Siemens SIMATIC Power Line Booster Operating Instructions Manual Download Page 53

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Plant installation

4.7 Rail grounding (PE rail)

Power Line Booster
Operating Instructions, 11/2019, A5E36203125A-AG

Note
Missing PE rail
If the installation of a PE rail is not possible next to the powerline communication rails (e.g.

plant modifications), the installation of shield plates may be considered in case of a reduced

number of devices. Please contact Technical Support (

mailto:PLB-

[email protected]

) for more information.

Rail quality
An electrical connection (contact resistance across the entire distance < 1 Ohm) of the

sliding contacts is required to ensure the function of the Power Line Booster.

4.7

Rail grounding (PE rail)

You must set up the powerline communication rails Rail A and Rail B as described in this

manual. You need to pay particular attention to ensure that the powerline rails are always

separated from the other rails by PE rails.
In addition, you must plan the system so that the PE rail is regularly grounded with low

impedance at each connecting piece (about every 6 meters), as well as at the rail ends (e.g.

at the segment end, at the segment change or at switches) on the carrier rail or over the

steel construction with a short cable (<= 10 cm).
Note that a ground cable that is too long will be ineffective for the high-frequency powerline

signal, and the PE rail will act as an antenna in this case.
Strict adherence to the grounding concept described below is essential for stable PROFINET

communication.

Note
You must ground the PE rail at regular distances, as well as at the rail start and the rail end,

with short cables (≤

10 cm) over the carrier rail.

Summary of Contents for SIMATIC Power Line Booster

Page 1: ... 11 2019 A5E36203125A AG Introduction 1 Device description 2 Plant planning 3 Plant installation 4 PROFINET Ethernet 5 System configuration and system status web interface 6 Maintenance and service 7 Technical specifications and approvals 8 Order numbers 9 ...

Page 2: ... by personnel qualified for the specific task in accordance with the relevant documentation in particular its warning notices and safety instructions Qualified personnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNING Siemens produc...

Page 3: ...19 2 3 BusAdapter 21 2 3 1 LED display 22 2 3 2 Network cable connection 23 2 4 PLB modem module 24 2 4 1 LED display 25 2 5 PLB Empty module 27 2 6 PLB TC module 28 2 7 Accessories 29 2 7 1 Carrier power supply 29 2 7 2 PLB connection cable 32 3 Plant planning 35 3 1 Overview of PLB applications 35 3 2 Single slider solution PSS 36 3 3 Double slider solution PDS 37 3 3 1 Maximum permissible veloc...

Page 4: ...tch in the communication segment 58 4 12 Insulation monitor 60 4 13 Installation 61 4 13 1 Power Line Booster PLB BM 61 4 13 2 PLB modem module BusAdapter 62 4 13 3 PLB connector 62 5 PROFINET Ethernet 63 5 1 PROFINET IO 63 5 1 1 Introduction 63 5 1 2 Startup parameters 63 5 1 3 IO address space cyclic data 64 5 1 4 Identification and maintenance data 68 5 1 5 Device specific data records 69 5 1 6...

Page 5: ...gnal configuration 100 6 4 2 2 Segment configuration master only 101 6 4 3 Status tables master only 102 6 4 3 1 Device status master only 103 6 4 3 2 Cycle time 104 6 4 4 Signal quality master only 106 6 4 4 1 Signal gain and transmission quality 106 6 4 4 2 Signal graphs 108 6 4 4 3 Tone Map 109 6 4 4 4 Signal strength 110 6 4 4 5 Signal to noise ratio 111 6 4 5 Voltage measurement master only 1...

Page 6: ...echnical specifications and approvals 125 8 1 Technical specifications 125 8 1 1 Mechanics 125 8 1 2 Shock values 126 8 1 3 Electrical characteristic values 126 8 1 4 MTBF 127 8 1 5 Climate 127 8 2 Approvals 127 8 2 1 CE conformity 127 8 2 2 cULus approval 128 9 Order numbers 129 Index 131 ...

Page 7: ...d this manual Experience in the use of PROFINET is also helpful 1 2 System overview and introduction The Power Line Booster system is a communication system for data transmission on conductive media The system provides Ethernet based communication connections between stationary plant controllers and mobile plant units The media can be sliding contact systems such as in electric overhead conveyors ...

Page 8: ...tomation components on mobile plant units It can be easily integrated into the SIMATIC product portfolio and it can be configured as a PROFINET device to retrieve status information for diagnostic purposes Product maintenance and innovation are guaranteed in the course of further SIMATIC development Note If you have any questions regarding system design and installation feel free to contact the te...

Page 9: ...n area of application is in transport applications based on sliding contacts such as electric monorail systems as well as storage and retrieval systems In this instance the Power Line Booster modulates the data frames that are received by standard Ethernet IEEE 802 3i 10BASE T IEEE 802 3u Fast Ethernet IEEE 802 3y 100BASE T2 to different carrier frequencies These carrier frequencies are located in...

Page 10: ...n a separate communication network 1 4 Insulation The Power Line Booster or Power Line Booster system is intended for operation in low voltage systems with up to 500 V AC The recommended components require that all voltages within the system are within the following limits Low voltage Max 500 V AC 15 line to line voltage with symmetrical ground This high limit applies to the system supply lines e ...

Page 11: ...Page 12 with a Power Line Booster Modem Module PLB MM see PLB Modem Module Page 24 and a BusAdapter Page 21 Termination and coupling modules PLB TC see also PLB TC Module Page 28 Carrier power supply Page 29 Additional system dependent components Overview Figure 2 1 Fully equipped device Der Power Line Booster consists of a PLB BM basic module which is equipped with the following modules 1 ET200SP...

Page 12: ... to be mounted stationary A PLB slave is usually mounted on the vehicle You can use several slaves in one segment NOTICE Plug or remove the Modem Module and the BusAdapter only in the de energized state 2 2 PLB Basic module Figure 2 2 PLB Basic module The Power Line Booster is available in this version PLB device MLFB PLB Basic module PLB BM LV M S 6ES7972 5AA10 0AB0 The basic module holds the Pow...

