3RK1902-0CB00 - SIEMENS - Product.Network

ecofast

ECOFAST System Manual 11/2004

System

ECOFAST

Manual

Order Number

3RK1703-0BB18-0AA1

Edition 11/2004

GWA 4NEB 950 5228-02

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

Glossary

Safety Guidelines

This manual contains notices which you should observe to ensure your own personal safety as well as to avoid prop-

erty 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.

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 prop-

erty damage.

Qualified Personnel

The device/system may only be set up and operated in conjunction with this documentation. Only qualified person-

nel should be allowed to install and work on the equipment. Qualified persons are defined as persons who are au-

thorized to commission, ground and tag circuits, equipment and systems in accordance with established safety

practices and standards.

Intended Use

Please note the following:

Trademarks

All designations marked with ® 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 propri-

etors.

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.

Warning

This device and its components may only be used for the applications described in the catalog or technical descrip-

tion, 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 ope-

rated and maintained as recommended.

The reproduction, transmission or use of this document or its contents is not permitted wit-

hout 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.

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 agree-

ment. However, the data in this manual are reviewed regularely and any necessary correc-

tions included in subsequent editions. Suggestions for improvement are welcomed.

Siemens AG

Automation and Drives

Postfach 4848, D-90327 Nürnberg

Subject to change without prior notice

Siemens Aktiengesellschaft

ECOFAST System Manual

GWA 4NEB 950 5228-02 iii

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

Specifications

This manual only describes shared components of the ECOFAST system.

Notice

Important information requiring particular attention is enclosed between two horizontal lines.

ECOFAST System Manual

iv GWA 4NEB 950 5228-02

Service and Support

Technical Assistance: Telephone: +49 (0) 911-895-5900 (8:00 - 17:00 CET)

Fax: +49 (0) 911-895-5907

E-mail: technical-assistance@siemens.com

Internet: www.siemens.de/lowvoltage/technical-assistance

Technical Support: 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.

ECOFAST System Manual
GWA 4NEB 950 5228-02 v
Contents
Introduction and Notes on Using the Manual..................................................................................................  iii
ECOFAST System Description  ............................................................................................................. 1-1
1 Philosophy of the ECOFAST System .......................................................................................  1-1
1.1 Requirements Specified for Innovative Automation and Drive Systems  .................................. 1-2
1.2 Desina and Field Bus Certificates  ............................................................................................ 1-3
1.3 ECOFAST certified and ECOFAST integrated  ......................................................................... 1-3
2 ECOFAST ES Software............................................................................................................  1-4
3 The ECOFAST Basic System...................................................................................................  1-4
3.1 Topology of the Network ........................................................................................................... 1-5
3.2 Overview of Interfaces .............................................................................................................. 1-6
Product Family  ....................................................................................................................................... 2-7
1 Power & Control Module (PCM) ...............................................................................................  2-7
1.1 Tasks of the Power & Control Module (PCM) ........................................................................... 2-7
1.2 Device Versions ........................................................................................................................ 2-8
1.3 PCM Order Numbers ................................................................................................................ 2-9
2 Alternative Power Supply .......................................................................................................  2-10
2.1 Simple Energy Unit (SEU)  ...................................................................................................... 2-10
2.2 ET 200S Motor Starter ............................................................................................................ 2-12
3 Power Tee Clamp Connector .................................................................................................  2-13
4 Hybrid Field Bus Connections ................................................................................................  2-15
5 Data Tee Plug Connector .......................................................................................................  2-17
6 Discriminating Module and Maintenance Switch ....................................................................  2-18
6.1 Discriminating Module  ............................................................................................................ 2-18
6.2 Maintenance Switch with M12 Connector  .............................................................................. 2-19
Installation Guidelines ......................................................................................................................... 3-21
1 Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable ..............  3-21
2 Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable 
(Fiber-optic Conductors).........................................................................................................  3-22
3 Guidelines for PROFIBUS-DP Standard Cables ....................................................................  3-24
3.1 Potential Equalization  ............................................................................................................. 3-24
3.2 Cable Shielding  ...................................................................................................................... 3-25
4 PNO Installation Guidelines....................................................................................................  3-27
5 Power Bus Installation Versions .............................................................................................  3-28
5.1 Unassembled set-up with power tee clamp connector and power cable ................................ 3-28
5.2 Connecting Consumers with a Spur Cable ............................................................................. 3-29
5.3 ET 200X Sub-Segmente with EM 300 Motor Starter .............................................................. 3-30
5.4 Possible Power Distribution with Discriminating Modules  ...................................................... 3-32

ECOFAST System Manual
vi GWA 4NEB 950 5228-02
5.5 Line Protection in Power Bus Segment for Motor Starters Without Thermal Motor Model 
(Installation in the Vicinity of the Motor) .................................................................................. 3-33
6 Installation Versions for Switching Devices and Control Circuit Devices................................  3-35
Installation .............................................................................................................................................. 4-1
1 Power & Control Module...........................................................................................................  4-1
1.1 Installation of the IP65 Version ................................................................................................. 4-1
1.2 Installation of the Cabinet Installation Version (IP00) ............................................................... 4-2
2 Alternative Power supply ..........................................................................................................  4-3
2.1 Simple Energy Unit (SEU)  ........................................................................................................ 4-3
2.2 ET 200S Motor Starter .............................................................................................................. 4-3
3 Power Tee Clamp Connector ...................................................................................................  4-4
4 Hybrid Field Bus Connections ..................................................................................................  4-5
5 Discriminating Module and Maintenance Switch ......................................................................  4-6
5.1 Discriminating Module  .............................................................................................................. 4-6
5.2 Maintenance Switch .................................................................................................................. 4-7
Connections ........................................................................................................................................... 5-1
1 Power & Control Module...........................................................................................................  5-1
1.1 Connections of the IP65 Version  .............................................................................................. 5-1
1.2 Connections of the Cabinet Installation Version ....................................................................... 5-3
2 Alternative Power Supply..........................................................................................................  5-6
2.1 Connections of the Simple Energy Unit (SEU)  ......................................................................... 5-6
2.2 ET 200S Motor Starter .............................................................................................................. 5-6
3 Power Tee Clamp Connector ...................................................................................................  5-7
4 Hybrid Field Bus Connections ..................................................................................................  5-8
5 Data Tee Plug Connector .......................................................................................................  5-14
5.1 Pin Assignment ....................................................................................................................... 5-14
6 Discriminating Module and Maintenance Switch ....................................................................  5-15
7 General Wiring and Interfaces................................................................................................  5-16
7.1 Rules for Wiring  ...................................................................................................................... 5-16
7.2 Power Cables, Preassembled at One End  ............................................................................. 5-17
7.3 AS-i Interface .......................................................................................................................... 5-21
Commissioning ...................................................................................................................................... 6-1
1 Power & Control Module...........................................................................................................  6-1
1.1 Diagnostics ............................................................................................................................... 6-2
2 Alternative Power Supply..........................................................................................................  6-3
2.1 Simple Energy Unit (SEU)  ........................................................................................................ 6-3
2.2 ET 200S motor starter  .............................................................................................................. 6-3
3 Hybrid Field Bus Connections ..................................................................................................  6-4
3.1 Passive Hybrid Field Bus Connection for Supply  ..................................................................... 6-5
3.2 Passive Hybrid Field Bus Connection for Conducting  .............................................................. 6-6
3.3 Active Hybrid Field Bus Connection for Supply  ........................................................................ 6-7

ECOFAST System Manual
GWA 4NEB 950 5228-02 vii
3.4 Active Hybrid Field Bus Connection for Conducting ................................................................. 6-8
3.5 Cascading of the Active Hybrid Field Bus Connections  ........................................................... 6-9
3.6 Power Supply of the Bus Terminating Connector ..................................................................... 6-9
3.7 Active Hybrid Field Bus Connection for Supply ...................................................................... 6-10
3.8 Active Hybrid Field Bus Connection for Supply ...................................................................... 6-11
3.9 Conveyor Section With Hybrid Field Bus Connections for Supply and Conducting  ............... 6-12
3.10 Installation System with PROFIBUS-DP - Cu ......................................................................... 6-13
3.11 PROFIBUS-DP – Fiber-optic Cable ........................................................................................ 6-14
3.12 PROFIBUS-DP (Cu) and Passive Hybrid Field Bus Connections with 2 Separate 
Power Supplies ....................................................................................................................... 6-15
3.13 PROFIBUS-DP (Cu) and Active Hybrid Field Bus Connections with 2 Separate 
Power Supplies ....................................................................................................................... 6-16
3.14 PROFIBUS-DP CU and Active Hybrid Field Bus Connections with 2 Separate 
Data Supplies  ......................................................................................................................... 6-17
4 Discriminating Module and Maintenance Switch ....................................................................  6-18
Technical Data ........................................................................................................................................ 7-1
1 Power & Control Module...........................................................................................................  7-1
1.1 IP65 Version  ............................................................................................................................. 7-1
1.2 IP00 Version (Control Cabinet Version)  ................................................................................... 7-4
2 Alternative Power Supplies.......................................................................................................  7-6
2.1 Simple Energy Unit (SEU)  ........................................................................................................ 7-6
2.2 ET 200S Motor Starter .............................................................................................................. 7-6
3 Hybrid Field Bus Connections ..................................................................................................  7-7
4 Data Tee Plug Connector .........................................................................................................  7-8
5 Discriminating Module ............................................................................................................  7-10
Dimension Drawings  ............................................................................................................................. 8-1
1 Power & Control Module...........................................................................................................  8-1
1.1 IP65 Version  ............................................................................................................................. 8-1
1.2 IP00 Version (Control Cabinet Version)  ................................................................................... 8-2
2 Alternative Power Supplies.......................................................................................................  8-3
2.1 Simple Energy Unit (SEU)  ........................................................................................................ 8-3
2.2 ET 200S Motor Starter .............................................................................................................. 8-5
3 Power Tee Clamp Connector ...................................................................................................  8-6
4 Hybrid Field Bus Connections ..................................................................................................  8-7
5 Data Tee Plug Connector .........................................................................................................  8-8
6 Discriminating Module and Maintenance switch.......................................................................  8-9
Order Numbers ....................................................................................................................................... 9-1
1 Motor Starters (Reversing Starters).......................................................................................... 9-1
2 Motor Connection Cables .........................................................................................................  9-2
3 Power Cables ...........................................................................................................................  9-3
4 Power & Control Modules (Infeed Modules).............................................................................  9-4

ECOFAST System Manual
viii GWA 4NEB 950 5228-02
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
A Questions and Answers  ........................................................................................................................A-1
A.1 Frequently Asked Questions..................................................................................................... A-1
B 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

ECOFAST System Manual
GWA 4NEB 950 5228-02 ix
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

xGWA 4NEB 950 5228-02

ECOFAST System Manual

GWA 4NEB 950 5228-02 1-1

ECOFAST System Description 1

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 stan-

dards whenever machines and plants need to be equipped with automation, control & distri-

bution 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 con-

nection 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.

