ECOFAST System Manual 11/2004 ecofast . System Description 1 Product Family 2 Installation Guidelines 3 Installation 4 Connection 5 Commisioning 6 Technical Data 7 Dimension Drawings 8 Order Numbers 9 Questions and Answers A ECOFAST Pilot Projects B System ECOFAST Manual Glossary Order Number 3RK1703-0BB18-0AA1 Edition 11/2004 GWA 4NEB 950 5228-02 Safety Guidelines This manual contains notices which you should observe to ensure your own personal safety as well as to avoid property damage. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage are not designated by a safety alert symbol. Depending on the danger level, the warnings will be displayed in descending sequence as follows. Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. Caution used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Caution used without safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. Notice indicates a potential situation which, if not avoided, may result in an undesirable result or state. When several danger levels apply, the notices of the highest level (lower number) are always displayed. If a notice refers to personal damages with the safety alert symbol, another notice may be added as a warning of potential property damage. Qualified Personnel The device/system may only be set up and operated in conjunction with this documentation. Only qualified personnel should be allowed to install and work on the equipment. Qualified persons are defined as persons who are authorized to commission, ground and tag circuits, equipment and systems in accordance with established safety practices and standards. Intended Use Please note the following: Warning This device and its components may only be used for the applications described in the catalog or technical description, and only in connection with devices or components from other manufacturers approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored, set up and installed correctly, and operated and maintained as recommended. Trademarks All designations marked with (R) are registered trademarks of Siemens AG. Other designations in this documentation might be trademarks which, if used by third parties for their purposes, might infringe upon the rights of the proprietors. Copyright Siemens AG 2004 All rights reserved. The reproduction, transmission or use of this document or its contents 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 model or design, are reserved. Siemens AG Automation and Drives Postfach 4848, D-90327 Nurnberg Siemens Aktiengesellschaft Disclaimer of Liability We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularely and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed. (c) Siemens AG 2004 Subject to change without prior notice Introduction and Notes on Using the Manual Purpose of the manual This manual is intended to serve as a reference document. The information it contains will help you operate the ECOFAST system with the PROFIBUS-DP and AS-Interface field buses. Topics This manual consists of instruction chapters and reference chapters. It covers the following topics, among others: * System Description * Product Family * Installation Guidelines * Installation * Connections * Commisioning * Technical Data * Dimension Drawings * Order Numbers * Questions and Answers * ECOFAST Pilot Projects * Glossary Note Notice Important information requiring particular attention is enclosed between two horizontal lines. Specifications This manual only describes shared components of the ECOFAST system. ECOFAST System Manual GWA 4NEB 950 5228-02 iii Service and Support Technical Assistance: Telephone: +49 (0) 911-895-5900 (8:00 - 17:00 CET) Fax: +49 (0) 911-895-5907 Technical Support: E-mail: technical-assistance@siemens.com Internet: www.siemens.de/lowvoltage/technical-assistance Telephone: +49 (0) 180 50 50 222 Correction sheet A correction sheet is attached at the end of this manual. Please enter any suggestions for improvements, additions or corrections there and return the sheet to us. In doing so, you can help us improve the next edition. iv ECOFAST System Manual GWA 4NEB 950 5228-02 Contents Introduction and Notes on Using the Manual.................................................................................................. iii 1 2 3 ECOFAST System Description ............................................................................................................. 1-1 1.1 1.1.1 1.1.2 1.1.3 Philosophy of the ECOFAST System ....................................................................................... 1-1 Requirements Specified for Innovative Automation and Drive Systems .................................. 1-2 Desina and Field Bus Certificates ............................................................................................ 1-3 ECOFAST certified and ECOFAST integrated ......................................................................... 1-3 1.2 ECOFAST ES Software............................................................................................................ 1-4 1.3 1.3.1 1.3.2 The ECOFAST Basic System................................................................................................... 1-4 Topology of the Network ........................................................................................................... 1-5 Overview of Interfaces .............................................................................................................. 1-6 Product Family ....................................................................................................................................... 2-7 2.1 2.1.1 2.1.2 2.1.3 Power & Control Module (PCM) ............................................................................................... 2-7 Tasks of the Power & Control Module (PCM) ........................................................................... 2-7 Device Versions ........................................................................................................................ 2-8 PCM Order Numbers ................................................................................................................ 2-9 2.2 2.2.1 2.2.2 Alternative Power Supply ....................................................................................................... 2-10 Simple Energy Unit (SEU) ...................................................................................................... 2-10 ET 200S Motor Starter ............................................................................................................ 2-12 2.3 Power Tee Clamp Connector ................................................................................................. 2-13 2.4 Hybrid Field Bus Connections ................................................................................................ 2-15 2.5 Data Tee Plug Connector ....................................................................................................... 2-17 2.6 2.6.1 2.6.2 Discriminating Module and Maintenance Switch .................................................................... 2-18 Discriminating Module ............................................................................................................ 2-18 Maintenance Switch with M12 Connector .............................................................................. 2-19 Installation Guidelines ......................................................................................................................... 3-21 3.1 Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable .............. 3-21 3.2 Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable (Fiber-optic Conductors)......................................................................................................... 3-22 3.3 3.3.1 3.3.2 Guidelines for PROFIBUS-DP Standard Cables .................................................................... 3-24 Potential Equalization ............................................................................................................. 3-24 Cable Shielding ...................................................................................................................... 3-25 3.4 PNO Installation Guidelines.................................................................................................... 3-27 3.5 3.5.1 3.5.2 3.5.3 3.5.4 Power Bus Installation Versions ............................................................................................. 3-28 Unassembled set-up with power tee clamp connector and power cable ................................ 3-28 Connecting Consumers with a Spur Cable ............................................................................. 3-29 ET 200X Sub-Segmente with EM 300 Motor Starter .............................................................. 3-30 Possible Power Distribution with Discriminating Modules ...................................................... 3-32 ECOFAST System Manual GWA 4NEB 950 5228-02 v 4 5 6 vi 3.5.5 Line Protection in Power Bus Segment for Motor Starters Without Thermal Motor Model (Installation in the Vicinity of the Motor) .................................................................................. 3-33 3.6 Installation Versions for Switching Devices and Control Circuit Devices................................ 3-35 Installation .............................................................................................................................................. 4-1 4.1 4.1.1 4.1.2 Power & Control Module........................................................................................................... 4-1 Installation of the IP65 Version ................................................................................................. 4-1 Installation of the Cabinet Installation Version (IP00) ............................................................... 4-2 4.2 4.2.1 4.2.2 Alternative Power supply .......................................................................................................... 4-3 Simple Energy Unit (SEU) ........................................................................................................ 4-3 ET 200S Motor Starter .............................................................................................................. 4-3 4.3 Power Tee Clamp Connector ................................................................................................... 4-4 4.4 Hybrid Field Bus Connections .................................................................................................. 4-5 4.5 4.5.1 4.5.2 Discriminating Module and Maintenance Switch ...................................................................... 4-6 Discriminating Module .............................................................................................................. 4-6 Maintenance Switch .................................................................................................................. 4-7 Connections ........................................................................................................................................... 5-1 5.1 5.1.1 5.1.2 Power & Control Module........................................................................................................... 5-1 Connections of the IP65 Version .............................................................................................. 5-1 Connections of the Cabinet Installation Version ....................................................................... 5-3 5.2 5.2.1 5.2.2 Alternative Power Supply.......................................................................................................... 5-6 Connections of the Simple Energy Unit (SEU) ......................................................................... 5-6 ET 200S Motor Starter .............................................................................................................. 5-6 5.3 Power Tee Clamp Connector ................................................................................................... 5-7 5.4 Hybrid Field Bus Connections .................................................................................................. 5-8 5.5 5.5.1 Data Tee Plug Connector ....................................................................................................... 5-14 Pin Assignment ....................................................................................................................... 5-14 5.6 Discriminating Module and Maintenance Switch .................................................................... 5-15 5.7 5.7.1 5.7.2 5.7.3 General Wiring and Interfaces ................................................................................................ 5-16 Rules for Wiring ...................................................................................................................... 5-16 Power Cables, Preassembled at One End ............................................................................. 5-17 AS-i Interface .......................................................................................................................... 5-21 Commissioning ...................................................................................................................................... 6-1 6.1 6.1.1 Power & Control Module........................................................................................................... 6-1 Diagnostics ............................................................................................................................... 6-2 6.2 6.2.1 6.2.2 Alternative Power Supply.......................................................................................................... 6-3 Simple Energy Unit (SEU) ........................................................................................................ 6-3 ET 200S motor starter .............................................................................................................. 6-3 6.3 6.3.1 6.3.2 6.3.3 Hybrid Field Bus Connections .................................................................................................. 6-4 Passive Hybrid Field Bus Connection for Supply ..................................................................... 6-5 Passive Hybrid Field Bus Connection for Conducting .............................................................. 6-6 Active Hybrid Field Bus Connection for Supply ........................................................................ 6-7 ECOFAST System Manual GWA 4NEB 950 5228-02 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 6.3.10 6.3.11 6.3.12 6.3.13 6.3.14 6.4 7 8 9 Active Hybrid Field Bus Connection for Conducting ................................................................. 6-8 Cascading of the Active Hybrid Field Bus Connections ........................................................... 6-9 Power Supply of the Bus Terminating Connector ..................................................................... 6-9 Active Hybrid Field Bus Connection for Supply ...................................................................... 6-10 Active Hybrid Field Bus Connection for Supply ...................................................................... 6-11 Conveyor Section With Hybrid Field Bus Connections for Supply and Conducting ............... 6-12 Installation System with PROFIBUS-DP - Cu ......................................................................... 6-13 PROFIBUS-DP - Fiber-optic Cable ........................................................................................ 6-14 PROFIBUS-DP (Cu) and Passive Hybrid Field Bus Connections with 2 Separate Power Supplies ....................................................................................................................... 6-15 PROFIBUS-DP (Cu) and Active Hybrid Field Bus Connections with 2 Separate Power Supplies ....................................................................................................................... 6-16 PROFIBUS-DP CU and Active Hybrid Field Bus Connections with 2 Separate Data Supplies ......................................................................................................................... 6-17 Discriminating Module and Maintenance Switch .................................................................... 6-18 Technical Data ........................................................................................................................................ 7-1 7.1 7.1.1 7.1.2 Power & Control Module........................................................................................................... 7-1 IP65 Version ............................................................................................................................. 7-1 IP00 Version (Control Cabinet Version) ................................................................................... 7-4 7.2 7.2.1 7.2.2 Alternative Power Supplies....................................................................................................... 7-6 Simple Energy Unit (SEU) ........................................................................................................ 7-6 ET 200S Motor Starter .............................................................................................................. 7-6 7.3 Hybrid Field Bus Connections .................................................................................................. 7-7 7.4 Data Tee Plug Connector ......................................................................................................... 7-8 7.5 Discriminating Module ............................................................................................................ 7-10 Dimension Drawings ............................................................................................................................. 8-1 8.1 8.1.1 8.1.2 Power & Control Module........................................................................................................... 8-1 IP65 Version ............................................................................................................................. 8-1 IP00 Version (Control Cabinet Version) ................................................................................... 8-2 8.2 8.2.1 8.2.2 Alternative Power Supplies....................................................................................................... 8-3 Simple Energy Unit (SEU) ........................................................................................................ 8-3 ET 200S Motor Starter .............................................................................................................. 8-5 8.3 Power Tee Clamp Connector ................................................................................................... 8-6 8.4 Hybrid Field Bus Connections .................................................................................................. 8-7 8.5 Data Tee Plug Connector ......................................................................................................... 8-8 8.6 Discriminating Module and Maintenance switch....................................................................... 8-9 Order Numbers ....................................................................................................................................... 9-1 9.1 Motor Starters (Reversing Starters).......................................................................................... 9-1 9.2 Motor Connection Cables ......................................................................................................... 9-2 9.3 Power Cables ........................................................................................................................... 9-3 9.4 Power & Control Modules (Infeed Modules)............................................................................. 9-4 ECOFAST System Manual GWA 4NEB 950 5228-02 vii A 9.5 Simple Energy Unit (SEU) ........................................................................................................ 9-4 9.6 Discriminating Modules............................................................................................................. 9-5 9.7 Maintenance Switch.................................................................................................................. 