Bosch CL550 User manual

Antriebs- und Steuerungstechnik

Controller Manual

CL550

Edition 101

CL550

Controller Manual

1070 072 263-101 (01.08) GB

E2001

by Robert Bosch GmbH, Erbach, Germany

Reproduction or distribution by any means subject to our prior written permission.

Discretionary charge 10.00 DM

Contents V

1070 072 263-101 (01.08) GB

Contents

Page

1 Safety Instructions 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Intended use 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Qualified Personnel 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Safety Markings on Components 1–3. . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Safety Instructions in this Manual 1–4. . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Safety Instructions for the Described Product 1–5. . . . . . . . . . . . . . .

1.6 Documentation, Software Release and Trademarks 1–7. . . . . . . . .

2 System Overview CL550 2–1. . . . . . . . . . . . . . . . . . . . . .

2.1 Controller Structure 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Communication via Ethernet 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Communication via LAN 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Decentralized In-/Outputs 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Configuration 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Programming 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Central Programming 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 Program Display 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3 WinSPS 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.4 WinDP 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.5 CMD Software (used only with operation of the ZS550-DP-IBS) 2–6

2.5 Installation 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Compliance with Statutes and Standards 2–8. . . . . . . . . . . . . . . . . . .

3 Mounting Rack GG4-9 3–1. . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Dimensions and Assembly 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Fan 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Installation and Electric Connection 3–3. . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Changing the Filter Matt 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Power Supply Module 4–1. . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Selection 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Power Supply NT4 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 NT1 / NT2 / NT3 / NT24 4–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Backup battery 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Data Backup prior to Power Supply Module Exchange 4–11. . . . . . .

Contents

1070 072 263-101 (01.08) GB

Page

5 ZS550 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Structure and Function 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Elements for Display and Operation 5–3. . . . . . . . . . . . . . . . . . . . . . .

5.2.1 PLC Functionality 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Busmaster Functionality 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 TCP/IP-COM Functionality 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.4 DP/V1-COM Functionality 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.5 Power Supply Functionality 5–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.6 InterBus-S Functionality (ZS550-DP-IBS only) 5–11. . . . . . . . . . . . . .

5.2.7 Functional and Configuration Mode 5–12. . . . . . . . . . . . . . . . . . . . . . . .

5.3 Serial Interface X31 (ZS550-DP-IBS only) 5–14. . . . . . . . . . . . . . . . . .

5.4 Serial Interface X32 5–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Serial Interface X33 (ZS550-DP-IBS only) 5–16. . . . . . . . . . . . . . . . . .

5.6 Ethernet Interface X71 5–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 PROFIBUS-DP Interface X72 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 InterBus-S Interface X73 (ZS550-DP-IBS only) 5–20. . . . . . . . . . . . . .

5.9 Technical Data 5–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CON550 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Structure and Function 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Address Settings 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Display Elements 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Ethernet Interfaces X71 and X72 6–3. . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Technical Data 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Commissioning and Configuration 7–1. . . . . . . . . . . . .

7.1 Project Configurator 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Address Assignment 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Accessories and Ordering Information 8–1. . . . . . . . .

A Appendix A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Abbreviations A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Glossary A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.3 Subject Index A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions 1–1

1070 072 263-101 (01.08) GB

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.

1.1 Intended use

This manual contains a comprehensive set of instructions and information

required for the standard operation of the described products. The described

products are used for installation and operation of a CL550 controller.

The described products

Dwere developed, manufactured, tested and documented in accordance

with the relevant safety standards. Normally, the product does not pres-

ent any danger for people or equipment provided that the specifications

and safety instructions relating to project planning, installation, and nor-

mal operation of the product are observed.

Dfully comply with the requirements of

DEMC Directives (89/336/EEC 93/68/EEC, and 93/44/EEC)

DLow-Voltage Directive (73/23/EEC)

DHarmonized standards EN 50081-2 and EN 50082-2

Dare designed for operation in an industrial environment (Class A emis-

sions), i.e.

Ddirect connection to the public low-voltage power supply is not per-

mitted;

DConnection to the medium and/or high-voltage system must be pro-

vided via transformer.

