Siemens SIMATIC S5 User manual

Notes for the Reader 1

IP 244 (-3AA22) Temperature

Controller Instructions 2

IP 244 B (-3AB31) Temperature

Controller Instructions 3

IP 244

Programming Instructions 4

FB 162 (64 Messages)

Programming Instructions 5

Test Program with FB 162

Utilization in S5 6

IP 244

Utilization in S7-400 7

IP 244

Checklist for Start-Up 8

Glossary 9

Index 10

Pocket Guide 11

C79000-G8576-C858-02

IP244

Temperature Controller

with Function Block FB 162

Manual

SIMATIC S5 and S7

SIMATICand SINECare registered trademarks of SIEMENS AG.

This manual contains notices which you should observe to ensure your own personal safety,

as well as to protect the product and connected equipment. These notices are highlighted in

the manual by a warning triangle and are marked as follows according to the level of danger:

!Gefahr

indicates that death, severe personal injury or substantial property damage

will result if proper precautions are not taken.

!Warnung

indicates that death, severe personal injury or substantial property damage

can result if proper precautions are not taken.

!Vorsicht

indicates that minor personal injury or property damage can result if proper

precautions are not taken.

Hinweis

draws your attention to particularly important information on the product, handling the pro-

duct or to a particular part of the documentation.

Only qualified personnel should be allowed to install and work on this equipment. Qualified

persons are defined as persons who are authorized to commission, to ground and to tag

equipment, systems and circuits in accordance with established safety practices and stan-

dards.

Note the following:

!Warnung

This device may only be used for the applications described in the catalog or technical

description, and only in connection with devices or components from other manufacturers

which have been approved or recommended by Siemens.

This product can only function correctly and safely if it is transported, stored and set up

carefully and correctly, and operated and maintained as recommended.

The reproduction, transmission, or use of this document or its

contents is not permitted without express written authority. Offenders

will be liable for damages. All rights, including rights created by

patent grant or registration of a utility model or design, are reserved.

Siemens AG 1995 6ES5998-2AB24

Disclaimer of Liability

We have checked the contents of this manual for agreement with the

hardware and software described. Since deviations cannot be

precluded entirely, we cannot guarantee full agreement. However, the

data in this manual are reviewed regularly and any necessary

corrections included in subsequent editions. Suggestions for

improvement are welcomed.

Technical data subject to change.

Safety

guidelines

Qualified personnel

Correct usage

Notes for the Reader

1 - 3

IP244

C79000–D8576–C858–02

Notes for the Reader

This manual describes

the SIMATIC S5 temperature controller module IP 244

the software package FB 162 and the test program for the temperature controller module

The software is on the accompanying diskette and comprises the following parts:

– organization blocks OB 1, 20, 21, 22

– function block FB 62, 63, 162

– data blocks DB 162, 163, 164, 172, 173

The software package and IP 244 module combine to form a unit for machine controls in pro-

cess control applications.

To familiarize you with the application of the temperature controller and to make information as

accessible as possible, the manual has been divided into several separate functional sections.

Definitions of process control terms used in the manual can be found in the glossary.

Part 2 Instructions for the IP 244 describes the hardware requirements. This part

describes the environment in which the module can be used and explains the

required connections.

Part 3 Programming Instructions for the IP 244 describes the function of the firm-

ware on the module and how to program the module. Using this desription, you

can calculate the required parameters and structure them for the data ex-

change between the programmable controller and the module.

Part 4 Programming Instructions for the Function Block FB 162 (64 messages)

describes the program package with which you can operate the IP 244

temperature controller module.

Part 5 You can use the Test Program for the IP 244 Temperature Controller

Module (FB 62, 63) to test the complete operation of the IP 244.

Part 6 Checklist for Start-Up provides notes about the step-by-step installation and

start-up of the hardware and software for the IP 244 temperature controller.

Part 7 In the Glossary you can find definitions of process control terms used in the

manual.

Part 8 The Index helps you to find the section in the manual you need quickly and

easily by means of key words.

Part 9 The Pocket Guide ”IP 244 Temperature Controller with Function Block FB 162”

provides you with an overview of all messages and the assignment of the data

blocks DB-A, DB-B and DB-C. It serves as a practical guide to help you create

and enter parameters.

Notes for the Reader

IP244

C79000–D8576–C858–02

1 - 4

The following procedure is recommended for problem-free installation and start-up:

Load the contents of the supplied diskette into the CPU of the programmable

controller using the programmer. Then enter a parameter set.

The function block can then be used to transfer the parameters to the tempera

ture controller module. You can now test individual functions and start control

functions by connecting analog signals.

Using FB 162, communication and data exchange is now possible with the

temperature controller module. Temperature control is of course only possible

when the module has been completely wired up.

Once the module has been successfully installed, you can transfer programs from blocks OB 1,

20, 21, 22 and FB 62, 63 to your user program. You are then also in a position to modify data

blocks DB 162, 163 and 164 to suit the requirements of your system.