Page 13: ...e bottom of the PLB Figure 2 3 FRES button Figure 2 4 Position of the FRES button Keeping the FRES button pressed for more than 5 seconds results in a restart and the factory settings are restored on the device A reset to factory settings is also possible on the Restart Reset Page 87 page in the web interface Note that the IP address is reset as well and must be reassigned ...

Page 14: ...ecial cases you may have to make additional settings The possible settings are listed in the Operator controls table The switches are located below the PLB EM Empty Module NOTICE Use the DIP switches for configuration only in the de energized state Table 2 1 Operator controls Operator control Labeling State Function DIP switch Master Slave M S Off factory state PLB slave operation On PLB master op...

Page 15: ...and slaves with identical channel settings can communicate with each other in a plant Table 2 2 Set master slave operating mode Power Line Booster in slave operating mode Power Line Booster in master operating mode Table 2 3 Channel setting examples Power Line Booster configured for channel 1 Power Line Booster configured for channel 2 2 2 3 LED display Figure 2 6 LED displays on the PLB basic mod...

Page 16: ...ed Off No error Flashes approx 1 Hz Station flash test PN together with the port LEDs of the ET200SP BusAdapter BA External error Short circuit between a phase and Rail A or Rail B External error Ground fault of Rail A or Rail B Flashes ap prox 4 Hz Firmware update of the basis in progress togeth er with RN and MT On LED test for about 0 5 s during startup 2 modems inserted or modem installed inco...

Page 17: ...r State Description Note If all LEDs are flashing permanently at a frequency of 1 Hz you are dealing with a configuration or device fault a Changing the DIP switch settings 2 2 4 Slots Slot X3 for the ET200SP BA BusAdapter Slot X4 for the PLB MM Modem Module Slot X3 for the PLB EM Empty Module Figure 2 7 Slots on the PLB basic module ...

Page 18: ...structions 11 2019 A5E36203125A AG 2 2 5 Power supply connection Figure 2 8 24 V DC power supply port X80 Terminal Connection X80 1 24 V DC SELV or LV C X80 2 0 V 2 2 6 Powerline connection Figure 2 9 Powerline port X2 Terminal Connection Name X2 1 42 V AC Rail A X2 2 Rail B ...

Page 19: ...the firmware via powerline The update is installed via the Secure File Transfer Protocol SFTP This means an SFTP client program such as WinSCP freeware must be installed on the PC The update packet installed via SFTP always contains a tgz and a sig file NOTICE Make sure that at least one firmware with version V1 3 0 is installed on the device and that a PLB modem with order number 6ES7972 5AA51 0A...

Page 20: ... will usually resume its normal function but it will now indicate that maintenance is required through its MT LED stays on Please contact Technical Support in this case We recommend resetting the PLB to factory settings after the update see Reset button Page 13 or Restart Page 87 NOTICE A firmware update can take up to five minutes When updating the Power Line Booster the power supply must not be ...

Page 21: ...n 2 3 BusAdapter Power Line Booster Operating Instructions 11 2019 A5E36203125A AG 21 2 3 BusAdapter Figure 2 10 BA 2xRJ45 BusAdapter RJ 45 Figure 2 11 BA 2xFC BusAdapter Fast Connect Figure 2 12 Slot for the BusAdapter ...

Page 22: ...ter Fast Connect ET200SP BA 2xFC This module is used for direct connection of ETHERNET or PROFINET connections to the PLB system 6ES7193 6AF00 0AA0 The BusAdapter offers to switch ports for the connection of Ethernet or PROFINET cables Because the BusAdapter has two LAN ports you can set up a line architecture Note You cannot use any BusAdapters other than the ones described above such as those wi...

Page 23: ...pprox 1 Hz Station flash test PN together with the MT RN and ER LEDs of the basic module PLB BM On LED test for about 0 5 s during startup Link at Port 1 or Port 2 Note If all LEDs are flashing permanently at a frequency of 1 Hz with deactivated station flash test you are dealing with a configuration or device fault 2 3 2 Network cable connection Figure 2 14 LAN ports X1 You can connect up to two ...

Page 24: ...re 2 15 PLB MM Figure 2 16 Slot for the PLB MM PLB device MLFB Modem module PLB MM 6ES7972 5AA51 0AB0 This device modulates or demodulates the Ethernet data frames into a form that is suitable for the Powerline transmission medium e g sliding contact lines NOTICE The previous PLB modem module 6ES7972 5AA50 0AB0 is no longer supported ...

Page 25: ...on the PLB modem module Table 2 6 LED PLB MM LED labeling Meaning Color State Description PWR Power Green Off Modem without power supply inactive or in RESET Flashes approx 4 Hz Synchronous with the PL LED and the MT LED from the basis Firmware update of the modem module a is running When restarting after a configuration change b On LED test for about 0 5 s during startup Modem power supply OK PL ...

Page 26: ...the modem firmware the power supply must not be switched off b Changing the DIP switch settings NOTICE A modem firmware update can take up to two minutes The modem firmware is part of the Power Line Booster basic firmware During system startup the PLB basic module checks the active firmware on the modem and if necessary starts the update on the modem When updating the modem firmware the power supp...

Page 27: ...e 2 19 Slot for the PLB EM PLB device MLFB PLB Empty Module PLB EM 5 pieces per packaging unit 6ES7972 5AA80 0XA0 The empty module is used to cover the module bay and the DIP switches The degree of protection IP20 applies to the fully equipped device i e only including all plugged in modules The slot of the empty module is intended for future expansions ...

Page 28: ...e 2 20 PLB TC module The PLB TC is used termination of segments Both ends of the communication cables of the respective segment are terminated by the termination module Details on installation of the TC module are available in the section Rail connection of the TC module Page 49 PLB device MLFB TC module PLB TC 6ES7972 5AB00 0XA0 ...

