Part of Totally
Integrated
Automation
ecofast
System Manual Edition 11/2003
Introduction and Notes,
Contents
ECOFAST System Description 1
Power & Control Modul (PCM) IP65 2
Power & Control Modul (PCM)
Cabinet Installation 3
Power Tee Connectors 4
Hybrid Field Bus Connections 5
Data Tee Plug Connector 6
Discriminating Module 7
Installation Guidelines 8
Wiring and Interfaces 9
Questions and Answers A
ECOFAST Pilot ProjectB
Order numbers C
Glossary
Edition 11/2003
System
ECOFAST
System Manual
GWA 4NEB 950 5060-02
Order number
3RK1703-0BB18-0AA0
Safety Guidelines
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:
Danger
indicates that death, severe personal injury or substantial property damage will result if proper precautions
are not taken.
Warning
indicates that death, severe personal injury or substantial property damage can result if proper precautions
are not taken.
Caution
indicates that minor personal injury or property damage can result if proper precautions are not taken.
Caution
indicates that property damage can result if proper precautions are not taken.
Note
draws your attention to particularly imporant information on the product, handling the product, or to a
paricular part of the documentation.
Qualified Personnel
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 circuits, equipment, and
systems in accordance with established safety practices and standards.
Correct Usage
Note the following:
Warning
This device and its components may only be used for the applications described in the catalog or the
technical descriptions, 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, set up, and installed correctly,
and operated and maintained as recommended.
Trademarks
SIMATIC®, SIMATIC HMI®, ECOFAST® and SIMATIC NET® are registered trademarks of SIEMENS AG.
Han Brid®, Han Q8®, Han 10E® are registered trademarks of Harting.
Some of other designations used in these documents are also registered trademarks; the owner´s rights
may be violated if they are used by third parties for their own purposes.
Siemens AG
Automation & Drives
Low Voltage Controls and Distribution
D-91050 Erlangen
Siemens Aktiengesellschaft
© Siemens AG 2003
Technical data subject to change.
Copyright Siemens AG 2003 All rlghts reserved
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority.
Offenders will be liable for damages. All rights, including rights
created by patent grant or registration of a utility model or design,
are reserved.
Disclaimer of Liability
We have checked the contents of this manual for agreement with
the hardware and software described. Since deviations cannot be
precluded entirely, we cannot guarantee full agreement. However,
the data in this manual are reviewed regularely and any necessary
corrections included in subsequent editions. Suggestions for
improvement are welcomed
Technical Assistance: Telephone: +49 (0) 9131-7-43833 (8°° - 17°° MEZ) Fax: +49 (0) 9131-7-42899
E-mail: nst.technical-assistance@siemens.com
Internet: www.siemens.de/lowvoltage/technical-assistance
Technical Support: Telephone: +49 (0) 180 50 50 222
Contents
ECOFAST System Manual
GWA 4NEB 950 5060-02 i
Contents
1 ECOFAST System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Philosophy of the ECOFAST System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.1 Requirements Specified for Innovative Automation and Drive Systems . . . . . . . . . 1-3
1.1.2 Desina and Field Bus Certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1. 1. 3 ECOFAST certified and ECOFAST integrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.4 ECOFAST ES Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.5 The ECOFAST Basic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.6 Topology of the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.7 Overview of Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2 Power & Control Module (PCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Connections of the IP 65 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Installation and Wiring of the IP 65 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.6 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
3 Power & Control Module (PCM), Cabinet Installation . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Connections of the Cabinet Installation Version . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Installation and Wiring of the Cabinet Installation Version . . . . . . . . . . . . . . . . . . . . 3-6
3.3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
4 Power Tee Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Contents
ECOFAST System Manual
ii GWA 4NEB 950 5060-02
5 Hybrid Field Bus Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Installation, Wiring, and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.5 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.6 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.7 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.7.1 Passive Hybrid Field Bus Connection for Supply . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.7.2 Passive Hybrid Field Bus Connection for Conducting . . . . . . . . . . . . . . . . . . . . . . 5-15
5.7.3 Active Hybrid Field Bus Connection for Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.7.4 Active Hybrid Field Bus Connection for Conducting . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.7.5 Active Hybrid Field Bus Connection for Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.7.6 Active Hybrid Field Bus Connection for Conducting . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.7.7 Active Hybrid Field Bus Connection for Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.7.8 Active Hybrid Field Bus Connection for Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.7.9 Conveyor Section With Hybrid Field Bus Connections for Supply and Conducting . . . . . 5-22