Fig. 1-1: Typical components of an automation system

ELMO pump

SIMATIC S7

COMBIMASTER -

Motor/converter unit ELMO-G side-channel compressor

ECOFAST -

Motor/starter unit

SIMATIC ET200X -

Components

ECOFAST System Description

Philosophy of the ECOFAST System

ECOFAST System Manual

1-2 GWA 4NEB 950 5228-02

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

• 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 1-3

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

• 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)

1.1.3 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 com-

patible 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 inte-

grated” certificate.

ECOFAST System Description

ECOFAST ES Software

ECOFAST System Manual

1-4 GWA 4NEB 950 5228-02

1.2 ECOFAST ES Software

The ECOFAST ES configuration tool supports power-engineering system design with the fol-

lowing 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

Fig. 1-4: The ECOFAST basic system

Operator control

and monitoring

e. g. OP 27

Motor starter

motor

plugged in

IP20 component

e. g.

SIMOCODE-DP

Power & Control

module (PCM)

ET 200X

COMBIMASTER

MM 411

Engineering software

ECOFAST ES

ECOFAST System Manual

GWA 4NEB 950 5228-02 1-5

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:

Fig. 1-5: 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.

Motor

starter

Infeed

Cable types

1 Power

2 Spur

3 Motor

4 Motor (freq. converter)

5 ET200 sub-segment

6 ET200 power

7 ET200 motor

Assembly type

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

Motor

starter

Motor

starter Motor

starter

Frequ.

conv. Discr.

mod.

Discr.

mod.

ECOFAST System Description

The ECOFAST Basic System

ECOFAST System Manual

1-6 GWA 4NEB 950 5228-02

1.3.2 Overview of Interfaces

Diagram

The diagram below shows an overview of the system interfaces using the example of a motor

starter:

Fig. 1-6: Overview of Interfaces

Field Bus Interfaces

ECOFAST components feature the following field bus interfaces, depending on the device

version:

Fig. 1-7: Field bus interfaces

*3RK1303-2AS54-.... motor starters only

Motor connector Digital inputs Data tee connector

Data connector

Motor terminal

Data terminal

Power connection Power tee connector

Local device interface*

Hybrid field bus

cable

Local

device

interface

Power cable

PROFIBUS-DP PROFIBUS-DP interface

with data terminal,

data tee connector,

data connector optionally for

copper cable (Cu)

or fiber-optic cable

AS-i interface

with insulation displacement technology

for yellow AS-i line (data and 24 V non-

switched) and black AS-i line (AUX PWR:

24 V DC switched)

AS-i

AUX PWR

AS-Interface

ECOFAST System Manual

GWA 4NEB 950 5228-02 2-1

Product Family 2

2.1 Power & Control Module (PCM)

2.1.1 Tasks of the Power & Control Module (PCM)

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

Product Family

Power & Control Module (PCM)

ECOFAST System Manual

2-2 GWA 4NEB 950 5228-02

2.1.2 Device Versions

The PCM is available in a housing version with degree of protection IP65 and for control cab-

inet 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 avail-

able 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: Power & Control Modules (PCM) IP65 and IP00

ECOFAST System Manual

GWA 4NEB 950 5228-02 2-3

Product Family

Power & Control Module (PCM)

2.1.3 PCM Order Numbers

Power and Control Module (PCM), version IP65 Order no.

Housing dimensions (W x H x D):

Overall dimensions w/o external connector (W x H x D):

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)

4FB2 111- 2 A ..1-0AA0

PROFIBUS master with S7-300 CPU

313C-2 DP + AS-i master with AS-i

power supply 2.4 A

4FB2 121-2A ..1-0AA0

AS-Interface

Safety at Work

4FB2 112-2A ..1-0AA0

SITOP DC 24 V,

10 A (NS), 10 A (S)

4FB2 112-2A ..2-0AA0

PROFIBUS slave with ET 200M SIGUARD

safety contactor

combination

SIDAC DC 24 V,

10 A (NS), 10 A (S)

4FB2 111- 2 A ..1-0AA1

SITOP DC 24 V,

10 A (NS), 10 A (S)

4FB2 111- 2 A ..2-0AA1

Power and Control Module (PCM), control cabinet mounting

Housing dimensions (W x H x D):

Overall dimensions w/o external connector (W x H x D):

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)

4FB2 111-2A ..1-0AA2

PROFIBUS master with S7-300 CPU

313C-2 DP + AS-i master with AS-i

power supply 2.4 A

4FB2 121-2A ..1-0AA1

AS-Interface

Safety at Work

4FB2 112-2A ..1-0AA1

SITOP DC 24 V,

10 A (NS), 10 A (S)

4FB2 112-2A ..2-0AA1

PROFIBUS slave mit ET 200M SIGUARD

safety contactor

combination

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

Main power supply Breaking capacity 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.

Product Family

Alternative Power Supply

ECOFAST System Manual

2-4 GWA 4NEB 950 5228-02

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 auto-

mation 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 through-

feeds 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.

Fig. 2-2: Simple Energy Unit (SEU)

Circuit-breaker

Contactor

EMERGENCY STOP

ECOFAST System Manual

GWA 4NEB 950 5228-02 2-5

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

Type

Circuit-breaker Contactor with

Auxiliary Switch

Type of coordination/Short-

Circuit Breaking Capacity

Order No. IN [A]

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: Device versions: Simple Energy Unit

Product Family

Alternative Power Supply

ECOFAST System Manual

2-6 GWA 4NEB 950 5228-02

2.2.2 ET 200S Motor Starter

For applications with an external 24 V auxiliary power supply or which require a different auto-

mation 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 trans-

mitted via profi bus for automation.

Fig. 2-3: Overview: ET 200S as incoming supply

IM 151

F-Kit 1

A2A1 A3

TM-PF30 S47-B1

PM-X

TM-X15S27-01

Power module motor starter

Terminal

module

400 V Power bus 400 V

EMERGENCY

STOP

PM-D

ECOFAST System Manual

GWA 4NEB 950 5228-02 2-7

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 sec-

ond 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:

Seals for Power Tee Clamp Connectors

Suitable seal sets are required for the power tee clamping connectors to attain degree of pro-

tection IP65/67. A seal set contains two seals, which are available with different internal diam-

eters 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 sep-

arately.

The following sealing sets 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

Order No. Round cable/mm ø

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: Sealing sets for power tee clamp connectors

Product Family

Power Tee Clamp Connector

ECOFAST System Manual

2-8 GWA 4NEB 950 5228-02

Design

Fig. 2-4: Power tee/tee-tee clamp connector

Fixing lug

Power tee clamp connector (cover open)

Terminal block with clamping screws

Sealing for round cable

or filler plug*)

Sealing for round cable

or filler plug*)

Cover

Power tee clamp connector

Han Q4/2-socket

to the load e. g. motor starter

*) not supplied

Sealing for round cable

or filler plug*)

Sealing for round cable

or filler plug*)

Cover

Fixing lug

Power tee-tee clamp connector

Han Q4/2-sockets

to the load e. g. motor starter

Deckelbefestigungslasche

ECOFAST System Manual

GWA 4NEB 950 5228-02 2-9

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.

Fig. 2-5: Hybrid field bus connections

3RK1911-1AB32

IP65 side (field bus level, external) IP20 side (in control cabinet)

Example:

Conducting:

fiber-optic cable

Notice

Please observe the set-up recommendations for PROFIBUS-DP (see chapter 3.2).

Product Family

Hybrid Field Bus Connections

ECOFAST System Manual

2-10 GWA 4NEB 950 5228-02

Versions

The following versions are currently available:

Passive and active

• Passive means that the signals are not regenerated. The IP20 and IP65 sides are electri-

cally 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

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) A/B terminals

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) Fast-Connect

Table 2-5: Hybrid field bus connection versions

ECOFAST System Manual

GWA 4NEB 950 5228-02 2-11

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: Data tee plug connector

Product Family

Discriminating Module and Maintenance Switch

ECOFAST System Manual

2-12 GWA 4NEB 950 5228-02

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

Fig. 2-7: Set-up of the discriminating module

Han Q4/2 socket

Han Q4/2 pin

M12 connector

Check-back contact

M12 connector

Check-back contact

ECOFAST System Manual

GWA 4NEB 950 5228-02 2-13

Product Family

Discriminating Module and Maintenance Switch

Device versions

Discriminating modules are available in three different device versions:

2.6.2 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 Ölflex 110H

cable and an HAN Q4/2 socket. The switching status can be checked via the built-in M12 con-

nector (pin) (DESINA Spec_11).

Maintenance switch with M12 connector, rated current 25 A:

6AG1264-1GP51-6AA0

Fig. 2-8: Maintenance switch with M 12 connector (pin) for check-back

Device version Current Order No.

1 25 A 3RK1911-4AB25

2 16 A 3RK1911-4AB16

3 8 A 3RK1911-4AB08

Table 2-6: Discriminating module versions

Product Family

Discriminating Module and Maintenance Switch

ECOFAST System Manual

2-14 GWA 4NEB 950 5228-02

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-1

Installation Guidelines 3

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.

Fig. 3-1: Set-up of a bus segments with RS 485

Power & Control Module (P&CM) with

Terminating resistor, connected internally

ECOFAST hybrid field bus cable Bus terminating connector

Data tee plug

Station 1

Station 2 Station 3 Station 4 Station 32

Station 33 Station 34 Station 35 Station 64

2 x 24 V DC

Screw cap

Power cable

Segment 1

Segment 2

- PLC

- 2 x 24 V DC Supply

- 400 V AC main power supply

or segment 2!

segment 2

3/PE-50/60 Hz;

400 V AC connector

2 x 24 V DC and data

Installation Guidelines

Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable (Fiber-optic Conductors)

ECOFAST System Manual

3-2 GWA 4NEB 950 5228-02

Key data of a bus segment

The maximum line length of a bus segment depends on the baud rate that is used:

3.2 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 distur-

bance fields must not be allowed to interfere with data traffic on the bus, you should use fiber-

optic 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

Baud rate Max. line length of a segment [m]

9.6 to 187.5 kBaud 1000

500 kBaud 400

1.5 MBaud 200

3 to 12 MBaud 100

Table 3-1: Permissible line length of a bus segment based on the baud rate

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-3

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 sta-

tions 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.

