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Bosch CL550 Manual

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Antriebs- und Steuerungstechnik
CL550
Controller Manual
Edition
101
Table of Contents
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Summary of Contents for Bosch CL550

  • Page 1 Antriebs- und Steuerungstechnik CL550 Controller Manual Edition...
  • Page 2 CL550 Controller Manual 1070 072 263-101 (01.08) GB E 2001 by Robert Bosch GmbH, Erbach, Germany All rights reserved, including applications for protective rights. Reproduction or distribution by any means subject to our prior written permission. Discretionary charge 10.00 DM...

  • Page 3: Table Of Contents

    Documentation, Software Release and Trademarks ..1–7 System Overview CL550 ..... . 2–1 Controller Structure .
  • Page 4 Contents Page ZS550 ........5–1 Structure and Function .

  • Page 5: Safety Instructions

    Safety Instructions 1–1 Safety Instructions Before you start working with the CL550 controller, we recommend that you thoroughly familiarize yourself with the contents of this manual. Keep this manual in a place where it is always accessible to all users.

  • Page 6: Qualified Personnel

    This manual is intended for especially qualified PLC experts. Interventions in the hardware and software of our products that are not de- scribed in this manual may only be performed by Bosch’s own specifically trained personnel. Unqualified interventions in the hardware or software or non-compliance with the warnings listed in this instruction manual or indicated on the product may result in serious personal injury or damage of the equipment.

  • Page 7: Safety Markings On Components

    Safety Instructions 1–3 Safety Markings on Components DANGER! High voltage! DANGER! Corrosive battery acid! CAUTION! Electrostatically sensitive components! Disconnect mains power before opening! Lug for connecting PE conductor only! Functional earthing or low-noise earth only! Screened conductor only! 1070 072 263-101 (01.08) GB...

  • Page 8: Safety Instructions In This Manual

    Safety Instructions 1–4 Safety Instructions in this Manual DANGEROUS ELECTRICAL VOLTAGE This symbol warns of the presence of dangerous electrical voltage. In- sufficient or non-compliance with this warning can result in personal in- jury. DANGER This symbol is used whenever insufficient or non-compliance with instruc- tions can result in personal injury.

  • Page 9: Safety Instructions For The Described Product

    The module could be destroyed. Turn off or unplug the controller’s power supply module, the external power supply and the signal voltage first. Only then plug or unplug the module! CAUTION Please use only spare parts that are approved by Bosch! 1070 072 263-101 (01.08) GB...
  • Page 10 Safety Instructions 1–6 CAUTION Please comply with all ESD protection measures when using the module! Avoid electrostatic discharges! Please comply with the following protection measures for electrostatically endangered modules and components (EEM)! D The employees responsible for storage, transport and handling must be trained in ESD protection.

  • Page 11: Documentation, Software Release And Trademarks

    WinDP 2.01 Trademarks All trademarks referring to software that is installed on Bosch products when shipped from the factory are the property of their respective manufacturers. At the time of shipment from the factory, the installed software is protected by copyright.
  • Page 12 Safety Instructions 1–8 1070 072 263-101 (01.08) GB...

  • Page 13: System Overview Cl550

    2–1 System Overview CL550 The CL550 is an open multiprocessor system with up to six democratic cen- tral units. Each central unit constitutes a closed control unit with all data areas and the entire I/O address range. Communication among the modules is processed via Ethernet.
  • Page 14 D The ZS550-DP-IBS mounting rack has been additionally provided with: InterBus-S interface CON550 If the CL550 contains more than one ZS550, a CON550 module can be added in order to enable the modules to communicate with each other via the backside.

  • Page 15: Communication Via Ethernet

    10 Mbits/s or 100 Mbits/s. Ethernet and Internet protocols are the basis for communication. On an Ethernet basis, the UDP/IP standard protocol is used to send Bosch BÜP commands.The thus created protocol is called BÜP-E. To do so, the ZS550 is provided with two Ethernet interfaces.