The following applies to the usage in residential settings, in business and

commercial areas and in small-industry settings:

DInstallation in an enclosure with high shield attenuation.

DCables that exit the screened area must be provided with filtering or

screening measures.

DThe user will be required to obtain an individual operating license is-

sued by the appropriate national authority or approval body. In Ger-

many, this is the Regulierungsbehörde für Post und

Telekommunikation(RegTP) (Regulatory Body for Post and Telecom-

munication), and/or its local offices.

.This is a Class A device. In a residential setting, this device may cause

radio interferences. In such a case, the user may be required to

introduce suitable countermeasures at his own costs.

Proper transport, handling and storage, placement and installation of the

product are indispensable prerequisites for its correct and safe operation.

Safety Instructions

1–2

1070 072 263-101 (01.08) GB

1.2 Qualified Personnel

The relevant requirements are based on the job specifications as outlined by

the ZVEI and VDMA in Germany. Please refer to the following German-Lan-

guage publication:

Weiterbildung in der Automatisierungstechnik

Editor: ZVEI and VDMA

Maschinenbau Verlag

Postfach 71 08 64

60498 Frankfurt/Germany

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.

Only trained electricians as per IEV 826-09-01 (modified) who are familiar

with the contents of this manual may undertake installation and mainte-

nance tasks regarding the described products.

These electricians

Dare, due to their professional training, skills and experience and based

upon their knowledge of and familiarity with applicable technical stan-

dards, capable of evaluating the work to be carried out, and of recogniz-

ing possible dangers.

Dpossess, based upon several years of working in a comparable field, a

level of knowledge and skills that may be deemed equal to that after for-

mal professional education.

With regard to the foregoing, please note our comprehensive training pro-

gram. For up-to-date information, web shop for teachware and online sem-

inar booking, please refer to http://www.bosch.de/at/didactic or call our

training center at (+49) (0) 60 62 78-258.

Safety Instructions 1–3

1070 072 263-101 (01.08) GB

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!

Safety Instructions

1–4

1070 072 263-101 (01.08) GB

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.

CAUTION

This symbol is used whenever insufficient or non-compliance with instruc-

tions can result in damage of equipment or data files.

.This symbol is used to alert the user to an item of special interest.

LThis symbol indicates an activity to be performed by the user.

Safety Instructions 1–5

1070 072 263-101 (01.08) GB

1.5 Safety Instructions for the Described Product

DANGER

Life endangered by ineffective EMERGENCY-STOP devices!

EMERGENCY-STOP safety devices must remain effective and acces-

sible during all operating modes of the system. Unlocking the EMER-

GENCY-STOP device must not cause an uncontrolled system restart!

First, test the EMERGENCY-STOP sequence, then restore power!

DANGER

Danger for persons and equipment!

Before operating the system, test every new program!

DANGER

Retrofits or modifications may interfere with the safety of the de-

scribed products!

The consequences may be severe personal injury or damage to the

equipment or the environment. Therefore, any retrofitting or modifi-

cation of the system utilizing components from other manufacturers

does require approval by Bosch.

DANGEROUS ELECTRICAL VOLTAGE

Unless described otherwise, maintenance procedures must only be

carried out when the system is turned off! During this process, the

system must be safe from unauthorized or inadvertent restart.

If measuring or testing procedures must be carried out when the sys-

tem is active, it must be done by trained electricians only.

CAUTION

Do not plug or unplug the module as long as the controller is

switched on! 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!

Safety Instructions

1–6

1070 072 263-101 (01.08) GB

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)!

DThe employees responsible for storage, transport and handling must be

trained in ESD protection.

DStore and transport EEMs in the specified protective packaging.

DWork with EEMs only at special ESD work stations equipped for this par-

ticular purpose.

DEmployees, work surfaces and all devices and tools that could come into

contact with EEMs must be on the same potential (e.g. earthed).

DAn approved earthing wrist strap must be worn. It must be connected to

the work surface via a cable with an integrated 1 MWresistor.

DEEMs must, under no circumstances, come into contact with objects sus-

ceptible to accumulating an electrostatic charge. Most items made of

plastic belong to this category.

DWhen installing EEMs in or removing them from an electronic device, the

power supply of the device must be switched OFF.

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