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 neigh-

boring 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.

Power & Control Moduel (P&CM) with

ECOFAST Hybrid field bus cable Bus terminating connector

Data tee plug

Station 1

Station 2 Station 3 Station 4 Station 32

Station 33 Station 34 Station 35 Station 64

2 x 24 V DC

Screw cap

Power cable

Segment 1

Segment 2

3~ - PLC

- 2 x 24 V DC supply

- 400 V AC main power supply

segment 2

3/PE-50/60 Hz;

400 V AC

2 x 24 V DC and data

connector

Fiber-optic cable Max. line length

between 2 stations [m]

Projection to 1 network

(= 32 stations) [m]

ECOFAST

hybrid field bus cable

50 1550

Table 3-2: Permissible line lengths in the optical PROFIBUS-DP network

Installation Guidelines

Guidelines for PROFIBUS-DP Standard Cables

ECOFAST System Manual

3-4 GWA 4NEB 950 5228-02

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,

• 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 connec-

ted at both ends to ground/protective conductors, it is important to ensure that the impe-

dance 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.

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-5

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 inter-

ference 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 low-

ohmic connection to the protective conductor, as otherwise the interference currents themsel-

ves 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 low-

frequency 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/protec-

tive 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.

Installation Guidelines

Guidelines for PROFIBUS-DP Standard Cables

ECOFAST System Manual

3-6 GWA 4NEB 950 5228-02

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: Securing shielded cables with cable clamps and cable ties (schematic diagram)

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-7

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-Nut-

zerorganistation (user organization) when using electrical networks. They describe important

measures to be taken as regards the wiring, cabling and commissioning of PROFIBUS net-

works.

Publisher

PROFIBUS-Nutzerorganisation e. V.

Haid-und-Neu-Straße 7

76131 Karlsruhe, Germany

Tel: ++49(0) 721 / 9658 590

Fax: ++49(0) 721 / 9658 589

Internet: http//www.profibus.com

Guideline order number: 2.111

Installation Guidelines

Power Bus Installation Versions

ECOFAST System Manual

3-8 GWA 4NEB 950 5228-02

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 accor-

dance with requirements.

• The power tee clamp connector can be connected at any point.

Diagram

Fig. 3-4: Set- up with power tee clamp connector

Connector with

socket insert

PCM/SEU/ET 200S

Supply

Main power Power tee clamp connector with

Han Q4/2 socket for consumer

Power cable

(cut to length)

Possible components:

Power cable Power tee clamp connector

Connector set

with pin insert

to connect PCM

Connector set

with socket insert

to connect the

final consumer

(cut to length)

Passende Dichtungssätze

alternatively: Power tee clamp connector

+ fillet plug

Power tee-tee clamp connector with

Han Q4/2 socket for consumer

Spur cable

Starter

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-9

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 con-

nector.

The spur cable can be ordered preassembled.

Diagram

Fig. 3-5: Set-up of sub-segment

Power tee clamp connector

with Han Q4/2 socket

Spur cable

preassembled

Installation Guidelines

Power Bus Installation Versions

ECOFAST System Manual

3-10 GWA 4NEB 950 5228-02

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

Fig. 3-6: Set-up of sub-segment

Power tee clamp connector

with Han Q4/2 socket

ET 200X

EM 300 EM 300 EM 148-FC

sub-segment cable

preassembled

Power bus

(Han Q4/2 – Han Q8/0)

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.

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-11

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 follo-

wing 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 sub-

segment.

• 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 sub-

segment 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.

Installation Guidelines

Power Bus Installation Versions

ECOFAST System Manual

3-12 GWA 4NEB 950 5228-02

3.5.4 Possible Power Distribution with Discriminating Modules

Diagram

The diagram below shows the possible power distribution arrangements with discriminating

modules:

Fig. 3-7: 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 ECO-

FAST 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.

4. ECOFAST consumer decoupled via discriminating module in the power bus segment

backbone.

Power cable

3/PE-50/60 Hz

400 V AC

ECOFAST

consumer

ECOFAST

consumer ECOFAST

consumer

Discriminating

Input:

Han Q4/2 pin

Output:

Han Q4/2 socket

12 3

Spur cable

module

Notice

The discriminating module cannot be connected without a cable if ECOFAST motor starters

are operated with the PROFIBUS-DP field bus.

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-13

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:

Fig. 3-8: Line protection for motor starters without thermal motor model

Power Cable

3/PE-50/60 Hz

400 V AC

Discriminating module

Motor starter

Motor supply lead

Motor

Motor protection:

Temperature sensor

thermal Motor model

full Motor protection

PCM

Supply

Mail power

Motor starter

Motor supply lead

Motor

Motor protection:

Temperature sensor

thermal Motor model

full Motor protection

Variant A

Variant B

Installation Guidelines

Power Bus Installation Versions

ECOFAST System Manual

3-14 GWA 4NEB 950 5228-02

Example

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 cur-

rent 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 3-15

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.

Installation Guidelines

Installation Versions for Switching Devices and Control Circuit Devices

ECOFAST System Manual

3-16 GWA 4NEB 950 5228-02

Switching device, plugged in (only motor starters, soft starters)

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)

Fig. 3-10: Switching device in the vicinity of the motor (only motor starters, soft starters)

Switching device with

plugged in

power tee clamp connector

Switching device with

displaced

power tee clamp connector

(spur cable)

Switching device with

plugged in

power tee clamp connector

Switching device with

displaced

power tee clamp connector

(spur cable)

ECOFAST System Manual

GWA 4NEB 950 5228-02 3-17

Installation Guidelines

Installation Versions for Switching Devices and Control Circuit

Control circuit device, plugged in (R2SS load regulator, MMI 411 frequency converter)

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 con-

verter)

Fig. 3-12: Control circuit device in the vicinity of the motor (R2SS load regulator, MMI 411 frequency

converter)

Control circuit device

plugged in

power tee clamp connector

Control circuit device

displaced

power tee clamp connector

(spur cable)

Control circuit device

plugged in

power tee clamp connector

Control circuit device

displaced

power tee clamp connector

(spur cable)

Installation Guidelines

Installation Versions for Switching Devices and Control Circuit Devices

ECOFAST System Manual

3-18 GWA 4NEB 950 5228-02

ET 200X Sub-segment (with EM 300 motor starter and EM148C frequency converter)

Fig. 3-13: ET 200X Sub-segment (with EM 300 motor starter and EM148C frequency converter)

ET 200X- EM 300 EM 148-FC

ECOFAST System Manual

GWA 4NEB 950 5228-02 4-1

Installation 4

4.1 Power & Control Module

4.1.1 Installation of the IP65 Version

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.

Step Description

Table 4-1:Installing the PCM, IP65 Version

The PCM is designed for wall mounting.

Choose a flat surface.

Allow the specified minimum clearance to

guarantee adequate convection.

PCM with PROFIBUS-DP interface on the

left-hand side: If you want to connect a PRO-

FIBUS-DP cable with a straight plug, you

must allow a clearance of approx. 150 mm

around this plug.

400

PCM

400

100*) 100

150*

Drill 4 holes for the screws.

4 x

695

576

Installation

Power & Control Module

ECOFAST System Manual

4-2 GWA 4NEB 950 5228-02

4.1.2 Installation of the Cabinet Installation Version (IP00)

Installation

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.

Step Description

Table 4-1:Installing the PCM, 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.

Step Description

Table 4-2:Installing the PCM, Cabinet Installation Version

The PCM is designed to be installed in

control cabinets. The degree of pro-

tection of the control cabinet must be

at least IP32.

Drill 4 holes for the screws.

4 x

809

350

ECOFAST System Manual

GWA 4NEB 950 5228-02 4-3

Installation

Alternative Power supply

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.

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.

Step Description

Table 4-2:Installing the PCM, Cabinet Installation Version

Installation

Power Tee Clamp Connector

ECOFAST System Manual

4-4 GWA 4NEB 950 5228-02

4.3 Power Tee Clamp Connector

Procedure for installing the power tee clamp connectors

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.

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!

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 insu-

lation displacement terminations.

10 Close the cover. The power tee clamp connector is now installed and connected.

Tabelle 4-3: Installing the power tee clamp connector

111

1111

222

22222

3333 3333

444

4444

130

ECOFAST System Manual

GWA 4NEB 950 5228-02 4-5

Installation

Hybrid Field Bus Connections

4.4 Hybrid Field Bus Connections

Step Description

Tabelle 4-4: Installing the hybrid field bus connection

Cut out the required section (90 mm x 80 mm) on the

control cabinet.

Note that the wall thickness must not exceed 5 mm.

Place the hybrid field bus connection into the cut-

out section.

ecure t

us connect

using the quick-clamping devices by

tightening the four screws.

4 x

Installation

Discriminating Module and Maintenance Switch

ECOFAST System Manual

4-6 GWA 4NEB 950 5228-02

4.5 Discriminating Module and Maintenance Switch

4.5.1 Discriminating Module

The table below lists the required components:

Installation

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

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.

ECOFAST System Manual

GWA 4NEB 950 5228-02 4-7

Installation

Discriminating Module and Maintenance Switch

To install the discriminating module, carry out the following steps:

4.5.2 Maintenance Switch

To install the maintenance switch, please follow the instructions enclosed with the device.

Step Description

1 Choose a flat surface for installation. You can choose any mounting position.

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: Installing the discriminating module

Drill 2 holes for the screws.

2 x

105

250

145

Installation

Discriminating Module and Maintenance Switch

ECOFAST System Manual

4-8 GWA 4NEB 950 5228-02

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-1

Connections 5

5.1 Power & Control Module

5.1.1 Connections of the IP65 Version

Connections and throughfeeds on the underside of the PCM

Fig. 5-1: Connections and throughfeeds on the underside of the PCM

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.

2 x Han-Brid sockets

for PROFIBUS-DP

and 2 x 24 V DC per channel

4 x M screwed gland

Access possible here for round cables

supplied

looped

through

400 V AC

2 x Han Q4/2 sockets

for supplying the power bus (400 V AC)

Cable throughfeeds

(access possible here,

e. g. for sensors)

PROFIBUS-DP

Main power

X10

X2 X3

Connections

Power & Control Module

ECOFAST System Manual

5-2 GWA 4NEB 950 5228-02

Connections on the inside

Fig. 5-2: Connections on the inside of the PCM

Schematic diagram

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

X08 terminal block

X08

X01

X01 terminal block

(N/L1/L2/L3/PE)

for start, EMERGENCY STOP,

AS-Interface for main power

Safety lock

Main switch

X01 terminal block

X08 terminal block (concealed)

F1 circuit breaker

X2/X3 Han Q4/2 sockets

X10 Han-Brid sockets (concealed)

Notice

All 5 conductors (N/L1/L2/L3/PE) must be wired.