  • Page 16: Configuration

    2–4 System Overview CL550 Configuration Elements for Dis- play + Operation Pentium platform 166 MHz under VxWorks (ZS550-DP-IBS only) 32 MB Random Access Memory 32 MB Flashdisk I/O connection Buffered SRAM for Profibus-DP V1 remanent data I/O connection InterBus-S (ZS550-DP-IBS only) The control part has been realized through a high-performance PC kernel under VxWorks, a real time operating system.

  • Page 17: Central Programming

    System Overview CL550 2–5 2.4.1 Central Programming The PLC program can be created with a programming device or a computer; a controller is not necessary. It will be loaded into the controller via the WinSPS utility program. 2.4.2 Program Display...

  • Page 18: Winsps

    The programming tool WinSPS is used for programming under Windows NT (version 3.51 or higher) or Windows 95, based on DIN EN 61131-3. For communication with WinSPS and other programs, the TCP/IP standard protocol with the BÜP (Bosch transmission protocol) command language is used. 2.4.4...

  • Page 19: Installation

    System Overview CL550 2–7 Installation Connection of mounting racks Local pro- Central gramming program- ming Connection mounting rack coupling Local Central program- program- ming ming Connection mounting rack coupling via hub/switch 1070 072 263-101 (01.08) GB...

  • Page 20: Compliance With Statutes And Standards

    2–8 System Overview CL550 Compliance with Statutes and Standards D EMC statute of 11-09-1992 D EN 50081-2 Electromagnetic compatibility; generic emission standard; part 2: industrial environment (March 1994) D EN 50082-2 Electromagnetic compatibility; generic emission standard (February 1996); part 2: industrial environment D EN 61131-2 (IEC 1131-2) Programmable controllers –...

  • Page 21: Mounting Rack Gg4-9

    Mounting Rack GG4-9 3–1 Mounting Rack GG4-9 The mounting rack consists of a metal housing with nine slots. To the lower front side of the mounting rack a cable duct can be installed. It opens to the front and provides the possibility to mark the installed modules. Dimensions and Assembly Dimensions Assembly...
  • Page 22 Mounting Rack GG4-9 3–2 Above and below the mounting rack, a clearance of at least 90 mm must be observed in order to ensure circulation of the ambient air. 90 mm at least 90 mm at least Insert mounting rack CAUTION Endangered module! Do not plug or unplug the module as long as the controller is...

  • Page 23: Fan

    Mounting Rack GG4-9 3–3 Heat accumulation can result in failure or damage of the module. Therefore, the mounting rack must be provided with a withdrawable fanning unit with two fans. 3.2.1 Installation and Electric Connection The withdrawable fanning unit will be installed in the lower part of the mount- ing rack.
  • Page 24 Mounting Rack GG4-9 3–4 Connect the protective earth conductor for the mounting rack to the cable lug at the mounting rack’s designated bolt. Connect the protective earth conductor for the withdrawable fanning unit to the cable lug at the unit’s designated threaded bolt. É...
  • Page 25 Mounting Rack GG4-9 3–5 The withdrawable fanning unit must be installed in the mounting rack from below, with the fan looking upwards and the filter matt grid downwards. View from below Quick release lock Quick release lock Rear edge Put the rear edge of the fanning unit on the supporting surface of the mount- ing rack.

  • Page 26: Changing The Filter Matt

    Mounting Rack GG4-9 3–6 3.2.2 Changing the Filter Matt The filter matt of the withdrawable fanning unit must be inspected and changed regularly. How often the filter matt must be changed depends on the degree of contamination of the ambient air. The fan monitor does not measure the degree of contamination! Order information D Filter matt 129 x 274: Order No.

  • Page 27: Power Supply Module

    Power Supply Module 4–1 Power Supply Module We offer five power supply modules: NT1, NT2, NT3, NT4 and NT24. The power supply module takes over the following tasks: D Providing the internal supply voltage D Monitoring the input voltage with regard to under- and overvoltage D Monitoring the power supply module’s temperature (60 °C and 10%) D Supply of the controller’s buffered memories in case of voltage failure via the backup battery.