9-5 9.8 Hybrid Field Bus Cables ........................................................................................................... 9-5 9.9 AS-Interface Shaped Cable ...................................................................................................... 9-6 9.10 Hybrid Field Bus Connections .................................................................................................. 9-7 9.11 Connectors ............................................................................................................................... 9-7 9.12 Project Engineering Software and Documentation ................................................................... 9-9 9.13 Tools, Connector Sets, Configuration..................................................................................... 9-10 Questions and Answers ........................................................................................................................A-1 A.1 B Frequently Asked Questions..................................................................................................... A-1 ECOFAST Pilot Projects ........................................................................................................................B-1 B.1 Production Line for SIRIUS 2 - Siemens Cham........................................................................ B-1 B.2 Configuration in the Automotive Industry - Production Planning .............................................. B-4 Glossary viii ECOFAST System Manual GWA 4NEB 950 5228-02 Tables Table 2-1: PCM device versions ...................................................................................................................... 2-9 Table 2-2: Device versions: Simple Energy Unit............................................................................................ 2-11 Table 2-3: Versions of power tee clamp connectors...................................................................................... 2-13 Table 2-4: Sealing sets for power tee clamp connectors ............................................................................... 2-13 Table 2-5: Hybrid field bus connection versions ............................................................................................ 2-16 Table 2-6: Discriminating module versions .................................................................................................... 2-19 Table 3-1: Permissible line length of a bus segment based on the baud rate ............................................... 3-22 Table 3-2: Permissible line lengths in the optical PROFIBUS-DP network.................................................... 3-23 Table 4-1: Installing the PCM, IP65 Version .................................................................................................... 4-1 Table 4-2: Installing the PCM, Cabinet Installation Version............................................................................. 4-2 Table 4-3: Installing the power tee clamp connector ....................................................................................... 4-4 Table 4-4: Installing the hybrid field bus connection ........................................................................................ 4-5 Table 4-5: Required components..................................................................................................................... 4-6 Table 4-6: Installing the discriminating module................................................................................................ 4-7 Table 5-1: Pin assignment of the Han Q4/2 pin/socket.................................................................................... 5-3 Table 5-2: Pin assignment of the hybrid field bus connection.......................................................................... 5-3 Table 5-3: Wiring of the PCM........................................................................................................................... 5-4 Table 5-4: Stripped lengths, cross-sections, terminal assignment................................................................... 5-5 Table 5-5: Connections for passive hybrid field bus connection (IP20 side) ................................................. 5-10 Table 5-6: Connections for active hybrid field bus connection (IP20 side) .................................................... 5-10 Table 5-7: Wiring the hybrid field bus connection .......................................................................................... 5-11 Table 5-8: Wiring of the Fast Connect Block ................................................................................................. 5-11 Table 5-9: Stripped lengths, cross-sections, terminal assignments............................................................... 5-13 Table 5-10: Pin assignment of the Han Q4/2 pin/socket.................................................................................. 5-15 Table 5-11: Rules for wiring ............................................................................................................................. 5-17 Table 5-12: Preparing connecting leads with Han Q4/2 .................................................................................. 5-20 Table 6-1: Sequence of steps for commissioning the PCM, IP65 version ....................................................... 6-1 Table 6-2: Sequence of steps for commissioning the PCM, control cabinet version ....................................... 6-1 Table 6-3: Diagnostics - missing voltages ....................................................................................................... 6-2 Table 6-4: Diagnostics - signal states .............................................................................................................. 6-3 Table 6-5: Procedure for commissioning the hybrid field bus connection........................................................ 6-4 Table 6-6: Diagnostics for active hybrid field bus connections ........................................................................ 6-4 Table 6-7: Sequence of steps for commissioning the discriminating module/maintenance switch................ 6-18 ECOFAST System Manual GWA 4NEB 950 5228-02 ix x ECOFAST System Manual GWA 4NEB 950 5228-02 1 ECOFAST System Description 1.1 Philosophy of the ECOFAST System ECOFAST - An integrated connection system for data and power on the field level The ECOFAST system (Energy and Communication Field Installation System) sets new standards whenever machines and plants need to be equipped with automation, control & distribution and drive technology. The central elements of the ECOFAST philosophy are extensive decentralization and modularization of the installation system and comprehensive diagnostics on the component level. ECOFAST links all components of an automation system together using an integrated connection technique for data and power that complies with the high IP65 degree of protection. ECOFAST is thus an integral part of "Totally Integrated Automation" and open from the point of view of both manufacturers and users. SIMATIC S7 Fig. 1-1: ECOFAST System Manual GWA 4NEB 950 5228-02 ECOFAST Motor/starter unit SIMATIC ET200X Components COMBIMASTER Motor/converter unit ELMO pump ELMO-G side-channel compressor Typical components of an automation system 1-1 ECOFAST System Description Philosophy of the ECOFAST System 1.1.1 Requirements Specified for Innovative Automation and Drive Systems * * * * Short phases for offering, planning and configuring machines and plants Rapid installation and assembly Quick and easy commissioning High system availability Short phases for offering, planning and configuring machines and plants * * * * * * * * * * Modular planning process for machines and plants Offers prepared by combining prefabricated modules Use of CAD/CAE macros Use of standardized bus systems such as PROFIBUS-DP and AS-Interface Rapid installation and assembly Cabinetless installation systems with a high degree of protection Use of prefabricated and tested functional units Smaller system footprint Rapid installation on site Standardized connection method for power and data lines Quick and easy commissioning * * * Potential fault sources reduced to a minimum thanks to standardized connectors Comprehensive diagnostics on the device and over the bus Improved EMC because the contact unit and the drive are linked together directly High system availability * * * * * 1-2 Shorter downtimes because devices can be replaced quickly and easily No need to interrupt the power and field buses in order to replace a device Automatic parameterization if a device is replaced Comprehensive status and diagnostic information Transfer of operating parameters, such as current values or status signals ECOFAST System Manual GWA 4NEB 950 5228-02 ECOFAST System Description Philosophy of the ECOFAST System 1.1.2 Desina and Field Bus Certificates Fig. 1-2: Desina and Field Bus Certificates Advantages * * * * * * 1.1.3 Common connection method for all modules PROFIBUS-DP connected using Han Brid connectors AS-Interface connected using the insulation displacement method Power connected with HAN Q4/2 connectors Recommended by Profibus International (PNO) and Verein Deutscher Werkzeugfabriken VDW (DESINA) ECOFAST certified and ECOFAST integrated Fig. 1-3: ECOFAST certified and ECOFAST integrated certificates ECOFAST certified The new "ECOFAST certified" certificate, which is assigned by an accredited test laboratory, guarantees reliable planning. It confirms that devices from different manufacturers are compatible with ECOFAST specifications. ECOFAST integrated Another user-friendly and time-saving feature. Plans and quantity/parts lists are created along with the entire system documentation for ECOFAST ES. Using an export function, they can then be easily integrated for further CAD processing. In addition to Siemens components, devices from other manufacturers can also be integrated in this configuration tool. Their integration and conformity is confirmed by the "ECOFAST integrated" certificate. ECOFAST System Manual GWA 4NEB 950 5228-02 1-3 ECOFAST System Description ECOFAST ES Software 1.2 ECOFAST ES Software The ECOFAST ES configuration tool supports power-engineering system design with the following range of functions: * Graphical configuration of the consumers, cables, and switching/protection functions * Power bus dimensioning by automatically determining cable cross-sections and automatic dimensioning of the switching/protection elements * Power-engineering design and testing according to the relevant standards and today's generally accepted practices * Creation of documentation: circuit diagram of the power bus, quantity/parts lists 1.3 The ECOFAST Basic System Operator control Motor starter IP20 component e. g. and monitoring motor plugged in SIMOCODE-DP e. g. OP 27 Power & Control module (PCM) ET 200X COMBIMASTER MM 411 Engineering software ECOFAST ES Fig. 1-4: 1-4 The ECOFAST basic system ECOFAST System Manual GWA 4NEB 950 5228-02 ECOFAST System Description The ECOFAST Basic System 1.3.1 Topology of the Network Block diagram The block diagram below shows a possible topology of the ECOFAST network: Cable types 1 Power 2 Spur 3 Motor 4 Motor (freq. converter) 5 ET200 sub-segment 6 ET200 power 7 ET200 motor Infeed Motor starter Frequ. conv. Pre-assembled: On one side, on both sides Cable with 1 or 2 connectors Length to be selected in the grid Cut-to length: Cable without connectors Discr. mod. Discr. mod. Motor starter Motor starter Fig. 1-5: Assembly type Motor starter Block diagram of the network topology Power & control module (PCM) * * * * Supplies power up to 690 V Generates 24 V for interfaces to the field bus and the sensors Generates 24 V for actuators (can be switched by EMERGENCY STOP modules in the power & control module) Integrates EMERGENCY STOP functionality Power bus The consumers are supplied by the power bus via power tee connectors. Field bus The DP master supplies the DP protocol to the hybrid line (fiber-optic or Cu). ECOFAST motor starters allow the stations on the PROFIBUS-DP to be connected without interruption to the data tee connector. The AS-i master supplies the AS-i protocol to the AS-i line. The stations on the AS-Interface are connected using the insulation displacement method. ECOFAST System Manual GWA 4NEB 950 5228-02 1-5 ECOFAST System Description The ECOFAST Basic System 1.3.2 Overview of Interfaces Diagram The diagram below shows an overview of the system interfaces using the example of a motor starter: Motor connector Digital inputs Data tee connector Data terminal Motor terminal Power connection Fig. 1-6: Hybrid field bus cable Local device interface Local device interface* *3RK1303-2AS54-.... Data connector Power cable Power tee connector motor starters only Overview of Interfaces Field Bus Interfaces ECOFAST components feature the following field bus interfaces, depending on the device version: PROFIBUS-DP PROFIBUS-DP interface with data terminal, data tee connector, data connector optionally for copper cable (Cu) or fiber-optic cable AS-Interface AS-i interface with insulation displacement technology for yellow AS-i line (data and 24 V nonswitched) and black AS-i line (AUX PWR: 24 V DC switched) AS-i R AUX PW Fig. 1-7: 1-6 Field bus interfaces ECOFAST System Manual GWA 4NEB 950 5228-02 Product Family 2.1 Power & Control Module (PCM) 2.1.1 Tasks of the Power & Control Module (PCM) 2 The PCM performs the following tasks in the ECOFAST system: * Supplying the connected ECOFAST components via two Han Q4/2 sockets with 400 V AC power * Short-circuit protection with the S2 circuit-breaker * Supplying the connected ECOFAST components via two Han Brid sockets with - 24 V DC switched (DC24V-S): This voltage is not always present. It is used to control the switching elements (e.g. contactor). - 24 V DC non-switched (DC24V-NS): This voltage is always present. It is used to supply power to the electronic ECOFAST components and sensors and interrogate auxiliary contacts. - PROFIBUS-DP * Supplying the AS-Interface profile lines with 24 V DC (switched) (black, AUX PWR) and 24 V DC (non-switched) (yellow, AS-i) via AS-Interface. * Protection and monitoring * PLC function - Central SIMATIC S7 module: CPU 313-2 DP, 16 DI + 16 DO x 24 V DC with 64K memory card or - SIMATIC S7 slave module: ET 200M with digital input output module: SM 323 16 DI + 16 DO x 24 V DC A program for controlling the PCM is installed in the CPU at the factory. You can also store the user program for controlling your system here. For more information, refer to "System Software for S7 300/400, System and Standard Functions Reference Manual". * EMERGENCY STOP function with contactor safety combination - Main switch function, rotary actuator - SIGUARD safety combination 3TK2 8... or - Safety at work 3RK1 1... - Stop category: 0 to EN 60204-1 (uncontrolled shutdown by means of immediate switch-off of power to the machine actuator components) - Category: 4 according to EN 954-1 ECOFAST System Manual GWA 4NEB 950 5228-02 2-1 Product Family Power & Control Module (PCM) 2.1.2 Device Versions The PCM is available in a housing version with degree of protection IP65 and for control cabinet mounting with degree of protection IP00. Set-up Depending on the device version, the PCM comprises the following components: * PLC (DP master, DP slave, AS-i master) * 3TK28 (SIGUARD) safety combination or AS-i monitor * 24 V DC (switched (DC24V-S)) and 24 V DC (non-switched (DC24V-NS)) * 24 V DC (switched (AUX PWR)) and 30 V DC (non-switched (AS-i)) for AS-Interface 24 V DC power supplies Safe separate supply according to PELV. The 24 V DC power supplies (switched (DC24V-S) and non-switched (DC24V-NS)) are available in two different versions. Features to take into consideration during configuration: * Version 1: SIDAC power supply - Equipped with a safety isolating transformer - Very high EMC resistance - Very robust * Version 2: SITOP power supply - Very high control accuracy for output voltage - Settable voltage level - Lightweight Fig. 2-1: 2-2 Power & Control Modules (PCM) IP65 and IP00 ECOFAST System Manual GWA 4NEB 950 5228-02 Product Family Power & Control Module (PCM) 2.1.3 PCM Order Numbers Power and Control Module (PCM), version IP65 Housing dimensions (W x H x D): Overall dimensions w/o external connector (W x H x D): Order no. 550 x 850 x 255 mm 600 x 920 x 310 mm Bus connection Safety system Generation of aux. voltage PROFIBUS master with S7-300 CPU 313C-2 DP SIGUARD safety contactor combination SIDAC DC 24 V, 10 A (NS), 10 A (S) PROFIBUS master with S7-300 CPU 313C-2 DP + AS-i master with AS-i power supply 2.4 A PROFIBUS slave with ET 200M AS-Interface Safety at Work SIGUARD safety contactor combination 4FB2 111-2A . . 1-0AA0 4FB2 121-2A . . 1-0AA0 4FB2 112-2A . . 1-0AA0 SITOP DC 24 V, 10 A (NS), 10 A (S) 4FB2 112-2A . . 2-0AA0 SIDAC DC 24 V, 10 A (NS), 10 A (S) 4FB2 111-2A . . 1-0AA1 SITOP DC 24 V, 10 A (NS), 10 A (S) 4FB2 111-2A . . 2-0AA1 Power and Control Module (PCM), control cabinet mounting Housing dimensions (W x H x D): 550 x 850 x 255 mm Overall dimensions w/o external connector (W x H x D): 600 x 920 x 310 mm Bus connection Safety system Generation of aux. voltage PROFIBUS master with S7-300 CPU 313C-2 DP SIGUARD SIDAC DC 24 V, 10 A (NS), 10 A (S) PROFIBUS master with S7-300 CPU 313C-2 DP + AS-i master with AS-i power supply 2.4 A PROFIBUS slave mit ET 200M safety contactor combination AS-Interface Safety at Work SIGUARD safety contactor combination Main power supply Breaking capacity 4FB2 111-2A . . 1-0AA2 4FB2 121-2A . . 1-0AA1 4FB2 112-2A . . 1-0AA1 SITOP DC 24 V, 10 A (NS), 10 A (S) 4FB2 112-2A . . 2-0AA1 SIDAC DC 24 V, 10 A (NS), 10 A (S) 4FB2 111-2A . . 1-0AA3 SITOP DC 24 V, 10 A (NS), 10 A (S) 4FB2 111-2A . . 2-0AA3 External back-up fuse*) 16 A 50 kA 100 A A0 20 A 50 kA 125 A B0 25 A 50 kA 125 A C0 32 A 50 kA 125 A D0 40 A 50 kA 160 A E0 Unregulated 1 Regulated 2 Table 2-1: PCM device versions *) External back-up fuse If the short-circuit current at the installation location exceeds Icu = 100 kA, a back-up fuse (gL/gG) with the maximum value specified in the table is required. Max. input voltage: 415 V AC. ECOFAST System Manual GWA 4NEB 950 5228-02 2-3 Product Family Alternative Power Supply 2.2 Alternative Power Supply 2.2.1 Simple Energy Unit (SEU) For applications with an external 24 V auxiliary power supply or which require a different automation structure, it is not necessary to use a complete PCM module with incoming supply, auxiliary power supply generation and automation component. In these cases we recommend using a circuit-breaker, two contactors and two cable throughfeeds as a "Simple Energy Unit" (SEU) which can be mounted in existing control cabinets. The SEU is used in a IP65 housing. The 24 V auxiliary power and the wiring including the EMERGENCY STOP must be provided by the plant. Circuit-breaker Fig. 2-2: 2-4 Contactor EMERGENCY STOP Contactor EMERGENCY STOP Simple Energy Unit (SEU) ECOFAST System Manual GWA 4NEB 950 5228-02 Product Family Alternative Power Supply Device versions The SEU is available for the following supply voltages: 8 A, 16 A, 20 A, 25 A, 32 A, 40 A, 50 A. The frame sizes S00 and S0 are provided for 8 A. With the exception of the version 8 A with frame size S00, the SEUs correspond to type of coordination 2, i.e. in case of a short circuit, the contactor and the overload relay must not endanger either personnel or the plant and must be suitable for further use. SEU Circuit-breaker Type Order No. IN [A] Contactor with Auxiliary Switch Type of coordination/ShortCircuit Breaking Capacity S00 3RV1011-1HA10 8.00 3RT1015-1BB44-3MA Type of coordination 1/Iq=50 kA S0 3RV1021-1HA10 8.00 3RT1024-1BB44-3MA Type of coordination 2/Iq=130 kA S2 3RV1031-4AA10 16.00 3RT1026-1BB44-3MA0 Type of coordination 2/Iq=130 kA S2 3RV1031-4BA10 20.00 3RT1026-1BB44-3MA0 Type of coordination 2/Iq=130 kA S2 3RV1031-4DA10 25.00 3RT1034-1BB44 Type of coordination 2/Iq=100 kA S2 3RV1031-4EA10 32.00 3RT1034-1BB44 Type of coordination 2/Iq=100 kA S2 3RV1031-4FA10 40.00 3RT1035-1BB44 Type of coordination 2/Iq=100 kA S2 3RV1031-4HA10 50.00 3RT1036-1BB44 Type of coordination 2/Iq=100 kA Table 2-2: ECOFAST System Manual GWA 4NEB 950 5228-02 Device versions: Simple Energy Unit 2-5 Product Family Alternative Power Supply 2.2.2 ET 200S Motor Starter For applications with an external 24 V auxiliary power supply or which require a different automation structure, it is not always necessary to use a complete PCM module with incoming supply, auxiliary power supply generation and automation component. In these cases, an ET 200S motor starter can be used as an alternative to the SEU, which can protect and switch a complete chain. In combination with the terminal and the power module, they form a completely wired unit. Up to 5 expansions (16 A each) can be achieved by linking terminal blocks. All parameterizations, messages and switching commands possible in ET 200S can be transmitted via profi bus for automation. Power module motor starter A3 DS ON IM 151 PM-D F1 A2 PM-X A1 400 V Fig. 2-3: 2-6 TM-X15S27-01 Terminal module TM-PF30 S47-B1 EMERGENCY STOP F-Kit 1 Power bus 400 V Overview: ET 200S as incoming supply ECOFAST System Manual GWA 4NEB 950 5228-02 Product Family Power Tee Clamp Connector 2.3 Power Tee Clamp Connector Tasks Power tee clamp connectors connect ECOFAST components with the power bus. The power bus is not interrupted when the ECOFAST components are unplugged. Two different versions are available: * Power tee clamp connector with Han Q4/2 socket. This version connects the power bus with the load. * Power tee-tee clamp connector with Han Q4/2 socket. This version connects the power bus with two loads. As an alternative, a further power bus segment can be fed via the second Han Q4/2 socket. The clamp connectors may be inserted anywhere within the wiring chain. The round cable is contacted via insulation displacement or screw-type terminals without interrupting the wires. Cables with individual wires according to DIN VDE 0281/0295 with conductor cross sections ranging from 2.5 to 6 mm2 are suitable for use. Versions The following versions are currently available: Order no. Version 3RK1911-2BF01 Power tee clamp connector Han Q4/2, cable cross section 2.5 - 4 mm2 3RK1911-2BF02 Power tee clamp connector Han Q4/2, cable cross section 4 - 6 mm2 3RK1911-2BG02 Power tee-tee clamp connector Han Q4/2, cable cross section 4 - 6 mm2 Table 2-3: Versions of power tee clamp connectors Seals for Power Tee Clamp Connectors Suitable seal sets are required for the power tee clamping connectors to attain degree of protection IP65/67. A seal set contains two seals, which are available with different internal diameters depending on the external diameter of the round cable used. ECOFAST power cables with 7 x 2.5 mm2 and 5 x 4 mm2 have an external diameter of approx. 