5.7.10 Installation Method with PROFIBUS-DP - Cu . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.7.11 PROFIBUS-DP – Optical-Fiber Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.7.12 PROFIBUS-DP (Cu) and Passive Hybrid Field Bus Connections
with 2 Separate Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
5.7.13 PROFIBUS-DP (Cu) and Active Hybrid Field Bus Connections
with 2 Separate Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
5.7.14 PROFIBUS-DP (Optical-Fiber Cable) and Passive Hybrid Field Bus Connections
with 2 Separate Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
6 Data Tee Plug Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1 Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.1 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
7 Discriminating Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3.1 Setting the Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3.2 Required Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.5 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.7 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Contents
ECOFAST System Manual
GWA 4NEB 950 5060-02 iii
8 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Installation Guidelines for PROFIBUS-DP with ECOFAST Hybrid Field Bus Cable . . . . . . 8-2
8.2 Installation Guidelines for PROFIBUS-DP with DESINA Hybrid Field Bus Cable . . . . . . 8-3
8.3 Guidelines for PROFIBUS-DP standard cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.3.1 Potential equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.3.2 Cable Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.4 PNO Installation Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.5 Power Bus Installation Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.5.1 Installation with Power Tee Connector and Power Cable (Prefabricated) . . . . . . . . . . . 8-10
8.5.2 Installation with Power Tee Clamping Connector and Power Cable (Not Prefabricated) . 8-11
8.5.3 Sub-Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5.4 ET 200X Sub-Segments with EM300 Motor Starter . . . . . . . . . . . . . . . . . . . 8-13
8.5.5 Possible power distribution with discriminating modules . . . . . . . . . . . . . . . . . 8-15
8.5.6 Line Protection in Power Bus Segment for Motor Starters
Without Thermal Motor Model (Installation Near Motor) . . . . . . . . . . . . . . . . . 8-16
9 Wiring and Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Securing Plug in Connections that are not Safe Against Finger Touch
When Using Frequency Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Wiring Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.1 Selecting the power leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.2 Unused Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3 Power Cables Prefabricated at One End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.3.1 Power Cables Prefabricated at One End with Han Q8 Pin . . . . . . . . . . . . . . . . . . . . 9-6
9.3.2 Power Cables Prefabricated at One End with Han 10E Pin . . . . . . . . . . . . . . . . 9-7
9.3.3 Prefabricating Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.4 AS Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.4.1 Connection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
A Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
B ECOFAST Pilot Projects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.1 Production line for SIRIUS 2 - Siemens Cham . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.2 Configuration in the Automotive Industry - Production Planning . . . . . . . . . . . . . . . . B-5
2.2.1 Configuration with ECOFAST ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
C Order numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1 Motor Starters (Reversing starters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C.2 Motor Connection Cables and Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
C.3 Power & Control Modules (Infeed Modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
C.4 Discriminating Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
C.5 Hybrid Fieldbus Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
C.6 AS-Interface Shaped Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
C.7 Hybrid Fieldbus Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
C.8 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
C.9 Project engineering software and Documentation . . . . . . . . . . . . . . . . . . . . . . . . C-11
C.10 Tools, Connector Sets, Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Contents
ECOFAST System Manual
iv GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
v
DeutschEnglish
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.
To p i c s
This manual consists of instruction chapters and reference chapters. It
covers the following topics, among others:
• System description
• Power & control module (PCM) IP65 and cabinet installation
• Power tee connector
• Hybrid field bus connections
• Data tee connector
• Discriminating module
• Installation guidelines
• Wiring and interfaces
• Questions and Answers
• ECOFAST pilot projects
• Order numbers
• Glossary
Note
Important information requiring particular attention is enclosed between
two horizontal lines.
Specifications
This manual only describes shared components of the ECOFAST system.