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-3

Connections

Power & Control Module

X2/X3 main circuit output

Output: 2 Han Q4/2 sockets, pin assignment acc. to DESINA:

PROFIBUS-DP field bus:X10

2 x hybrid field bus socket connections, pin assignment acc. to DESINA:

5.1.2 Connections of the Cabinet Installation Version

Connections on the front side of the PCM

Fig. 5-4: Connections on the front side of the PCM (Cabinet Installation Version)

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

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

A/B Field bus —

Table 5-2: Pin assignment of the hybrid field bus connection

X01 terminal block

(N/L1/L2/L3/PE)

Power supply

X08 terminal block

for start and

EMERGENCY STOP

X2/X3 terminal block

Output

Main circuit

400 V AC

X10 terminal block

2 x 24 V DC

(switched and

non switched)

PROFIBUS-DP

2 x 9-pin

SUB-D sockets

X08

X01

X2/X3X10

Connections

Power & Control Module

ECOFAST System Manual

5-4 GWA 4NEB 950 5228-02

X01 power supply

Supplying and looping through the main power.

Terminal block N/L1/L2/L3/PE

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

Notice

All 5 conductors (N/L1/L2/L3/PE) must be wired.

Step Description

1 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-Inter-

face 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 under-

side 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 left-

hand side.

7 This completes wiring. Close the F1 circuit-breaker.

Table 5-3: Wiring of the PCM

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-5

Connections

Power & Control Module

Stripped lengths, cross-sections, terminal assignment

Table 5-4: Stripped lengths, cross-sections, terminal assignment

X08

X08 / 1-2 3-4 5 (+) 6 (–) 7 (+) 8 (–) X01 / L1 L2 L3 N PE

AS-i AUX PWR

0.08 ... 4 mm² 0.08 ... 4 mm² 0.2 ... 16 mm2

AWG 28...12 AWG 28...12 AWG 24...6

IP65

4FB2 111-2A...-0AA0 xx—— x

4FB2 121-2A...-0AA0 xx x x x

4FB2 111-2A...-0AA1 xx—— x

4FB2 112-2A...-0AA0 x—xx x

IP00

4FB2 111-2A...-0AA2 xx—— x

4FB2 121-2A...-0AA1 xx x x x

4FB2 111-2A...-0AA3 xx—— x

4FB2 112-2A...-0AA1 x—xx x

IP00

X10 / 1-2 3-4 X2/X3 L1 L2 L3 N PE

24 V DC

+NS/–NS

24 V DC

+S/–S

0.08 ... 4 mm² 0.08 ... 4 mm² 0.2 ... 10 mm2

AWG 28...12 AWG 28...12 AWG 24...8

9Start 17

917

912

X01

Cage Clamp

Connections

Alternative Power Supply

ECOFAST System Manual

5-6 GWA 4NEB 950 5228-02

5.2 Alternative Power Supply

5.2.1 Connections of the Simple Energy Unit (SEU)

Fig. 5-5: Wiring diagram of a SEU (example) under the responsibility of the user

5.2.2 ET 200S Motor Starter

Fig. 5-6: Wiring scheme of a ET 200S motor starter (example) under the responsibility of the user

13513

A2( )

A1(+) 21 31 43

3222

13513

A2( )

A1(+) 21 31 43

3222

135

462

L1 L2 L3

T1 T2 T3

Power IN 400 V

Power OUT 400 V

Power ON

Check-back

Start

EMERGENCY

STOP

24 V

Circuit-breaker

Contactor with

auxiliary switch

1L1

1L2

1L3

400 V AC

F01F03

16 A

Fault Fault

L+

1L+

2L+

1L+ 24 V DC

1L1

3L2

5L3

2L+ 24 V DC

A1+

A2

2T1

4T2

6T3

2T1

4T2

6T3

PM-D DS1-x DS1-x

PE/NPE/N

IM 151

E 108.1

E 108.0

E 108.3

S 110.0

E 108.5

E 108.4

E 108.7

S 110.4S 110.2 S 110.2

Power supply

Electronics

Power supply

Contactor

PROFIBUS-DP

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-7

Connections

Power Tee Clamp Connector

5.3 Power Tee Clamp Connector

Connections

Fig. 5-7: Pin assignment for 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.

Termminal Assignment Core No.*

1 Phase L1

2 Phase L2

3 Phase L3

4 Neutral conductor N

5 Reserved

6 Reserved

222

333

444

111

555

666

Power tee clamp connector

Terminal numbers and Han Q4/2 pin numbers

do not have the same assignment

333

Caution

Note that core numbers and terminal numbers are not

identical for preassembled power cables.

* Core No.

Connections

Hybrid Field Bus Connections

ECOFAST System Manual

5-8 GWA 4NEB 950 5228-02

5.4 Hybrid Field Bus Connections

Connections on the IP65 side

Fig. 5-8: Connections on the IP65 side

Connections on the IP20 side

Fig. 5-9: Connections on the IP20 side

pin socket

IP65 side (field bus level, external)

Conducting

LWL

Han-Brid

Supply

LWL

socket socket

Han-Brid

IP20 side (in control cabinet)

Terminal block for 2 x 24 V DC (S and NS)

Shield clamp

Terminals A2 (green)/B2 (red)

Terminal block for 2 x 24 V DC (S and NS)

SUB-D socket

for PROFIBUS-DP

Channel 2

Terminal block for 2 x 24 V DC (S und NS) Insulation displ. terminals

for PROFIBUS-DP

Channel 2

A2 (green)/B2 (red)

for PROFIBUS-DP

Channel 1

A1 (green)/B1 (red)

III

Terminals A1 (green)/B1 (red)

for PROFIBUS-DP

Channel 1

Fast-Connect-Block

for PROFIBUS-DP

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-9

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:

Fig. 5-10: Pin assignment for hybrid field bus connection (IP65 side)

A1 B1

A2 B2

Pin Socket

Pin 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

Field bus —

A1/A2 Line A

field bus

—

B1/B2 Line B

field bus

—

Shield

field bus

—

RxD TxD

Copper

Fiber-optic cable Pin 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

Pin Socket

Connections

Hybrid Field Bus Connections

ECOFAST System Manual

5-10 GWA 4NEB 950 5228-02

Connections for passive hybrid field bus connection (IP20 side)

Connections for active 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

Shield field bus

Fast-Connect-Block for PROFIBUS-DP

A1/A2 Line A field bus

(green)

B1/B2 Line B field bus

(red)

Shield field bus

Table 5-5: Connections for passive hybrid field bus connection (IP20 side)

green

red

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

1 Shield

2—

3 RxD/TxD-P (+)

4 CNTR-P

5DGND

6VP

7—

8 RxD/TxD-N (–)

Table 5-6: Connections for active hybrid field bus connection (IP20 side)

Channel 1

Channel 2

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-11

Connections

Hybrid Field Bus Connections

Wiring

Steps for connecting the "Fast Connect Block"

Step Description

1 Strip the lines. For more information on stripped lengths, cross-sections, and ter-

minal 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 termi-

nals.

—

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

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.

The bus cable is contacted vi the insula-

tion 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 This completes the wiring.

Table 5-8: Wiring of the Fast Connect Block

Connections

Hybrid Field Bus Connections

ECOFAST System Manual

5-12 GWA 4NEB 950 5228-02

Schematic diagram

Fig. 5-11: Schematic diagram for wiring the hybrid field bus connection

Passive hybrid field bus connection Active hybrid field bus connection

2 x 24 V DC 2 x 24 V DC

9-pole

SUB-D socket

Shield terminals

A1 B1 A2 B2

+NS –NS –S +S

Jumpers for supplying

24 V DC NS

24 V DC S

S1 with 2 x 24 V DC

24 V DC wiring:

Passive hybrid field bus connection (Fast-Connect Block)

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-13

Connections

Hybrid Field Bus Connections

Stripped lengths, cross-sections, terminal assignments

Table 5-9: Stripped lengths, cross-sections, terminal assignments

2 x 24 V DC

+NS –NS – S + S

PROFIBUS-DP

A1 B1 A2 B2

PROFIBUS-DP

"Fast-Connect"

PROFIBUS-DP

9-pin SUB-D

3RK1911-1AA22 x x

3RK1911-1AA32 x x

3RK1911-1AF22 x x

3RK1911-1AF32 x x

3RK1911-1AB22 x x

3RK1911-1AB32 x x

3RK1911-1AE22 x x

3RK1911-1AE32 x x

1.5 mm²

AWG 15

999

green

red

Cage Clamp

A1B1

A2 B2

Cage Clamp

Connections

Data Tee Plug Connector

ECOFAST System Manual

5-14 GWA 4NEB 950 5228-02

5.5 Data Tee Plug Connector

5.5.1 Pin Assignment

Fig. 5-12: Pin assignment for the data tee plug connector/core assignment for the hybrid field bus

cable

Pin 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

Shield field bus

Data tee connector PROFIBUS-DP Cu

RD TD

Pin 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

Data tee connector PROFIBUS-DP fiber-optic cable

Pin Socket

Input Output

OF field bus

Data plug

connector

(socket)

Data plug

connector

(pin)

*) Core colors of the DESINA

hybrid field bus cable

RD TD

RD TD RD TD RD TD

Pin Socket

Input Output

Assignment of the fiber-optic field bus

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-15

Connections

Discriminating Module and Maintenance Switch

5.6 Discriminating Module and Maintenance Switch

Power bus connection

Input: Han Q4/2 pin

Output: Han Q4/2 socket

Pin assignment acc. to DESINA:

Check-back

Fig. 5-13: M 12 connector (pin) for check-back signals

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.

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

red

black

yellow

NO NC

Connections

General Wiring and Interfaces

ECOFAST System Manual

5-16 GWA 4NEB 950 5228-02

5.7 General Wiring and Interfaces

5.7.1 Rules for Wiring

Selecting the power leads

The core cross-section of the power leads must be matched to the respective ambient condi-

tions. 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:

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.