15 mm. If a power tee clamp connector is the last connector on the power bus, i.e. if the power cable is not continued, the cable throughfeed has to be sealed with a filler plug. Sealing sets are not supplied with the power tee clamp connector. They must be ordered separately. The following sealing sets are currently available: Round cable/mm o Order No. 3RK1911-5BA00 10 to 13 3RK1911-5BA10 13 to 16 3RK1911-5BA20 16 to 19 3RK1911-5BA30 19 to 22 3RK1911-5BA50 Filler plug Table 2-4: ECOFAST System Manual GWA 4NEB 950 5228-02 Sealing sets for power tee clamp connectors 2-7 Product Family Power Tee Clamp Connector Design Power tee clamp connector Cover Sealing for round cable or filler plug*) Fixing lug Deckelbefestigungslasche Han Q4/2-socket to the load e. g. motor starter Sealing for round cable or filler plug*) Power tee-tee clamp connector Cover Sealing for round cable or filler plug*) Fixing lug Sealing for round cable or filler plug*) Han Q4/2-sockets to the load e. g. motor starter *) not supplied Power tee clamp connector (cover open) Terminal block with clamping screws Fig. 2-4: 2-8 Power tee/tee-tee clamp connector ECOFAST System Manual GWA 4NEB 950 5228-02 Product Family Hybrid Field Bus Connections 2.4 Hybrid Field Bus Connections Tasks In the ECOFAST system, hybrid field bus connections act as an interface between the control cabinet/terminal box (IP20) and the field bus level (IP65/67). In the ECOFAST system, hybrid field bus connections perform the following functions: * Supply: - data via RS 485, shielded copper cable (Cu) or fiber-optic cable. - 2 x 24 V DC, switched (S) and non-switched (NS). * Conducting: - data via RS 485, shielded copper cable (Cu) or fiber-optic cable. - 2 x 24 V DC, switched (S) and non-switched (NS). * Repeater function * Media converter Installation Hybrid field bus connections always have 2 channels (2 Han-Brid on the IP65 side). Depending on the device version, the hybrid field bus connection comprises the following components: * IP65 side (field bus level) - Han-Brid pin/socket for conducting - Han-Brid socket/socket for supplying IP20 to IP65 * IP20 side (in control cabinet) - Terminal block for 2 x 24 V DC (switched and non-switched) - PROFIBUS-DP: Shielding terminals and A/B terminals or SUB-D socket (9-pin) or Fast-Connect. IP65 side (field bus level, external) IP20 side (in control cabinet) Example: Conducting: fiber-optic cable 3RK1911-1AB32 Fig. 2-5: Hybrid field bus connections Notice Please observe the set-up recommendations for PROFIBUS-DP (see chapter 3.2). ECOFAST System Manual GWA 4NEB 950 5228-02 2-9 Product Family Hybrid Field Bus Connections Versions The following versions are currently available: Order No. Function Segment 1/2 - Medium PROFIBUS-DP - IP20 3RK1911-1AA22 Supply (passive) Socket/socket (copper) A/B terminals 3RK1911-1AA32 Conducting (passive) Pin/socket (copper) 3RK1911-1AB22 Supply (active) Socket/socket (fiber-optic cable) SUB-D socket 3RK1911-1AB32 Conducting (active) Pin/socket (fiber-optic cable) SUB-D socket 3RK1911-1AE22 Supply (active) Socket/socket (copper) SUB-D socket 3RK1911-1AE32 Conducting (active) Pin/socket (copper) SUB-D socket 3RK1911-1AF22 Supply (passive) Socket/socket (copper) Fast-Connect 3RK1911-1AF32 Conducting (passive) Pin/socket (copper) Table 2-5: A/B terminals Fast-Connect Hybrid field bus connection versions Passive and active * * Passive means that the signals are not regenerated. The IP20 and IP65 sides are electrically connected. Active means that the signals are regenerated (repeater function). The IP20 and IP65 sides are electrically isolated for versions with a fiber-optic cable. 24 V DC non-switched supply voltage (NS) This voltage is required for: * supplying the electronics (in the case of the active versions) * transfer connection 24 V DC switched supply voltage (S) This voltage is required for: * transfer connection 2-10 ECOFAST System Manual GWA 4NEB 950 5228-02 Product Family Data Tee Plug Connector 2.5 Data Tee Plug Connector Definition Data tee plug connectors connect the components of an automation system with * PROFIBUS DP Two data tee plug connectors are available in the ECOFAST system: - Data tee plug connector with copper cable (PROFIBUS-DP Cu) - Data tee plug connector with fiber-optic cable (PROFIBUS-DP LWL) * Non-switched supply voltage 24 V DC (DC24V-NS) * Switched supply voltage 24 V DC (DC24V-S) Non-switched supply voltage 24 V DC This voltage is required for * supplying the electronics in the motor starter * interrogating the auxiliary contacts Switched supply voltage 24 V DC This voltage is required for * controlling the switching elements (e.g. contactor) Fig. 2-6: ECOFAST System Manual GWA 4NEB 950 5228-02 Data tee plug connector 2-11 Product Family Discriminating Module and Maintenance Switch 2.6 Discriminating Module and Maintenance Switch 2.6.1 Discriminating Module The discriminating module performs the following tasks in the ECOFAST system: * Protecting the line when the cross-section is reduced * Expanding the system with the same or a smaller line cross-section * Switching off part of the system selectively in the event of an overload or short circuit * Disconnecting part of the system and securing this operating status with padlocks Set-up The discriminating module comprises a circuit-breaker, mains switch and alarm switch. The discriminating module has the following connections: * Han Q4/2 pin for supplying the power * Han Q4/2 socket for conducting the power * M12 connector for check-back contact Han Q4/2 pin M12 connector Check-back contact Han Q4/2 socket Fig. 2-7: 2-12 M12 connector Check-back contact Set-up of the discriminating module ECOFAST System Manual GWA 4NEB 950 5228-02 Product Family Discriminating Module and Maintenance Switch Device versions Discriminating modules are available in three different device versions: Device version Current Order No. 1 25 A 3RK1911-4AB25 2 16 A 3RK1911-4AB16 3 8A 3RK1911-4AB08 Table 2-6: 2.6.2 Discriminating module versions Maintenance Switch with M12 Connector The maintenance switch in the ECOFAST system is based on the 3LD2164-1GP51 standard main switch (type: black/gray). The rated current is 25 A. The maintenance switch is equipped with an HAN Q4/2 connecting unit (pin insert) for the power supply infeed. The power is transferred via a 0.5 m Olflex 110H cable and an HAN Q4/2 socket. The switching status can be checked via the built-in M12 connector (pin) (DESINA Spec_11). Maintenance switch with M12 connector, rated current 25 A: 6AG1264-1GP51-6AA0 Fig. 2-8: ECOFAST System Manual GWA 4NEB 950 5228-02 Maintenance switch with M 12 connector (pin) for check-back 2-13 Product Family Discriminating Module and Maintenance Switch 2-14 ECOFAST System Manual GWA 4NEB 950 5228-02 3 Installation Guidelines 3.1 Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable ECOFAST hybrid field bus cable ECOFAST hybrid field bus cables are suitable for trailing. They are shielded with two copper cores for PROFIBUS-DP and four 1.5 mm2 copper cores for 24 V DC switched (DC24V-S) and 24 V DC non-switched (DC24V-NS). What is a bus segment? The PROFIBUS-DP consists of at least one bus segment. Each bus segment has at least two stations, of which at least one is a DP master. Maximum configuration of a bus segment A bus can consist of up to 32 stations, all physically connected by means of an ECOFAST hybrid field bus cable. You must connect the bus terminating connector at the beginning and end of the bus. 2 x 24 V DC 3~ Station 1 Power & Control Module (P&CM) with - PLC - 2 x 24 V DC Supply - 400 V AC main power supply Terminating resistor, connected internally or segment 2! Screw cap or segment 2 ECOFAST hybrid field bus cable 2 x 24 V DC and data Power cable 3/PE-50/60 Hz; 400 V AC Bus terminating connector Data tee plug connector Segment 1 Station 2 Station 3 Station 4 Station 32 Segment 2 Station 33 Station 34 Station 35 Station 64 Fig. 3-1: ECOFAST System Manual GWA 4NEB 950 5228-02 Set-up of a bus segments with RS 485 3-1 Installation Guidelines Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable (Fiber-optic Conductors) Key data of a bus segment The maximum line length of a bus segment depends on the baud rate that is used: . Baud rate 9.6 to 187.5 kBaud 1000 500 kBaud 400 1.5 MBaud 200 3 to 12 MBaud 100 Table 3-1: 3.2 Max. line length of a segment [m] Permissible line length of a bus segment based on the baud rate Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable (Fiber-optic Conductors) ECOFAST hybrid field bus cable ECOFAST hybrid field bus cables are suitable for trailing. They have two plastic fiber-optic conductors for PROFIBUS-DP and four 1.5 mm2 copper cores for 24 V DC switched (DC24V-S) and 24 V DC non-switched (DC24V-NS). Connection to PROFIBUS-DP If you want to bridge long distances with the field bus regardless of the baud rate, or if disturbance fields must not be allowed to interfere with data traffic on the bus, you should use fiberoptic cables instead of copper cables. The PROFIBUS-DP stations are connected to the PROFIBUS-DP by means of * Separate data tee plug connectors with fiber-optic cables (PROFIBUS-DP LWL) * Integrated plug connectors, e.g. ET 200X base module BM143 Advantages and applications Fiber-optic cables have the following advantages compared to electrical conductors: * Electrical isolation of the PROFIBUS-DP components * Insensitivity to electromagnetic interference (EMC) * No electromagnetic radiation into the environment * Additional grounding and shielding measures can consequently be dispensed with * No need to comply with minimum distances from other lines on account of EMC * No need for equipotential bonding jumpers * No need for lightning protection elements * Maximum permissible line lengths are no longer dependent on the baud rate 3-2 ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Optical PROFIBUS-DP network with line topology The optical PROFIBUS-DP network is designed with a line topology. The PROFIBUS-DP stations are connected together in pairs by means of DESINA hybrid field bus cables. If one PROFIBUS-DP station fails, the line topology means that all downstream DP slaves are no longer accessible to the DP master. Faults can thus be easily localized. 2 x 24 V DC 3~ Station 1 Power & Control Moduel (P&CM) with - PLC - 2 x 24 V DC supply - 400 V AC main power supply Screw cap or segment 2 ECOFAST Hybrid field bus cable 2 x 24 V DC and data Power cable 3/PE-50/60 Hz; 400 V AC Bus terminating connector Data tee plug connector Segment 1 Station 2 Station 3 Station 4 Station 32 Segment 2 Station 33 Station 34 Station 35 Station 64 Fig. 3-2: Optical PROFIBUS-DP network with line topology Baud rate The optical PROFIBUS-DP network with a line topology can be operated with the following baud rates: 9.6, 19.2, 45.45, 93.75, 187.5, 500 kbaud, 1.5 and 12 Mbaud. Line lengths If fiber-optic cables are used, the length of the transmission link is independent of the baud rate. Every PROFIBUS-DP station connected to the optical PROFIBUS-DP network has a repeater functionality. The distances specified below therefore refer to the distance between two neighboring PROFIBUS-DP stations in the line topology. The maximum line length between two PROFIBUS-DP stations is dependent on the type of fiber-optic cable that is used. Fiber-optic cable ECOFAST hybrid field bus cable Table 3-2: ECOFAST System Manual GWA 4NEB 950 5228-02 Max. line length between 2 stations [m] Projection to 1 network (= 32 stations) [m] 50 1550 Permissible line lengths in the optical PROFIBUS-DP network 3-3 Installation Guidelines Guidelines for PROFIBUS-DP Standard Cables 3.3 Guidelines for PROFIBUS-DP Standard Cables 3.3.1 Potential Equalization When do differences in potential occur? Differences in potential can occur, for example, when different mains supplies are used. Damage may be caused to the system as a result of potential differences between various system parts if: * programmable controllers and inputs/outputs are connected by potentialbonded couplings, or * cable shields are connected at both ends and grounded to different parts of a system. Avoiding potential differences It is important to install potential equalization lines in order to minimize potential differences and ensure the functionality of the electronic components. When and why do you need potential equalization? Potential equalization has the following advantages: * Devices with a grounded interface may be destroyed as a result of potential differences. * The shielding of the PROFIBUS cable must not be used for potential equalization. This is the case, however, with any parts of the system that are linked together via the cable shield, but are connected to different grounding points. * Potential equalization is a precondition of lightning protection. Rules for potential equalization Note the following points: * The smaller the impedance of the potential equalization line, the higher the efficiency of potential equalization. * If shielded signal cables are installed between certain parts of the system and are connected at both ends to ground/protective conductors, it is important to ensure that the impedance of the additional potential equalization line is not in excess of 10% of the shield impedance. * Use connectors with large contact areas to connect the potential equalization conductors to the ground/protective conductor. * Protect the potential equalization conductors against corrosion. * Use potential equalization conductors made of copper or galvanized steel. * Route the potential equalization conductors in such a way that the areas bounded by the potential conductor and the signal lines are as small as possible. * Use equipotential bonding conductors made of copper or galvanized steel. Notice Equipotental bonding conductors are not necessary if the parts of the system are connected to each other exclusively by means of fiber-optic cables. 3-4 ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines Guidelines for PROFIBUS-DP Standard Cables 3.3.2 Cable Shielding Definition Shielding is a means of weakening (attenuating) magnetic, electric and electromagnetic interference fields. Interference currents on cable shields are diverted to ground via the shield busbar, which forms a conductive connection with the housing. It is particularly important to ensure a lowohmic connection to the protective conductor, as otherwise the interference currents themselves may become a source of interference. Measures for cable shielding Note the following points: * If possible, use only cables with braided shields. The shield density should be more than 80%. Avoid using cables with foil shielding, because tensile and compressive loads at the attachments can easily damage the foil. The result is a reduction in shield efficiency. * Always connect the cable shields at both ends. It is only when the shielding is connected at both ends that interference suppression is effective at the high end of the frequency range. Exceptions: It may be better to connect the shield at one end only, if - for some reason it is not possible to install potential equalization lines, - analog signals (in the low mV or A range) are transmitted, or - foil shielding (static shields) is used. Note, however, that if the shield is connected at one end only it can suppress only lowfrequency interference. Connect the shield of the data line to the plug body. If the system is installed for stationary operation, it is advisable to remove the insulation from the shielded cable without interruption and connect the cable to the shielding/protective conductor busbar. * * Notice If a potential difference occurs between the grounding points, an equalization current can flow through a shield connected at both ends. In this case, install an additional potential equalization line. ECOFAST System Manual GWA 4NEB 950 5228-02 3-5 Installation Guidelines Guidelines for PROFIBUS-DP Standard Cables Correct Shield Installation Observe the following points: * Use cable clamps made of metal to secure the braided shield. * The enclosing clamps must hold a large part of the shield and make good contact (see Figure). * Connect the shield to a shield busbar immediately adjacent to the point where the cable enters the cabinet. Fig. 3-3: 3-6 Securing shielded cables with cable clamps and cable ties (schematic diagram) ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines PNO Installation Guidelines 3.4 PNO Installation Guidelines PNO installation guidelines Please comply with the PROFIBUS-DP/FMS Installation Guidelines of the PROFIBUS-Nutzerorganistation (user organization) when using electrical networks. They describe important measures to be taken as regards the wiring, cabling and commissioning of PROFIBUS networks. Publisher PROFIBUS-Nutzerorganisation e. V. Haid-und-Neu-Strae 7 76131 Karlsruhe, Germany Tel: Fax: ++49(0) 721 / 9658 590 ++49(0) 721 / 9658 589 Internet: http//www.profibus.com Guideline order number: 2.111 ECOFAST System Manual GWA 4NEB 950 5228-02 3-7 Installation Guidelines Power Bus Installation Versions 3.5 Power Bus Installation Versions 3.5.1 Unassembled set-up with power tee clamp connector and power cable Installation The consumers are connected to the power bus via the power tee clamp connector. The power cable is installed in one piece in the plant. In the set-up shown in the figure below, only one HAN Q4/2 connector set has to be assembled at the beginning and at the end of the power cable. Benefits * * In principle, any cable with a diameter between 10 mm and 22 mm can be used in accordance with requirements. The power tee clamp connector can be connected at any point. Diagram Supply Power tee clamp connector with Main power PCM/SEU/ET 200S Han Q4/2 socket for consumer Power tee-tee clamp connector with Han Q4/2 socket for consumer Connector with socket insert Power cable (cut to length) Spur cable Starter Possible components: Connector set with pin insert to connect PCM Power cable (cut to length) Power tee clamp connector Passende Dichtungssatze Connector set with socket insert to connect the final consumer + alternatively: Power tee clamp connector + fillet plug Fig. 3-4: 3-8 Set- up with power tee clamp connector ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines Power Bus Installation Versions 3.5.2 Connecting Consumers with a Spur Cable Set-up The consumers are connected to the power bus via a spur cable and a power tee clamp connector. The spur cable can be ordered preassembled. Diagram Power tee clamp connector with Han Q4/2 socket Spur cable preassembled Fig. 3-5: ECOFAST System Manual GWA 4NEB 950 5228-02 Set-up of sub-segment 3-9 Installation Guidelines Power Bus Installation Versions 3.5.3 ET 200X Sub-Segmente with EM 300 Motor Starter Installation When using 200X sub-segments with an EM300 motor starter, an ET 200X is connected to the power bus using an ET 200X sub-segment cable and a power tee clamp connector. The sub-segment cable can be ordered preassembled. Diagram Power tee clamp connector with Han Q4/2 socket Power bus EM 300 Fig. 3-6: ET 200X sub-segment cable preassembled (Han Q4/2 - Han Q8/0) EM 300 EM 148-FC Set-up of sub-segment Notice The ET 200X sub-segment cable can only be used for ET 200X sub-segments that are equipped with at least one EM300 motor starter. The ET 200X sub-segment cable features a phase displacement for connecting the EM300 motor starters to the power bus. The motor starters are always connected to the power bus. 3-10 ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines Power Bus Installation Versions Guidelines for the ET 200X Sub-Segment Distributed ET 200X peripheral devices can be integrated in the ECOFAST system. The following rules, however, must be followed: * An ET 200X sub-segment comprises the ET 200X sub-segment cable and a distributed ET 200X peripheral device with at least one feeder. * A maximum of 6 motor starters or frequency converters can be used in one ET 200X subsegment. * Motor starters must be installed on the base module upstream of frequency convertors (see diagram). * The EM300 motor starters are connected to the motor with a preassembled line (line type: ET 200X motor). * The EM148-FC frequency converters are connected to the motor with a preassembled line (line type: ET 200X FU motor). * The preassembled ET 200X power cables must be used for connecting the ET 200X subsegment to the power bus and for transferring the power. Notice The ET 200X sub-segment cable and the power cable for transferring the power are two separate cables. They can only be used for their intended purpose. ECOFAST System Manual GWA 4NEB 950 5228-02 3-11 Installation Guidelines Power Bus Installation Versions 3.5.4 Possible Power Distribution with Discriminating Modules Diagram The diagram below shows the possible power distribution arrangements with discriminating modules: 1 2 3 4 s Power cable 3/PE-50/60 Hz 400 V AC s Spur cable s ECOFAST consumer Spur cable Input: Han Q4/2 pin ECOFAST consumer s Discriminating module ECOFAST consumer Fig. 3-7: Output: Han Q4/2 socket Possible power distribution with discriminating modules 1. ECOFAST consumer without a discriminating module directly in the power bus segment backbone. 