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
vi GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
1-1
ECOFAST System Description 1
Section Topic Page
1.1 Philosophy of the ECOFAST System 1-2
1.1.1 Requirements Specified for Innovative Automation and
Drive Systems
1-2
1.1.2 Desina and Field Bus Certificates 1-4
1.1.3 ECOFAST certified and ECOFAST integrated 1-4
1.1.4 ECOFAST ES Software 1-5
1.1.5 The ECOFAST Basic System 1-5
1.1.6 Topology of the Network 1-6
1.1.7 Overview of Interfaces 1-8
ECOFAST System Description
ECOFAST System Manual
1-2 GWA 4NEB 950 5060-02
1.1 Philosophy of the ECOFAST System
ECOFAST - An integrated connection system for data and power on the field level
The ECOFAST system (Energy and Communication Field Installation System)
sets new standards whenever machines and
plant need to be equipped with automation, control & distribution and drive
technology. The central elements of the ECOFAST philosophy are extensive
decentralization and modularization of the installation system and
comprehensive diagnostics on the component level.
ECOFAST links all the components of an automation system together using
an integrated connection technique for data and power that complies with
the high IP65 degree of protection. ECOFAST is thus an integral part of
"Totally Integrated Automation" and open from the point of view of both
manufacturers and users.
Fig. 1-1: Typical components of an automation system
Motor starter
ELMO pump
SIMATIC ET 200X
SIMATIC S7
COMBIMASTER -
Motor/converter unit ELMO-G side-channel compressor
ECOFAST System Description
ECOFAST System Manual
GWA 4NEB 950 5060-02
1-3
1.1.1 Requirements Specified for Innovative Automation and Drive Systems
• Short phases for offering, planning and configuring machines and plant
• Rapid installation and assembly
• Quick and easy commissioning
• High system availability
Short phases for offering, planning and configuring machines and plant
• Modular planning process for machines and plant
• 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 Description
ECOFAST System Manual
1-4 GWA 4NEB 950 5060-02
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 Q8/0 connectors
• Recommended by Profibus International (PNO) and
Verein Deutscher Werkzeugfabriken VDW (DESINA)
1.1.3 ECOFAST certified and ECOFAST integrated
Fig. 1-3: Zertifikate ECOFAST certified and ECOFAST integrated
ECOFAST certified
The new "ECOFAST certified" certificate, which is assigned by an accredited
test laboratory, guarantees reliable planning. It confirms that devices from
different manufacturers are compatible with ECOFAST specifications.
ECOFAST integrated
Another user-friendly and time-saving feature. Plans and quantity lists/bills
of material 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 manu-
facturers can be integrated in this configuration tool. Their integration and
conformity is confirmed by the "ECOFAST integrated" function.
ECOFAST System Description
ECOFAST System Manual
GWA 4NEB 950 5060-02
1-5
1.1.4 ECOFAST ES Software
The ECOFAST ES configuration tool supports power-engineering system
design with the following range of functions:
• Graphical configuration of the consumers, cables, and switching/protection
functions
• Power bus dimensioning by automatically determining cable cross-sections
and automatic dimensioning of the switching/protection elements
• Power-engineering design and testing according to the relevant standards and
today's generally accepted practices
• Creation of documentation: circuit diagram of the power bus, bills of material
and quantity lists
1.1.5 The ECOFAST Basic System
Fig. 1-4: The ECOFAST basic system
Engineering software
ECOFAST ES
Operator control
and monitoring
e.g. OP 27
Motor starter
motor
plugged in
IP20 component
e.g. SIMOCODE-DP
COMBIMASTER
MM 411
Power & Control
module (PCM)
Motor starter
motor nearby
ET 200X
ECOFAST System Description
ECOFAST System Manual
1-6 GWA 4NEB 950 5060-02
1.1.6 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 with
- PROFIBUS-DP Master
- AS-i Master
- Power Supply 1 x AS-i, 2 x 24 V DC
- 400 V AC Main Power Supply
Power Cable
3/PE-50/60 Hz; 400 V AC
Hybrid Field Bus Cable
2 x 24 V DC and Data
3
a
2 x 24 V DC
1 x AS-i
Bus Terminating
Connector
Data tee
plug
connector
Station 1
Power Tee Plug
Connector
ECOFAST
Consumer
Station 2
ECOFAST
Consumer
Station 32
ECOFAST
Consumer
Station 3
ECOFAST
Consumer
Station 4
ECOFAST
Consumer
Station 1
ECOFAST
Consumer
Station 3
ECOFAST
Consumer
Station 2
Yellow AS-i Line 1 x AS-i and Data
Black AS-i Line 1 x 24 V DC (AUX PWR)
As-i
AUX
PWR
3 x AC
400 V
Insulation Displacement Method
ECOFAST System Description
ECOFAST System Manual
GWA 4NEB 950 5060-02
1-7
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 into the hybrid line (optical fiber or
Cu). ECOFAST motor starters allow the stations on the PROFIBUS-DP to be
connected uninterruptibly to the data tee connector.