Page 29: ...keeps the contact between slider and rail clean It is not necessary for actual powerline communication No carrier voltage is required in applications without sliding contacts e g communication over flexible cables or those in which the materials used prevent oxidation of the contact surface Infeed system The infeed system consists of the circuit breaker transformer and filter Figure 2 21 Segment i...

Page 30: ... that you use the transformer in the example below Table 2 7 Example of a transformer for supply of the carrier voltage Primary voltage 230 400 V AC Secondary voltage 42 V AC Secondary current 1 5 A Rated power 63 VA Manufacturer mdexx Order designation TAM3242 8JV00 0EA0 Details on installation of the transformer are available in the section Rail connection of the master and carrier power supply ...

Page 31: ... the end marked with LOAD to the powerline and the LINE end to the transformer Table 2 9 Requirements for the line filter Attenuation for common mode signals and push pull signals between 1 MHz and 40 MHz 50 dB Output impedance between 1 MHz and 40 MHz 100 Ω The isolation strength of the filter especially against PE FE has to be matched to the isolation coor dination in the system NOTICE In slidin...

Page 32: ...lugs Figure 2 23 Line filter up to 16 A See also section Rail connection of master and carrier power supply Page 48 2 7 2 PLB connection cable The connection cables in a powerline system have a strong impact on the signal attenuation and cause poles in the frequency range used This is why the selection of cables also has an effect on the maximum configuration limit For details on this see section ...

Page 33: ...AN 3 EMC 09 62 003 0801 Socket insert female HAN Q 5 0 F 09 12 005 3101 Contact insert male HAN Q 5 0 F 09 12 005 3001 Crimp contact female HAN E 2 5 mm gold plated 09 33 000 6223 Crimp contact male HAN E 2 5 mm gold plated 09 33 000 6123 Crimp contact female HAN E 1 5 mm gold plated 09 33 000 6216 Crimp contact male HAN E 1 5 mm gold plated 09 33 000 6116 The connector enclosure must have a surfa...

Page 34: ......

Page 35: ...inguish between single segment systems and multi segment systems If uninterruptible communication is required two PLB slaves are used on the vehicle each on its own slider PDS Powerline Double Slider Otherwise you only need one PLB slave per vehicle in case of a single slider application PSS Powerline Single Slider Figure 3 1 Overview of PLB applications ...

Page 36: ...e Ethernet data into a powerline signal and feeds this signal into the communication rails One Power Line Booster in slave configuration is installed on each of the vehicles This PLB converts the signal back into an Ethernet signal Figure 3 2 Basic principle of the single slider solution Each powerline segment should be considered as an independent and separate communication area in which either a...

Page 37: ...this case You must set the Short Network ID SNID Page 101 differently for neighboring masters to implement shorter transfer times During a segment change the front slider of a vehicle travels out of the first communication segment shown in red in the figure Page 38 below and the front PLB PLB Slave B loses the connection to the master of this segment PLB Master 1 Thanks to the redundant communicat...

Page 38: ...en slider and rail must be ensured During the segment change the maximum permissible velocity depends on the distance of the sliders on a vehicle and the transfer time defined in the section Registration and transfer times Page 46 It must always be ensured that the PLB on the front slider is securely registered before the rear slider leaves the segment The maximum velocity during segment change ca...

Page 39: ...igh network load or a reduction of the broadcast bandwidth with a large number of stations Because the PLB master knows the Ethernet stations in its segment it can block frames to unknown stations to prevent flooding The process for handling frames to unknown stations can be configured via the Buffer configuration of the Traffic Manager Page 96 Jumbo frames with MTU The standard MTU Maximum Transm...

Page 40: ...mend that you stay below this number We will therefore only look at the maximum number recommended for real time applications The rules for determining the maximum configuration limit are listed below Note that the reductions per segment in percentage always apply in addition to the maximum configuration PLB connection cable 1 meter long For connection cables 1 meter a maximum of 40 vehicles are p...

Page 41: ...al When using switches or lifters in a segment the communication rail must be separated and the powerline signal must be transmitted to a different rail section via cables Note that these cables must always be shielded We recommend using PLB standard cables Page 33 As soon as a communication segment consists of multiple rail sections connected via cables instead of an integrated rail the total of ...

Page 42: ...ns that with a PSS application the PLB slave farthest removed from a master may be located a maximum of 28 positions away from the master 40 slaves 70 28 slaves 2 A maximum of 40 of the slaves permissible for the maximum configuration may be present between PLB master and the registration location rail start A PLB slave entering the segment in a PSS application thus may be located a maximum of 16 ...

Page 43: ...icles maximum configuration PSS 40 5 m 16 vehicles 5 m 80 m Maximum distance to rail end 40 vehicles maximum configuration PSS 70 5 m 28 vehicles 5 m 140 m Position in reference to rail start 180 m 140 m 40 m Conclusion The PLB master must be fed in somewhere in the range between 40 meters and 80 meters The position after about one third of the distance equals 60 meters is ideal Example 2 PDS appl...

Page 44: ...te rail segments 2 7 14 Besides the lifter must be connected using a cable of individual length because the 8 m cable is not sufficient 10 reduction Number of stations reduced by 14 10 40 vehicles 9 6 vehicles Due to the installation in front of the PLB master the attenuation resulting from the lifter of about 10 vehicles only affects this area This means the maximum number of vehicles between mas...

Page 45: ...ributed over max 8 PN stations per PLB slave 2048 bytes distributed over max 8 PN stations per PLB slave Recommended PN cycle time Page 72 vehicles per segment 40 vehicles 64 ms 20 vehicles 32 ms 10 vehicles 16 ms 1 vehicle 8 ms 20 vehicles 32 ms 10 vehicles 16 ms 1 vehicle 8 ms PN monitoring time Page 73 PROFIsafe time vehicles per segment 40 vehicles min 1600 ms 20 vehicles min 900 ms 10 vehicle...