  • Page 28: Selection

    Power Supply Module 4–2 Selection The selection of the power supply module depends on the configuration of the controller: D NT1: maximum of 1 x ZS550 + 1 x CON550 D NT2: maximum of 2 x ZS550 + 1 x CON550 D NT3: maximum of 3 x ZS550 + 1 x CON550 D NT4: maximum of 6 x ZS550 + 1 x CON550 D NT24: maximum of 3 x ZS550 + 1 x CON550...
  • Page 29 Power Supply Module 4–3 Description of the NT4 power supply LED green: 5 V 5 V voltage supply of the modules from the power supply unit is available 5 V voltage supply of the modules from the power supply unit is not available LED red: Battery failure Backup battery on the power supply empty or defect Backup battery is o.k.
  • Page 30 Power Supply Module 4–4 Technical Data Technical Data Order number 1070 083 441 Input voltage 220/230 V automatic switching to 110/115 V, –15 % to +10 %, 47 to 63 Hz Jumpering of power failures at the One full wave, repetition rate w10 s power supply module Continuous input current 1.9 A...

  • Page 31: Nt1 / Nt2 / Nt3 / Nt24

    Power Supply Module 4–5 NT1 / NT2 / NT3 / NT24 LED green: 5 V 5 V voltage supply of the modules from the power supply unit is available 5 V voltage supply of the modules from the power supply unit is not available LED green: ISO 12 V ISO 12 V available ISO 12 V not available...
  • Page 32 Power Supply Module 4–6 Fuses Mains fuse Replace only with fuse of the same type Mains connection 230 VAC Neutral conductor Potential earth (protective earth conductor) Connect in compliance with the corresponding regulations; refer to the manuals of the exter- nal peripherals.
  • Page 33 Power Supply Module 4–7 Technical Data NT24 Order number 1070 071 376 1070 062 687 1070 062 309 1070 068 046 Input voltage 220/230 V automatic switching to 110/115 V, 24 VDC, –15 % to +10%, 47 to 63 Hz –33 % to +71 % Jumpering of power One full wave,...

  • Page 34: Backup Battery

    Power Supply Module 4–8 Backup battery In case of a supply voltage failure and the turn-off of the power supply mod- ule, the backup battery serves D to centrally secure the remanently set areas for markers, timers, counters, data field and data buffers D to supply the internal RAM D to supply the internal RAM program memory modules.
  • Page 35 Power Supply Module 4–9 Failure contact The failure contact of the power supply module opens D in case of a failure of the internal 5 V supply voltage D in case of a controller stop Jumper 1 must be in position 1-2, Jumper 2 in position 2-3. Also refer to Jumper settings, chapter 4.2 and 4.3.
  • Page 36 Power Supply Module 4–10 Insertion and exchange Data loss The removal of the backup battery with the power supply module being turned off results in the loss of all remanent data and the PLC program in the RAM! Exchange the backup battery only with the power supply module being turned on! NT1 and NT2 NT3, NT4 and NT 24...

  • Page 37: Data Backup Prior To Power Supply Module Exchange

    120 ms after the occurrence of a voltage failure or the turn-on/off of the CL550 alive. This time is sufficient to store all data for an new start in the static RAM of the ZS550.
  • Page 38 Software Manual”. D Backup on demand secures the remanent areas upon request by PLC instructions; for further information, please refer to ”PLC and CL550 Pro- gramming and Operation, Software Manual”. When using the backup commands for remanent areas, the data in the static RAM always corresponds to the latest storage procedure.

  • Page 39: Structure And Function

    ZS550 5–1 ZS550 Each ZS550 central processing unit constitutes a closed control unit with all data areas and the entire I/O address range. The ZS550s are a democratic system and the units are connected via the system bus by means of an Ethernet coupling.
  • Page 40 ZS550 5–2 ZS550-DP-IBS RESET button LED red: Stop Stop/Run switch LEDs green: Disabled outputs (AS) Select button Fixed in-/outputs (Fix) 7-segment display: Functionality (device) LED red: Select 7-segment display: Status V.24 interface CMD coupling for InterBus-S V.24 interface Ethernet LED green: Speed (S) Ethernet LED green: Link (L) Ethernet connection PROFIBUS-DP connection...