2. Discriminating module directly in the power bus segment backbone. Connection to ECOFAST consumer via spur cable with Han Q4/2 pin/socket. 3. The ECOFAST consumer and the discriminating module form a power bus sub-segment. They are connected directly to each other without a cable. Connection to the power bus segment backbone via spur cable with Han Q4/2 pin/socket. Notice The discriminating module cannot be connected without a cable if ECOFAST motor starters are operated with the PROFIBUS-DP field bus. 4. ECOFAST consumer decoupled via discriminating module in the power bus segment backbone. 3-12 ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines Power Bus Installation Versions 3.5.5 Line Protection in Power Bus Segment for Motor Starters Without Thermal Motor Model (Installation in the Vicinity of the Motor) Diagram The power bus segment to be protected contains motor feeders with: * Motor starters that only have motor protection with a temperature sensor, and * Motors with motor supply leads (installation in the vicinity of the motor). The motor supply lead is not protected by the motor starter. In this case, the maximum permissible current-carrying capacity of the motor supply lead must be set on the next upstream protection module: * Variant A: discriminating module, circuit-breaker * Variant B: PCM, circuit-breaker F1. The following diagram shows the set-up: Variant A Motor Power Cable 3/PE-50/60 Hz 400 V AC Motor supply lead Motor starter Motor protection: Temperature sensor Discriminating module No thermal Motor model No full Motor protection Variant B PCM Motor Supply Mail power Motor supply lead Motor starter Motor protection: Temperature sensor No thermal Motor model No full Motor protection Fig. 3-8: ECOFAST System Manual GWA 4NEB 950 5228-02 Line protection for motor starters without thermal motor model 3-13 Installation Guidelines Power Bus Installation Versions Example 3-14 Motor starter used: ECOFAST motor starter Order No.: 3RK1323-2AS51-1AA3 Motor supply lead: 1.5 mm2 (max. current-carrying capacity: 18.5 A) Installation type: E (reduction factor: 0.650 at 30 C) Setting value: 12 A Variant A: 16 A and 25 A discriminating modules must be opened so that they can be set.The 8 A discriminating module limits the current to 8 A (nothing is set). Variant B: The PCM must be opened so that it can be set. ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines Installation Versions for Switching Devices and Control Circuit 3.6 Installation Versions for Switching Devices and Control Circuit Devices Legend for switching devices and control circuit devices Motor Switching device Frequency converter, R2SS load regulator Power tee clamp connector HanDrive Spur cable (Han Q4/2 pin - socket) Sub-segment line (Han Q4/2 pin - Han Q8/0 socket) Motor line, both ends Han 10E, unshielded Motor line, both ends Han 10E, shielded Motor line Han Q8/2 pin - Han 10E socket unshielded/shielded, assembled by user. As an alternative instead of Han 10E socket, open cable end in motor terminal box with M-screw fitting. ECOFAST System Manual GWA 4NEB 950 5228-02 3-15 Installation Guidelines Installation Versions for Switching Devices and Control Circuit Devices Switching device, plugged in (only motor starters, soft starters) Switching device with displaced power tee clamp connector (spur cable) Switching device with plugged in power tee clamp connector Fig. 3-9: Plugged in switching device (only motor starters, soft starters) Switching device in the vicinity of the motor (only motor starters, soft starters) Switching device with displaced power tee clamp connector (spur cable) Switching device with plugged in power tee clamp connector Fig. 3-10: 3-16 Switching device in the vicinity of the motor (only motor starters, soft starters) ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Guidelines Installation Versions for Switching Devices and Control Circuit Control circuit device, plugged in (R2SS load regulator, MMI 411 frequency converter) Control circuit device displaced power tee clamp connector (spur cable) Control circuit device plugged in power tee clamp connector Fig. 3-11: Control circuit device, plugged in (R2SS load regulator, MMI 411 frequency converter) Control circuit device in the vicinity of the motor (R2SS load regulator, MMI 411 frequency converter) Control circuit device displaced power tee clamp connector (spur cable) Control circuit device plugged in power tee clamp connector Fig. 3-12: converter) ECOFAST System Manual GWA 4NEB 950 5228-02 Control circuit device in the vicinity of the motor (R2SS load regulator, MMI 411 frequency 3-17 Installation Guidelines Installation Versions for Switching Devices and Control Circuit Devices ET 200X Sub-segment (with EM 300 motor starter and EM148C frequency converter) ET 200X- Fig. 3-13: 3-18 EM 300 EM 148-FC ET 200X Sub-segment (with EM 300 motor starter and EM148C frequency converter) ECOFAST System Manual GWA 4NEB 950 5228-02 4 Installation 4.1 Power & Control Module 4.1.1 Installation of the IP65 Version Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. Installation 1 Description The PCM is designed for wall mounting. Choose a flat surface. Allow the specified minimum clearance to guarantee adequate convection. 100*) 100 400 Step PCM 400 *) PCM with PROFIBUS-DP interface on the left-hand side: If you want to connect a PRO150* FIBUS-DP cable with a straight plug, you must allow a clearance of approx. 150 mm around this plug. 2 Drill 4 holes for the screws. 576 4x 695 8 Table 4-1:Installing the PCM, IP65 Version ECOFAST System Manual GWA 4NEB 950 5228-02 4-1 Installation Power & Control Module Step Description 3 Screw the screws into the wall. The screws should protrude approx. 5 mm to enable the PCM to be mounted. 4 Hook the PCM onto the screws. Make sure it is fastened so that it is absolutely secure (it is very heavy!). 5 Tighten the screws. Table 4-1:Installing the PCM, IP65 Version 4.1.2 Installation of the Cabinet Installation Version (IP00) Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. Installation Step Description 1 The PCM is designed to be installed in control cabinets. The degree of protection of the control cabinet must be at least IP32. 2 Drill 4 holes for the screws. 350 4x 809 8 Table 4-2:Installing the PCM, Cabinet Installation Version 4-2 ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Alternative Power supply Step Description 3 Screw the screws into the cabinet. The screws should protrude approx. 5 mm to enable the PCM to be mounted. 4 Hook the PCM onto the screws. Make sure it is fastened so that it is absolutely secure (it is very heavy!). 5 Tighten the screws. Table 4-2:Installing the PCM, Cabinet Installation Version 4.2 Alternative Power supply 4.2.1 Simple Energy Unit (SEU) To install the circuit-breaker or contactor, please follow the operating instructions enclosed with the device. 4.2.2 ET 200S Motor Starter To install the ET 200S motor starter, please refer to the manual in the 6ES7151-1AA10-8AA0 documentation package. ECOFAST System Manual GWA 4NEB 950 5228-02 4-3 Installation Power Tee Clamp Connector 4.3 Power Tee Clamp Connector Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. Procedure for installing the power tee clamp connectors Step Procedure 1 Connect the power tee clamp connector to the Han Q4/2 power terminal on the matching mating component (e.g. the consumer or the power supply). Secure the connection with the locking device. 2 If required, you can screw the fixing lugs on the power tee clamp connector onto a flat surface using screws with a diameter of 5 mm. 3 Loosen the four screws in the cover. Open the cover. 4 Unscrew the clamping screws. 5 Strip the insulation from the power cable over a length of approximately 130 mm. Take care not to damage the insulation of the individual wires! 130 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 6 Place the seal around the round cable in such a way that there is approx. 10 mm of unstripped cable between the seal and the stripped part of the cable. 7 Insert the individual wires in the insulation displacement terminations. Make sure the terminals are assigned correctly. 8 Insert the throughfeeds with the round cable. Align the stripped part of the cable centrally inside the housing. 9 Firmly secure the clamping screws. The individual wires are bonded via the insulation displacement terminations. 10 Close the cover. The power tee clamp connector is now installed and connected. Tabelle 4-3: 4-4 1 2 Installing the power tee clamp connector ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Hybrid Field Bus Connections 4.4 Hybrid Field Bus Connections Step Cut out the required section (90 mm x 80 mm) on the control cabinet. 90 1 Description Note that the wall thickness must not exceed 5 mm. 80 2 Place the hybrid field bus connection into the cutout section. 3 Secure the hybrid field bus connection using the quick-clamping devices by tightening the four screws. 4x Tabelle 4-4: ECOFAST System Manual GWA 4NEB 950 5228-02 Installing the hybrid field bus connection 4-5 Installation Discriminating Module and Maintenance Switch 4.5 Discriminating Module and Maintenance Switch 4.5.1 Discriminating Module The table below lists the required components: Item Ordering data Order No. 1 Discriminating Module 3RK1911-4AA.. depending on the version 2 2 fixing screws (dia. 4 mm), if necessary nuts, spring washers, plain washers -- 3 Power line with Han Q4/2 socket (discriminating module at input) preassembled or prepared by customer 3RK1911-0.. depending on the length and cross-section 4 Power line with Han Q4/2 pin (discriminating module at output) preassembled or prepared by customer 3RK1911-0.. depending on the length and cross-section 5 Optional: sensor cable -- 6 Optional: Line end covers for sealing open ends of lines (1 set = 10 pieces) 3RK1901-1MN00 Tabelle 4-5: Required components Installation Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. 4-6 ECOFAST System Manual GWA 4NEB 950 5228-02 Installation Discriminating Module and Maintenance Switch To install the discriminating module, carry out the following steps: Step Description 1 Choose a flat surface for installation. You can choose any mounting position. 2 Drill 2 holes for the screws. 145 250 105 4 2x 3 Screw the discriminating module onto the flat surface. 4 Connect the discriminating module to the power line with the Han Q4/2 pin (discriminating module at the output). Secure the connections with the locking devices. 6 Connect the discriminating module to the power line with the Han Q4/2 socket (discriminating module at the input). Secure the connections with the locking devices. Tabelle 4-6: 4.5.2 Installing the discriminating module Maintenance Switch To install the maintenance switch, please follow the instructions enclosed with the device. ECOFAST System Manual GWA 4NEB 950 5228-02 4-7 Installation Discriminating Module and Maintenance Switch 4-8 ECOFAST System Manual GWA 4NEB 950 5228-02 5 Connections 5.1 Power & Control Module Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. 5.1.1 Connections of the IP65 Version Connections and throughfeeds on the underside of the PCM Cable throughfeeds (access possible here, e. g. for sensors) 2 x Han Q4/2 sockets for supplying the power bus (400 V AC) PROFIBUS-DP Main power supplied 400 V AC X10 X2 2 x Han-Brid sockets for PROFIBUS-DP and 2 x 24 V DC per channel Fig. 5-1: ECOFAST System Manual GWA 4NEB 950 5228-02 X3 Main power looped through 400 V AC 4 x M screwed gland Access possible here for round cables Connections and throughfeeds on the underside of the PCM 5-1 Connections Power & Control Module Connections on the inside X01 X08 X08 terminal block for start, EMERGENCY STOP, AS-Interface Fig. 5-2: X01 terminal block for main power (N/L1/L2/L3/PE) Connections on the inside of the PCM Schematic diagram Safety lock F1 circuit breaker Main switch X01 terminal block X08 terminal block (concealed) Safety lock X2/X3 Han Q4/2 sockets X10 Han-Brid sockets (concealed) Fig. 5-3: Schematic diagram for wiring the PCM X01 power supply Supplying and looping through the main power. Terminal block N/L1/L2/L3/PE Notice All 5 conductors (N/L1/L2/L3/PE) must be wired. 5-2 ECOFAST System Manual GWA 4NEB 950 5228-02 Connections Power & Control Module X2/X3 main circuit output Output: 2 Han Q4/2 sockets, pin assignment acc. to DESINA: Pin Assignment Comment 1 Phase L1 -- 2 Phase L2 -- 3 Phase L3 -- 4 Neutral N -- PE -- 11 -- Reserved 12 -- Reserved Table 5-1: Pin assignment of the Han Q4/2 pin/socket PROFIBUS-DP field bus:X10 2 x hybrid field bus socket connections, pin assignment acc. to DESINA: Pin Assignment Comment 1 + 24 V Non switched 2 0 V DC Corresponds to 1 3 0 V DC Corresponds to 4 4 + 24 V Switched Field bus -- A/B Table 5-2: 5.1.2 Pin assignment of the hybrid field bus connection Connections of the Cabinet Installation Version Connections on the front side of the PCM X01 PROFIBUS-DP 2 x 9-pin SUB-D sockets X10 X10 terminal block 2 x 24 V DC (switched and non switched) X2/X3 terminal block Output Main circuit 400 V AC Fig. 5-4: ECOFAST System Manual GWA 4NEB 950 5228-02 X2/X3 X08 X08 terminal block X01 terminal block for start and Power supply EMERGENCY STOP (N/L1/L2/L3/PE) Connections on the front side of the PCM (Cabinet Installation Version) 5-3 Connections Power & Control Module X01 power supply Supplying and looping through the main power. Terminal block N/L1/L2/L3/PE Notice All 5 conductors (N/L1/L2/L3/PE) must be wired. X2/X3 main circuit output To supply the power bus 2 x terminal block N/L1/L2/L3/PE PROFIBUS-DP 2 x 9-pin SUB-D socket directly on PLC Wiring Step Strip the lines. For more information about the stripped lengths, cross-sections and terminal assignments, refer to the table on the next page. In the case of the IP65 model, please open the door of the PCM first. To do so, unlock the two safety locks and turn the main switch counter clockwise. 2 Insert the lines for Start, EMERGENCY STOP and, if necessary, the AS-Interface through the M screwed glands on the underside and into the PCM up to the X08 terminal block. Connect the lines to the X08 terminal block with Cage Clamps. 3 Insert the lines for the main power through the M screwed glands on the underside and into the PCM up to the X01 terminal block. Connect the lines to the X01 terminal block with cage clamps. 4 Connect the hybrid field bus cables (maximum of 2) to the X10 if you are using a PCM with PROFIBUS-DP 5 Connect a maximum of 2 power cables to X2 and X3. 6 Attach suitable screw caps to the underside of any unused throughfeeds to attain degree of protection IP65. Close the screw cap of the MPI plug on the lefthand side. 7 This completes wiring. Close the F1 circuit-breaker. Table 5-3: 5-4 Description 1 Wiring of the PCM ECOFAST System Manual GWA 4NEB 950 5228-02 ECOFAST System Manual GWA 4NEB 950 5228-02 IP65 IP00 Table 5-4: IP00 3-4 x -- x x x -- x x x x x x 4FB2 111-2A...-0AA1 4FB2 112-2A...-0AA0 4FB2 111-2A...-0AA2 4FB2 121-2A...-0AA1 4FB2 111-2A...-0AA3 4FB2 112-2A...-0AA1 X01 9 9 9 24 V DC +S/-S AWG 28...12 AWG 24...8 12 3 2 1 0.2 ... 10 mm2 L1 L2 L3 N PE x -- x -- x -- x -- AUX PWR 7 (+) 8 (-) 12 12 X2/X3 x -- x -- x -- x -- AS-i 5 (+) 6 (-) Cage Clamp AWG 28...12 0.08 ... 4 mm 0.08 ... 4 mm 24 V DC +NS/-NS 3-4 x x 4FB2 121-2A...-0AA0 1-2 x x 4FB2 111-2A...-0AA0 X10 / AWG 28...12 0.08 ... 4 mm 0.08 ... 4 mm Start 1-2 AWG 28...12 9 9 9 X08 / AWG 24...6 17 x x x x x x x x 0.2 ... 16 mm2 L1 L2 L3 N PE 17 17 X01 / X08 Connections Power & Control Module Stripped lengths, cross-sections, terminal assignment Stripped lengths, cross-sections, terminal assignment 5-5 Connections Alternative Power Supply 5.2 Alternative Power Supply 5.2.1 Connections of the Simple Energy Unit (SEU) 24 V Power IN 400 V L1 L2 L3 1 3 5 Start 2 EMERGENCY STOP I v I v I v Circuit-breaker 4 6 Power ON Check-back T1 T2 T3 A1(+) 1 3 5 13 21 31 43 A2( ) 2 4 6 14 22 32 44 Contactor with auxiliary switch A1(+) 1 3 5 13 21 31 43 A2( ) 2 4 6 14 22 32 44 Power OUT 400 V Fig. 5-5: ET 200S Motor Starter F01F03 16 A L+ 1 8 M 2 9 1L+ 2L+ 1M 2M 3 4 5 6 8 Fault E 108.1 S 110.0 E 108.0 PM-D Fig. 5-6: 5-6 E 108.4 DS1-x PE/N PE E 108.7 S 110.2 DS1-x PE/N PE N PE 2L+ 24 V DC 2M E 108.5 S 110.4 2T1 4T2 6T3 Power supply Contactor E 108.3 S 110.2 PE N PE IM 151 Fault 2T1 4T2 6T3 PROFIBUS-DP 1L1 400 V AC 1L2 1L3 1L+ 24 V DC 1M 1L1 3L2 5L3 Power supply Electronics 4 A1+ 10 5 A2 11 5.2.2 Wiring diagram of a SEU (example) under the responsibility of the user Wiring scheme of a ET 200S motor starter (example) under the responsibility of the user ECOFAST System Manual GWA 4NEB 950 5228-02 Connections Power Tee Clamp Connector 5.3 Power Tee Clamp Connector Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. Connections Power tee clamp connector Termminal Assignment Core No.* 1 1 Phase L1 2 2 2 2 2 Phase L2 3 3 3 3 3 Phase L3 4 4 4 PE 4 5 6 4 Neutral conductor N 1 1 1 5 Reserved 5 5 5 6 Reserved 6 6 6 Terminal numbers and Han Q4/2 pin numbers do not have the same assignment * Core No. Caution Note that core numbers and terminal numbers are not identical for preassembled power cables. 