Page 46: ...gment to the next communication segment with the maximum number of slaves The maximum transfer time is 4 seconds 98 of transfers take less than 2 seconds Time for 98 of registrations Maximum time Registration time of one slave into a full segment 1 second 4 seconds Transfer time of one slave to a full segment 2 seconds 4 seconds Registration time of 40 slaves into a segment 12 seconds 15 seconds N...

Page 47: ...ules You can install short cables with a length of less than one meter unshielded and with 2 5 mm single cores for example You should still ensure that these cables are separated in the control cabinet and that they are not installed parallel to other cables All cables that conduct powerline signals and are longer than one meter must always be shielded to prevent overcoupling to other plant parts ...

Page 48: ...th shielding The positioning of the master is described in the section Master position Page 42 Make sure to keep all powerline cables in the control cabinet of the master shown in blue in the figure below as short as possible and to separate them so that there can be no overcoupling of the powerline signal to other cables You can find the detailed structure of the carrier power supply including ca...

Page 49: ... 4 Rail connection TC module You must install the PLB TC module Page 28 in an enclosure e g a rail terminal box to ensure its isolation Connect the end of the rail pair Rail A Rail B to the ports X1 1 and X1 2 of the PLB TC module Use relatively short 2 5 mm cables with a maximum length of 0 5 meters for the connection between rail and rail terminal box Terminal Connection Color X1 1 A Rail A Red ...

Page 50: ...rough the cumulation of multiple faults or due to individual specific devices machines contact our Technical Support mailto PLB Support industry siemens com If you are operating the Power Line Booster with the factory settings interferences up to 73 dB µV QPk corresponds to 1 Vpp see EN 61000 6 4 2007 do not result in communication errors If the incoming level of a PLB in the plant e g of the mast...

Page 51: ... when a different channel is selected in a different plant see DIP switches Page 14 In contrast to digital transmission lines buses or point to point connections which can be shielded relatively easily and reliably powerline connections are susceptible to interferences by any device in their proximity which intermittently or continuously can interfere on strictly limited channels or emit broadband...

Page 52: ...2 L3 PE Rail A and Rail B Figure 4 3 Arrangement of the rails It is necessary however that except for the regularly grounded PE rail Page 53 there are no other rails in addition to the powerline rails Rail A and Rail B otherwise signal couplings and crosstalk will occur The PE rail is also used as shielding in this case Due to the positioning the PE rail provides additional spacing between the liv...

Page 53: ...ls Rail A and Rail B as described in this manual You need to pay particular attention to ensure that the powerline rails are always separated from the other rails by PE rails In addition you must plan the system so that the PE rail is regularly grounded with low impedance at each connecting piece about every 6 meters as well as at the rail ends e g at the segment end at the segment change or at sw...

Page 54: ...dule You must not exceed the maximum cable length of 50 cm in this case We recommend installing the required TC modules directly in a rail terminal box Page 48 to keep the cables as short as possible To minimize crosstalk between the segments via the PE rail you must ground them with short cables 10 cm to the support rail or via the steel construction at the level of the respective segment ends or...

Page 55: ...end on the separate rail section Note that the maximum number of vehicles permitted between master and the vehicles on the separate rail section is significantly reduced due to the signal attenuation by the TC module Page 42 Figure 4 5 Rail interruption for example at a lifter 4 10 Loops Closed loops are generally not possible in powerline applications because the circular signal results in interf...

Page 56: ...ster and the most remote slave must be observed From this value you must then still subtract the number for the additional segment see Interruptions of the communication rail Page 40 For the connection between master and rail we recommend using the 8 meter PLB connection cable Page 33 Figure 4 6 Loop with interrupt section See also PLB connection cable Page 32 ...

Page 57: ...ommend installing an additional short separator on the rail sections see figure Segment cut Page 54 in front of and behind the switch This prevents the vehicle sliders from temporarily connecting a long and non terminated rail section with the communication segment when traveling over the cut The sudden impedance change caused by such a connection would result in communication problems The ends of...

Page 58: ...d in the segment with a reduction of the maximum number of PLB slaves The cabling of the power cables can be done in accordance with the section Switch as segment cut Page 57 The rail sections in front of and behind the switch are connected directly over the 8 meter PLB connection cable to the PLB master for example If possible the cables should be installed relatively close to the switch to preve...

Page 59: ... a closed loop from forming via the two connection cables when a slider bridges the cut We recommend installing the TC module directly at the rail in a rail terminal box If this is not possible for mechanical reasons the powerline connection cable can also be connected using a HAN connector see Selection table Page 33 In this case the TC module must be installed in the control cabinet of the maste...

Page 60: ...ge plants up to 500 V AC A single short circuit between a phase L1 or L2 or L3 and Rail A or Rail B may represent a fault for this device as indicated by the error LED but this does not prevent communication However this means that dangerous contact voltages are present on Rail A or Rail B and the connected components without the function being impaired You need to consider this during maintenance...

Page 61: ...e Power Line Booster onto a vertically mounted DIN rail TS 35 DIN Rail see photo Figure 4 9 PLB mounted on a DIN rail rear view If you plug the Power Line Booster onto a vertical DIN rail or one installed horizontally however the maximum permissible ambient temperature is reduced to 50 C You must always keep a clearance of 60 mm above and below the Power Line Booster ...

Page 62: ...river 0 5x3 0 5x3 5 Installation sequence 1 PLB modem module PLB empty module 2 BusAdapter For stability reasons you must attach the Ethernet connecting cables at a suitable location for example with a cable tie as strain relief 4 13 3 PLB connector The connectors to the ports X2 Page 18 and X80 Page 18 are spring loaded terminals If you are using flexible cables it may be necessary to open the cl...

Page 63: ...The PROFINET device and the mechanisms for assigning PN names and IP addresses are only available when the Ethernet connection to X1P1 or X1P2 is connected The Power Line Booster system works with a shared medium This means all stations share one medium Topology recognition is not possible with a shared medium The PLB system can forward PROFIsafe When planning this safety function you have to take...