  • Page 41: Elements For Display And Operation

    ZS550 5–3 Elements for Display and Operation Operation elements RESET button Stop/Run switch Select button Operation element Description RESET button Restart (admissible in exceptional situations only) Stop/Run switch Change between Run/Stop D Program runs D Outputs are triggered D Timer and counter values are processed Stop D The CPU (ZS...) is in Stop mode D All outputs are set to ”0”.
  • Page 42 ZS550 5–4 For the display of the ZS550 functionalities (device) applies the following: PLC functionality Busmaster-DP functionality (cyclic I/O processing) TCP/IP-COM functionality via backside; systembus communication (channel 0) TCP/IP-COM functionality via frontside; external communication (channel 1) DP/V1-COM functionality (channel 2) V.24-COM functionality, serial interface –...

  • Page 43: Plc Functionality

    ZS550 5–5 5.2.1 PLC Functionality Status display Select : PLC functionality Status display refers to PLC functionality Display Description status Application program runs Remanence error, data loss at user operands Storage error, missing application program Cyclic time error (HW and SW) Application program error (application stack error, module task error, no DM active) Application program error...

  • Page 44: Busmaster Functionality

    ZS550 5–6 LED displays LED display Description LED red: Stop Module stop by ZS (CPU) (detailed info on 7-segment status display) ZS (CPU) in Run mode LED green: AS Outputs disabled: D all outputs are set to ”0”. D PLC program is processed D I/O image is processed Outputs not disabled LED green: Fix...
  • Page 45 ZS550 5–7 Display Description status OERATE mode (error-free operation); The busmaster is in cyclic I/O data transfer CLEAR mode, cause: D controller in Stop D controller in CLAB (disable outputs) The busmaster is in cyclic I/O data transfer For the outputs 00H will be transferred (outputs canceled) New master parameter set (MPS) is loaded OFFLINE mode The busmaster is offline...

  • Page 46: Tcp/Ip-Com Functionality

    ZS550 5–8 5.2.3 TCP/IP-COM Functionality Status display Select: TCP/IP-COM functionality Status display refers to TCP/IP-COM functionality Display Description status The channel is not active or processes external jobs only (server operation) The central job displayed here is faulty (0–F corresponds to Job ID 0–15) At least one central job with an ID >...

  • Page 47: Dp/V1-Com Functionality

    ZS550 5–9 LED displays of the front Ethernet interface LED display Description LED green: L (Link) No connection Connection is o.k., no activity flashes Connection is o.k., activity LED green: S (Speed) 10 Mbits/s 100 Mbits/s 5.2.4 DP/V1-COM Functionality Status display Select: DP/V1-COM functionality Status display refers to DP/V1-COM functionality Display...

  • Page 48: Power Supply Functionality

    ZS550 5–10 LED ’Send’ of the PROFIBUS interface: LED display Description LED green: Send Bus interface active Bus interface not active. 5.2.5 Power Supply Functionality Status display Select: Power supply (backup battery monitoring) Status display refers to the power supply (backup battery monitoring) Display Description...

  • Page 49: Interbus-S Functionality (Zs550-Dp-Ibs Only)

    ZS550 5–11 5.2.6 InterBus-S Functionality (ZS550-DP-IBS only) Status display Select: InterBus-S functionality Status display refers to InterBus-S functionality Display Description status ACTIVE: InterBus-S in active status USER: User error/parameterization READY: InterBus-S in ready status PF: Peripheral fault DETECT: Diagnosis routine is active Bus error Busmaster cannot access the bus (no idle state level) Possible causes:...

  • Page 50: Functional And Configuration Mode

    ZS550 5–12 5.2.7 Functional and Configuration Mode In functional and configuration mode, the following settings are available: Display Display Description status Cancel fixation Overlay non-remanent start-up, reset remanence error Release output Outputs disabled Serial interface has been assigned with BÜP19E Connecting a programming device is possible Serial interface assigned by tracer (Job reporting) Cancel MPS of DP busmaster part selectively...
  • Page 51 ZS550 5–13 Use the Stop/Run switch within approximately 10 seconds in order to change to configuration mode. The upper display additionally shows a dot. If you do not use the Stop/Run switch within approximately 10 sec- onds, the display ”C” disappears. Select menu items Press the Select button in order to select the requested menu item.