øTU 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: Reduction values for installation type B2 with three loaded cores

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-17

Connections

General Wiring and Interfaces

Observe the following rules when carrying out wiring:

Unused Connections

Close off unused connections with screw caps; this is the only way of ensuring degree of pro-

tection 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 con-

nector or terminal block.

Fig. 5-14: Numbers printed on the power cable cores

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

2.5 mm2

4.0 mm2

6.0 mm2

12 A

20 A

30 A

48 A

15 A

25 A

35 A

54 A

Permissible outer diameter of the cable sealing

insert Green

Red

White

7.0 to 10.5 mm

9.0 to 13.0 mm

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

333

Numbers are printed on the cores for identification

purposes.

The core number/pin assignments are specified in the

following two sections.

Connections

General Wiring and Interfaces

ECOFAST System Manual

5-18 GWA 4NEB 950 5228-02

Power cables, preassembled at one end with Han Q4/2 pin

Fig. 5-15: Power cables, preassembled at one end with Han Q4/2 pin

Pin Core no. Assignment

1 2 Phase L1

2 3 Phase L2

3 4 Phase L3

4 1 Neutral N

11 5 Reserved

12 6 Reserved

PE (yellow/green)

11 12

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-19

Connections

General Wiring and Interfaces

Power cables, preassembled at one end with Han 10E pin

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.

Pin Core no.

(7-core)

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— 5Brake

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)

Connections

General Wiring and Interfaces

ECOFAST System Manual

5-20 GWA 4NEB 950 5228-02

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

Han Q4/2 power connectors

The power connectors consist of the following components:

Fig. 5-17: Han Q4/2 power connector

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)

• 2.5 mm2: 3RK1911-2BR50

• 4.0 mm2: 3RK1911-2BR10

• 6.0 mm2: 3RK1911-2BR30

Han Q4/2 pin (straight)

• 2.5 mm2: 3RK1911-2BS60

• 4.0 mm2: 3RK1911-2BS20

• 6.0 mm2: 3RK1911-2BS40

Han Q4/2 socket (angular)

• 2.5 mm2: 3RK1911-2BE50

• 4.0 mm2: 3RK1911-2BE10

• 6.0 mm2: 3RK1911-2BE30

Han Q4/2 pin (angular)

• 2.5 mm2: 3RK1911-2BF60

• 4.0 mm2: 3RK1911-2BF20

• 6.0 mm2: 3RK1911-2BF40

Table 5-13: Preparing connecting leads with Han Q4/2

Connector housing Connector housing

Socket insert

Jacks Contact pins

Pin insert

Han Q4/2 socket

for looping through the main power

for connecting the main power

Han Q4/2 pin

ECOFAST System Manual

GWA 4NEB 950 5228-02 5-21

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:

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.

Fig. 5-19: Contacting the AS-i cables

AS-i

AUX PWR

AS-i cable

Communication and

non switched auxiliary power

Switched auxiliary power

Motor starter

AS-i cover

AS-i (–)

AUX PWR (–)

AUX PWR (+)

AS-i (+)

AS-i

AUX PWR

AS-i Cover

Connections

General Wiring and Interfaces

ECOFAST System Manual

5-22 GWA 4NEB 950 5228-02

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.

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-1

Commissioning 6

6.1 Power & Control Module

IP65 Version:

Control cabinet 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.

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 protec-

tion 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

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 protec-

tion 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

Commissioning

Power & Control Module

ECOFAST System Manual

6-2 GWA 4NEB 950 5228-02

lll.

6.1.1 Diagnostics

Missing voltages

4 Configure the AS-i monitor if necessary. The password assigned in the factory is

“ECOFAST”. Note the information below.

Step Description

Table 6-2: Sequence of steps for commissioning the PCM, control cabinet version

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.

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

24 V internal 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

24 V switched 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, blade-

type fuse defective

Short circuit

24 V non switched D1/D2 E0.6 OFF F2/ channel 3 red Overload

D1/D2 E0.6 OFF F2/ channel 3 red, blade-

type fuse defective

Short circuit

24 V AS-i switched 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

30 V AS-i non switched D5 or D3 G2 Overload

Table 6-3: Diagnostics - missing voltages

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-3

Commissioning

Alternative Power Supply

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 instruc-

tions 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.

Signal Was fehlt? Möglicher 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 over-

loaded

D1/D2 E 0.7 OFF 24 V switched F2/ channel 1 F2/ channel 2 over-

loaded

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

Commissioning

Hybrid Field Bus Connections

ECOFAST System Manual

6-4 GWA 4NEB 950 5228-02

6.3 Hybrid Field Bus Connections

To commission the hybrid field bus connections carry out the following steps:

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.

Fig. 6-1: Diagnostics LEDs for active hybrid field bus connections

Examples of typical hybrid field bus connections are listed on the following pages.

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

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 mas-

ter 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

LED yellow

LED green

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-5

Commissioning

Hybrid Field Bus Connections

6.3.1 Passive Hybrid Field Bus Connection for Supply

Fig. 6-2: 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)

Cage Clamp

non switched (NS)

switched (S)

Cage Clamp

Han-Brid Hybrid field bus connection Bus terminating

right

Slave 4

left

Note:

SIMATIC

PROFIBUS standard cable

IP20 (inside)

IP65 (in the field)

Hybrid field bus cable RS 485

Slave 3

e. g. 6ES7 9720BA50-0AA0

Supply: 3RK1911-1AA22 (socket/socket) connector

segment

e. g. 6XV1830-7BH30

segment

Bus terminating

connectors are

plugged directly

onto the data tee

connector

e. g. CPU 315-2 DP

Power supply

Commissioning

Hybrid Field Bus Connections

ECOFAST System Manual

6-6 GWA 4NEB 950 5228-02

6.3.2 Passive Hybrid Field Bus Connection for Conducting

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

Bus plug

e. g. OP 27

Slave 4

non switched (NS)

PROFIBUS standard cable

PROFIBUS-DP

Cage Clamp Cage Clamp

IP20 (inside)

e. g. Power & Control Module (P&CM)

IP65 (in the field)

Hybrid field bus connection

Han-Brid

Bus terminating

Slave 5

Hybrid field bus cable RS 485

2 x 24 V DC

Station 1

Slave 3

e. g. 6ES7972-0BA50-0XA0

RS 485

Conducting: 3RK1911-1AA32 (pin/socket)

connector

e. g. 6XV1830-7BH30

Note:

Bus terminating

connectors are

plugged directly

onto the data tee

connector

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-7

Commissioning

Hybrid Field Bus Connections

6.3.3 Active Hybrid Field Bus Connection for Supply

Fig. 6-4: 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)

SIMATIC

e. g. CPU 315-2 DP

Power supply

non switched (NS)

Cage Clamp

Hybrid field bus connection

Supply: 3RK1911-1AB22 (socket/socket)

Cap

Slave 4Slave 3

Hybrid field bus fiber-optic cable

e. g. 6XV1830-6DH30

Cap

Han-Brid

IP65 (in the field)

IP20 (inside)

PROFIBUS standard cable

PROFIBUS-DP

RS 485

Sub-D

switched (S)

Commissioning

Hybrid Field Bus Connections

ECOFAST System Manual

6-8 GWA 4NEB 950 5228-02

6.3.4 Active Hybrid Field Bus Connection for Conducting

Fig. 6-5: 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 connec-

tion 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

non switched (NS)

Cage Clamp

Hybrid field bus connection

Cap

Slave 5Slave 3

Cap

Han-Brid

IP65 (in the field)

IP20 (inside)

PROFIBUS-DP switched (S)

RS 485 Sub-D

Conducting: 3RK1911-1AB32 (pin/socket)

Hybrid field bus fiber-optic cable

e. g. 6XV1830-6DH30

PROFIBUS standard cable

Bus plug

e. g. 6ES7 972-0BB11-0XA0 e. g. OP 27

Slave 4

Station 1

2 x 24 V DC

e. g. Power & Control Module (PCM)

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-9

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.

Fig. 6-6: Schematic diagram of the use of bus terminating connectors

SPS

+S –S –NS +NS

BU BU

S1 S1‘

S1‘

+S –S –

NS +NS

Sti BU

S1 S1‘

Slave

MBK

Slave

MBK

2 m

20 m

200 m

5 m

S1‘

SPS

+S –S –NS

BU BU

S1 S1‘

S1‘

+S –S –NS

Sti BU

S1 S1‘

S1‘

Slave

MBK

Slave

MBK

2 m

20 m

200 m

5 m

Commissioning

Hybrid Field Bus Connections

ECOFAST System Manual

6-10 GWA 4NEB 950 5228-02

6.3.7 Active Hybrid Field Bus Connection for Supply

Fig. 6-7: 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)

Cage Clamp

Slave 4Slave 3

IP65 (in the field)

IP20 (inside)

Hybrid cable RS 485

non

switched (NS)

Power supply

Bus terminating

connector

Hybrid feld bus connection

Supply: 3RK1911-1AE22 (socket/socket)

SIMATIC

e. g. CPU 315-2 DP

PROFIBUS-DP

RS 485 switched (S)

SUB-D

Note:

Bus terminating

connectors are

plugged directly

onto the data tee

connector

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-11

Commissioning

Hybrid Field Bus Connections

6.3.8 Active Hybrid Field Bus Connection for Supply

Fig. 6-8: 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 con-

nection 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)

Power supply

SIMATIC S7

switched (S)

segment 1/2/3

non

switched. (NS)

segment 1-3

3RK1911-1AE22

Segment 1

left

Segment 1

right

Segment 2

left

Segment 2

right

Segment 3

left

Segment 3

right

PROFIBUS-DP

RS 485

Hybrid field bus cable

6XV1830-7AHxx

9-pin SUB-D

e. g. 6ES7972-0BA50-0AA0

PROFIBUS-DP

RS 485

(socket/socket)

Commissioning

Hybrid Field Bus Connections

ECOFAST System Manual

6-12 GWA 4NEB 950 5228-02

6.3.9 Conveyor Section With Hybrid Field Bus Connections for Supply and

Conducting

Fig. 6-9: Conveyor section with hybrid field bus connections for supply and conducting