The AS-i master supplies the AS-i protocol into the AS-i line. The stations on
the AS-Interface are connected using the insulation displacement method.
ECOFAST System Description
ECOFAST System Manual
1-8 GWA 4NEB 950 5060-02
1.1.7 Overview of Interfaces
Diagram
The diagram below shows an overview of the system interfaces, taking 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
*3RK1 303-2AS51-.... motor starters only
Motor connector Digital inputs Data tee connector
Data connector
Motor terminal
Data terminal
Power terminal Power connector
Power tee connectorLocal device interface*
Hybrid field bus
cable
Local
device
interface
PROFIBUS-DP
PROFIBUS-DP interface
with data terminal,
data tee connector,
data connector optionally for
copper cable (Cu)
or optical-fiber cable
AS-i interface
with insulation displacement method
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 5060-02
2-1
Power & Control Module (PCM) 2
Section Topic Page
2.1 Description 2-2
2.2 Connections of the IP65 Version 2-4
2.3 Installation and Wiring of the IP65 Version 2-6
2.3.1 Installation 2-6
2.3.2 Wiring 2-7
2.3.3 Commissioning 2-9
2.4 Diagnostics 2-10
2.5 Dimension Drawings 2-12
2.6 Technical Specifications 2-13
Power & Control Module (PCM)
ECOFAST System Manual
2-2 GWA 4NEB 950 5060-02
2.1 Description
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 Q8/0 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 fac-
tory. 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
Power & Control Module (PCM)
ECOFAST System Manual
GWA 4NEB 950 5060-02
2-3
Set-up
Depending on the device version, the PCM comprises the following
components:
– PLC (DP master, DP slave, AS-i master)
– 24 V DC (switched) (DC24V-S) and 24 V DC (non-switched) (DC24V-NS)
– 24 V DC switched (AUX PWR) and non-switched (AS-i) for AS-Interface
– 3TK28 (SIGUARD) safety combination or AS-i monitor
Fig. 2-1: Power & control module (PCM) IP65
24 V DC power supplies
The 24 V DC power supplies (switched (24 V DC-S)) and non-switched (24 V
DC-NS)) are available in two different variants. Features you can consider
during configuration:
•Variant 1: SIDAC power supply
– Contains a safety isolating transformer
– Very high EMC resistance
– Very robust
•Variant 2: SITOP power supply
– Very high control accuracy for output voltage
– Settable voltage level
– Lightweight
Power & Control Module (PCM)
ECOFAST System Manual
2-4 GWA 4NEB 950 5060-02
Device versions
Power & control modules are currently available in the following versions:
Table 2-1: PCMl 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 requi-
red.
Max. input voltage: 415 V AC
Device version Order No.
Power and Control Module (PCM), version IP65
Housing dimensions (W x H x D) in mm: 550 x 850 x 255
Overall dimensions
without external connector (W x H x D) in mm: 600 x 920 x 310
Main power supply Safety system Generation
of auxiliary 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
1-0AA0
PROFIBUS master
with S7-300 CPU 313C-2 DP
plus AS-Interface bus master
with 2.4 A AS-Interface
power supply
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- 2A
1-0AA1
SITOP DC 24 V, 10 A (NS),
10 A (S)
4FB2 111- 2A
2-0AA1
Main power supply Breaking capacity External back-up fuse*)
16 A 50 KA 100 A A 0
20 A 50 KA 125 A B 0
25 A 50 KA 125 A C 0
32 A 50 KA 125 A D 0
40 A 50 KA 160 A E 0
Unregulated
Regulated
1
2
Power & Control Module (PCM)
ECOFAST System Manual
GWA 4NEB 950 5060-02
2-5
2.2 Connections of the IP 65 Version
Connections and throughfeeds on the underside
Fig. 2-2: Connections and throughfeeds on the underside of the PCM
Connections on the inside
Fig. 2-3: Connections on the inside of the PCM
2 x Han Brid socket
for PROFIBUS-DP
and 2 x 24 V DC per channel
4 x M screwed gland
Access possible here for round cables
and AS-Interface profile lines
Main
supplied
looped
through
400 V AC
400 V AC
2 x Han Q8/0 socket
for supplying the power bus (400 V AC)
Cable feed-throughs
(access possible here,
e.g. for sensors)
PROFIBUS-DP/
MPI plug
power
Main
power
X10
X2 X3
X08 terminal block
X08
X01
X01 terminal block
(N/L1/L2/L3/PE)
for start, EMERGENCY STOP,
AS-Interface
for main power
Power & Control Module (PCM)
ECOFAST System Manual
2-6 GWA 4NEB 950 5060-02
Power supply X01
Supplying and looping through the main power.