Page 64: ...tter B 8 bits words with W 16 bits and double words with D 32 bits All slots can be configured on devices with the slave configuration as well as on masters but may not contain any data depending on the configuration Slot 0 PLB basic module No data Slot 1 Common Data Input byte operating mode IB x unsigned 8 Bit 0 Operating mode master slave 0 Slave 1 Master Bits 1 7 reserved status not defined By...

Page 65: ... Booster cycle time Page 72 in ms For PLB slave 0 word x 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Input word number of active slaves IWB x 3 unsigned 16 master only For PLB slave 0 word x 3 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Input word PL channel IW x 5 unsigned16 word x 5 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Power Line channel 1 4 set with DIP switches See also setting DIP switch ...

Page 66: ...r at left modem Bit 6 Right modem inserted Bit 7 Log backup Bit 8 Rescue mode Bit 9 to 15 System reserve Byte x 7 6 5 4 3 2 1 0 LogBack Modem R Modem L CoreD Overv PL_A FE PL_B FE PL Phase Byte x 1 7 6 5 4 3 2 1 0 Rescue Input word PLB Warnings IW x 2 unsigned 16 Bit 0 Undervoltage Bit 1 to 15 System reserve Byte x 2 7 6 5 4 3 2 1 0 Underv Byte x 3 7 6 5 4 3 2 1 0 Input byte signal quality IW x 4 ...

Page 67: ...imum value of 255 is reached For PLB slave 0 Byte x 1 7 6 5 4 3 2 1 0 Slot 6 IP address master IW x slave only Input byte IP address of connected master IW x 0 4 unsignt8 The IP address can be used to determine the segment in which the slave is currently located This position information may be useful for some applications For PLB master 0 Byte x Byte 3 Byte 2 Byte 1 Byte 0 IP_3 IP_2 IP_1 IP_0 Slo...

Page 68: ...ata or read write M data on the module Identification data I M0 Manufacturer information on the module to which you only have read access and some of which may be printed on the module housing for example article number and serial number Maintenance data I M1 2 3 System dependent information for example the installation location Maintenance data is created during configuration and written to the m...

Page 69: ...ta Access Default Description Identification data 0 data record index AFF0 hex VendorIDHigh Read 1 byte 00H The vendor name is stored here 42D SIEMENS AG VendorIDLow Read 1 byte 2AH Order_ID Read 20 bytes 6ES7972 5AA10 0AB0 Article number of the module IM_SERIAL_NUMBER Read 16 bytes Serial number device specific IM_HARDWARE_REVISION Read 2 bytes 1 corresponding hardware version IM_SOFTWARE_REVISIO...

Page 70: ...ausibility 32 bits 00504C42H Version of the data record 16 bits 0000H Number of entries 16 bits number of slaves master Returning block for the master and subsequently all slaves that can be reached The number of list entries transferred is limited to the number available Consecutive number for identification Index MAC address BM MAC address MM PROFINET device name IP address only for permanently ...

Page 71: ...agnostic messages in the Power Line Booster 5 2 Ethernet and IP address assignment If you do not operate the Power Line Booster as a PROFINET device or do not couple it with an IO controller you must use the PROFINET mechanisms DCP to assign the IP address e g for update Regardless of the application you can use the same tools STEP 7 PST PRONETA etc that are customary in the PROFINET environment S...

Page 72: ...eeds to contact the currently registered slaves once and to exchange data with them The PLB cycle time of a master depends on the number of slaves in the segment For the average cycle time we only want to consider the case when no vehicle enters or exits the segment The master needs about 2 3 ms for the data exchange with each slave In addition the so called registration phase Hello Phase see sect...

Page 73: ...lt in a longer cycle in this case 4 Interference on the medium e g caused by EMC or short term deterioration of the contact quality of the sliders 5 Cyclic sounding of carrier frequencies to optimize the connection 6 Crosstalk of the powerline signals Page 116 from other plants or plant units This effect must be prevented by suitable insulation and attenuation during installation of the plant To d...

Page 74: ...d between controller and device PLB cycle at which the powerline system forwards data to the slaves This cycle is independent of the number of slaves and from interference You can assume 400 ms for this cycle PROFINET update time that is configured between controller and device Cycle between vehicle controller and the devices Figure 5 2 Example consideration of cycles between plant and vehicle con...

Page 75: ...TLat 2 TCtr TPN 2 TPLB When you replace these with typical values TCtr 30 ms TPN 128 ms TPLB 400 ms TDev 10 ms you get TLat 2 30 ms 128 ms 2 400 ms 988 ms The following graphic serves as a starting point for determining the PROFINET times The gray graph shows the calculated average PLB cycle time depending on the number of slaves You can use the blue graph to determine the recommended PROFINET upd...

Page 76: ...g on the slaves as follows 40 slaves 1600 ms 25 update cycles at 64 ms PN update time 20 slaves 928 ms 29 update cycles at 32 ms PN update time 10 slaves 656 ms 41 update cycles at 16 ms PN update time 1 slave 265 ms 33 update cycles at 8 ms PN update time Note With typical PLB applications e g electric monorail system we can assume that several vehicles do not leave the communication segments at ...

Page 77: ...ng If you experience display problems or after switching a PLB from Master to Slave mode it may therefore be necessary to restart the browser and delete the cache 6 1 1 Print preview All pages are also available in a view optimized for printing If you want to save measurement results in particular it is recommended to use this function via the respective save button and to archive the results as P...

Page 78: ... 2 Login screen To connect to the Power Line Booster PLB you must enter the IP address of this device in the address line of the browser The IP address is assigned using the standard PROFINET tools STEP7 PRONETA PST etc The browser and the PLB are connected via the encrypted HTTPS protocol and a self signed SSL certificate The browser will therefore point out that this is not a valid signature Bec...