SIMATIC S7

Internal bus station

2 x 24 V DC

non switched

switched

RS 485

Hybrid field bus connection

ET 200X-RS 485

Slave 6

PROFIBUS DP

PROFIBUS standard cable

Bus terminating connector

Hybrid field bus connection

Slave 5 Slave 7

OP in local box ET 200S in local box

OP 27

Hybrid field bus cable RS 485

Slave 3 Slave 4

Bus terminating connector

Conducting: 3RK1911-1AA32

pin/socket

e. g. ET 200S/M

RS 485

Supply: 3RK1911-1AA22

socket/socket

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-13

Commissioning

Hybrid Field Bus Connections

6.3.10 Installation System with PROFIBUS-DP - Cu

Fig. 6-10: Installation method with PROFIBUS-DP – Cu

Typical application: Installation system withPROFIBUS DP in Cu

Power & Control Module (PCM) with

Terminating resistor

Bus terminating

Main power cable

PROFIBUS

e. g. CPU 315-2DP

Hybrid field bus cable RS 485

Data tee

Right segment

Left segment

Right segment

Left segment

Slave 3 Slave 4 Slave 5 Slave 9

Slave 11 Slave 12 Slave 32Slave 10

connector

- PLC

- 2 x 24 V DC supply

- 400 V AC main power supply

PROFIBUS CONNECTOR

connected internally

or left segment

connector

or left segment

3/PE-50/60 Hz

400 V AC

CONNECTOR

2 x 24 V cc

Bus terminating connector

Commissioning

Hybrid Field Bus Connections

ECOFAST System Manual

6-14 GWA 4NEB 950 5228-02

6.3.11 PROFIBUS-DP – Fiber-optic Cable

Fig. 6-11: Installation system with PROFIBUS DP fiber-optic cable

Slave 3 Slave 4 Slave 5

Slave 11Slave 10 Slave 12

Slave 9

Slave 32

e. g. CPU 315-2DP

2 x 24 V cc

Typical application: Installation system with PROFIBUS DP fiber-optic cable

Power & Control Module (PCM) with

Terminating resistor

Screw cap

Main power cable

Hybrid field bus fiber-optic cable

Right segment

Data tee

Left segment

connector

Right segment

Left segment

PROFIBUS

- PLC

- 2 x 24 V DC supply

- 400 V AC main power supply

or left segment

3/PE-50/60 Hz

400 V AC

CONNECTOR

PROFIBUSCONNECTOR

connected internally

Screw cap

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-15

Commissioning

Hybrid Field Bus Connections

6.3.12 PROFIBUS-DP (Cu) and Passive Hybrid Field Bus Connections with

2 Separate Power Supplies

Fig. 6-12: PROFIBUS-DP (Cu) and passive hybrid field bus connections with 2 separate power sup-

plies

Slave 5 Slave 6 Slave 8 Slave 9

Typical application: Installation system with PROFIBUS DP (Cu) and passive hybrid field bus connections with 2 separate power supplies

e. g. CPU 315-2 DP 2 x 24 V DC

Power supply

switched

non switched

e. g. OP 27

The power supply is not jumpered

Power supply

Slave 7

on the hybrid field bus connection

on Slave 7

=> Segment 1 supplies the OP (Slave 7)

=> Segment 2 of the hybrid field bus

connectopn on Slave 7 is supplied

by the second power supply

Bus terminating

Hybrid field bus cable RS 485

switched

non switched

Slave 3 Slave 4

2 x 24 V DC

connector

with power

MMMM

BBAA+S -NS +NS

S1’S1

S1S1’

BBAA+S -S -NS +NS IP20

IP65

IP20

IP65

-S

+S -S -NS +NS

+S -NS +NS-S

S1’S1

S1S1’

3RK1911-1AA32

3RK1911-1AA 22

Commissioning

Hybrid Field Bus Connections

ECOFAST System Manual

6-16 GWA 4NEB 950 5228-02

6.3.13 PROFIBUS-DP (Cu) and Active Hybrid Field Bus Connections with 2 Sep-

arate Power Supplies

Fig. 6-13: PROFIBUS-DP (Cu) and active hybrid field bus connections with 2 separate power sup-

plies

Typical application: Installation system with PROFIBUS DP (Cu) and active hybrid field bus connections with 2 separate power supplies

Power supply

Screw cap

switched

non switched

2 x 24 V cc

Slave 8

e. g. CPU 315-2 DP

2 x 24 V DC

Power supply

switched

non switched

e. g. OP 27

Hybrid field bus cable

9-pin SUB-D

IP20

IP65

IP20

IP65

Slave 5 Slave 6 Slave 7 Slave 9Slave 3 Slave 4

The power supply is not jumpered

on the hybrid field bus connection

on slave 8

=> Segment 1 supplies the OP (Slave 8)

=> Segment 2 of the hybrid field bus connection

on slave 8 is supplied by the

second power supply

with power

MMMM

-S

-S -NS

-NS

+NS

-S-NS

-NS

+NS

-S

S1S1’

3RK1911-1AE32

3RK1911-1AE22

ECOFAST System Manual

GWA 4NEB 950 5228-02 6-17

Commissioning

Hybrid Field Bus Connections

6.3.14 PROFIBUS-DP CU and Active Hybrid Field Bus Connections with 2 Sep-

arate Data Supplies

Fig. 6-14: PROFIBUS-DP CU and active hybrid field bus connections with 2 seperate data supplies

Typical application: Installation system with PROFIBUS DP and active hybrid field bus application with 2 separate data supplies

Slave 5 Slave 6

e. g. CPU 315-2 DP

2 x 24 V DC

Power supply

switched

non switched

Slave 3 Slave 4

9-pin SUB-D

Screw cap

Slave 3 Slave 4

Data segment 2

e. g. CPU 315-2 DP

Hybrid field bus

Data segment 1

IP20

IP65

IP20

IP65

In the active hybrid field

bus connection, data is

jumpered as a standard

=> The second hybrid field bus

segment (Data segment 2)

connection in station 2 is

MMMM MM

necessary to supply a new data

-NS

+NS

-S

-NS

+NS

-S

-NS

+NS

-S +S

-S

S1S2’

S1S2

S1S1’

S2 S2

3RK1911-1AB22

3RK1911-1AB 32

3RK1911-1AB32

fiber-optic cable

Commissioning

Discriminating Module and Maintenance Switch

ECOFAST System Manual

6-18 GWA 4NEB 950 5228-02

6.4 Discriminating Module and Maintenance Switch

To commission the discriminating module/maintenance switch, and thus also the downstream

power bus (sub-)segment, carry out the following steps:

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.

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 protec-

tion 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: Sequence of steps for commissioning the discriminating module/maintenance switch

ECOFAST System Manual

GWA 4NEB 950 5228-02 7-1

Technical Data 7

7.1 Power & Control Module

7.1.1 IP65 Version

Order number 4FB2111-2A...-

0AA0

4FB2121-2A...-

0AA0

4FB2111-2A...-

0AA1

4FB2112-2A...-

0AA0

Ausführung

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

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%

Backup min. 20 ms min. 20 ms min. 20 ms min. 20 ms

30 V DC non switched (AS-i)

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

ECOFAST System Manual

GWA 4NEB 950 5228-02 7-2

Protection and monitoring

Short circuit protection

Main circuit Built-in circuit-breaker

Auxiliary circuits Built-in residual current-operated protective device

Signaling devices Green (ready for operation)

Yellow (power connected)

Red (internal fault)

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 3 g

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

Order number 4FB2111-2A...-

0AA0

4FB2121-2A...-

0AA0

4FB2111-2A...-

0AA1

4FB2112-2A...-

0AA0

ECOFAST System Manual

GWA 4NEB 950 5228-02 7-3

Connections/throughfeeds

Input connections Cage – Clamp max. 2 x 16 mm2 max. current carrying capacity

(Throughfeeds 2 x M40x1.5)

Output connections

Main circuit

2 x Han Q4/2 socket (DESINA)

Output connections

Auxiliary circuits/field bus

2 x Han-Brid socket/socket (DESINA)

Output connections

AS-Interface

— Cage – Clamp,

2.5 mm2

Throughfeeds

4 x ASi-seal

Cage – Clamp,

2.5 mm2

Throughfeeds

4 x ASi-seal

—

Output connections

EMERGENCY STOP

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

SIMATIC connections Cage – Clamp, 1.5 mm2

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

S7-300,

CPU 313C-2 DP

I/O module

AS Interface master

ET 200M

I/O module

Data transfer rate 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 PROFIBUS-DP PROFIBUS-DP PROFIBUS-DP PROFIBUS-DP

Order number 4FB2111-2A...-

0AA0

4FB2121-2A...-

0AA0

4FB2111-2A...-

0AA1

4FB2112-2A...-

0AA0

ECOFAST System Manual

GWA 4NEB 950 5228-02 7-4

7.1.2 IP00 Version (Control Cabinet Version)

Order number 4FB2111-2A...-

0AA2

4FB2121-2A...-

0AA1

4FB2111-2A...-

0AA3

4FB2112-2A...-

0AA1

Ausführung

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

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

30 V DC non switched (AS-i)

Output voltage AS-i — DC 30 V

(29.5 V to 31.6 V)

— DC 30V

(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

Protection and monitoring

Short circuit protection

Main circuit Built in circuit-breaker

Auxiliary circuit Built in residual current-operated protective device

Signaling devices Green (ready for operation)

Yellow (power connected)

Red (internal fault)

ECOFAST System Manual

GWA 4NEB 950 5228-02 7-5

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 3 g

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

Input connections Cage – Clamp max. 2 x 16 mm2 max. current carrying capacity

Output connections

Main circuit

Cage – Clamp,

2.5 mm2Cage – Clamp,

2.5 mm2

Output connections

Auxiliary circuits

Cage – Clamp,

2.5 mm2Cage – 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 mm2Cage – Clamp,

2.5 mm2

SIMATIC connections Cage – Clamp, 1.5 mm2

Dimensions/weight

Dimensions (WxHxD) 520 x 830 x 240

Fixing dimensions (WxH) 350 x 809

Fixing holes 4 x M8

Weight max. 55 kg

Order number 4FB2111-2A...-

0AA2

4FB2121-2A...-

0AA1

4FB2111-2A...-

0AA3

4FB2112-2A...-

0AA1

ECOFAST System Manual

GWA 4NEB 950 5228-02 7-6

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 enc-

losed 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.

SIMATIC

Controllers 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

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

Order number 4FB2111-2A...-

0AA2

4FB2121-2A...-

0AA1

4FB2111-2A...-

0AA3

4FB2112-2A...-

0AA1

ECOFAST System Manual

GWA 4NEB 950 5228-02 7-7

7.3 Hybrid Field Bus Connections

General technical Data

Location On the system Mounted directly on the control cabinet

Installation position Any

Degree of protection Control cabinet

Field bus

IP20

IP65/67

Enclosure dimensions (HxWxD) 103 x 93 x 65

Weight ca. 250 g

Operating temperature –25 °C to +50 °C

Storage-/transport temperature –40 °C to +80 °C

Vibratory load 5 g

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

Electrical Data Auxiliary Power

Rated voltage

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

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 7-8

7.4 Data Tee Plug Connector

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.