The following figure shows possible combinations between the IP 244 and the function block FB

162 in all versions delivered so far:

Versions of

the IP 244 Versions of

the FB 162

FB 162

32 messages

FB 162

64 messages

version I

FB 162

64 messages

version II

6ES5 244–

3AA21

6ES5 244–

3AA22

6ES5 244–

3AA13

6ES5 244–

3AA22

6ES5 244–

3AB31 FC 162

for S7-400

Contents

IP244

C79000–B8576–C859–02

2–2

Contents Page

1 Technical Description 2–3

1.1 Application 2–3

1.2 Design 2–3

1.3 Mode of Operation 2–5

1.4 Technical Data 2–7

2 Installation and Operation 2–11

2.1 Inserting and Removing the Module 2–11

2.2 Connecting Signal Lines and the Power Supply 2–11

2.2.1 Analog Inputs (Plug Connector X3) 2–11

2.2.2 Digital Outputs and One Digital Input (Socket Connector X4) 2–12

2.3 Slots 2–14

2.4 Wiring between the PLC and the Plant 2–15

3 Operation 2–19

3.1 Configuring and Connecting the Analog Inputs 2–19

3.1.1 Wiring the Inputs for Channels 0 to 12 when Connecting Thermocouples 2–19

3.1.2 Wiring the Inputs for Channels 13 and 14 to Connect Transducers 2–21

3.1.3 Wiring the Inputs for Channel 15 (Compensation Channel) 2–22

3.1.4 Using the Module for Resistance-Type Sensors (Pt 100) 2–24

3.1.5 Configuring Analog Inputs 0 to 6 2–25

3.1.6 Configuring Analog Inputs 7 to 14 (15) 2–25

3.1.7 Line Break Monitoring 2–26

3.2 Digital Outputs and Comparator Channel 2–26

3.2.1 Digital Outputs 2–26

3.2.2 Comparator Channel 2–26

3.3 Interface to the CPU 2–27

3.4 Jumpers, Switches and Resistors RS and RP 2–28

3.4.1 Setting the Module Address 2–32

3.4.2 Setting the Conversion Time Per Channel 2–33

3.4.3 Setting the Clock 2–34

3.4.4 BASP Evaluation 2–34

3.5 Pin Assignment 2–35

3.6 Pin Assignment of Connecting Cables 2–35

4 Spare Parts 2–37

Technical Description

2–3

IP244

C79000–B8576–C859–02

1 Technical Description

1.1 Application

The IP 244 temperature controller can be used in SIMATIC S5-115U, S5-135U and S5-155U

programmable controllers and expansion units as an intelligent I/O module for automatic control

of machines. When used in the S5-115U, an adapter casing is required (order number:

6ES5 491-0LA11). The IP 244 module is used in S5 systems not only for temperature control

but also for measured value acquisition and limit value monitoring of analog transmitter signals.

The manipulated variables output by the controller are digital. One special application of the

module is in the temperature control of plastic injection molding machines and monitoring the

injection pressure and mold clamping force.

The module is configured as follows:

either: – 15 analog input channels to connect voltage sensors directly.

When delivered, channels 0 to 12 are prepared for thermocouples

(0 to 51.2 mV)

Channels 13 and 14 are used to acquire transducer signals    

Channel 15 is used as a compensation channel for thermocouples and is

suitable for the direct connection of a Pt 100 resistance thermometer

or: – 8 analog input channels for connecting resistance-type sensors

directly using a 4-wire connection (0 to 512 mV)

– A comparator output and 17 digital output channels to output the manipulated variable of the

controller (pulse-duration modulated). Actuators can be operated directly (rated output

current).

– Automatic controller for up to 13 control loops.

– Control function independent of the status of the CPU of the PLC.

1.2 Design

The IP 244 temperature controller module is a compact module in a double-height Eurocard

format belonging to the ES 902 packaging system with a 48-pin backplane connector. The

backplane connector is the interface to the SIMATIC S5 bus.

The front panel contains a 37-pin socket connector for the analog inputs (X3)

L+ (24 V load voltage) is supplied via a tab connector on the front panel, L– is connected to the

reference potential of the controller (central grounding point in the cabinet). L– is supplied to the

module via the Mext pin (external chassis).

20 green LEDs on the front panel indicate the operating status of the temperature controller

module, the input and outputs. A red LED indicates that one or more digital outputs are

short-circuited.

Technical Description

IP244

C79000–B8576–C859–02

2–4

So ket onne tor with 1

digital input (DI) and 17

digital outputs (DQ) and 1

omparator output

R = run LED lit when

module is in operation

E = on LED lit when

ontroller is in operation

i.e. signal 1 at input

K = omparator LED lit

when input voltage on

hannel 13 is greater

than the preset

threshold voltage (see

Se tion 3.2.2)

Plug onne tor with

15 analog inputs (AI)

(13 thermo ouple inputs,

2 transdu er inputs)

and

1 ompensation hannel

Controller

Operation

Short ir uit indi ator

(red)

L+

Fig 1.2/1 Front panel

Technical Description

2–5

IP244

C79000–B8576–C859–02

1.3 Mode of Operation

As shown in the block diagram (Fig. 1.3/1), the analog input signals are switched to an analog

to digital converter (ADC) by a multiplexer. With a maximum conversion time of 80 ms, the ADC

digitalizes the input voltage using the dual slope technique. The 13 control loops (8 with Pt 100

sensors) are processed cyclically. Before the voltage is digitalized, the signal lines are checked

for line breaks and any detected faults are signalled.