Page 79: ...ns and can therefore configure the device user user Users only have read permissions They cannot configure the device The password can be changed in the User administration NOTICE Safety note For security reasons we recommend that you change the password If you cannot remember your login information you can reset it to the factory settings with the factory reset button FRES on the device Note The ...

Page 80: ...English PROFINET name of the device e g pn name plb PLB mode Master or Slave Channel number 1 4 Communication mode PROFINET Modus or Point to point connection Number of errors n errors and orange exclamation mark for at least one warning or red exclamation mark for at least one error PROFINET AR status Online or Offline AR Application relation Number of active Powerline connections n and green dis...

Page 81: ...FINET IO Figure 6 3 System overview When you use the default password you are notified on the home page that you need to change the password in the User administration NOTICE Safety note For security reasons we recommend that you change the password 6 2 2 Error status and warnings of the device Figure 6 4 Error status of the device Error status and warnings of the device On this page you can see a...

Page 82: ...cates that the modem is inserted on the right Insert the modem into the left slot Error at left modem This error indicates that the communication between base and left modem is faulty or that the modem is defective Check the contacts or replace the modem Modem Core Dump available When the modem firmware is restarted after a fatal error a core dump including all log files of the modem is created fo...

Page 83: ...hat is dangerous to the touch is present on all Powerline rails and all cables and plant units connected to them Measure Shut down plant Undervoltage on PL This warning indicates that no voltage was detected on the Powerline rail This is normal for sections or areas without communication because they are not supplied with 42 V Possible causes of error for supplied Powerline rails Failure of the PL...

Page 84: ...1 2019 A5E36203125A AG 6 2 3 Versions Version information of the device On this page you can see the version information of the existing hardware and software Note The MAC address of the PLB Modem module is only required for the powerline communication and is not visible to the outside Figure 6 5 Version information ...

Page 85: ...2 4 Log tables Figure 6 6 Log information of the device Log information of the device On this page you can see the log information of the device From left to right a log message consists of the time stamp the log level I Info M Modem D Debug W Warning E Error P Panic the module name of the respective software the process ID and the log text ...

Page 86: ... additionally contains the log levels Info and Modem Various events are saved in the log You can for example identify the affected PLB slave in case of connection problems using the PN name and the IP address and see the position if transferred via PROFINET Page 64 at the time of the fault Using entry field you can select the number of displayed log entries The table is reloaded with the Update bu...

Page 87: ...tart the Power Line Booster and reset it to the factory settings Restart Press the Restart button to reboot the Power Line Booster After confirming a dialog you are directed to the login page and must log in again after the restart Reset configuration This allows you to reset the parameter configuration of the PLB to the default values In comparison to the reset to factory settings the IP address ...

Page 88: ...ou must assign an IP address to the device again 6 3 2 Update Figure 6 8 Firmware update of the local PLB Firmware update of the local PLB On this page you can update the firmware By pressing the Select file button you can navigate to the zip file with the firmware update and select it for an update Then you start the update process by clicking the Update local device button During the update the ...

Page 89: ... productive systems and to upgrade the masters first in case of a system update NOTICE Firmware update Do not disconnect the Power Line Booster from the power supply during the update This may cause irreparable damage to the device 6 3 3 Loading and saving Figure 6 9 Upload Download Delete On this page you can upload or download a variety of files or delete them All files Here you can download all...

Page 90: ... The file contains all data of the currently connected slaves as well as the list of all slaves that have been connected to the device since the last reboot The list of devices that are not connected can be deleted with the Delete measured values of devices that are not connected function The unique identification criterion of each entry here is the MAC address of the associated PLB basic module D...

Page 91: ...re 6 10 Automatic logout For security reasons a user is automatically logged off after a defined period of inactivity You can configure this period on this page As long as you are actively logged in on the device the timer for automatic logout is reset with each interaction The remaining time until automatic log off is shown in the status bar at the top right ...

Page 92: ...again in the associated field You save the new password with the Change password button The new password must be at least 8 characters max 20 long It must also contain the following At least one upper case letter At least one lower case letter At least one number optionally also special characters ASCII 0x20 0x7E If you are logged in as admin user type with administrator rights you can also change...

Page 93: ...e master The slaves always get their time from the master to which they are currently connected Note that the PLB does not retain the time if the supply voltage is interrupted 6 3 6 1 Setting the time manually Figure 6 12 Setting the time manually Setting the time manually In addition to an automatic update of the time you can also set the time manually on the master To do so you either enter the ...

Page 94: ... Figure 6 13 Setting the time of day of the NTP client Setting the time of day of the NTP client On this page you can activate the NTP client to synchronize the system time of the Power Line Booster Enter the IP address of the NTP server in the respective field and apply it by clicking Save The NTP server must be reachable over port 123 and be located in the same subnet as the PLB ...

Page 95: ... a cycle PLB slave is faulty or has dropped out of the segment the master waits for the time configured under 1st timeout before it tries to contact the next connected station If it does not receive a response in the second cycle it only waits for the time defined under 2nd timeout Because the likelihood that the station has dropped out of the segment gets greater with each attempt the timeout tim...

Page 96: ...pond If entering and leaving the communication segment is not an application for example in plants with only one segment you can also set the Hello Phase to 0 ms The cycle time is reduced by the duration of the Hello Phase in this case Visibility of the parameters The Hello Phase timer and the timeout values are parameters that can only be configured in the Master operating mode Dependencies The H...

Page 97: ...t configuration the size of the Prio 1 buffer must be increased The Prio 2 buffer is reserved for PROFINET alarms The selected default is configured so that there is sufficient space for any alarms that may occur in the PROFINET devices connected to the PLB The Prio 3 buffer is for User prioritized data If this buffer is activated the Unicast frames are buffered in the ports specified for TCP UDP ...

Page 98: ...ission rate but also in longer cycle times To achieve short cycle times only one container is transmitted for each station per cycle The number of additional containers can be set with the Additional containers parameter Additional containers are only created until either the buffers are empty or the maximum number of containers has been reached Note With more than one container the cycle time inc...