General Technical Data

Location On the system Connected to motor starter

Installation position 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 7-9

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

General Technical Data

Electrical Data Auxiliary Power

Non switched Voltage, DC24V-NS Switched Voltage DC24V-S

Voltage range 20.4 V DC to 28.8V DC standard power supply acc. to DIN 19240

Maximum current-carrying capa-

city 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 7-10

7.5 Discriminating Module

General Technical Data

Location On the system Wall mounting

Mounted directly on the

ECOFAST consumer *)

Installation position 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 5 g

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 8-1

Dimension Drawings 8

8.1 Power & Control Module

8.1.1 IP65 Version

Fig. 8-1: Power & Control Module, IP65 version

600 ± 2

576

850 ± 2

50 ± 0.2

695 ± 1

Ø 9

Ø 15

4 x

255 max.

310 max.

920 max.

695

576

4 x

Drilling dimensions:

Clearance (hatched):

400

PCM

400

100* 100

150*

* Allow clearance for plug if necessary!

Dimension Drawings

Power & Control Module

ECOFAST System Manual

8-2 GWA 4NEB 950 5228-02

8.1.2 IP00 Version (Control Cabinet Version)

Fig. 8-2: Power & Control Module, IP00 version (control cabinet version)

520

350

830

809

Ø 9

2 x

224

2 x

Ø 9

809

350

4 x

Drilling dimensions:

ECOFAST System Manual

GWA 4NEB 950 5228-02 8-3

Dimension Drawings

Alternative Power Supplies

8.2 Alternative Power Supplies

8.2.1 Simple Energy Unit (SEU)

Circuit-breaker

Fig. 8-3: 3RV10.. circuit-breaker

S00

918

4512

3,5

105

45 556

18 18

106

5518 18

109

121

127

132

144

140

125

130

Dimension Drawings

Alternative Power Supplies

ECOFAST System Manual

8-4 GWA 4NEB 950 5228-02

Contactors

Fig. 8-4: Contactors 3RT10..

171 a

112

15 64 110

159

107 5

Test

STOP RESET

S00

4 5

2 )

1 4 3

6 3

8 6

10 135

7 2

1 5 , 5

1 0

8 6

3 5

6 0

Drill pattern

5 9

68 109

ECOFAST System Manual

GWA 4NEB 950 5228-02 8-5

Dimension Drawings

Alternative Power Supplies

8.2.2 ET 200S Motor Starter

Fig. 8-5: ET 200S motor starter

138

149

126

100

290

333

DS=65

RS=130

135

Connection area

Sectional rail

35 x 7,5 mm

min. 35 mm

Clearance for

heat dissipation

min. 35 mm

Clearance for

heat dissipation

Sectional rail

35 x 7,5 mm

Dimension Drawings

Power Tee Clamp Connector

ECOFAST System Manual

8-6 GWA 4NEB 950 5228-02

8.3 Power Tee Clamp Connector

Fig. 8-6: Power tee/tee-tee clamp connector

112.6

158

130 55

142.5

78.5

Ø5.5

Power tee clamp connector

112.6

158

130 55

142.5

78.5

Ø5.5

Power tee-tee clamp connector

Seals for power tee/tee-tee clamp connector

D: Depends on the cable cross section

ECOFAST System Manual

GWA 4NEB 950 5228-02 8-7

Dimension Drawings

Hybrid Field Bus Connections

8.4 Hybrid Field Bus Connections

Fig. 8-7: Dimension drawing of the hybrid field bus connection

103

5 max.

IP20 IP65

Cut out section on control cabinet:

Dimension Drawings

Data Tee Plug Connector

ECOFAST System Manual

8-8 GWA 4NEB 950 5228-02

8.5 Data Tee Plug Connector

Fig. 8-8: Dimension drawing of the data tee plug connector

ECOFAST System Manual

GWA 4NEB 950 5228-02 8-9

Dimension Drawings

Discriminating Module and Maintenance switch

8.6 Discriminating Module and Maintenance switch

Fig. 8-9: Discriminating module with M12 connector

Fig. 8-10: Maintenance switch

105

230

135

155

KHM

A= 94 B= 125 A1 = 110

B1 = 80 C= 36 d= 4.5

D = 4 x PG16 E= 21 F= n/a

G= n/a H= 82 K= 67

M= 36

Dimension Drawings

Discriminating Module and Maintenance switch

ECOFAST System Manual

8-10 GWA 4NEB 950 5228-02

ECOFAST System Manual

GWA 4NEB 950 5228-02 9-1

Order Numbers 9

9.1 Motor Starters (Reversing Starters)

Setting Range*Motor Protection/

Switching

Technology

Brake Field Bus Order Number

ECOFAST Motor Starters

0.3 A - 9 A (4 kW) Temperature

sensor/

Mechanical

AS-Interface 3RK1323-2AS54-1AA0

400 V AC AS-Interface 3RK1323-2AS54-1AA3

0.3 A - 9 A (4 kW) Temperature

sensor/

Mechanical

PROFIBUS-DP 3RK1303-2AS54-1AA0

400 V AC PROFIBUS-DP 3RK1303-2AS54-1AA3

ECOFAST Motor Starter High Feature

0.3 A - 3 A (1.1 kW) Thermal

Motor Model/

Mechanical

PROFIBUS-DP 3RK1303-5BS44-3AA0

2.4 A - 9 A (4 kW) PROFIBUS-DP 3RK1303-5CS44-3AA0

0.3 A - 3 A (1.1 kW) 400 V AC PROFIBUS-DP 3RK1303-5BS44-3AA3

2.4 A - 9 A (4 kW) 400 V AC PROFIBUS-DP 3RK1303-5CS44-3AA3

0.3 A - 3 A (1.1 kW) Thermal

Motor Model/

Mechanical

AS-Interface 3RK1323-5BS44-3AA0

2.4 A - 9 A (4 kW) AS-Interface 3RK1323-5CS44-3AA0

0.3 A - 3 A (1.1 kW) 400 V AC AS-Interface 3RK1323-5BS44-3AA3

2.4 A - 9 A (4 kW) 400 V AC AS-Interface 3RK1323-5CS44-3AA3

0.3 A - 3 A (1.1 kW) Full Motor

Protection/

Electronic-Soft

PROFIBUS-DP 3RK1303-6BS74-3AA0

2.4 A - 12 A (5.5 kW) PROFIBUS-DP 3RK1303-6DS74-3AA0

0.3 A - 3 A (1.1 kW) 400 V AC PROFIBUS-DP 3RK1303-6BS74-3AA3

2.4 A - 12 A (5.5 kW) 400 V AC PROFIBUS-DP 3RK1303-6DS74-3AA3

0.3 A - 3 A (1.1 kW) Full Motor

Protection/

Electronic-Soft

AS-Interface 3RK1323-6BS74-3AA0

2.4 A - 12 A (5.5 kW) AS-Interface 3RK1323-6DS74-3AA0

0.3 A - 3 A (1.1 kW) 400 V AC AS-Interface 3RK1323-6BS74-3AA3

2.4 A - 12 A (5.5 kW) 400 V AC AS-Interface 3RK1323-6DS74-3AA3

0.6 A - 4 A (1.5 kW) Full Motor

Protection/

Electronic-Soft

(Duo-Reversing

Soft)

400 V AC AS-Interface 3RK1323-6ES84-3AA3

0.6 A - 4 A (1.5 kW) 400 V AC PROFIBUS-DP 3RK1303-6ES84-3AA3

*) Power descriptions are valid for 400 V AC

Order Numbers

Motor Connection Cables

ECOFAST System Manual

9-2 GWA 4NEB 950 5228-02

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

- 7 x 1.5 mm2 < 3 m, any length

- 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

3RK1911-0BG10

3RK1911-0CG20

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

- 11 x 1.5 mm2 < 3 m, any length

- 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

3RK1911-0BJ10

3RK1911-0CJ20

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

- 7 x 1.5 mm2 < 3 m, any length

- 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

3RK1911-0BH10

3RK1911-0CH20

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

- 11 x 1.5 mm2 < 3 m, any length

- 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

3RK1911-0BK10

3RK1911-0CK20

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

- 8 x 1.5 mm2 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

- 8 x 1.5 mm2 5.0 m

3RK1911-0CV10

3RK1911-0BV10

3RK1911-0CV20

3RK1911-0BV20

3RK1911-0CV30

3RK1911-0BV30

ECOFAST System Manual

GWA 4NEB 950 5228-02 9-3

Order Numbers

Power Cables

9.3 Power Cables

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

- 8 x 1.5 mm2 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

- 8 x 1.5 mm2 5.0 m

3RK1911-0CU10

3RK1911-0BU10

3RK1911-0CU20

3RK1911-0BU20

3RK1911-0CU30

3RK1911-0BU30

Unassembled

- 8 x 1.5 mm2 20 m

- 8 x 1.5 mm2 50 m

- 8 x 1.5 mm2 100 m

3RK1911-0BW60

3RK1911-0BW70

3RK1911-0BW80

Description Order No.

Spur cables

Han Q4/2 pin/Han Q4/2 socket

- 5 x 4.0 mm2 < 3 m. any length

- 5 x 4.0 mm2 > 3 m to < 5 m, any length

- 5 x 4.0 mm2 > 5 m to < 10, any length

- 5 x 4.0 mm2 > 10 m to < 15 m, any length

- 5 x 6 mm2 < 3 m, any length

- 5 x 6 mm2 > 3 m to < 5 m, any length

- 5 x 6 mm2 > 5 m to < 10 m, any length

- 5 x 6 mm2 > 10 m to < 15m, any length

3RK1911-0CP21

3RK1911-0CP31

3RK1911-0CP41

3RK1911-OCP51

3RK1911-0CP22

3RK1911-0CP32

3RK1911-0CP42

3RK1911-0CP52

ET200X sub-segment lines

Han Q4/2 pin/Han Q8/0 socket

- 5 x 4.0 mm2 < 3 m, any length

- 5 x 4.0 mm2 > 3 m to < 5 m, any length

- 5 x 4.0 mm2 > 5 m to < 10, any length

- 5 x 4.0 mm2 > 1 0 m to < 15 m, any length

3RK1911-0CR21

3RK1911-0CR31

3RK1911-0CR41

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

- 5 x 6.0 mm2 20 m

- 5 x 6.0 mm2 50 m

- 5 x 6.0 mm2 100 m

3RK1911-0AG60

3RK1911-0AG70

3RK1911-0AG80

3RK1911-0AH60

3RK1911-0AH70

3RK1911-0AH80

Order Numbers

Power & Control Modules (Infeed Modules)

ECOFAST System Manual

9-4 GWA 4NEB 950 5228-02

9.4 Power & Control Modules (Infeed Modules)

9.5 Simple Energy Unit (SEU)

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

Description 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 9-5

Order Numbers

Discriminating Modules

9.6 Discriminating Modules

9.7 Maintenance Switch

9.8 Hybrid Field Bus Cables

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.