1 1 2 2 1 2 3 3 3 4 5 4 4 5 5 Fig. 5-7: ECOFAST System Manual GWA 4NEB 950 5228-02 Pin assignment for power tee clamp connector 5-7 Connections Hybrid Field Bus Connections 5.4 Hybrid Field Bus Connections Connections on the IP65 side IP65 side (field bus level, external) Supply Cu Conducting Cu Han-Brid socket Supply LWL Fig. 5-8: Han-Brid pin socket socket Conducting LWL Connections on the IP65 side Connections on the IP20 side IP20 side (in control cabinet) I Terminal block for 2 x 24 V DC (S and NS) Shield clamp Terminals A1 (green)/B1 (red) for PROFIBUS-DP Channel 1 II Terminal block for 2 x 24 V DC (S and NS) SUB-D socket for PROFIBUS-DP Terminals A2 (green)/B2 (red) for PROFIBUS-DP Channel 2 III Terminal block for 2 x 24 V DC (S und NS) Fast-Connect-Block for PROFIBUS-DP Insulation displ. terminals A1 (green)/B1 (red) for PROFIBUS-DP Channel 1 A2 (green)/B2 (red) for PROFIBUS-DP Channel 2 Fig. 5-9: 5-8 Connections on the IP20 side ECOFAST System Manual GWA 4NEB 950 5228-02 Connections Hybrid Field Bus Connections Connections for PROFIBUS-DP and 2 x 24 V DC (IP65 side) 2 x Han-Brid socket/socket or pin/socket, pin assignment acc. to DESINA: Pin Copper A1 B1 A2 B2 2 3 2 3 1 4 1 4 Comment 1 +24 V DC Non switched 2 0 V DC Corresponds to 1 3 0 V DC Corresponds to 4 4 +24 V DC Switched Field bus -- A1/A2 Line A field bus -- B1/B2 Line B field bus -- Shield field bus -- Assignment Comment 1 +24 V DC Non switched 2 0 V DC Corresponds to 1 3 0 V DC Corresponds to 4 4 +24 V DC Switched TxD Field bus transmitter Fiber-optic cable field bus RxD Field bus receiver Fiber-optic cable field bus Socket Pin Pin Fiber-optic cable RxD TxD RxD TxD 2 3 2 3 1 4 1 4 Pin Fig. 5-10: ECOFAST System Manual GWA 4NEB 950 5228-02 Assignment Socket Pin assignment for hybrid field bus connection (IP65 side) 5-9 Connections Hybrid Field Bus Connections Connections for passive hybrid field bus connection (IP20 side) Connection Assignment Comment Klemmenblock 24 V +NS +24 V DC Non switched -NS 0 V DC Corresponds to +NS -S 0 V DC Corresponds to +S +S +24 V DC Switched Terminal block A/B for PROFIBUS-DP A1/A2 Line A field bus B1/B2 Line B field bus green AB Shield field bus red Fast-Connect-Block for PROFIBUS-DP A1/A2 Line A field bus (green) B1/B2 Line B field bus (red) Channel 1 Channel 2 Shield field bus Table 5-5: Connections for passive hybrid field bus connection (IP20 side) Connections for active hybrid field bus connection (IP20 side) Connection Assignment Comment Terminal block 24 V +NS +24 V DC Non switched - NS 0 V DC Corresponds to +NS -S 0 V DC Corresponds to +S +S +24 V DC Switched SUB-D socket for PROFIBUS-DP RxD/TxD-P (+) 4 CNTR-P 5 DGND 6 VP 7 -- 8 RxD/TxD-N (-) Table 5-6: 5-10 1 3 Pin 5 -- 6. Shield 2 9. 1 Connections for active hybrid field bus connection (IP20 side) ECOFAST System Manual GWA 4NEB 950 5228-02 Connections Hybrid Field Bus Connections Wiring Step Description 1 Strip the lines. For more information on stripped lengths, cross-sections, and terminal assignments, refer to the table on the next page. 2 Use the Cage Clamps to connect the 24 V DC cables (S and NS) to the 24 V DC terminal block. Passive hybrid field bus connection Active hybrid field bus connection 3 Use the Cage Clamps to connect the PROFIBUS-DP cables to terminals A1/B1 and A2/B2. Connect the PROFIBUS-DP cable to the 9-pin SUB-D socket. 4 Connect the shield to the shield terminals. -- 5 If you want to connect a bus terminating connector, this must be supplied with 24 V DC. To do so, jumper terminals S1 and S2 of the non-switched (NS) 24 DC (see below). 6 This completes the wiring. Table 5-7: Wiring the hybrid field bus connection Steps for connecting the "Fast Connect Block" Step Description 1 Prepare the bus cable according to the drawing. Do not strip the cable ends! 2 Unsrew the locking srew, open the cover and then lift the terminal block. 3 Insert the cable end into the terminal and push the terminal block back down. 15 8 The bus cable is contacted vi the insulation piercing termination. 4 Close the cover and tighten the locking srew. The shield is contacted via the pressure of the cover and the cable is relieved from strain. 5 Table 5-8: ECOFAST System Manual GWA 4NEB 950 5228-02 This completes the wiring. Wiring of the Fast Connect Block 5-11 Connections Hybrid Field Bus Connections Schematic diagram Passive hybrid field bus connection A1 B1 A2 B2 Active hybrid field bus connection 2 x 24 V DC 2 x 24 V DC 9-pole SUB-D socket Shield terminals Passive hybrid field bus connection (Fast-Connect Block) 24 V DC wiring: S1 Jumpers for supplying S1 with 2 x 24 V DC S2 24 V DC NS 24 V DC S +NS -NS -S +S Fig. 5-11: 5-12 Schematic diagram for wiring the hybrid field bus connection ECOFAST System Manual GWA 4NEB 950 5228-02 Table 5-9: ECOFAST System Manual GWA 4NEB 950 5228-02 x x x x x x x 3RK1911-1AA32 3RK1911-1AF22 3RK1911-1AF32 3RK1911-1AB22 3RK1911-1AB32 3RK1911-1AE22 3RK1911-1AE32 3 1 x x red green 9 1 2 S2 A2 B2 AB 2 Cage Clamp x 3RK1911-1AA22 AWG 15 1.5 mm 9 S1 Cage Clamp A1B1 9 x x "Fast-Connect" A1 B1 A2 B2 +NS -NS - S + S 9 PROFIBUS-DP PROFIBUS-DP 2 x 24 V DC x x x x 9-pin SUB-D PROFIBUS-DP Connections Hybrid Field Bus Connections Stripped lengths, cross-sections, terminal assignments Stripped lengths, cross-sections, terminal assignments 5-13 Connections Data Tee Plug Connector 5.5 Data Tee Plug Connector 5.5.1 Pin Assignment Data tee connector PROFIBUS-DP Cu A B A Assignment Color*) 1 +24 V DC non switched Black 1 2 0 V DC non switched Black 2 3 0 V DC switched Black 3 4 +24 V DC switched Black 4 A Line A field bus Green B Line B field bus Red Pin B 2 3 2 3 1 4 1 4 Shield field bus Socket Output Pin Input Data tee connector PROFIBUS-DP fiber-optic cable RD TD RD 2 3 2 3 1 4 1 4 Pin Input Assignment Color*) 1 +24 V DC non switched Black 1 2 0 V DC non switched Black 2 3 0 V DC switched Black 3 4 +24 V DC switched Black 4 TD Fiber-optic cable field bus transmitter see Fig. below RD Fiber-optic cable field bus receiver see Fig. below Pin TD Socket Output *) Core colors of the DESINA hybrid field bus cable Assignment of the fiber-optic field bus RD TD RD TD RD TD RD TD Data plug connector (socket) Data plug connector (pin) OF field bus Fig. 5-12: cable 5-14 Pin assignment for the data tee plug connector/core assignment for the hybrid field bus ECOFAST System Manual GWA 4NEB 950 5228-02 Connections Discriminating Module and Maintenance Switch 5.6 Discriminating Module and Maintenance Switch Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. Power bus connection Input: Han Q4/2 pin Output: Han Q4/2 socket Pin assignment acc. to DESINA: Pin Assignment Comment 1 Phase L1 Switched 2 Phase L2 Switched 3 Phase L3 Switched 4 Neutral conductor N Looped through 11 -- Reserved 12 -- Reserved PE, ground Looped through Table 5-10: Pin assignment of the Han Q4/2 pin/socket Check-back red black C 2 NO NC 1 5 3 4 yellow Fig. 5-13: ECOFAST System Manual GWA 4NEB 950 5228-02 M 12 connector (pin) for check-back signals 5-15 Connections General Wiring and Interfaces 5.7 General Wiring and Interfaces 5.7.1 Rules for Wiring Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. Selecting the power leads The core cross-section of the power leads must be matched to the respective ambient conditions. The decisive factors for choosing the core cross-section are as follows: * set current on the device * installation method * ambient temperature * type of material (PVC, rubber) For PVC power leads installed in a cable duct, for example, the maximum current carrying capacity as a function of ambient temperature is as follows: o TU 30 C 40 C 45 C 50 C 55 C 1.5 mm2 14 A 12.2 A 11.1 A 9.9 A 8.5 A 2.5 mm2 19 A 16.5 A 15.0 A 13.5 A 11.6 A 4.0 mm2 26 A 22.6 A 20.5 A 18.5 A 15.9 A 6.0 mm2 33 A 28.7 A 26.0 A 23.4 A 20.1 A Table 5-11: 5-16 Reduction values for installation type B2 with three loaded cores ECOFAST System Manual GWA 4NEB 950 5228-02 Connections General Wiring and Interfaces Observe the following rules when carrying out wiring: Rules for flexible cables Data Current carrying capacity of the plug connection as a function of the connectable core cross-sections and ambient temperature Tu = 55 C 40 C 1.5 mm2 12 A 15 A 2 20 A 25 A 4.0 mm2 30 A 35 A 2 48 A 54 A 2.5 mm 6.0 mm Permissible outer diameter of the cable sealing insert Green 7.0 to 10.5 mm Red 9.0 to 13.0 mm White 11.5 to 15.5 mm Length of insulation to strip from cores 8 mm Length of insulation to strip from cable sheath 20 mm Table 5-12: Rules for wiring Unused Connections Close off unused connections with screw caps; this is the only way of ensuring degree of protection IP65. Order number 3 RK1 902-0CJ00 (10 screw caps) or 3 RK1 902-0CK00 (1 screw cap). 5.7.2 Power Cables, Preassembled at One End Power cables which are preassembled at one end are available in different lengths (see appendix for order numbers). One end of the cable is fitted with a power plug connector with pins. The other end is free. Here, you can strip the cores and, for example, attach a plug connector or terminal block. . 1 Numbers are printed on the cores for identification purposes. 1 2 2 1 The core number/pin assignments are specified in the following two sections. 2 3 3 3 4 5 4 4 5 5 Fig. 5-14: ECOFAST System Manual GWA 4NEB 950 5228-02 Numbers printed on the power cable cores 5-17 Connections General Wiring and Interfaces Power cables, preassembled at one end with Han Q4/2 pin Pin Core no. Assignment 1 2 Phase L1 1 2 2 3 Phase L2 11 12 3 4 Phase L3 4 1 Neutral N 11 5 Reserved 12 6 Reserved 3 4 PE (yellow/green) Fig. 5-15: 5-18 Power cables, preassembled at one end with Han Q4/2 pin ECOFAST System Manual GWA 4NEB 950 5228-02 Connections General Wiring and Interfaces Power cables, preassembled at one end with Han 10E pin Core no. (7-core) Pin Core no. (11-core) Assignment 1 1 1 Phase L1 2 2 2 Phase L2 3 3 3 Phase L3 4 -- 4 Brake (reference potential) 5 -- 5 Brake 6 4 6 Winding terminal W2 7 5 7 Winding terminal U2 8 6 8 Winding terminal V2 9 -- 9 Temperature sensor (terminal a) 10 -- 10 Temperature sensor (terminal b) PE (yellow/green) Fig. 5-16: Motor supply leads preassembled at one end with Han 10E pin Notice Shielded motor supply leads must be used for frequency converters. ECOFAST System Manual GWA 4NEB 950 5228-02 5-19 Connections General Wiring and Interfaces Preassembled power cables (e. g. spur cable) To prepare power cables, you need a crimping tool (soldering is possible as an alternative) and the accessories listed in the table. Power cables with Han Q4/2 To connect the main power to the motor starter/power connector, To loop through the main power from the power connector, you need... a flexible Cu cable 5 x 2.5 mm2 (3 conductors + N + PE) 5 x 4 mm2 (3 conductors + N + PE) 5 x 6 mm2 (3 conductors + N + PE) Han Q4/2 socket (straight) 2: Han Q4/2 pin (straight) * 2.5 mm 3RK1911-2BR50 * 2.5 mm2: 3RK1911-2BS60 * 4.0 mm2: 3RK1911-2BR10 * 4.0 mm2: 3RK1911-2BS20 * 6.0 mm2: 3RK1911-2BR30 * 6.0 mm2: 3RK1911-2BS40 Han Q4/2 socket (angular) mm2: Han Q4/2 pin (angular) * 2.5 3RK1911-2BE50 * 2.5 mm2: 3RK1911-2BF60 * 4.0 mm2: 3RK1911-2BE10 * 4.0 mm2: 3RK1911-2BF20 * 6.0 mm2: 3RK1911-2BE30 * 6.0 mm2: 3RK1911-2BF40 Table 5-13: Preparing connecting leads with Han Q4/2 Han Q4/2 power connectors The power connectors consist of the following components: Han Q4/2 socket for connecting the main power Han Q4/2 pin for looping through the main power Connector housing Jacks Socket insert Fig. 5-17: 5-20 Connector housing Contact pins Pin insert Han Q4/2 power connector ECOFAST System Manual GWA 4NEB 950 5228-02 Connections General Wiring and Interfaces 5.7.3 AS-i Interface Connection Techniques The following AS-i cables are used: * Yellow AS-i cable for AS-i communication and non-switched 24 V DC auxiliary power for supplying sensors and electronics * Black AUX PWR AS-i cable for switched 24 V DC auxiliary power for supplying actuators The diagram below shows the position and coding of the AS-i cables on the motor starter: Motor starter AS-i cable AS-i cover AS-i Communication and non switched auxiliary power Switched auxiliary power AS-i (+) AS-i (-) WR AUX P AUX PWR (+) AUX PWR (-) Fig. 5-18: AS Interface Contacting The AS-i cables are contacted automatically using the insulation piercing method when the AS-i cover is screwed on. AS-i Cover AUX PWR AS-i Fig. 5-19: ECOFAST System Manual GWA 4NEB 950 5228-02 Contacting the AS-i cables 5-21 Connections General Wiring and Interfaces 24 V DC voltage supply (AS-i) non-switched (yellow AS-i cable) This voltage is constantly available. It is required for: * supplying the electronics in the motor starter * interrogating the auxiliary contacts The voltage is not disconnected in the event of an EMERGENCY STOP or safety shutdown, thereby ensuring that the system can always communicate with the ECOFAST component. 24 V DC voltage supply (AUX PWR) switched (black AS-i cable) This voltage is not constantly available. It is only required for: * driving the switching elements, e.g. a contactor The voltage can be disconnected in the event of an EMERGENCA STOP or safety shutdown (category 1 according to EN 954-1), so that all switching elements are safely disconnected with the connected motors. Response to undervoltage (24 V DC < 18.5 V) and power failure: * In the event of prolonged undervoltage or power failure > 20 ms, the switching elements and the brake output are disconnected. * When the power supply is restored, the disconnection command and the associated signal bits and error bits are acknowledged automatically. 5-22 ECOFAST System Manual GWA 4NEB 950 5228-02 6 Commissioning 6.1 Power & Control Module Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. IP65 Version: Step Description 1 Turn the rotary switch on the front of the CPU to "RUN". 2 If you are using motor starters without a thermal motor model and with a motor supply lead (installation in the vicinity of the motor), also observe the line protection guidelines in 3.5.5 on page 3-13. 3 Close the door of the PCM and lock both safety locks. Turn the main switch clockwise. 4 Switch on the 400 V AC main power supply. 5 Switch on the PCM. 6 Reset the external EMERG. STOP if necessary and actuate the external start switch. The power bus(es) and the field bus(es) are now supplied with power. 7 Configure the AS-i monitor if necessary. The factory-assigned password is "ECOFAST". Note the information below. Table 6-1: Sequence of steps for commissioning the PCM, IP65 version Control cabinet version: Step Description 1 If you are using motor starters without a thermal motor model and with a motor supply lead (installation in the vicinity of the motor), also observe the line protection guidelines in 3.5.5 on page 3-13. 2 Switch on the 400 V AC main power supply. 3 Reset the external EMERG. STOP if necessary and actuate the external start switch. The power bus(es) and the field bus(es) are now supplied with power Table 6-2: Sequence of steps for commissioning the PCM, control cabinet version ECOFAST System Manual GWA 4NEB 950 5228-02 6-1 Commissioning Power & Control Module Step 4 Description Configure the AS-i monitor if necessary. The password assigned in the factory is "ECOFAST". Note the information below. Table 6-2: Sequence of steps for commissioning the PCM, control cabinet version lll. Notice The AS-i monitor "measures" the connected cables and saves the configuration. During commissioning, the factory default configuration is still stored. For this reason, the system displays a prompt after you have entered your password because the system has to be reconfigured. 6.1.1 Diagnostics Missing voltages Voltage missing Shown by Potential fault Cause 400 VAC D1/D2 E0.0 OFF Q1 OFF -- D1/D2 E0,1 OFF Q1 OFF Overload D1/D2 E0.2 OFF Q1 OFF Short circuit D1/D2 E0.3 OFF K1 and/or K2 AUS EMERGENCY STOP, 24 V internal, D5 or K5 All OFF Q1 OFF -- All OFF F1 OFF -- F2/ channel 4 red F2 Overload F2/ channel 4 red F2, blade-type fuse defective Short circuit D1/D2 E0.4, D1/D2 E0.7 OFF K3 and/or K4 OFF D5 or K5, EMERGENCY STOP D1/D2 E0.7 OFF F2/ channel 1 red Overload D1/D2 E0.7 OFF F2/ channel 1 red, bladetype fuse defective Short circuit D1/D2 E0.6 OFF F2/ channel 3 red Overload D1/D2 E0.6 OFF F2/ channel 3 red, bladetype fuse defective Short circuit D1/D2 E1.1, D1/D2 E0.4 K3 and/or K4 OFF D5 or K5, EMERGENCY STOP E1.1 F2/ channel 2 Overload E1.1 F2/ channel 2, blade-type fuse defective Short circuit D5 or D3 G2 Overload 24 V internal 24 V switched 24 V non switched 24 V AS-i switched 30 V AS-i non switched Table 6-3: 6-2 Diagnostics - missing voltages ECOFAST System Manual GWA 4NEB 950 5228-02 Commissioning Alternative Power Supply Signal states Signal Was fehlt? Moglicher Fehler Ursache D1/D2 E 0.0 OFF All OFF Q1 OFF - D1/D2 E 0.1 OFF All OFF Q1 Overload - D1/D2 E 0.2 OFF All OFF Q1 Short circuit - D1/D2 E 0.3 OFF 400 VAC K1, K2 OFF D5(K5), EMERGENCY STOP, 24 V internal D1/D2 E 0.4 OFF 24 V switched 24 V AS-i K3, K4 OFF D5(K5), EMERGENCY STOP, 24 V internal, F2/ channel 1 D1/D2 E 0.5 OFF 400 V, 24 V switched, 24 V AS-i K1, K2, K3, K4 EMERGENCY STOP D1/D2 E 0.6 OFF 24 V non switched F2/ channel 3 F2/ channel 3 overloaded D1/D2 E 0.7 OFF 24 V switched F2/ channel 1 F2/ channel 2 overloaded D1/D2 E 1.0 OFF All OFF F1 OFF Overload, Short circuit D1/D2 E 1.1 OFF 24 V AS-i F2/ channel 2 Overload, Short circuit F2/ channel 1 red ON 24 V switched F2/ channel 1 Overload, Short circuit F2/ channel 2 red ON 24 V AS-i F2/ channel 2 Overload, Short circuit F2/ channel 3 red ON 24 V non switched F2/ channel 3 Overload, Short circuit F2/ channel 4 red ON All OFF F2/ channel 4 Overload, Short circuit Table 6-4: Diagnostics - signal states 6.2 Alternative Power Supply 6.2.1 Simple Energy Unit (SEU) For the commissioning of the circuit breakers and the contactors please refer to the instructions enclosed with the device. 6.2.2 ET 200S motor starter For the commissioning of the motor starter ET 200S please refer to the manual in the 6ES7151-1AA10-8AA0 documentation package. ECOFAST System Manual GWA 4NEB 950 5228-02 6-3 Commissioning Hybrid Field Bus Connections 6.3 Hybrid Field Bus Connections To commission the hybrid field bus connections carry out the following steps: Step Description 1 Connect up to 2 hybrid field bus cables. 2 Close the control cabinet. 3 Attach bus terminating connectors or screw caps to any unused connections. 4 Switch on the main power. Table 6-5: Procedure for commissioning the hybrid field bus connection Diagnostics Certain faults are highlighted by 2 LEDs for the active hybrid field bus connections. The LEDs are located on the IP20 side (in the control cabinet) in front of the SUB-D socket. LED yellow LED green Fig. 6-1: Diagnostics LEDs for active hybrid field bus connections Fault Display/LED Remedy No supply voltage from 24 V DC (NS) LED green OFF Connect 24 V DC (NS) supply voltage No supply voltage from 24 V DC (NS) LED yellow OFF Connect 24 V DC (NS) supply voltage No signal from master Check signal cable from master for interruption Baud rate not recognized Plug in bus terminating connnector Baud rate not recognized LED yellow flickers Plug in bus terminating connnector Check bus station in direction of master fault Table 6-6: Diagnostics for active hybrid field bus connections Examples of typical hybrid field bus connections are listed on the following pages. 