...reshold exceeded for output temperature No supply voltage 24V DC supply voltage not connected Off Internal logic not ready PRB defective ON PRB ready Green Supply voltage OK Off No message frames received on PROFIBUS side DP Bus activity PROFIBUS On Flickers No message frames received on PROFIBUS side Off No message frames received on Power Rail side PR Bus activity Power Rail On Flickers No messa...

Page 36: ...e valid again at the end of the message frame break the system does not send a new status message frame since the current status corresponds to that of the last message frame If there is a change the system carries out transmission with the current status bits 7 2 1 Message Frame Structure The transferred character is one byte comprising eight bits of user data For synchronization the system addit...

Page 37: ...ransfer time for one message frame is 800 ms There must be a pause of at least one second minimum character delay time between transfers of two message frames 7 3 Fault Scenarios in a DP Master System with PRBs The Figure below shows possible fault locations in a DP master system with Power Rail Boosters Fig 31 Possible fault locations in a DP master system with Power Rail Boosters Locations and d...

Page 38: ... 6 Vcc 5V 10 50mA PIN assignments See Documentation Chapter 6 3 2 4 Galvanic isolation Yes POWER RAIL interface Input Output signal Differential signal up to 40V Input voltage endurance Differential signal up to 60V against ground 2 5kV PIN assignment See Documentation Chapter 6 3 2 2 Shock proof Yes to EN 61131 2 Galvanic isolation Yes not to internal logic Supply voltage interface PIN assignment...

Page 39: ...ice environment Ambient temperature with preferred mounting 0 C to 60 C IEC 68 2 1 IEC 68 2 2 position Ambient temperature with other mounting position 0 C to 45 C Storage temperature 40 C to 70 C IEC 68 2 14 Relative humidity 95 no condensation IEC 68 2 30 Mechanical ambience conditions Vibration during operation 10 to 58 Hz 0 075 mm displacement 58 to 150 Hz 9 8 m s 2 1 g acceleration IEC 68 2 6...

Page 40: ...ment A B from Segment A to Segment B during the transition This segment switching process is carried out automatically and has no effect on PROFIBUS message frame traffic The input signal of an external sensor triggers switchover of PRB segments A and B The Segment Controller chooses a break between two message frames as the switchover instant This means that switchover is carried out without dist...

Page 41: ...0 Page 40 of 49 The following illustration shows an example application Fig 33 Example of a Segment Controller U Note For more comprehensive information on the sample application refer to the PRB Segment Controller manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 42: ...h the application via OPC When doing this the application accesses the data of the SIMATIC NET OPC server as an OPC client Downloading is carried out controlled by the S7 command interface by means of routing via the plant s head end directly into the overhead conveyor system s vehicle Advantages for users Completely automatic updating of the vehicles software in the case of changes No need for st...

Page 43: ...akes available the received diagnostics datum to the user program Advantages for users Detailed diagnosing of an error established by the PRB No longer necessary for time consuming searches for the causes of errors Possible to quickly initiate selective measures to remove the error Since function block PRB Diagnostics is a sample application for use in a plant Siemens AG offers users no warranty o...

Page 44: ...es The product satisfies the requirements as long as the installation guidelines operating guidelines and safety information presented in the User s Guide for the Power Rail Booster are carefully followed Certificate of conformity The EU certificates of conformity are held for viewing by the appropriate authorities at Siemens Electronic Design and Manufacturing Services GmbH Co KG SEDM Weissacher ...

Page 45: ... 6ES7 972 4AA02 0XA0 Page 44 of 49 UL conformity valid with labelling of the device Underwriters Laboratories Inc following UL 508 Industrial Control Equipment File number NRAQ E256131 und NRAQ7 E256131 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 46: ...rail system Contact Rail System A contact rail system consists of sliding contacts and contact rails A contact rail system can be used to transport power and data the contact rail system ensuring mobile contact between stationary and mobile components Distributed I O Distributed I O are input output units which are not plugged into the central controller but are set up at a greater distance from t...

Page 47: ...s conductive parts to the same or almost the same potential in order to prevent damaging or dangerous voltages between these parts FO Fiber optics Ground Conductive ground whose electrical potential can be set to equal zero at any point In the presence of a grounding electrode ground can have a potential unequal zero The term reference potential is often used to describe this set of circumstances ...

Page 48: ...erial fieldbus system PROFIBUS is available with DP Distributed I Os FMS Fieldbus Message Specification PA Process Automation or TF Technological Functions protocol PROFIBUS Address Every bus node must have a PROFIBUS address for unambiguous identification of that node on the PROFIBUS PCs PGs have the PROFIBUS address 0 PTP Connection Point to point connection Reference Potential Potential at whic...

Page 49: ...f a contact rail system Tbit Bit duration length of a bit To ground To ground means to connect an electrically conductive component with the grounding electrode via a grounding system Transfer Resistance Electrical resistance between a contact rail and a sliding contact during travel The transfer resistance depends on the amount of contamination on sliding contact and contact rail as well as on th...

Page 50: ...tors 25 Fig 16 Preferred arrangement of the wires in cables 26 Fig 17 Front view of the Power Rail Booster 28 Fig 18 Installing a PRB on a standard top hat rail 29 Fig 19 Overview of interfaces on the Power Rail Booster 30 Fig 20 Wiring guidelines for the interfaces of the Power Rail Booster 30 Fig 21 Terminal assignment for the Power Rail interface 31 Fig 22 Terminal assignment for the PROFIBUS R...

Page 51: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

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