Terminal block N/L1/L2/L3/PE
Caution
All 5 conductors (N/L1/L2/L3/PE) must be wired.
Main circuit output X2/X3
Output: 2 x Han Q8 socket
Pin assignment acc. to DESINA:
AS-Interface field bus: X08
AS-Interface(s) for AS-Interface profile line(s)
• yellow
•black
Assignment page 2-9
PROFIBUS-DP field bus: X10
2 x hybrid field bus socket connection
Pin assignment acc. to DESINA:
Pin Assignment Comment
1 Neutral conductor N —
2 Phase L2 —
3 Brake Optional
4— —
5— —
6 Phase L3 —
7 Brake Optional
8 Phase L1 —
9 PE, ground —
Table 2-2: Pin assignment of the Han Q8 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 2-3: Pin assignment of the hybrid field bus connection
Power & Control Module (PCM)
ECOFAST System Manual
GWA 4NEB 950 5060-02
2-7
2.3 Installation and Wiring of the IP 65 Version
Note
Warning
Hazardous electrical voltages! These may cause electric shock and burns.
Disconnect the system and device from the power supply before starting work.
Caution
Refer to the information in the operating instructions.
2.3.1 Installation
To install the PCM, carry out the following steps:
Table 2-4: Installing the PCM, IP 65 Version
Step Description
1
2
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.
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
PROFIBUS-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.
8
4 x
695
576
Power & Control Module (PCM)
ECOFAST System Manual
2-8 GWA 4NEB 950 5060-02
2.3.2 Wiring
To wire the PCM, carry out the following steps:
Table 2-5: Wiring of the PCM
Step Description
1Open the door of the PCM. To do so, unlock the two safety locks and turn the
main switch counter clockwise.
2Strip the lines. For more information on stripped lengths, cross-sections, and
terminal assignments, refer to the table on the next page.
3Insert the lines for Start, EMERGENCY STOP and if necessary AS-Interface
through the M screwed glands on the underside and into the PCM up to the
X08 terminal block.
4Connect the lines to the X08 terminal block with Cage Clamps.
5Insert the lines for the main power through the M screwed glands on the
underside and into the PCM up to the X01 terminal block,
6Connect the lines to terminal block X01 with cage clamps.
7Connect the hybrid field bus cables (maximum of 2) to X10 if you are using a
PCM with PROFIBUS-DP.
8Connect a maximum of 2 power cables to X2 and X3.
9Attach 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.
10 This completes wiring. Close the F1 circuit-breaker.
Safety lock
Safety lock
Main switch
X01 terminal block
X08 terminal block
(concealed)
F1 circuit breaker
MPI-connector
X10 Han-Brid sockets
(concealed)
Power & Control Module (PCM)
ECOFAST System Manual
GWA 4NEB 950 5060-02
2-9
Stripped lengths, cross sections, terminal assignment
Table 2-6: Stripped lengths, cross sections, terminal assignment
Start EMERGENCY
STOP
AS-Interface AUX PWR Main power
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 mm
2
AWG 28...12 AWG 28...12 AWG 24..0.6
4FB2 111-2AE01-0AA0
xx—— x
4FB2 121-2AE01-0AA0
xx x x x
4FB2 111-2AE01-0AA1
xx—— x
4FB2 112-2AC01-0AA0
x—xx x
4FB2 112-2AC02-0AA0
x—xx x
9
Start
17
917
917
Power & Control Module (PCM)
ECOFAST System Manual
2-10 GWA 4NEB 950 5060-02
2.3.3 Commissioning
Sequence of steps
After installing and wiring the PCM, you must commission it.