6-4 ECOFAST System Manual GWA 4NEB 950 5228-02 Commissioning Hybrid Field Bus Connections 6.3.1 Passive Hybrid Field Bus Connection for Supply SIMATIC e. g. CPU 315-2 DP Power supply PROFIBUS standard cable e. g. 6ES7 9720BA50-0AA0 Cage Clamp IP20 (inside) IP65 (in the field) Note: Bus terminating connectors are plugged directly onto the data tee connector non switched (NS) Han-Brid left segment switched (S) Cage Clamp Hybrid field bus connection Supply: 3RK1911-1AA22 (socket/socket) Hybrid field bus cable RS 485 e. g. 6XV1830-7BH30 Slave 3 Fig. 6-2: Bus terminating connector right segment Slave 4 3RK1911-1AA22 passive hybrid field bus connection (socket/socket) Typical set-up: IP20 (inside): * PLC/DP master/PROFIBUS-DP via RS 485 * Power supply for switched/non-switched voltage * Passive hybrid field bus connection for combining * PROFIBUS-DP (Cage Clamp) + power supplies (Cage Clamp) * Segment divided between left and right IP65 (in the field): * Supply to PROFIBUS-DP in RS 485 in the left and right segments via Han Brid (sockets) * Left and right bus terminating connectors on the last data tee Connectors of the left and right segments * Supply to the power supplies (NS + S) via Han Brid (sockets) ECOFAST System Manual GWA 4NEB 950 5228-02 6-5 Commissioning Hybrid Field Bus Connections 6.3.2 Passive Hybrid Field Bus Connection for Conducting Bus plug e. g. 6ES7972-0BA50-0XA0 e. g. OP 27 Slave 4 non switched (NS) PROFIBUS standard cable PROFIBUS-DP RS 485 Cage Clamp Cage Clamp IP20 (inside) IP65 (in the field) e. g. Power & Control Module (P&CM) Hybrid field bus connection Conducting: 3RK1911-1AA32 (pin/socket) 2 x 24 V DC 3~ Note: Bus terminating connectors are plugged directly onto the data tee connector Han-Brid Station 1 Bus terminating connector Hybrid field bus cable RS 485 e. g. 6XV1830-7BH30 Slave 5 Slave 3 Fig. 6-3: 3RK1911-1AA32 passive hybrid field bus connection (pin/socket) Typical set-up: Integration of an operator panel (OP) IP20 (inside): * PROFIBUS-DP and power supply to the components separated by the hybrid field bus connection * Standard PROFIBUS-DP line connected to the hybrid field bus connection with Cage Clamp * PROFIBUS-DP line connected to the component with a 9-pole SUB-D RS 485 bus plug * Power supply to the component (e.g. operator panel) connected to the hybrid field bus connection with Cage Clamp (NS + S) * Standard IP20 component (e.g. operator panel) IP65 (in the field): * Supply to PROFIBUS-DP in RS 485 and power supply via the hybrid field bus line to the pins of the hybrid field bus connection. PROFIBUS-DP and power supplies conducted into the hybrid field bus line via the sockets of the hybrid field bus connection * Left and right bus terminating connectors on the last data tee connectors 6-6 ECOFAST System Manual GWA 4NEB 950 5228-02 Commissioning Hybrid Field Bus Connections 6.3.3 Active Hybrid Field Bus Connection for Supply SIMATIC e. g. CPU 315-2 DP Power supply PROFIBUS standard cable non switched (NS) PROFIBUS-DP RS 485 Sub-D IP20 (inside) IP65 (in the field) Han-Brid switched (S) Cage Clamp Hybrid field bus connection Supply: 3RK1911-1AB22 (socket/socket) Slave 3 Fig. 6-4: Cap Hybrid field bus fiber-optic cable e. g. 6XV1830-6DH30 Cap Slave 4 3RK1911-1AB22 active hybrid field bus connection (socket/socket) Typical set-up: IP20 (inside): * PLC/DP master/PROFIBUS-DP via RS 485 * Power supply for switched/non-switched voltage * Active hybrid field bus connection for combining PROFIBUS-DP 9-pin SUB-D (socket) + power supplies (terminals) * Segment divided left and right IP65 (in the field): * PROFIBUS-DP supply with fiber-optic cables in the segment (left/right) via versatile link module * Bus terminating connector (left/right) on the last data tee connector * Power supply (NS + S) via Han-Brid (sockets) ECOFAST System Manual GWA 4NEB 950 5228-02 6-7 Commissioning Hybrid Field Bus Connections 6.3.4 Active Hybrid Field Bus Connection for Conducting Bus plug e. g. 6ES7 972-0BB11-0XA0 e. g. OP 27 Slave 4 non switched (NS) PROFIBUS standard cable switched (S) PROFIBUS-DP RS 485 Sub-D Cage Clamp IP20 (inside) IP65 (in the field) e. g. Power & Control Module (PCM) 2 x 24 V DC Han-Brid Hybrid field bus connection Conducting: 3RK1911-1AB32 (pin/socket) 3~ Station 1 Cap Cap Hybrid field bus fiber-optic cable e. g. 6XV1830-6DH30 Slave 3 Fig. 6-5: Slave 5 3RK1911-1AB32 active hybrid field bus connection (pin/socket) Typical set-up: integrating an operator panel (OP) IP20 (inside) * Active hybrid field bus connection for separating PROFIBUS-DP and converting fiber-optic cable to RS 485 + power supplies (NS + S) for the components * Standard PROFIBUS-DP cable connected to hybrid field bus connection with 9-pin SUB-D socket * PROFIBUS-DP cable connected to the component with 9-pin SUB-D bus plug * Component power supply (e.g. for operator panel) connected to hybrid field bus connection with cage clamp (NS + S) * Standard IP20 component (e.g. operator panel) IP65 (in the field): * Supply to PROFIBUS-DP with fiber-optic cables and power supplies via hybrid field bus line to pins of hybrid field bus connection * PROFIBUS-DP and power supplies conducted to hybrid field bus line via sockets of hybrid field bus connection * Screw caps (left and right) on the last data tee connector 6-8 ECOFAST System Manual GWA 4NEB 950 5228-02 Commissioning Hybrid Field Bus Connections 6.3.5 Cascading of the Active Hybrid Field Bus Connections The active hybrid field bus connections 3RK1911-1AE22 and 3RK1911-1AE32, as well as 3RK1911-1AB22 and RK1911-1AB32 have only one repeater function from IP20 (S2) to IP67 (S1, S1') and vice versa. Not between S1 and S1'. S1 and S1' are only looped through internally. 6.3.6 Power Supply of the Bus Terminating Connector All bus terminating connectors that are connected at the IP67 side have to be supplied via a 24 V DC operating voltage, i.e. the voltage (+NS and -NS) applied, for example, at segment S1', must be jumpered to segment S1 at the terminal. Without a terminating resistor, safe data operation cannot be guaranteed. Slave SPS MBK R R 20 m 2m +S -S -NS +NS +S -S -NS +NS R R S1 S1 S1` S1` S1` S1` Slave BU BU Sti BU S1 S1` S1 S1` MBK R R 5m 200 m Slave SPS MBK R R 2m 20 m +S -S -NS +S -S -NS R R S1 S1 S1` S1` S1` S1` Slave BU BU Sti BU S1 S1` S1 S1` MBK R R 5m 200 m Fig. 6-6: ECOFAST System Manual GWA 4NEB 950 5228-02 Schematic diagram of the use of bus terminating connectors 6-9 Commissioning Hybrid Field Bus Connections 6.3.7 Active Hybrid Field Bus Connection for Supply e. g. CPU 315-2 DP Power supply SIMATIC PROFIBUS-DP RS 485 SUB-D IP20 (inside) non switched (NS) switched (S) Cage Clamp IP65 (in the field) Note: Bus terminating connectors are plugged directly onto the data tee connector Bus terminating connector Hybrid cable RS 485 Slave 3 Fig. 6-7: Hybrid feld bus connection Supply: 3RK1911-1AE22 (socket/socket) Slave 4 3RK1911-1AE22 active hybrid field bus connection (socket/socket) Typical set-up: IP20 (inside): * PLC/DP master/PROFIBUS-DP via RS 485 * Power supply for switched/non-switched voltage * Active hybrid field bus connection for combining PROFIBUS-DP 9-pin SUB-D (socket) + power supplies (Cage Clamp) * Segment divided left and right IP65 (in the field): * PROFIBUS-DP supply with RS 485 in the segment (left and right) via Han-Brid (sockets) * Bus terminating connector (left/right) on the last data tee connector * Power supply (NS + S) via Han-Brid (sockets) 6-10 ECOFAST System Manual GWA 4NEB 950 5228-02 Commissioning Hybrid Field Bus Connections 6.3.8 Active Hybrid Field Bus Connection for Supply SIMATIC S7 Power supply non switched. (NS) segment 1-3 switched (S) segment 1/2/3 PROFIBUS-DP RS 485 9-pin SUB-D e. g. 6ES7972-0BA50-0AA0 3RK1911-1AE22 (socket/socket) Hybrid field bus cable 6XV1830-7AHxx PROFIBUS-DP RS 485 Segment 1 left Fig. 6-8: Segment 1 Segment 2 right left Segment 2 right Segment 3 left Segment 3 right 3RK1911-1AE22 active hybrid field bus connection (socket/socket) Typical set-up: IP20 (inside): * PLC/DP master with PROFIBUS-DP via RS 485 * Power supply for several non-switched and independently-switched voltages (creation of several EMERGENCY STOP circuits, disconnection of individual segments) via cage clamp * Linear design of PROFIBUS DP on the inside (IP20) of the hybrid field bus connections with terminating resistors for the last 9-pin SUB-D connector of the hybrid field bus connection and on the CP of SIMATIC S7 IP65 (in the field): * PROFIBUS-DP supply with RS 485 in three segments (left/right) via Han-Brid (sockets) * Bus terminating connector (left/right) on the last data tee connector * Power supply (NS + S) via Han-Brid (sockets) ECOFAST System Manual GWA 4NEB 950 5228-02 6-11 Fig. 6-9: 6-12 M Slave 3 Bus terminating connector M Slave 4 Hybrid field bus cable RS 485 PROFIBUS DP Internal bus station e. g. ET 200S/M Slave 5 OP in local box OP 27 non switched switched SV 2 x 24 V DC M FU Hybrid field bus connection Conducting: 3RK1911-1AA32 pin/socket Slave 6 ET 200X-RS 485 ET 200S in local box Slave 7 Bus terminating connector 6.3.9 PROFIBUS standard cable RS 485 RS 485 Hybrid field bus connection Supply: 3RK1911-1AA22 socket/socket SIMATIC S7 Commissioning Hybrid Field Bus Connections Conveyor Section With Hybrid Field Bus Connections for Supply and Conducting Conveyor section with hybrid field bus connections for supply and conducting ECOFAST System Manual GWA 4NEB 950 5228-02 Fig. 6-10: ECOFAST System Manual GWA 4NEB 950 5228-02 Bus terminating connector or left segment Left segment Right segment Main power cable 3/PE-50/60 Hz 400 V AC PROFIBUS CONNECTOR Slave 4 Slave 11 Slave 3 Slave 10 Terminating resistor PROFIBUS CONNECTOR connected internally or left segment Power & Control Module (PCM) with - PLC - 2 x 24 V DC supply 2 x 24 V cc - 400 V AC main power supply Slave 12 Slave 5 Hybrid field bus cable RS 485 Data tee connector Left segment Right segment Slave 32 Slave 9 Bus terminating connector 6.3.10 3~ e. g. CPU 315-2DP Typical application: Installation system withPROFIBUS DP in Cu Commissioning Hybrid Field Bus Connections Installation System with PROFIBUS-DP - Cu Installation method with PROFIBUS-DP - Cu 6-13 Fig. 6-11: 6-14 Left segment Right segment Main power cable 3/PE-50/60 Hz 400 V AC PROFIBUS CONNECTOR Screw cap or left segment Slave 10 Slave 3 2 x 24 V cc Slave 11 Slave 4 Slave 12 Slave 5 Hybrid field bus fiber-optic cable Terminating resistor PROFIBUSCONNECTOR connected internally or left segment Power & Control Module (PCM) with - PLC - 2 x 24 V DC supply - 400 V AC main power supply Left segment Right segment Data tee connector Typical application: Installation system with PROFIBUS DP fiber-optic cable Slave 32 Slave 9 Screw cap 6.3.11 3~ e. g. CPU 315-2DP Commissioning Hybrid Field Bus Connections PROFIBUS-DP - Fiber-optic Cable Installation system with PROFIBUS DP fiber-optic cable ECOFAST System Manual GWA 4NEB 950 5228-02 Fig. 6-12: plies ECOFAST System Manual GWA 4NEB 950 5228-02 M M B A Slave 4 B A S1' M Slave 5 +S -S -NS +NS +S -S -NS +NS The power supply is not jumpered on the hybrid field bus connection on Slave 7 => Segment 1 supplies the OP (Slave 7) with power => Segment 2 of the hybrid field bus connectopn on Slave 7 is supplied by the second power supply M Slave 6 3RK1911-1AA 22 Hybrid field bus cable RS 485 B A S1 S1' B A M M Bus terminating connector 3RK1911-1AA32 IP65 IP20 Slave 9 S1' S1 Slave 8 +S -S -NS +NS +S -S -NS +NS non switched S1' S1 Slave 3 IP65 IP20 S1 switched Power supply 2 x 24 V DC switched e. g. OP 27 Slave 7 non switched Power supply 2 x 24 V DC 6.3.12 e. g. CPU 315-2 DP Typical application: Installation system with PROFIBUS DP (Cu) and passive hybrid field bus connections with 2 separate power supplies Commissioning Hybrid Field Bus Connections PROFIBUS-DP (Cu) and Passive Hybrid Field Bus Connections with 2 Separate Power Supplies PROFIBUS-DP (Cu) and passive hybrid field bus connections with 2 separate power sup- 6-15 Fig. 6-13: plies 6-16 9-pin SUB-D M M Slave 4 S2 M Slave 5 +S -S -NS+NS +S -S -NS+NS S1' S1 Slave 3 IP65 IP20 M Slave 6 3RK1911-1AE22 switched non switched Power supply 2 x 24 V DC S2 Hybrid field bus cable M Slave 7 The power supply is not jumpered on the hybrid field bus connection on slave 8 => Segment 1 supplies the OP (Slave 8) with power => Segment 2 of the hybrid field bus connection on slave 8 is supplied by the second power supply e. g. OP 27 Slave 8 +S -S -NS+NS +S -S -NS +NS IP20 M Slave 9 Screw cap IP65 3RK1911-1AE32 non switched switched Power supply 2 x 24 V cc 6.3.13 e. g. CPU 315-2 DP Typical application: Installation system with PROFIBUS DP (Cu) and active hybrid field bus connections with 2 separate power supplies Commissioning Hybrid Field Bus Connections PROFIBUS-DP (Cu) and Active Hybrid Field Bus Connections with 2 Separate Power Supplies S1' S1 PROFIBUS-DP (Cu) and active hybrid field bus connections with 2 separate power sup- ECOFAST System Manual GWA 4NEB 950 5228-02 Fig. 6-14: ECOFAST System Manual GWA 4NEB 950 5228-02 9-pin SUB-D M M M Slave 6 3RK1911-1AB32 Data segment 1 M Slave 5 S1' S1 Slave 4 +S -S -NS +NS +S -S -NS +NS Hybrid field bus fiber-optic cable IP65 IP20 S2 +S -S -NS +NS +S -S -NS +NS In the active hybrid field bus connection, data is jumpered as a standard => The second hybrid field bus connection in station 2 is necessary to supply a new data segment (Data segment 2) 3RK1911-1AB 32 e. g. CPU 315-2 DP M Data segment 2 Slave 3 +S -S -NS+NS +S -S -NS+NS 3RK1911-1AB22 M Slave 4 S2' S1 Slave 3 S2 switched non switched Power supply S2 S1 Screw cap IP65 IP20 e. g. CPU 315-2 DP 6.3.14 2 x 24 V DC Typical application: Installation system with PROFIBUS DP and active hybrid field bus application with 2 separate data supplies Commissioning Hybrid Field Bus Connections PROFIBUS-DP CU and Active Hybrid Field Bus Connections with 2 Separate Data Supplies PROFIBUS-DP CU and active hybrid field bus connections with 2 seperate data supplies 6-17 Commissioning Discriminating Module and Maintenance Switch 6.4 Discriminating Module and Maintenance Switch Warning Hazardous electrical voltages! These may cause electric shock and burns. Disconnect the system and device from the power supply before starting work. Notice Refer to the information in the operating instructions. To commission the discriminating module/maintenance switch, and thus also the downstream power bus (sub-)segment, carry out the following steps: Step Activity 1 If you are using motor starters without a thermal motor model and with a motor supply lead (installation in the vicinity of the motor), also observe the line protection guidelines in 3.5.5 on page 3-13. 2 Switch on the 400 V AC main power supply 3 Switch on the discriminating module/maintenance switch. Table 6-7: 6-18 Sequence of steps for commissioning the discriminating module/maintenance switch ECOFAST System Manual GWA 4NEB 950 5228-02 7 Technical Data 7.1 Power & Control Module 7.1.1 IP65 Version Order number 4FB2111-2A...0AA0 4FB2121-2A...0AA0 4FB2111-2A...0AA1 4FB2112-2A...0AA0 Master/slave PROFIBUS-DP (Master) PROFIBUS-DP (Master) AS-Interface (Master) PROFIBUS-DP (Slave) PROFIBUS-DP (Master) AS-Interface (Master) Protection SIGUARD SIGUARD SIGUARD AS-I monitor Ausfuhrung Power supply Input voltage/range 3AC 400 V/-10% +6% System frequency/range 50, 60 Hz 5% Main power supply See table "PCM device versions", on page 2-3 Output main power circuit 3 AC 400 V 24 V switched (24 V S) Output voltage DC 24 V (20.4 V to 28.8 V) Output current 5 A DC when AS-Interface fitted 10 A DC when AS-Interface not fitted Residual ripple < 5% Backup min. 20 ms 24 V DC non switched (24 V NS) Output voltage DC 24 V (20.4 V to 28.8 V) Output current DC 10 A DC 10 A DC 10 A DC 10 A Residual ripple < 5% < 5% < 5% < 5% min. 20 ms min. 20 ms min. 20 ms min. 20 ms Output voltage AS-i -- DC 30 V (29.5 V to 31.6 V) -- DC 30 V (29.5 V to 31.6 V) Output current -- DC 2.4 A -- DC 2.4 A Residual ripple -- < 300 mVss -- < 300 mVss Backup -- min. 20 ms -- min. 20 ms Backup 30 V DC non switched (AS-i) ECOFAST System Manual GWA 4NEB 950 5228-02 7-1 Order number 4FB2111-2A...0AA0 4FB2121-2A...0AA0 4FB2111-2A...0AA1 4FB2112-2A...0AA0 Protection and monitoring Short circuit protection Main circuit Auxiliary circuits Signaling devices Built-in circuit-breaker Built-in residual current-operated protective device Green (ready for operation) Yellow (power connected) Red (internal fault) Safety Degree of protection Approvals (in preparation) Safety class IP65 CE, UL, CSA I EMC Emitted interference EN 55 081-2 Noise immunity EN 61000-6-2 Temperatures Ambient temperature Transport-/storage temperature Relative humidity Air pressure 0 C to +40 C, +50 C with derating in the main circuit/auxiliary circuits -25 C to +70 C 15% to 75% at 25C (non-condensing) 700 to 1060 hPa Mechanical environmental conditions Transport Vibratory load Shock 3g 15 g with 11 ms Operation Vibratory load Shock ECOFAST System Manual GWA 4NEB 950 5228-02 f = 10 to 58 Hz, d = 0.075 mm/58 to 100 Hz, 10 g 10 g with 6 ms/6 g with 10 ms 7-2 Order number 4FB2111-2A...0AA0 4FB2121-2A...0AA0 4FB2111-2A...0AA1 4FB2112-2A...0AA0 Connections/throughfeeds Cage - Clamp max. 2 x 16 mm2 max. current carrying capacity (Throughfeeds 2 x M40x1.5) Input connections Output connections Main circuit 2 x Han Q4/2 socket (DESINA) Output connections Auxiliary circuits/field bus Output connections AS-Interface Output connections EMERGENCY STOP 2 x Han-Brid socket/socket (DESINA) -- Cage - Clamp, 2.5 mm2 Throughfeeds 4 x ASi-seal Cage - Clamp, 2.5 mm2 Throughfeeds 4 x ASi-seal -- Cage - Clamp, 2.5 mm2 Throughfeeds via cable throughfeed flange Cage - Clamp, 2.5 mm2 Throughfeeds via cable throughfeed flange Cage - Clamp, 2.5 mm2 Throughfeeds via cable throughfeed flange Cage - Clamp, 2.5 mm2 Throughfeeds via cable throughfeed flange Cage - Clamp, 1.5 mm2 SIMATIC connections Cable throughfeed flanges 8 x 3.8 to 6.3 mm 2 x 6.1 to 8.8 mm 2 x 7.8 to 10.7 mm Dimensions/weight Housing dimensions (WxHxD) 550 x 850 x 255 Overall dimensions (WxHxD) 600 x 920 x 310 Fixing dimensions (WxH) 575 x 695 Fixing holes 4 x M8 Weight max. 77 kg Fasteners Double-bit key SIMATIC Controller S7-300, CPU 313C-2 DP I/O module S7-300, CPU 313C-2 DP I/O module AS Interface master Data transfer rate S7-300, CPU 313C-2 DP I/O module AS Interface master ET 200M I/O module max. 12 Mbit/s Main memory EEPROM MMC IM151, 64 KByte IM151, 64 KByte IM151, 64 KByte -- MMC Included Included Included -- Unassigned SIMATIC inputs 6 6 6 6 Unassigned SIMATIC outputs 13 13 13 13 External interfaces ECOFAST System Manual GWA 4NEB 950 5228-02 PROFIBUS-DP PROFIBUS-DP PROFIBUS-DP PROFIBUS-DP 7-3 7.1.2 IP00 Version (Control Cabinet Version) Order number 4FB2111-2A...0AA2 4FB2121-2A...0AA1 4FB2111-2A...0AA3 4FB2112-2A...0AA1 PROFIBUS-DP (master) PROFIBUS-DP (master) PROFIBUS-DP (slave) PROFIBUS-DP (master) Ausfuhrung Master/slave AS-Interface (master) Protection SIGUARD AS-Interface (master) SIGUARD SIGUARD AS-I monitor Power supply Input voltage/range 3AC 400 V/-10% +6% System frequency/range 50, 60 Hz 5% Main power supply See table "PCM device versions", on page 2-3 Output/Main circuit 3 AC 400 V 24 V switched (24 V S) Output voltage DC 24 V (20.4 V to 28.8 V) Output current 5 A DC when AS-Interface fitted 10 A DC when AS-Interface not fitted Residual ripple < 5% Backup min. 20 ms 24 V DC non switched (24 V NS) Output voltage DC 24 V (20.4 V bis 28.8 V) Output current DC 10 A DC 10 A DC 10 A DC 10 A Residual ripple < 5% < 5% < 5% < 5% Backup min. 20 ms min. 20 ms min. 20 ms min. 20 ms Output voltage AS-i -- DC 30 V -- DC 30V Output current -- DC 2.4 A -- DC 2.4 A Residual ripple -- < 300 mVss -- < 300 mVss Backup -- min. 20 ms -- min. 20 ms 30 V DC non switched (AS-i) (29.5 V to 31.6 V) (29.5 V to 31.6 V) Protection and monitoring Short circuit protection Main circuit Auxiliary circuit Signaling devices ECOFAST System Manual GWA 4NEB 950 5228-02 Built in circuit-breaker Built in residual current-operated protective device Green (ready for operation) Yellow (power connected) Red (internal fault) 7-4 Order number 4FB2111-2A...0AA2 4FB2121-2A...0AA1 4FB2111-2A...0AA3 4FB2112-2A...0AA1 Safety Degree of protection IP65 Approvals (in preparation) CE, UL, CSA Safety class I EMC Emitted interference EN 55 081-2 Noise immunity EN 61000-6-2 Temperatures Ambient temperature 0 C to +40 C, +50 C with derating in the main circuit/auxiliary circuits Transport-/storage temperature -25 C to +70 C Relative humidity 15% to 75% at 25 C (non-condensing) Air pressure 700 to 1060 hPa Mechanical environmental conditions Transport Vibratory load 3g Shock 15 g with 11 ms Operation Vibratory load f = 10 to 58 Hz, d = 0.075 mm/58 to 100 Hz, 10 g Shock 10 g with 6 ms/6 g with 10 ms Connections/throughfeeds Cage - Clamp max. 2 x 16 mm2 max. current carrying capacity Input connections Output connections Main circuit Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Output connections Auxiliary circuits Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Output connections AS-Interface -- Cage - Clamp, 2.5 mm2 Throughfeeds 4 x ASi-Dichtung Cage - Clamp, 2.5 mm2 Throughfeeds 4 x ASi-Dichtung -- Output connections EMERGENCY STOP Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 Cage - Clamp, 2.5 mm2 SIMATIC connections Cage - Clamp, 1.5 mm2 Dimensions/weight Dimensions (WxHxD) Fixing dimensions (WxH) Fixing holes Weight ECOFAST System Manual GWA 4NEB 950 5228-02 520 x 830 x 240 350 x 809 4 x M8 max. 55 kg 7-5 Order number 4FB2111-2A...0AA2 4FB2121-2A...0AA1 4FB2111-2A...0AA3 4FB2112-2A...0AA1 S7-300, CPU 313C-2 DP I/O module S7-300, CPU 313C-2 DP I/O module AS-interface master S7-300, CPU 313C-2 DP I/O module AS-interface master ET 200M I/O module SIMATIC Controllers Data transfer rate to 12 Mbit/s Main memoryEEPROM MMC IM151, 64 KByte IM151, 64 KByte IM151, 64 KByte -- MMC Included Included Included -- Unassigned SIMATIC inputs 6 6 6 6 Unassigned SIMATIC outputs 13 13 13 13 External interfaces PROFIBUS-DP PROFIBUS-DP PROFIBUS-DP PROFIBUS-DP 7.2 Alternative Power Supplies 7.2.1 Simple Energy Unit (SEU) For the technical data of the circuit-breaker and the contactor, please refer to the manual enclosed with the device. 