Page 99: ... 10 ms Here you can set when and which mode is used for the transmission A detailed description of the topics Timeout and Powerline cycle can be found in Time configuration Page 95 For most applications we recommend using the medium stability transfer mode for fault free operation without timeouts In the case of retries you should first configure the maximum stability with a frame lifetime of 15 m...

Page 100: ...nection is available at the most remote slave even in case of external interferences On the other hand there must be no crosstalk between two neighboring powerline segments The crosstalk limit can be determined with the crosstalk measurement Page 116 As soon as crosstalk occurs for the high frequency powerline signal the cycle time multiplies and data transmission in real time of PROFINET can no l...

Page 101: ...eceive gain parameter However this value must not be selected too low to still provide the powerline unit with a sufficient working range If there is no additional powerline communication in the environment of the powerline application the Static receive gain can be reduced because there is never any crosstalk into another segment 6 4 2 2 Segment configuration master only Segment configuration Fig...

Page 102: ...e measured values since the last restart of the device or since the last manual reset of the measured values This measuring duration is always shown above the table on the respective page By pressing the Reset long term measured values button you reset the long term measured values of the entire system However you only have access to this function in your capacity as an administrator Measured valu...

Page 103: ...yed as well You can find a detailed description of the errors in Error status and warnings of the device Page 81 Rescue Mode A slave restarted with the Rescue firmware after a fatal error Log backup A slave has created a backup of the log files after restart in Rescue mode to determine the cause of the error Core Dump The modem firmware of a slave has restarted after a fatal error and log files we...

Page 104: ...age The following columns are displayed by default in the table of slaves Connected on Time at which the connection to the slave was set up PN name PROFINET name of the slave IP address IP address of the slave You can display the current position of the slaves via the Position info switch However this value is only available if the current position of the PLB slave is transmitted via the PROFINET ...

Page 105: ...switch to the expert view which shows you these additional table columns Poll Sequence Position in which the slave is polled by the master Poll Min Minimum polling time to a slave Gap Min Minimum time between two frames to one slave Gap Path Min Minimum time between two frames to one vehicle PDS applications Blacklist Number of connection aborts to a slave Whitelist Number of established connectio...

Page 106: ...iption of the tables in Status tables Page 102 By default the table shows the following values Connected on Time at which the connection to the slave was set up PN name PROFINET name of the slave IP address IP address of the slave You can display the current position of the slaves via the Position info switch However this value is only available if the current position of the PLB slave is transmit...

Page 107: ...ations have very different values this may indicate an error and the vehicle cabling should be checked among other things for EMC interferences deviating cable material incorrect cable lengths or cable break A detailed evaluation of the modulation is possible using the Tone Map Page 109 BPS M Current value of the modulation bits per symbol of this connection on the master BPS S Current value of th...

Page 108: ...urement with the button and stop it again The data is updated cyclically as long as the measurement is in progress In the graphs you can see the values that were received last in blue while red and green indicate the minimum and maximum values for each frequency respectively You can reset extreme values with a button Some carriers are locked by the system for transmission The reason for this is di...

Page 109: ...s that the more bits can be modulated onto a carrier the better the connection and thus the transmission rate Some carriers locked for modulation by the system are shown with 1 in the grayed out area of the graph The closer a PLB slave is to the master the better the modulation If the slave is located directly at the master it should be possible to transmit 6 bits carrier across all approved frequ...

Page 110: ... takes place with the switch next to the button for starting the measurement In the PSD mode you can display the signal strength of the powerline signal and determine for example to what extent which frequencies are attenuated along the path Due to laws of physic higher frequencies are attenuated more strongly than lower frequencies along the path By comparing the graphs of two neighboring slaves ...

Page 111: ...st stand out from the background noise This means the signal to noise ratio must be sufficiently large If the SNR drops the error rate increases and the modulation of the respective carrier is reduced which is then also reflected in the Tone Map Page 109 For a relatively good signal to noise ratio the transmit level set under Signal configuration Page 110 should be as high as possible If the SNR i...

Page 112: ...ult Connected on Time at which the connection to the slave was set up PN name PROFINET name of the slave IP address IP address of the slave You can display the current position of the slaves via the Position info switch However this value is only available if the current position of the PLB slave is transmitted via the PROFINET IO interface Position Shows the current position of the slave only if ...

Page 113: ... the touch is present on all Powerline rails and all cables and plant units connected to them Measure Shut down plant Note that faulty voltages often affect the entire segment and that all slaves in the segment therefore show the same error 6 5 Expert functions Expert functions are available on the PLB for diagnostics and commissioning of a Power Line Booster system The functions often engage deep...

Page 114: ...g you can change the NMK temporarily using the Expert functions Page 113 for example to reach slaves in the segment with a different NMK You can select the four possible NMKs in the pull down menu and apply the key temporarily For plant installations with permanent communication and switchover of the sliders via relay double slider solution in an application the slaves on the vehicle have differen...

Page 115: ...al acknowledgment If no measurement is active the sliders are set to the levels configured under Signal configuration Page 110 The top slider is the static transmit gain of the powerline signal To achieve a good signal to noise ratio the transmit level should be set relatively high during regular operation The center slider sets the Limit for the dynamic receive gain of the PLB modem The PLB commu...

Page 116: ...figuration and system status web interface 6 5 Expert functions Power Line Booster 116 Operating Instructions 11 2019 A5E36203125A AG 6 5 3 Crosstalk measurement Figure 6 28 Crosstalk measurement positive example ...

Page 117: ...equired during commissioning The measurement is a functionality of the PLB Expert function Page 113 can be run through this page To determine the crosstalk limit you must move exactly one vehicle with exactly one PLB slave in two directly neighboring segments close to the intersection you want to measure With this configuration you can achieve the maximum signal level at the intersection because t...

Page 118: ...ue if no stable Powerline connection can be set up between master and slave at the lowest level value When you start the measurement all PLBs involved in the measurement both masters and both slaves will run through the level values between defined start and end value synchronously step by step The cycle time in the segments is determined for each level value and recorded in the graph As soon as t...