  • Page 52: Serial Interface X31 (Zs550-Dp-Ibs Only)

    ZS550 5–14 Serial Interface X31 (ZS550-DP-IBS only) Upon delivery, the function of the X31 serial interface on the front of the ZS550-DP-IBS is to connect the programming device to the central proces- sing unit. The interface is provided with a 9-pin sub-D socket. The assign- ment of the interface can be changed by the user.

  • Page 53: Serial Interface X32

    ZS550 5–15 Serial Interface X32 The X32 serial interface on the front of the ZS550 serves to connect the pro- gramming device to the central processing unit or as a computer interface. The interface is provided with a 9-pin sub-D socket. The serial interface is operated as COM1.

  • Page 54: Serial Interface X33 (Zs550-Dp-Ibs Only)

    ZS550 5–16 Serial Interface X33 (ZS550-DP-IBS only) The X33 serial interface on the front of the ZS550-DP-IBS serves to couple the CMD software for the InterBus-S. The interface cannot be addressed via the applications program. The interface is provided with a 9-pin sub-D socket.

  • Page 55: Ethernet Interface X71

    ZS550. Ethernet and Internet protocols are the basis for communication. On an Ethernet basis, the UDP/IP standard protocol is used in order to send Bosch BÜP commands. The interface can be addressed directly from the PLC program. It can be operated with a transfer rate of up to 100 Mbits/s.

  • Page 56: Profibus-Dp Interface X72

    ZS550 5–18 PROFIBUS-DP Interface X72 The decentralized peripherals will be connected via a DP/V1 master inter- face. The data exchange with the decentralized bus stations (slaves) is cyclic. I.e. that the master reads the input information from the slaves and writes the output information to the slaves.
  • Page 57 ZS550 5–19 Interconnecting cable When operating a PROFIBUS system, both stations that represent the bus connection must be activated (active bus connection). For PROFIBUS wiring, the following components are available: Designation Order No. Trailing cable, type of line: A 1070 917 201 Bus cable, type of line: A 1070 917 202 Bus connector with inductivities...

  • Page 58: Interbus-S Interface X73 (Zs550-Dp-Ibs Only)

    ZS550 5–20 InterBus-S Interface X73 (ZS550-DP-IBS only) With the ZS550-DP-IBS, the decentralized peripherals can be connected via the DP/V1 master interface and also via an InterBus-S master interface. The data exchange with the decentralized bus stations (slaves) is cyclic. I.e. that the master reads the input information from the slaves and writes the output information to the slaves.

  • Page 59: Technical Data

    FIFO memory 4 x 1024 Remanence optional for M, DF, T, C Serial programming unit interface V.24 interface with 9.6 to 115.2 Kbaud Dimensions Measures of the front plate correspond to a slot of the CL550 1070 072 263-101 (01.08) GB...
  • Page 60 ZS550 5–22 Notes: 1070 072 263-101 (01.08) GB...

  • Page 61: Con550

    CON550 6–1 CON550 The module CON550 is an Ethernet switch for the CL550 system. It provides eight 10/100Base-T interfaces: D 6 interfaces on the frontside for communication with other stations in the network. D 2 interfaces on the backside for communication with other modules of the basic device.

  • Page 62: Address Settings

    6–2 Address Settings The ID of the CL550’s mounting rack is set with both the 10-steps rotary switches. Each mounting rack ID can only be given once in a controlling sys- tem. It identifies each unit in the system unambiguously. The mounting rack ID has already been reserved and shall not be assigned otherwise.

  • Page 63: Ethernet Interfaces X71 And X72

    CON550 6–3 LEDs Link, Transmit/Receive Each of the 8 Ethernet channels is provided with two LED displays. LED display Meaning Connection between CON550 and data terminal LED green: L (ZS550, external switch, etc.) is available The LED must always be lit LED green: T/R No data traffic Data traffic...

  • Page 64: Technical Data

    8 Ethernet interfaces (2 x RJ45, 6 x backside) Data memory 512 Kbyte SRAM Interference immunity factor according EN 50081-2, EN 50082-2 Dimensions Dimensions of the front plate corre- spond to a slot of the CL550 1070 072 263-101 (01.08) GB...