7.2.2 ET 200S Motor Starter For the technical data of the motor starter ET 200S, please refer to the manual in the 6ES7151-1AA10-8AA0 documentation package. ECOFAST System Manual GWA 4NEB 950 5228-02 7-6 7.3 Hybrid Field Bus Connections General technical Data Location On the system Mounted directly on the control cabinet Degree of protection Control cabinet Field bus IP20 IP65/67 Enclosure dimensions (HxWxD) 103 x 93 x 65 Installation position Any Weight ca. 250 g Operating temperature -25 C to +50 C Storage-/transport temperature -40 C to +80 C Vibratory load 5g Rated insulation voltage 500 V AC Standards, approvals DIN VDE 0627, DIN EN 61984, DIN EN 60529, DIN VDE 0160, DIN EN 50178, DIN EN 50170 UL 1977, CSA in preparation 24 V DC, non-switched (NS) 24 V DC -25%/+50% 18 V to 36 V 24 V DC, switched (S) 24 V DC -25%/+50% 18 V to 36 V Electrical Data Auxiliary Power Rated voltage Rated current max. 10 A For each rated voltage Voltage supply from 24 V DC non-switched (NS) Current consumption max. 130 mA Voltage failure bypass > 20 ms ECOFAST System Manual GWA 4NEB 950 5228-02 7-7 Electrical Data for Communikation Passive Active RS 485 version RS 485 version Fiber-optic cable version Baud rates supported 12,000 kBd 6,000 kBd 3,000 kBd 1,500 kBd 500 kBd 187.5 kBd 93.75 kBd 45.45 kBd 19.2 kBd 9.6 kBd 12,000 kBd 6,000 kBd 3,000 kBd 1,500 kBd 500 kBd 187.5 kBd 93.75 kBd 45.45 kBd 19.2 kBd 9.6 kBd 12,000 kBd (6,000 kBd) not permitted (3,000 kBd) not permitted 1,500 kBd 500 kBd 187.5 kBd 93.75 kBd 45.45 kBd 19.2 kBd 9.6 kBd Cascade depth*) - 3 9 at 12,000 kBd 32 at other baud rates Maximum permissible RS 485/ fiber-optic cable length (POF) between 2 stations - Depending on the baud rate 50 m *) Maximum number of hybrid field bus connections in the RS 485/fiber-optic cable segment. If the DP master for a fiber-optic cable system is located centrally with regard to topology, the maximum cascade depth is permissible at each fiber-optic cable segment connected to the DP master. 7.4 Data Tee Plug Connector General Technical Data Location On the system Installation position Connected to motor starter Any Degree of protection IP65/67 Watertight acc. to IEC 529 (DIN 40050) Cooling Convection No additional cooling required Weight 105 g 100 g Copper variante Fibe-optic cable variant Operating temperature -20 C to + 40 C Non condensing Max. 55 C with reduktion of IDC24V-NS and IDC24V-S each with je 0.3 A per K Storage/transport temperature -40 C to +80 C Relative humidity 5% to 95% Non condensing Site altitude 2000 m No restrictions Vibratory load f = 5 to 26 Hz; d = 0.75 mm 10 Zyklen/f = 26 to 150 Hz; a = 2 g Shock a = 150 m/s2 (15 g) with 11 ms each with 3 shocks in all axes (=18) ESD 8 kV air discharge 6 kV contact discharge IEC 1000-4-2 Severity 3 Electromagnetic fields 10 V/m IEC 1000-4-3 Severity 3 ECOFAST System Manual GWA 4NEB 950 5228-02 7-8 General Technical Data BURST 2 kV/5 kHz supply voltage 1 kV/5 kHz data cables 2 kV/5 kHz process cables IEC 1000-4-4 Severity 3 Emitted interference Limit value class A EN 55011 Non switched Voltage, DC24V-NS Switched Voltage DC24V-S Electrical Data Auxiliary Power Voltage range 20.4 V DC to 28.8V DC standard power supply acc. to DIN 19240 Maximum current-carrying capacity from Han-brid to Han-brid 10 A 10 A Polarity protection no no Short circuit protection/ overload protection no no Insulation voltage 500 V DC between auxiliary voltages and PE Electrical Data for Communication Copper Variant Fiber-optic Cable Variante Baud rates supported 12,000 kBd 6,000 kBd 3,000 kBd 1,500 kBd 500 kBd 187.5 kBd 93.75 kBd 45.45 kBd 19.2 kBd 9.6 kBd 12,000 kBd (6,000 kBd) not permitted (3,000 kBd) not permitted 1,500 kBd 500 kBd 187.5 kBd 93.75 kBd 45.45 kBd 19.2 kBd 9.6 kBd Cascade depth*) - 9 at 12,000 kBd 32 at other baud rates Maximum permissible fiber-optic cable length (POF) between 2 stations - 50 m *) Maximum number of data tee connectors in the fiber-optic cable segment. If the DP master for a fiber-optic cable system is located centrally with regard to topology, the maximum cascade depth is permissible at each fiber-optic cable segment connected to the DP master. ECOFAST System Manual GWA 4NEB 950 5228-02 7-9 7.5 Discriminating Module General Technical Data Location On the system Installation position Wall mounting Mounted directly on the ECOFAST consumer *) Any Degree of protection IP65/67 Watertight acc. to IEC 529 (DIN 40050) Enclosure dimensions (HxWxD) 205 x 105 x 140 Weight 1.5 kg Operating temperature -20 C to +40 C Storage-/transport temperature -40 C to +80 C Vibratory load 5g Rated insulation voltage 500 V AC Locking device 3 padlocks acc. to IEC 60 204-1 Standards, approvals IEC 69 947, IEC 60 204-1, DIN VDE 0627 UL 1977, CSA *) Not possible if ECOFAST motor starters are operated with PROFIBUS-DP ECOFAST System Manual GWA 4NEB 950 5228-02 7-10 8 Dimension Drawings Power & Control Module 8.1.1 IP65 Version 100* Clearance (hatched): 4x O9 O 15 600 2 576 100 400 310 max. 255 max. 8.1 PCM 400 150* * Allow clearance for plug if necessary! 920 max. 695 1 850 2 Drilling dimensions: 695 50 0.2 576 8 4x Fig. 8-1: Power & Control Module, IP65 version ECOFAST System Manual GWA 4NEB 950 5228-02 8-1 Dimension Drawings Power & Control Module IP00 Version (Control Cabinet Version) 224 8.1.2 2x O9 520 Drilling dimensions: 350 809 830 809 350 8 4x 2x O9 Fig. 8-2: 8-2 Power & Control Module, IP00 version (control cabinet version) ECOFAST System Manual GWA 4NEB 950 5228-02 Dimension Drawings Alternative Power Supplies 8.2 Alternative Power Supplies 8.2.1 Simple Energy Unit (SEU) Circuit-breaker 25 S00 3,5 45 90 105 45 12 5 9 18 45 18 5 62 70 76 72 14 S0 25 45 90 97 106 45 12 5 18 45 18 56 69 80 91 5 9 S2 20 30 121 130 45 85 140 125 89 5 8 18 55 9 Fig. 8-3: ECOFAST System Manual GWA 4NEB 950 5228-02 18 5 109 127 132 144 3RV10.. circuit-breaker 8-3 Dimension Drawings Alternative Power Supplies Contactors Drill pattern 5 9 5 35 68 36 45 50 25 37 44 47 60 5 S00 109 S0 1 0 1 3 5 8 6 4 5 1 0 5 a 3 5 6 0 7 2 5 1 4 3 6 3 2 ) 1 5 ,5 S2 8 6 5 159 a 55 35 18 110 15 5 10 64 14 45 171 75 95 72 112 5 Test STOP RESET 0 1 H A 20 Fig. 8-4: 8-4 107 5 Contactors 3RT10.. ECOFAST System Manual GWA 4NEB 950 5228-02 Dimension Drawings Alternative Power Supplies ET 200S Motor Starter 149 138 7 48 Sectional rail 35 x 7,5 mm 290 333 100 135 23 Sectional rail 35 x 7,5 mm 66 RS=130 DS=65 min. 35 mm Clearance for heat dissipation 8.2.2 min. 35 mm Clearance for heat dissipation Connection area Fig. 8-5: ECOFAST System Manual GWA 4NEB 950 5228-02 43 99 126 ET 200S motor starter 8-5 Dimension Drawings Power Tee Clamp Connector 8.3 Power Tee Clamp Connector Power tee clamp connector 158 130 112.6 78.5 55 O 5.5 O 5.5 142.5 Power tee-tee clamp connector 158 130 112.6 78.5 55 O 5.5 O 5.5 142.5 Seals for power tee/tee-tee clamp connector D 34 34 Fig. 8-6: 8-6 D: Depends on the cable cross section Power tee/tee-tee clamp connector ECOFAST System Manual GWA 4NEB 950 5228-02 Dimension Drawings Hybrid Field Bus Connections 8.4 Hybrid Field Bus Connections IP20 IP65 90 Cut out section on control cabinet: 80 5 max. 103 65 93 Fig. 8-7: ECOFAST System Manual GWA 4NEB 950 5228-02 Dimension drawing of the hybrid field bus connection 8-7 Dimension Drawings Data Tee Plug Connector 8.5 Data Tee Plug Connector Fig. 8-8: 8-8 Dimension drawing of the data tee plug connector ECOFAST System Manual GWA 4NEB 950 5228-02 Dimension Drawings Discriminating Module and Maintenance switch 8.6 Discriminating Module and Maintenance switch 155 135 230 105 Fig. 8-9: Discriminating module with M12 connector A K H A1 M A1 d G C F A B1 D G M Fig. 8-10: ECOFAST System Manual GWA 4NEB 950 5228-02 = = = = = 94 80 4 x PG16 n/a 36 B C E H = = = = 125 36 21 82 A1 d F K = = = = 110 4.5 n/a 67 Maintenance switch 8-9 Dimension Drawings Discriminating Module and Maintenance switch 8-10 ECOFAST System Manual GWA 4NEB 950 5228-02 9 Order Numbers 9.1 Motor Starters (Reversing Starters) Setting Range* Motor Protection/ Switching Technology Brake Field Bus Order Number AS-Interface 3RK1323-2AS54-1AA0 AS-Interface 3RK1323-2AS54-1AA3 PROFIBUS-DP 3RK1303-2AS54-1AA0 PROFIBUS-DP 3RK1303-2AS54-1AA3 PROFIBUS-DP 3RK1303-5BS44-3AA0 PROFIBUS-DP 3RK1303-5CS44-3AA0 PROFIBUS-DP 3RK1303-5BS44-3AA3 ECOFAST Motor Starters 0.3 A - 9 A (4 kW) 0.3 A - 9 A (4 kW) Temperature sensor/ Mechanical Temperature sensor/ Mechanical 400 V AC 400 V AC ECOFAST Motor Starter High Feature 0.3 A - 3 A (1.1 kW) 2.4 A - 9 A (4 kW) 0.3 A - 3 A (1.1 kW) Thermal Motor Model/ Mechanical 2.4 A - 9 A (4 kW) 0.3 A - 3 A (1.1 kW) 2.4 A - 9 A (4 kW) 0.3 A - 3 A (1.1 kW) 400 V AC Thermal Motor Model/ Mechanical 2.4 A - 9 A (4 kW) 0.3 A - 3 A (1.1 kW) 2.4 A - 12 A (5.5 kW) 0.3 A - 3 A (1.1 kW) Full Motor Protection/ Electronic-Soft 2.4 A - 12 A (5.5 kW) 0.3 A - 3 A (1.1 kW) 2.4 A - 12 A (5.5 kW) 0.3 A - 3 A (1.1 kW) 0.6 A - 4 A (1.5 kW) PROFIBUS-DP 3RK1303-5CS44-3AA3 AS-Interface 3RK1323-5BS44-3AA0 AS-Interface 3RK1323-5CS44-3AA0 400 V AC AS-Interface 3RK1323-5BS44-3AA3 400 V AC AS-Interface 3RK1323-5CS44-3AA3 PROFIBUS-DP 3RK1303-6BS74-3AA0 PROFIBUS-DP 3RK1303-6DS74-3AA0 PROFIBUS-DP 3RK1303-6BS74-3AA3 400 V AC 400 V AC Full Motor Protection/ Electronic-Soft 2.4 A - 12 A (5.5 kW) 0.6 A - 4 A (1.5 kW) 400 V AC Full Motor Protection/ Electronic-Soft (Duo-Reversing Soft) PROFIBUS-DP 3RK1303-6DS74-3AA3 AS-Interface 3RK1323-6BS74-3AA0 AS-Interface 3RK1323-6DS74-3AA0 400 V AC AS-Interface 3RK1323-6BS74-3AA3 400 V AC AS-Interface 3RK1323-6DS74-3AA3 400 V AC AS-Interface 3RK1323-6ES84-3AA3 400 V AC PROFIBUS-DP 3RK1303-6ES84-3AA3 *) Power descriptions are valid for 400 V AC ECOFAST System Manual GWA 4NEB 950 5228-02 9-1 Order Numbers Motor Connection Cables 9.2 Motor Connection Cables Description Order No. Motor Connection Cables (not shielded) Han 10 E pin on one side to connect the motor starter with the motor (for mounting in the vicinity of the motor) - 7 x 1.5 mm2 1.5 m 3RK1911-0BG10 - 7 x 1.5 mm2 < 3 m, any length 3RK1911-0CG20 - 7 x 1.5 mm2 3.0 m - 7 x 1.5 mm2 > 3 m to < 5 m, any length - 7 x 1.5 mm2 5.0 m 3RK1911-0BG20 3RK1911-0CG30 3RK1911-0BG30 Han 10 E pin on one side to connect the motor starter with the motor (for mounting in the vicinity of the motor) - 11 x 1.5 mm2 1.5 m 3RK1911-0BJ10 - 11 x 1.5 mm2 < 3 m, any length 3RK1911-0CJ20 - 11 x 1.5 mm2 3.0 m - 11 x 1.5 mm2 > 3 m to < 5 m, any length - 11 x 1.5 mm2 5.0 m 3RK1911-0BJ20 3RK1911-0CJ30 3RK1911-0BJ30 Han 10 E on both sides to connect the motor starter with the motor (for mounting in the vicinity of the motor) - 7 x 1.5 mm2 1.5 m 3RK1911-0BH10 - 7 x 1.5 mm2 < 3 m, any length 3RK1911-0CH20 - 7 x 1.5 mm2 3.0 m - 7 x 1.5 mm2 > 3 m to < 5 m, any length - 7 x 1.5 mm2 5.0 m 3RK1911-0BH20 3RK1911-0CH30 3RK1911-0BH30 Han 10 E on both sides to connect the motor starter with the motor (for mounting in the vicinity of the motor) - 11 x 1.5 mm2 1.5 m 3RK1911-0BK10 - 11 x 1.5 mm2 < 3 m, any length 3RK1911-0CK20 - 11 x 1.5 mm2 3.0 m - 11 x 1.5 mm2 > 3 m to < 5 m, any length - 11 x 1.5 mm2 5.0 m 3RK1911-0BK20 3RK1911-0CK30 3RK1911-0BK30 Motor Connection Cables (shielded) Han 10 E pin on one side to connect the motor starter with the motor (for mounting in the vicinity of the motor) - 8 x 1.5 mm2 < 1.5 m 3RK1911-0CV10 - 8 x 1.5 mm2 1.5 m 3RK1911-0BV10 - 8 x 1.5 mm2 < 3 m, any length - 8 x 1.5 mm2 3.0 m - 8 x 1.5 mm2 > 3 m to < 5 m, any length - 8 x 1.5 mm2 5.0 m 9-2 3RK1911-0CV20 3RK1911-0BV20 3RK1911-0CV30 3RK1911-0BV30 ECOFAST System Manual GWA 4NEB 950 5228-02 Order Numbers Power Cables Description Order No. Motor Connection Cables (shielded) Han 10 E on both sides to connect the motor starter with the motor (for mounting in the vicinity of the motor) - 8 x 1.5 mm2 < 1.5 m 3RK1911-0CU10 mm2 3RK1911-0BU10 - 8 x 1.5 1.5 m - 8 x 1.5 mm2 < 3 m, any length - 8 x 1.5 mm2 3.0 m - 8 x 1.5 mm2 > 3 m to < 5 m, any length 3RK1911-0BU20 3RK1911-0CU30 5.0 m 3RK1911-0BU30 Unassembled - 8 x 1.5 mm2 20 m 3RK1911-0BW60 - 8 x 1.5 mm2 50 m 3RK1911-0BW70 - 8 x 1.5 mm2 100 m 3RK1911-0BW80 - 8 x 1.5 9.3 mm2 3RK1911-0CU20 Power Cables Description Order No. Spur cables Han Q4/2 pin/Han Q4/2 socket - 5 x 4.0 mm2 < 3 m. any length 3RK1911-0CP21 - 5 x 4.0 mm2 > 3 m to < 5 m, any length 3RK1911-0CP31 - 5 x 4.0 mm2 > 5 m to < 10, any length 3RK1911-0CP41 - 5 x 4.0 mm2 > 10 m to < 15 m, any length 3RK1911-OCP51 - 5 x 6 mm2 < 3 m, any length 3RK1911-0CP22 - 5 x 6 mm2 > 3 m to < 5 m, any length 3RK1911-0CP32 - 5 x 6 mm2 > 5 m to < 10 m, any length 3RK1911-0CP42 - 5 x 6 mm2 > 10 m to < 15m, any length 3RK1911-0CP52 ET200X sub-segment lines Han Q4/2 pin/Han Q8/0 socket - 5 x 4.0 mm2 < 3 m, any length 3RK1911-0CR21 - 5 x 4.0 mm2 > 3 m to < 5 m, any length 3RK1911-0CR31 - 5 x 4.0 mm2 > 5 m to < 10, any length 3RK1911-0CR41 - 5 x 4.0 mm2 > 1 0 m to < 15 m, any length 3RK1911-OCR51 Cut-to-length - 5 x 4.0 mm2 20 m - 5 x 4.0 mm2 50 m - 5 x 4.0 mm2 100 m mm2 3RK1911-0AG60 3RK1911-0AG70 3RK1911-0AG80 20 m 3RK1911-0AH60 - 5 x 6.0 mm2 50 m 3RK1911-0AH70 - 5 x 6.0 - 5 x 6.0 ECOFAST System Manual GWA 4NEB 950 5228-02 mm2 100 m 3RK1911-0AH80 9-3 Order Numbers Power & Control Modules (Infeed Modules) 9.4 9.5 Power & Control Modules (Infeed Modules) Description Order No. PROFIBUS S7-300 (Master) Main power supply 3 AC 400 V, 40 A Auxiliary power supply 2x DC 24 V Rotary actuator with main switch functions SIGUARD contactor safety combination Autostart Dimensions (W x H x D) in mm: 400 x 650 x 248 4FB2111-2AE01-0AA0 PROFIBUS S7-300 (Master) and AS-i-Bus (Master) Main power supply 3 AC 400 V, 40 A Auxiliary power supply 2 x DC 24 V, 1x AS-i Rotary actuator with main switch functions SIGUARD contactor safety combination Autostart Dimensions (W x H x D) in mm: 400 x 650 x 248 4FB2121-2AE01-0AA0 PROFIBUS S7-300 (Master) und AS-i-Bus (Master) Main power supply 3 AC 400 V, 25 A Auxiliary power supply 2x DC 24 V, 1x AS-i Rotary actuator with EMERGENCY STOP functions AS-i monitor for SAFETY AT WORK Dimensions (W x H x D) in mm: 400 x 650 x 248 4FB2112-2AC01-0AA0 PROFIBUS ET 200B (Slave) Main power supply 3 AC 400 V, 40 A Auxiliary power supply 2x DC 24 V Rotary actuator with main switch functions SIGUARD contactor safety combination Autostart Dimensions (W x H x D) in mm: 400 x 650 x 248 4FB2111-2AE01-0AA1 Simple Energy Unit (SEU) Description 9-4 Circuit-Breaker Contactor with Aux. Switch S00 8.00 A 3RV10 11-1HA10 3RT1015-1BB44-3MA S0 8.00 A 3RV10 21-1HA10 3RT1024-1BB44-3MA S2 16.00 A 3RV10 31-4AA10 3RT1026-1BB44-3MA0 S2 20.00 A 3RV10 31-4BA10 3RT1026-1BB44-3MA0 S2 25.00 A 3RV10 31-4DA10 3RT1034-1BB44 S2 32.00 A 3RV10 31-4EA10 3RT1034-1BB44 S2 40.00 A 3RV10 31-4FA10 3RT1035-1BB44 S2 50.00 A 3RV1031-4HA10 3RT1036-1BB44 ECOFAST System Manual GWA 4NEB 950 5228-02 Order Numbers Discriminating Modules 9.6 Discriminating Modules Description Order No. Discriminating Module * Used to selectively disconnect feeders with a repair switch function in order to protect the line in case of a change in cross-section and to increase the size of the segments. Connected to AS-Interface. - - - 9.7 9.8 for 400 V AC, 8 A for 400 V AC, 16 A for 400 V AC, 25 A 3RK1911-4AB08 3RK1911-4AB16 3RK1911-4AB25 Maintenance Switch Description Order No. Maintenance switch with M12 connector 25 A rated current 6AG1264-1GP51-6AA0 Hybrid Field Bus Cables Description Order No. PROFIBUS ECOFAST Hybrid field bus fiber-optic cable Trailing cable (PUR casing) with two plastic FO conductors for PROFIBUS-DP and four copper cores with 1.5 mm2 (DESINA-compatible) Pre-assembled with two ECOFAST connectors 1.5 m 6XV1 830-7DH15 3m 6XV1 830-7DH30 5m 6XV1830-7DH50 10 m 6XV1830-7DN10 15 m 6XV1830-7DN15 Unassembled cable 20 m 6XV1830-7CN20 50 m 6XV1830-7CN50 100 m 6XV1830-7CT10 ECOFAST System Manual GWA 4NEB 950 5228-02 9-5 Order Numbers AS-Interface Shaped Cable Description Order No. PROFIBUS ECOFAST Hybrid Cable - Copper Trailing cable (PUR casing) with two shielded copper conductors for PROFIBUS-DP and four copper cores with 1.5 mm2 Pre-assembled with two ECOFAST connectors 1.5 m 6XV1830-7BH15 3m 6XV1830-7BH30 5m 6XV1830-7BH50 10 m 6XV1830-7BN10 15 m 6XV1830-7BN15 20 m 6XV1830-7BN20 25 m 6XV1830-7BN25 30 m 6XV1830-7BN30 35 m 6XV1830-7BN35 40 m 6XV1830-7BN40 45 m 6XV1830-7BN45 50 m 6XV1830-7BN50 Unassembled cable 9.9 Cut-to-length 6XV1830-7AH10 20 m 6XV1830-7AN20 50 m 6XV1830-7AN50 100 m 6XV1830-7AT10 AS-Interface Shaped Cable Description Order No. Material Color Quantity Rubber Yellow (AS-Interface) 100 m roller 3RX9010-0AA00 1 km drum 3RX9012-0AA00 100 m roller 3RX9020-0AA00 1 km drum 3RX9022-0AA00 Black (DC 24 V) TPE Yellow (AS-Interface) Black (DC 24 V) 3RX9013-0AA00 1 km drum 3RX9014-0AA00 100 m roller 3RX9023-0AA00 1 km drum 3RX9024-0AA00 TPE Special design acc. to UL Class2 Yellow (AS-Interface) 100 m roller 3RX9017-0AA00 Black (DC 24 V) 100 m roller 3RX9027-0AA00 PUR Yellow (AS-Interface) 100 m roller 3RX9015-0AA00 1 km drum 3RX9016-0AA00 100 m roller 3RX9025-0AA00 1 km drum 3RX9026-0AA00 Black (DC 24 V) 9-6 100 m roller ECOFAST System Manual GWA 4NEB 950 5228-02 Order Numbers Hybrid Field Bus Connections 9.10 Hybrid Field Bus Connections Description Order No. Hybrid field bus connection Interface between control cabinet/infeed module (IP20) and the field IP67 Data via 2 x copper shielded/FO 2 x 24 V DC for switched/non-switched voltage Infeeding of data and 2 x 24 V into the hybrid fieldbus cable, 2 channels Hybrid field bus connection Cu/Cu, socket/socket for supply Hybrid field bus connection Cu/Cu, pin/socket conducting Hybrid field bus connection Cu//FO, socket/socket for supply (active) Hybrid field bus connection Cu/FO, pin/socket conducting (active) Hybrid field bus connection Cu/Cu, socket/socket for supply (active) Hybrid field bus connection Cu/Cu, pin/socket conducting (active) Hybrid field bus connection Cu/Cu, Fast Connect, for supply Hybrid field bus connection Cu/Cu, Fast Connect, conducting 9.11 3RK1911-1AA22 3RK1911-1AA32 3RK1911-1AB22 3RK1911-1AB32 3RK1911-1AE22 3RK1911-1AE32 3RK1911-1AF22 3RK1911-1AF32 Connectors Description Order No. Data + 24 V Data tee Connector Cu Data tee Connector FO 3RK1911-2AG00 3RK1911-2AH00 Bus terminating connector for PROFIBUS-DP, 1 piece Bus terminating connector for PROFIBUS-DP, 5 pieces 6GK1905-0DA10 6GK1905-0DA00 PROFIBUS FO plug connector FO, 5 pieces with 2x plastic FO and 4x copper conductors 1.5 mm2 with pin insert with socket insert 6GK1905-0BA00 6GK1905-0BB00 PROFIBUS copper-cable plug connector, 5 pieces with 2x shielded copper and 4x copper conductors 1.5 mm2 with pin insert with socket insert ECOFAST System Manual GWA 4NEB 950 5228-02 6GK1905-0CA00 6GK1905-0CN00 9-7 Order Numbers Connectors Description Order No. Power Power tee clamp connector (round cable adapter) for 400 V AC Used to connect feeders to any point on the power bus by means of standard round cables (insulation displacement method). 