Page 119: ...is shown under Errors and warnings and in the header area of all web pages In the first step the core dump must be imported from the modem and saved on the system to be downloaded later While the file is being created there may be communication problems this is why this process should not take place during production hours It can take up to 20 minutes for the download file to be created Only after...

Page 120: ... with short cable no connecting cables of the respective segments via the center line of the segment cut etc Is the 42 V carrier voltage supply available in all segments or have the circuit breakers tripped due to short circuits for example Is the shielding of the powerline connection cables 1 meter correctly executed Is the DIP switch position of the devices correct master slave and network key A...

Page 121: ...segments as well as to all slaves Only the slave at Poll order 1 can should have slightly higher values depending on the system If the measured values of one slave differ from those of the others longer cycle time more timeouts etc please check this slave for faults for example its cabling In the signal quality table you will notice that the values of the slaves deteriorate with the distance to th...

Page 122: ...one device config ured as master Do all PLBs have the same network key Transfer time for segment change takes too long Do the neighboring masters have a different SNID configuration see Segment configuration Page 101 One segment often suffers from com munication problems Is there an electrical connection between slider and rail at all times Do sliders lift off at curves separators switches or lift...

Page 123: ...rie Service GmbH Tor 1 4 Kraftwerkstr 25A D 9156 Erlangen Germany During longer operation environmental influences act on the device for example temperature humidity and air pressure Send the device to the Return Center for a verification of the function and measuring accuracy Flat rate charges are specified for the verification and if necessary for the repair Spare parts Spare parts and accessori...

Page 124: ...Maintenance and service 7 2 Recycling and disposal Power Line Booster 124 Operating Instructions 11 2019 A5E36203125A AG ...

Page 125: ...imensions without connecting cables Degree of protection Table 8 3 Power Line Booster Degree of protection IP20 The degree of protection is only fulfilled for the fully equipped device This means only including all plugged in modules Table 8 4 PLB TC Degree of protection IP20 When installed Installation You can clip the PLB onto a 35 mm DIN rail TS 35 EN50022 You can use the DIN rail in the horizo...

Page 126: ...150 m s Duration 11 ms Pulse shape half sine Shocks in pos and neg direction to each axis 3 shocks 11 ms with 15 G 8 1 3 Electrical characteristic values Device Rated voltage Current consumption Power consumption min Typical max Typical max Typical max PLB BM LV M S incl Modules MM BM X80 19 2 V DC 28 8 V DC 0 29 A 0 63 A 7 0 W 12 0 W PLB BM LV M S incl modules MM BM X2 0 V AC 42 V AC 48 3 V AC 4 ...

Page 127: ...ontal mounting surface the maximum ambient temperature is reduced to 50 C Distance to adjacent devices 60 mm above and below the PLB The storage temperature is 40 C 70 C Max operation altitude 2000 m above sea level All components are designed for continuous operation 24 h 7 d 8 2 Approvals 8 2 1 CE conformity The PLB modules PLB BM PLB MM and PLB TC in the version sold by us conforms with the dir...

Page 128: ... 6 2 2005 PLB BM PLB MM EN 61000 6 4 2007 A1 2011 PLB BM PLB MM EN 61010 1 2010 PLB BM PLB MM PLB TC EN 61010 2 201 2013 PLB BM PLB MM PLB TC 8 2 2 cULus approval Underwriters Laboratories Inc to UL 61010 1 Ed 3 Rev 2018 11 21 and UL 61010 2 201 Ed 2 Published 2018 05 14 CSA C22 2 No 61010 1 Ed 3 Rev 2018 11 and CSA C22 2 No 61010 2 201 Ed 2 Published 2018 02 The approval is for the PLB modules PL...

Page 129: ...C PLB MM modem module PLB MM 6ES7972 5AA51 0AB0 SIMATIC PLB Termination and Cou pling PLB TC 6ES7972 5AB00 0XA0 SIMATIC PLB Empty Module empty enclosure as cover 5 pieces per packing unit PLB EM 6ES7972 5AA90 0XA0 Connecting cables Table 9 2 Order numbers for connecting cables of the PLB devices Connecting cables 8 m length Without plug 6ES7903 1AH40 0AB0 With plug male 6ES7903 1AH41 0AB0 With two...

Page 130: ...X80 PLB BM SPC 5 2 ST 7 62 BK PU 50 pcs Phoenix Contact Order no 17 24 239 Phoenix Contact Order no 17 07 524 Shield clamp for X2 PLB BM PU 10 pcs SKS 14 D for X2 PLB BM PU 10 pcs LF Z SKL 8 11 also requires M4x 6 fixing screw Phoenix Contact Order no 32 40 214 icotek Order no 36925 Carrier voltage trans former TSV mdexx Order no TAM3242 8JV00 0EA0 Line filter 1 Schurter 5500 2349 clip DIN rail 2 ...

Page 131: ...urrent consumption 126 Cycle time PLB cycle time 72 72 D Degree of pollution 30 126 DIN rail 125 127 E Expansion point 52 F Factory RESET 13 Factory settings 13 Fast Connect 21 22 Firmware update 16 16 FRES 13 I I M data 68 Input data 64 IO controller 71 IP address 13 J Jumbo frames 39 L Latency 73 Latency time 75 Lateral attenuation 50 LED display 22 PLB Basic module 15 PLB modem module 25 Line f...

Page 132: ...PN update time 72 75 76 PN update time 72 75 76 PN watchdog time 76 Power consumption 126 PROFINET System Description 71 PRONETA 71 PST 71 R Rail terminal box 125 Real time capability 72 Real time conditions 7 S SCALANCE X204RNA 39 Segment infeed system 29 Shield plate 52 Sounding 73 Station flash test 16 23 STEP7 71 Storage temperature 127 System latency 73 T Terminal box 125 Trailing cable 73 Tr...

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