– for 400 V AC, 8 A

– for 400 V AC, 16 A

– for 400 V AC, 25 A

3RK1911-4AB08

3RK1911-4AB16

3RK1911-4AB25

Description Order No.

Maintenance switch with M12 connector

25 A rated current 6AG1264-1GP51-6AA0

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

3 m 6XV1 830-7DH30

5 m 6XV1830-7DH50

10 m 6XV1830-7DN10

15 m 6XV1830-7DN15

Unassembled cable

20 m 6XV1830-7CN20

50 m 6XV1830-7CN50

100 m 6XV1830-7CT10

Order Numbers

AS-Interface Shaped Cable

ECOFAST System Manual

9-6 GWA 4NEB 950 5228-02

9.9 AS-Interface Shaped Cable

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

3 m 6XV1830-7BH30

5 m 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

Cut-to-length 6XV1830-7AH10

20 m 6XV1830-7AN20

50 m 6XV1830-7AN50

100 m 6XV1830-7AT10

Description Order No.

Material Color Quantity

Rubber Yellow (AS-Interface) 100 m roller 3RX9010-0AA00

1 km drum 3RX9012-0AA00

Black (DC 24 V) 100 m roller 3RX9020-0AA00

1 km drum 3RX9022-0AA00

TPE Yellow (AS-Interface) 100 m roller 3RX9013-0AA00

1 km drum 3RX9014-0AA00

Black (DC 24 V) 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

Black (DC 24 V) 100 m roller 3RX9025-0AA00

1 km drum 3RX9026-0AA00

ECOFAST System Manual

GWA 4NEB 950 5228-02 9-7

Order Numbers

Hybrid Field Bus Connections

9.10 Hybrid Field Bus Connections

9.11 Connectors

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

3RK1911-1AA22

3RK1911-1AA32

3RK1911-1AB22

3RK1911-1AB32

3RK1911-1AE22

3RK1911-1AE32

3RK1911-1AF22

3RK1911-1AF32

Description Order No.

Data + 24 V

Data tee Connector Cu

Data tee Connector FO

Bus terminating connector for PROFIBUS-DP, 1 piece

Bus terminating connector for PROFIBUS-DP, 5 pieces

3RK1911-2AG00

3RK1911-2AH00

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

6GK1905-0CA00

6GK1905-0CN00

Order Numbers

Connectors

ECOFAST System Manual

9-8 GWA 4NEB 950 5228-02

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).

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

Seals for power tee clamp connector

For power cable with Ø 10 to 13 mm

For power cable with Ø 13 to 16 mm

For power cable with Ø 16 to 19 mm

For power cable with Ø 19 to 22 mm

Filler plug

3RK1911-2BF01

3RK1911-2BF02

3RK1911-2BG02

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

Connector set Han 10E pin EMC

Connector set Han 10E socket EMC

3RK1911-2BK00

3RK1911-2BL00

3RK1911-2BM00

3RK1911-2BN00

3RK1911-2BL10

3RK1911-2BN10

Description Order No.

ECOFAST System Manual

GWA 4NEB 950 5228-02 9-9

Order Numbers

Project Engineering Software and Documentation

9.12 Project Engineering Software and Documentation

Description Order No.

Project Engineering Software

ECOFAST ES

• Graphical power bus configuration

• Power bus dimensioning

• Operator prompting for selection of Siemens A&D products

• Norm-compliant power system design

• Documentation

3ZS1200-0CC13-0YA0

Switch ES

• 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 inter-

face 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

3ZS1310-0CC20-0YA0

Upgrade Switch ES Motorstarter from Version 1.0 up to 2.0 3ZS1 310-0CC20-0YE0

Documentation

ECOFAST Manual (German)

ECOFAST Manual (English)

ECOFAST Motor Starters Manual (German/English)

ECOFAST Motor Starters High Feature Manual (German)

ECOFAST Motor Starters High Feature Manual (English)

3RK1703-0AB18-0AA1

3RK1703-0BB18-0AA1

3RK1702-2GB18-0AA0

3RK1702-3AB18-1AA0

3RK1702-3BB18-1AA0

Order Numbers

Tools, Connector Sets, Configuration

ECOFAST System Manual

9-10 GWA 4NEB 950 5228-02

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

• for contact pins and sockets 2.5 to 4.0 mm2

3RK1902-0AH00

3RK1902-0CT00

Disassembling tool for contact pins and sockets 1 3RK1902-0AJ00

Cover for power sockets Han Q8/0 1

3RK1902-0CK00

3RK1902-0CJ00

Connector set for power infeed Han Q8/0 2.5 mm2:

1 connector enclosure with PG 16,

1 socket insert and 9 contact sockets 2.5 mm2

1 3RK1902-0CA00

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

1 3RK1902-0CB00

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

1 3RK1902-0CC00

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

1 3RK1902-0CD00

Mounting plate (for motor plugged in) 1 3RK1911-3AA00

Identification Plug 1 6ES7194-1KB00-

0XA0

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-1

Questions and Answers A

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 addi-

tion, 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-Inter-

face), 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 inte-

grated 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 manufac-

turer 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 excee-

ded, this feeder must be started separately on the power side.

5 Is ECOFAST suitable

for sub-zero tempera-

tures (outdoor applica-

tions, 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 inte-

grated in ECOFAST?

The power & control module can optionally be supplied with an inte-

grated PLC for ECOFAST. The S7 315-2 DP is planned in the first

stage. The PLC can, of course, also be accommodated in a conventi-

onal control cabinet. In this case it is integrated into the system by

means of control cabinet throughfeeds (hybrid field bus connections).

Questions and Answers

Frequently Asked Questions

ECOFAST System Manual

A-2 GWA 4NEB 950 5228-02

8 Are frequency conver-

ters available for ECO-

FAST?

Yes.

A frequency converter up to 1.5 kW is available for the ET 200X

which can also be operated as stand-alone. Furthermore, the

Combi 411 and R28S are also available.

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 star-

ter) 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 standardi-

zed interfaces, we decided to use it as a basis for ECOFAST. ECO-

FAST 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 (Profi-

safe, Safety at work)?

EMERGENCY STOP circuits can be connected to the power & cont-

rol 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 integra-

ted 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. SIMO-

CODE or ET 200S)

also be integrated into

ECOFAST?

Yes.

These components can also be connected to ECOFAST. The switch-

box 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. Integra-

tion into the complete system is thus very straightforward.

13 How can the bus and

the power supplies

(24 V auxiliary volta-

ges) 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 through-

feeds). 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 visuali-

zation 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 con-

trol 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 (soft-

ware 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 inte-

grated?

Switching devices of this kind can be integrated in local boxes as

IP20 components by means of the control cabinet throughfeeds (hyb-

rid 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.

No. Question Answer

ECOFAST System Manual

GWA 4NEB 950 5228-02 A-3

Questions and Answers

Frequently Asked Questions

17 Is a repair switch pro-

vided? 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 (soft-

ware 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 consi-

derably 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 star-

ters of the ET 200X?

No.

Different ECOFAST solutions are offered intentionally to facilitate

maximum adaptability to each particular application.

The following solutions are possible:

• 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)

24 Is ECOFAST very

expensive?

Although the connector technique is slightly more expensive than

simple terminals, it is important to consider the overall costs of ECO-

FAST, namely both material and installation costs. The potential

savings concern the costs of installation and servicing.

No. Question Answer

Questions and Answers

Frequently Asked Questions

ECOFAST System Manual

A-4 GWA 4NEB 950 5228-02

ECOFAST System Manual

GWA 4NEB 950 5228-02 B-1

ECOFAST Pilot Projects B

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 preassemb-

led connections.

Fig. B-1: SIRIUS 2 pilot system - production

Power & Control Modul

PROFIBUS-DP ECOFAST Hybrid Kabel

Energieleitung

Bandstrecke 2 Bandstrecke 3 Bandstrecke 4

Power & Control Module

PROFIBUS-DP ECOFAST Hybrid Cable

Power cable

Conveyor section 1 Conveyor section 2 Conveyor section 3 Conveyor section 4

ECOFAST System Manual

GWA 4NEB 950 5228-02 B-2

Configuration with ECOFAST ES

Fig. B-2: SIRIUS 2 pilot system - configuration with ECOFAST ES

ECOFAST System Manual

GWA 4NEB 950 5228-02 B-3

Production

Fig. B-3: SIRIUS 2 pilot system - production

ECOFAST System Manual

GWA 4NEB 950 5228-02 B-4

B.2 Configuration in the Automotive Industry - Production Plan-

ning

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-5

Configuration with ECOFAST ES

Fig. B-4: Configuration with ECOFAST ES

ECOFAST System Manual

GWA 4NEB 950 5228-02 B-6

ECOFAST System Manual

GWA 4NEB 950 5228-02 1

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 viola-

ted, 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 stan-

dard 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, PROFI-

BUS, and uses the DP protocol.

DP slave The DP slave is a slave that is operated on the PROFIBUS bus with the PROFIBUS-DP pro-

tocol 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 exten-

sive diagnostics on the component level.

ECOFAST System Manual

2GWA 4NEB 950 5228-02

ECOFAST certified Confirms that devices from different manufacturers are compatible with ECOFAST specifica-

tions.

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 inte-

grated” certificate.

Host A host is a system or unit that contains at least one DP Master. For example, the program-

mable 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 Func-

tions).

PROFIBUS address Each station must be assigned a PROFIBUS address for the purpose of unique identifica-

tion. 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.

ECOFAST System Manual

GWA 4NEB 950 5228-02 3

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

4GWA 4NEB 950 5228-02

ECOFAST System Manual

GWA 4NEB 950 5228-02

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.

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

GWA 4NEB 950 5228-02

Siemens Aktiengesellschaft

Automation and Drives

Low Voltage Controls and Distribution

Postfach 48 48

D-90327 Nürnberg

w w w . s i e m e n s . d e / e c o f a s t Order No. 3RK1703-0BB18-0AA1