9-8 Power tee clamp connector up to 4 mm2 Power tee clamp connector up to 6 mm2 Power tee-tee clamp connector up to 6 mm2 3RK1911-2BF01 3RK1911-2BF02 3RK1911-2BG02 Seals for power tee clamp connector For power cable with O 10 to 13 mm For power cable with O 13 to 16 mm For power cable with O 16 to 19 mm For power cable with O 19 to 22 mm Filler plug 3RK1911-5BA00 3RK1911-5BA10 3RK1911-5BA20 3RK1911-5BA30 3RK1911-5BA50 Connector set Han 10E pin in thin coupling enclosure PG 16 Connector set Han 10E pin in thick coupling enclosure PG 21 Connector set Han 10E socket in thin funnel enclosure PG 16 Connector set Han 10E socket in thick funnel enclosure PG 21 3RK1911-2BK00 3RK1911-2BL00 3RK1911-2BM00 3RK1911-2BN00 Connector set Han 10E pin EMC Connector set Han 10E socket EMC 3RK1911-2BL10 3RK1911-2BN10 ECOFAST System Manual GWA 4NEB 950 5228-02 Order Numbers Project Engineering Software and Documentation 9.12 Project Engineering Software and Documentation Description Order No. Project Engineering Software ECOFAST ES * * Power bus dimensioning * Operator prompting for selection of Siemens A&D products * Norm-compliant power system design * Documentation Switch ES * 3ZS1200-0CC13-0YA0 Graphical power bus configuration 3ZS1310-0CC20-0YA0 Switch ES Motor Starter 2004 - - - - - - - * for parameterizing, visualizing, diagnosing and testing the ECOFAST motor starters via PROFIBUS-DP with online help German/English selectable tested for execution under Windows 95/98/2000/NT system System requirements: PROFIBUS-DP interface: CP5411 (ISA), CP5412 (ISA), CP5511 (PCMCIA) - P5611 (PCI), Smart Cable for serial communication via a serial interface and - Teleservice, CP5613 and CP5614 (new CP card) and MPI interface on PG7xx - and its driver software (view interactive catalog CA01) - CD-ROM drive STEP7 object manager - - - - - - for integrating the ECOFAST starter as an S7 slave in SIMATIC S7 for calling Switch ES from STEP7 System requirements: SIMATIC: S7, M7, C7, PCS7 STEP7: Version 5.0 or higher CD-ROM drive Upgrade Switch ES Motorstarter from Version 1.0 up to 2.0 3ZS1 310-0CC20-0YE0 Documentation ECOFAST Manual (German) 3RK1703-0AB18-0AA1 ECOFAST Manual (English) 3RK1703-0BB18-0AA1 ECOFAST Motor Starters Manual (German/English) 3RK1702-2GB18-0AA0 ECOFAST Motor Starters High Feature Manual (German) 3RK1702-3AB18-1AA0 ECOFAST Motor Starters High Feature Manual (English) 3RK1702-3BB18-1AA0 ECOFAST System Manual GWA 4NEB 950 5228-02 9-9 Order Numbers Tools, Connector Sets, Configuration 9.13 Tools, Connector Sets, Configuration Description Pieces per Package Order No. Crimping tool * for contact pins and sockets 1.5 to 2.5 mm2 1 * mm2 1 Disassembling tool for contact pins and sockets 1 3RK1902-0AJ00 Cover for power sockets Han Q8/0 1 3RK1902-0CK00 10 3RK1902-0CJ00 1 3RK1902-0CA00 1 3RK1902-0CB00 1 3RK1902-0CC00 1 3RK1902-0CD00 for contact pins and sockets 2.5 to 4.0 Connector set for power infeed Han Q8/0 2.5 mm2: 3RK1902-0AH00 3RK1902-0CT00 1 connector enclosure with PG 16, 1 socket insert and 9 contact sockets 2.5 mm2 Connector set for power infeed Han Q8/0 4.0 mm2: 1 connector enclosure with PG 16, 1 socket insert and 9 contact sockets 4.0 mm2 Connector set for looping through power Han Q8/0 2.5 mm2: 1 connector enclosure with PG 16, 1 pin insert and 9 contact pins 2.5 mm2 Connector set for looping through power Han Q8/0 4.0 mm2: 1 connector enclosure with PG 16, 1 1 pin insert and 9 contact pins 4.0 mm2 9-10 Mounting plate (for motor plugged in) 1 3RK1911-3AA00 Identification Plug 1 6ES7194-1KB000XA0 PC cable with memory submodule 1 3RK1911-0BN20 Test connector set 1 3RK1911-2AM00 Cable end covers for AS-Interface shaped cable 1 3RK1901-1MN00 Addressing and diagnostic unit for AS-i 1 3RK1904-2AB01 ECOFAST System Manual GWA 4NEB 950 5228-02 A Questions and Answers A.1 Frequently Asked Questions No. Question Answer 1 Is ECOFAST the DESINA system from Siemens? No. ECOFAST is based on interfaces standardized by DESINA. ECOFAST goes beyond the DESINA specification, e.g. ECOFAST also includes transmission technology for the AS-Interface. In addition, ECOFAST can optionally be supplied with special configuring software. 2 Can components from other manufacturers also be integrated in ECOFAST? Yes. ECOFAST is designed as an open system. ECOFAST is based on open bus systems (Profibus-DP, AS-Interface), and its interfaces (connections) are both standardized and open (in accordance with DESINA). Any manufacturer offering devices that comply with these specifications can thus easily be integrated in an ECOFAST system. 3 Can connectors from other manufacturers be used as well? Yes. ECOFAST is an open system with standardized interfaces. Siemens currently cooperates with Harting as a connector manufacturer and supplier regarding connection techniques. Other connectors and cables from other manufacturers can, however, also be used at any time, providing their design and their pin assignment can be adapted to the specification (DESINA). Non-Siemens products can also be integrated in ECOFAST ES. 4 Can SIMOCODE be integrated? Yes. SIMOCODE must be installed in a local switchbox. It is integrated in ECOFAST by means of the switch cabinet throughfeeds (hybrid field bus connections). If the maximum permissible current of the power bus (40 A) is exceeded, this feeder must be started separately on the power side. 5 Is ECOFAST suitable for sub-zero temperatures (outdoor applications, cold stores)? No. ECOFAST is designed for ambient temperatures between 0 and 60 degrees Celsius. 6 Can ECOFAST be used in potentially explosive areas? No. ECOFAST is not designed for use in potentially explosive areas. 7 How is the PLC integrated in ECOFAST? The power & control module can optionally be supplied with an integrated PLC for ECOFAST. The S7 315-2 DP is planned in the first stage. The PLC can, of course, also be accommodated in a conventional control cabinet. In this case it is integrated into the system by means of control cabinet throughfeeds (hybrid field bus connections). ECOFAST System Manual GWA 4NEB 950 5228-02 A-1 Questions and Answers Frequently Asked Questions A-2 No. Question 8 Are frequency conver- Yes. ters available for ECO- A frequency converter up to 1.5 kW is available for the ET 200X FAST? which can also be operated as stand-alone. Furthermore, the Combi 411 and R28S are also available. Answer 9 If ECOFAST is based on DESINA, how can it be connected to a SINUMERIK? It is connected by means of the control cabinet throughfeeds (hybrid field bus connections), i.e. the control cabinet can be factory-wired (interface to SINUMERIK) and the peripheral devices (I/Os and starter) are then connected externally. 10 If ECOFAST is based on DESINA, does this mean that it is only designed for machine tools? No. Machine tools are only one target industry. Since DESINA pursues the same objective of cutting overall costs and already has standardized interfaces, we decided to use it as a basis for ECOFAST. ECOFAST is more versatile than DESINA, however, being designed for use across industry boundaries. Conveyor systems and production machines are among our other target markets. 11 What about the safety technology interface via bus systems (Profisafe, Safety at work)? EMERGENCY STOP circuits can be connected to the power & control module. The AS-I motor for Safety at Work can also be installed in this module. Safety-oriented (two-channel) modules are required to transmit safety-oriented signals via Profibus-DP. They will be integrated depending on availability (e.g. in the ET 200X). We are unable to provide a definite date at the present time. Compatible with Safety/ Profisafe. 12 Can components with the IP20 degree of protection (e.g. SIMOCODE or ET 200S) also be integrated into ECOFAST? Yes. These components can also be connected to ECOFAST. The switchbox can be factory-wired with plug-in control cabinet throughfeeds (hybrid field bus connections). The switchbox can be factory-wired on the inside; the plug-in connections are located on the outside. Integration into the complete system is thus very straightforward. 13 How can the bus and the power supplies (24 V auxiliary voltages) be combined in the hybrid cable? The bus (PROFIBUS-DP) and the 24 V power supplies are combined by means of the hybrid field bus connections (control cabinet throughfeeds). These are available in several different versions (for copper, fiber-optic, active and passive). In other words, no additional terminal blocks are required in the control cabinet or the switchbox. 14 How can an OP be integrated for visualization purposes? OPs are normally designed with the IP20 degree of protection and are therefore installed either in a control cabinet or in a local box. They can be integrated in an ECOFAST system by means of the control cabinet throughfeeds (hybrid field bus connections). 15 How many feeders fit into one segment? Very easily. The communication and power components are simply hooked onto the PROFIBUS or the power bus. The communication components must, of course, be configured with STEP7 or COM PROFIBUS (software integration). The power components can be integrated and tested with ECOFAST ES. The wiring can be reoptimized, or the existing wiring tested and documented, taking account of the newly connected consumer. 16 How can switching devices with a higher power than ECOFAST starters (4 kW) be integrated? Switching devices of this kind can be integrated in local boxes as IP20 components by means of the control cabinet throughfeeds (hybrid field bus connections). If the maximum permissible current of the "power bus" (40 A) is exceeded, this feeder must be started separately on the power side. ECOFAST System Manual GWA 4NEB 950 5228-02 Questions and Answers Frequently Asked Questions No. Question Answer 17 Is a repair switch provided? Do the starters have a repair switch? There is a lockable repair switch on the power & control module, in other words the connected segment is disconnected. The starters themselves are not fitted with a repair switch. There is also a lockable version for the connector on the motor. The discriminating module can be used as a repair switch. A maintenance switch will be available in Autumn 2004. 18 How can a system built with ECOFAST be extended? Very easily. The communication and power components are simply hooked onto the PROFIBUS or the power bus. The communication components must, of course, be configured with STEP7 or COM PROFIBUS (software integration). The power components can be integrated and tested with ECOFAST ES. The wiring can be reoptimized, or the existing wiring tested and documented, taking account of the newly connected consumer. 19 What is the maximum power allowed for the electronic starter (soft starter)? Soft starters in output classes of up to 1.1 kW and of up to 5.5 kW can be supplied. 20 Is ECOFAST UL-listed? The individual components (devices) of ECOFAST are UL-listed. As far as ECOFAST's UL listing as a complete system is concerned, we are still negotiating with the responsible bodies, because the handling of acceptances and certifications for complete systems varies considerably from one system to another. Importance is attached, for instance, to the definition of a self-contained unit (complete machine or system?). The same applies to the cable laying types (the cables do not necessarily have to be "piped" in self-contained units), for example in concatenated units. 21 Is a metal version of the connectors also available? Only molded-plastic versions of the bus and power connectors are available at present. Metal versions of motor feeder connectors are also available (for FUs, due to shielded motor line). Metal versions of the plug cases can be requested from Harting. 22 What is the situation regarding Ethernet communication? The ECOFAST communication philosophy is based on Profibus-DP and AS-Interface. With regard to Ethernet, a considerable amount of work still needs to be invested in industry-standard connection methods. The ECOFAST devices, such as ECOFAST starters, have a modular internal set-up, so that additional bus interfaces can be implemented easily as and when necessary (which is not the case with Ethernet). 23 Is it true that ECOFAST starters compete with the starters of the ET 200X? No. Different ECOFAST solutions are offered intentionally to facilitate maximum adaptability to each particular application. The following solutions are possible: 24 ECOFAST System Manual GWA 4NEB 950 5228-02 Is ECOFAST very expensive? * Standalone starters (1 starter = 1 bus station) for branch drives * Isolated solutions (ET 200X) for drives that are physically close together * Installation near the motor * Integration in the motor (starter on motor) Although the connector technique is slightly more expensive than simple terminals, it is important to consider the overall costs of ECOFAST, namely both material and installation costs. The potential savings concern the costs of installation and servicing. A-3 Questions and Answers Frequently Asked Questions A-4 ECOFAST System Manual GWA 4NEB 950 5228-02 B ECOFAST Pilot Projects B.1 Production Line for SIRIUS 2 - Siemens Cham Production planning Location: Siemens Cham Application: Production line for SIRIUS 3RT contactors Task: Conveyor system with 5 autonomous cells for screwing, testing, inscribing and repairing Set-up: Power & control module with S7-300 PLC, PROFIBUS-DP and AS-i. Total of 21 motor starters for 0.18 and 0.3 kW motors Objective: To replace central drive systems with distributed peripheral devices in an installation system with diagnostics-capable motor starters and preassembled connections. Power & Power & Control ControlModul Module PROFIBUS-DP ECOFAST Hybrid Cable PROFIBUS-DP ECOFAST Hybrid Kabel Energieleitung Power cable Conveyor section 1 Fig. B-1: ECOFAST System Manual GWA 4NEB 950 5228-02 Conveyor section22 Conveyor section33 Conveyor section Bandstrecke Bandstrecke Bandstrecke 4 4 SIRIUS 2 pilot system - production B-1 Configuration with ECOFAST ES Fig. B-2: SIRIUS 2 pilot system - configuration with ECOFAST ES ECOFAST System Manual GWA 4NEB 950 5228-02 B-2 Production Fig. B-3: ECOFAST System Manual GWA 4NEB 950 5228-02 SIRIUS 2 pilot system - production B-3 B.2 Configuration in the Automotive Industry - Production Planning Production planning Application: Production of wheel hubs Task: Conveyor system with 4 cells Set-up: Power & control module with S7-300 PLC, PROFIBUS-DP, AS-interface and AS-interface monitor (Safety at Work) Total of 6 motor starters for motors with 0.55 KW Objective: To replace centrally controlled drive technology with a distributed installation system. To integrate pneumatics and EMERGENCY STOP functionality in a single system technology. ECOFAST System Manual GWA 4NEB 950 5228-02 B-4 Configuration with ECOFAST ES Fig. B-4: ECOFAST System Manual GWA 4NEB 950 5228-02 Configuration with ECOFAST ES B-5 ECOFAST System Manual GWA 4NEB 950 5228-02 B-6 Glossary 3-phase AC current for contactor The 3-phase AC current for the contactor is the rated operational current for switch off during the operation of the squirrel-cage motors. Baud rate The baud rate is the rate of data transmission and indicates the number of bits transmitted per second (baud rate = bit rate). Baud rates of 9.6 kilobaud to 12 megabaud are possible with PROFIBUS-DP Bus Common transmission path via which all stations are connected. It has two defined ends. With PROFIBUS, the bus is a two-wire line (copper wire) or a fiber-optic cable. Bus segment See Segment Bus system The bus system comprises all the stations that are physically connected via a bus cable. Current limit You can set an upper and/or a lower current limit. Example: "Substance for mixing too thick", that is, the upper current limit has been exceeded. "No-load operation because drive belt is torn", that is, the lower current limit has been undershot. The current limits and the block protection are not activated in order to bypass start-up until the class time has elapsed (e.g. after 10 seconds for class 10). If the current limits are violated, the motor starter responds with either a shutdown or warning. Setting range for lower current limit: 20%..0.100% of the rated operational current. Setting range for upper current limit: 50%...150% of the rated operational current. Data tee connectors Data tee connectors connect the components of an automation system with PROFIBUS-DP. Two data tee connectors are available in the ECOFAST system: * With copper cable (PROFIBUS-DP Cu) * With fiber-optic cable (PROFIBUS-DP fiber-optic cable) DESINA Decentralized and standardized installation system for machine tools: Developed by the Association of Machine Tool Manufacturers with the aim of defining a standard for the design and installation of machine tool components. DMD Device master data (DMD) contains DP slave descriptions in a standardized format. The use of DMD makes configuring the master and the DP slave easier. DP master The DP master is a master that functions in accordance with EN 50 170, Volume 2, PROFIBUS, and uses the DP protocol. DP slave The DP slave is a slave that is operated on the PROFIBUS bus with the PROFIBUS-DP protocol and functions in accordance with EN 50 170 standard, Volume 2, PROFIBUS. DP standard The DP standard is the bus protocol of the ET 200 distributed I/O system based on the EN 50 170 standard, Volume 2, PROFIBUS. ECOFAST Energy and Communication Field Installation System: A system that decentralizes and modularizes installation to a large extent and permits extensive diagnostics on the component level. ECOFAST System Manual GWA 4NEB 950 5228-02 1 ECOFAST certified Confirms that devices from different manufacturers are compatible with ECOFAST specifications. ECOFAST ES The ECOFAST ES configuration tool supports power-engineering system design. ECOFAST integrated In addition to Siemens components, devices from other manufacturers can be integrated in this configuration tool. Their integration and conformity is confirmed by the "ECOFAST integrated" certificate. Host A host is a system or unit that contains at least one DP Master. For example, the programmable controller with the CPU is the host, and the IM 308-C is the DP master. Hybrid field bus connector The hybrid field bus connector is the physical connection between the station and the bus cable. IM 308-C The IM 308-C is a DP master for the ET 200 distributed I/O system. The IM 308-C can be used together with COM PROFIBUS and plugged into the S5-115U, S5-135U and S5-155U programmable controllers. IrDA Infrared Data Association: standard for an infrared interface driver. Load feeder A load feeder is a branch from the main circuit to the load with "Switching" and "Protection" functions. The "Protection" function comprises: * Protection of the line from the load feeder to the load (line protection), * Protection of the load against overloading (load protection). Master When they are in possession of the token, masters can send data to other stations and request data from these stations (= active station). Master interface Module for a distributed configuration. The distributed inputs and outputs are "connected" to the programmable controller via the master interface C. Master system All slaves that are assigned to a master with a reading and writing function form a master system together with the master. Master-slave method A bus access method whereby only one station at a time is the master and all other stations are slaves. Power bus Linear, primary power distribution bus. Power tee clamp connnector Power tee clamp connectors connect ECOFAST components to the power bus. The power bus is not interrupted when the ECOFAST component is unplugged. Process image An "image" of the states of all inputs (= PII) or all outputs (= PIO) at a particular instant in time. You can access the process image in the controller program. PROFIBUS PROcess FIeld BUS, European process and fieldbus standard which is defined in the PROFIBUS standard (EN 50 170, Volume 2, PROFIBUS). It specifies functional, electrical and mechanical properties for a one-bit, serial fieldbus system. PROFIBUS is a bus system which networks PROFIBUS-compatible automation systems and field devices at the cell and field levels. PROFIBUS is available with the following protocols: DP (= Distributed Input/Output), FMS (= Fieldbus Message Specification), PA (Process Automation) and TF (= Technological Functions). PROFIBUS address Each station must be assigned a PROFIBUS address for the purpose of unique identification. The PC/PU or the ET 200 hand-held unit have the PROFIBUS address "0". The master and slaves have a PROFIBUS address within the range from 1 to 125. 2 ECOFAST System Manual GWA 4NEB 950 5228-02 PROFIBUS-DP PROFIBUS bus system with the DP protocol. DP stands for distributed I/O system. The primary task of PROFIBUS-DP is fast cyclical exchange of data between the central DP Master and the peripheral devices. Segment The bus line between two terminating resistors forms a segment. A segment contains 0 to 32 stations. Segments can be coupled via RS 485 repeaters. Slave A slave can only exchange data with a master after being requested to do so by the master. Slaves include, for example, all DP slaves, such as motor starters, frequency converters, etc. Station A station is a device that can send, receive, or amplify data via the bus (e.g. a master, a slave, an RS 485 repeater, or an active star coupler). Station number See PROFIBUS address. Terminating resistor Each bus line connecting the individual motor starters to each other must be terminated with a resistor at the beginning and end. This prevents line reflections. ECOFAST System Manual GWA 4NEB 950 5228-02 3 4 ECOFAST System Manual GWA 4NEB 950 5228-02 To: Sender (please fill out) SIEMENS AG Name A&D CD MM3 P.O. Box 1954 Company/Department 92220 Amberg Address Fax: **49-9621-80-3337 Telephone ECOFAST System Manual Have you found any typographical errors while reading this manual? Please use this form to tell us about them. We would also welcome any ideas and suggestions you may have. ECOFAST System Manual GWA 4NEB 950 5228-02 ECOFAST System Manual GWA 4NEB 950 5228-02 Siemens Aktiengesellschaft Automation and Drives Low Voltage Controls and Distribution Postfach 48 48 D-90327 Nurnberg www.siemens.de/ecofast Order No. 3RK1703-0BB18-0AA1