A line break is recognized when the total line resistance is greater than 1 kohm or when the

transmitter (thermocouple or resistance-type sensor) has a contact resistance greater than 1

kohm compared with the reference potential. If voltage dividers or shunt resistors are used to

adapt the measuring range, no line break can be signalled. When delivered, no line break signal

is possible for channels 13 and 14.

The parameters and control commands transferred from the CPU via the data bus are stored in

a 2048 byte RAM area which is divided into 64 messages each 32 bytes long. The module

occupies 32 bytes in the address area of the PLC.

A microprocessor controls the functions of the controller module according to the firmware

which is stored in a 64 Kbyte EPROM.

The calculated manipulated variables are output in digital form (pulse-duration modulated) to

output drivers via an output register. If the 5 V power supply fails, the module is reset.

If the 24 V load voltage fails, the module continues to operate; the digital outputs can, however,

no longer be activated. The NAU (power failure) signal is not evaluated by the module.

The digital outputs can be disabled with the BASP signal, the content of the registers is retained

(see Section 3.4.4 BASP Evaluation).

The controller’s integrator values are buffered if the IP 244 controller module is inserted in a slot

with battery back-up (UBATT). The presence of battery back-up is detected by the module

automatically.

Technical Description

IP244

C79000–B8576–C859–02

2–6

The various functions of the controller module are processed by the microprocessor:

– measured value acquisition via multiplexer and ADC

– measured value processing according to the control algorithm, (system error formation,

manipulated variable calculation, self-optimization)

– monitoring limit values of measured values and generation of interrupts

– output of manipulated variables via registers and output drivers

– calculation of the temperature compensation value according to the reference junction

temperature (Pt 100)

– comparison of an analog input value with a digital value (limit value monitoring disabled)

– controlling the interface to the S5 system bus

LED

red ( )

Comparator

M13-

L -

LED (K)

L+

DQ 18

(K)

Differential

amplifier

5Ćbit

subĆaddresses

Channel no.

LED

(E)



Pt 100

Digital inputControl ON/OFF

L +

LED 1

    

     

R/W

13 BASP

Module address



LED

(R)

Analog signal

distribution

Wire break

detecton

internal data bus

Output

drivers

Semiconductor

multiplexer

Address

8/12Ćbit

address

+PESP

A

D

17 Bit

P

Interface

logic

Collision

control

LED 17

DA 1DA17

EPROM

RAM

8Ćbit

data

Data/address

selection

S5 bus

D

Fig. 1.3/1 Block diagram of the temperature controller 244-3AA22

The module can be operated as a switching two or three step controller with percentage output

according to the control algorithm stored in the EPROM.

The controller action (P, PI, PD, PID) is selected by inputting the appropriate parameters. Data

(setpoints and parameters) is exchanged between the CPU and the temperature control module

by means of 64 messages each with a length of 32 bytes.

Technical Description

2–7

IP244

C79000–B8576–C859–02

1.4 Technical Data

Analog inputs

Number of input channels and input voltages:

as delivered

–0 to 51.2 mV = 2048

units for thermocouples 13 (channels 0 to 12)

–0 to 20.48 V = 2048 E 2 (channels 13 and 14)

–for Pt 100 resistance thermometer in 3-wire connection

to compensate the reference junction temperature 1 (channel 15)

configurable

–0 to 512 mV = 2048 units

for resistance-type sensor in 4-wire connection

0 to 999 mV = 3997 units

for voltage sensors

 

15 

–selectable current/voltage ranges by means

of soldered divider/shunt resistors 9 (channels 7 to 15)

Temperature ranges:

FE-constantan (type L and type J) 0 to 700 C

NiCr-Ni (type K) 0 to 1200 C

Pt 10 % Rh-Pt (type S) 0 to 1600 C

Pt 13 % Rh-Pt (type R) 0 to 1600 C

Pt 100 0 to 830 C

reference junction via Pt 100 –20 to +60C

Auxiliary current for resistance measurement 2.56 mA

Isolated no

Permissible potential difference between sensor

and reference potential of the controller (UCM) < 1 V pp

Max. permissible input voltage without damage 18 V for channels without

series and shunt resistors

 60 V for channels 13 and

14 as supplied

0 V for channel 15 (only for

passive sensors) as supplied

Input resistance

–for 0 to 51.2 mV or 512 mV > 10 Mohm

–for 0 to 20 V > 50 kohm

Errors, related to rated value (internal)

linearity 1 unit

digitalization error 1 unit

polarity reversal error 1 unit

Interference suppression for 50/60 Hz

–mains frequency with common mode interference –86 dB, max. 1 Vpp

–with series mode interference 40 dB, max. 100 % of the

measuring range, relative to

the peak value

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