  • Page 65: Commissioning And Configuration

    7–1 Commissioning and Configuration Project Configurator The project configurator is a software tool for the CL550 controller. It is called from within the utility program WinSPS. Call project configurator The project configurator makes it possible for the user to define his/her own system which can be interconnected with several other manufacturing sys- tems.
  • Page 66 Please send the key with the attached fax form to Robert Bosch GmbH. The transmitted number is used to generate a key code that is to be entered into the input field. This key code releases the protected functions.

  • Page 67: Address Assignment

    ZS550 controllers. A connec- tion via the IP addresses will be established. For further information, please refer to the Software Manual, CL550 chapter 3,4, Configuration and Commissioning. 1070 072 263-101 (01.08) GB...
  • Page 68 Commissioning and Configuration 7–4 Notes: 1070 072 263-101 (01.08) GB...

  • Page 69: Accessories And Ordering Information

    Accessories and Ordering Information 8–1 Accessories and Ordering Information Designation Order No. Mounting rack GG4-9, basic device, 9 slots, without withdraw- 1070 081 960 able fanning unit 1070 071 376 1070 062 687 1070 062 309 1070 083 441 NT24 1070 068 046 Central processing unit ZS550 1070 081 964...
  • Page 70 Accessories and Ordering Information 8–2 Notes: 1070 072 263-101 (01.08) GB...

  • Page 71: A Appendix

    Appendix A–1 Appendix Abbreviations Abbreviation Description ANSI American National Standards Institute SRAM Static Random Access Memory BÜP Bosch Transmission Protocol (Bosch- Software Übertragungs-Protokoll) TCP/IP Proto- Transmission Control Protocol/Internet COMx Serial Interface x Protocol Central Processing Unit see CPU Direct Current, Gleichstrom...

  • Page 72: Glossary

    Appendix A–2 Glossary Term Description PROFIBUS- Bus system that is tailored specifically for the requirements of decentralized periph- 10Base-T Ethernet with a transmission speed of 10 erals. Communication of the PROFIBUS- MBit/s via starshaped UTP or STP cab- DP proceeds via a two-wire line. There ling.

  • Page 73: Subject Index

    Appendix A–3 Subject Index Numbers 100Base–T, 6–1, A–2 Data backup, 4–11 10Base–T, 6–1, A–2 cyclic, 4–12 24 V voltage supply, 3–4 on demand, 4–12 7–segment displays, 5–3 Data buffer, 4–11 Data exchange acyclic, 5–18 Accessories, 8–1 cyclic, 5–18, 5–20 Address assignment, 7–3 Data field, 4–11 Address of the mounting rack, 2–2 Data loss, 4–10, 5–5...
  • Page 74 Appendix A–4 Hub, 2–3, 2–7, A–2 NT24, 4–5, 4–7 Remanence, 4–12 NT3, 4–7 I/O address range, 2–1 Remanence, 4–12 IEEE 802, A–2 NT4, Remanence, 4–11 Input, 5–21 Input voltage, 4–4, 4–7 Inrush current, 4–4 Ordering information, 8–1 Insert mounting rack, 3–2 Organization module, 5–21 Instructions list, 2–5 OSI model, A–2...
  • Page 75 Appendix A–5 STP, A–2 Structured text, 2–5 Supply voltage, 4–4, 4–7 Failure, 4–8 Switch, 2–2, 2–3, 2–7, 5–1, 6–1, 6–4, A–2 Switching impulse current, 4–7 Switching voltage, 4–7 System area, 5–21 TCP/IP Protocol, A–2 Technical data Power supply module, 4–7 ZS550, 5–21 Timer, 5–21 Timers, 4–11...
  • Page 76 Appendix A–6 Notes: 1070 072 263-101 (01.08) GB...
  • Page 77 A–1 Bosch-Automationstechnik Robert Bosch GmbH Robert Bosch GmbH Österreich Geschäftsbereich Geschäftsbereich Robert Bosch AG Automationstechnik Automationstechnik Geschäftsbereich Industriehydraulik Antriebs- und Steuerungstechnik Automationstechnik Postfach 30 02 40 Postfach 11 62 Hüttenbrennergasse 5 D-70442 Stuttgart D-64701 Erbach A-1030 Wien Fax (07 11) 8 11-18 57...

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