To commission the PCM, and thus also the connected field bus(es) and
power bus (sub-)segments, carry out the following steps:
Table 2-7: Sequence of steps for commissioning the PCM
Caution
The AS-i monitor "measures" the connected cables and saves the configura-
tion. During commissioning, the factory-side configuration is still stored. For
this reason, the system displays a prompt after you have entered your pass-
word because the system has to be reconfigured.
Diagram
Fig. 2-4: Commissioning diagram
Step Description
1Turn the rotary switch on the front of the CPU to "RUN".
2If you are using motor starters without a thermal motor model and with a
motor supply lead (installation near motor), also observe the line protection
guidelines in 8.5.6 on page 8-16.
3Close the door of the PCM and lock the two safety locks. Turn the main switch
clockwise.
4Switch on the 400 V AC main power supply.
5Switch on the PCM.
6Reset the external EMERGENCY STOP if necessary and actuate the external
start switch. The power bus(es) and the field bus(es) are now supplied with
power.
7Configure the AS-i monitor if necessary. The password assigned in the factory
is "ECOFAST". Note the information below.
Rotary switch on
Safety lock
Main switch
Safety lock
CPU (concealed)
Main power
External
start switch
Start
Power & Control Module (PCM)
ECOFAST System Manual
GWA 4NEB 950 5060-02
2-11
2.4 Diagnostics
Missing voltages
Table 2-8: Diagnostics - missing voltages
Voltage missing Shown by Potential fault Cause
400 V AC 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 OFF 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
Power & Control Module (PCM)
ECOFAST System Manual
2-12 GWA 4NEB 950 5060-02
Signal states
Table 2-9: Diagnostics - signal states
Signal What’s wrong? Potential fault Cause
D1/D2 E 0.0 OFF All OFF Q1 OFF ---
D1/D2 E 0.1 OFF All OFF Q1 overloaded ---
D1/D2 E 0.2 OFF All OFF Q1 short circuit ---
D1/D2 E 0.3 OFF 400 V AC K1, K2 OFF D5 (K5), emergency
stop, 24 V internal
D1/D2 E 0.4 OFF 24 V switched, 24 V
AS-i
K3, K4 OFF D5 (K5), emergency
stop, 24 V internal, F2/
channel 1
D1/D2 E 0.5 OFF 400 V, 24 V switched,
24 V AS-i
K1, K2, K3, K4 Emergency stop
D1/D2 E 0.6 OFF 24 V non-switched F2/channel 3 F2/channel 3
overloaded
D1/D2 E 0.7 OFF 24 V switched F2/channel 1 F2/channel 2
overloaded
D1/D2 E 1.0 OFF All OFF F1 OFF Overload, short circuit
D1/D2 E 1.1 OFF 24 V AS-i F2/channel 2 Overload, short circuit
F2/channel 1 red ON 24 V switched F2/channel 1 Overload, short circuit
F2/channel 2 red ON 24 V AS-i F2/channel 2 Overload, short circuit
F2/channel 3 red ON 24 V non-switched F2/channel 3 Overload, short circuit
F2/channel 4 red ON All OFF F2/channel 4 Overload, short circuit
Power & Control Module (PCM)
ECOFAST System Manual
GWA 4NEB 950 5060-02
2-13
2.5 Dimension Drawings
Fig. 2-5: Dimension drawings of the power & control module
600 ± 2
576
850 ± 2
50 ± 0.2
695 ± 1
Ø 9
Ø 15
4 x
255 max.
310 max.
920 max.
695
576
8
4 x
Drilling dimensions: Clearance (hatched):
400
PCM
400
100* 100
150*
* Allow clearance for plug if necessa
Power & Control Module (PCM)
ECOFAST System Manual
2-14 GWA 4NEB 950 5060-02
2.6 Technical Specifications
Order number 4FB2111-2AE01-
0AA0
4FB2121-2AE01-
0AA0
4FB2111-2AE01-
0AA1
4FB2112-2AC0. -
0AA0
Version
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 3 AC 400 V/10% +6%
System frequency I range 50, 60 Hz ± 5%
Main power supply See table Seite 2-4
Output
Main circuit 3 AC 400 V
24 V switched (24 V S)
Output voltage 24 V DC (20.4 V to 28.8 V)
Output current DC 5 A when AS-Interface fitted
DC 10 A when AS-Interface not fitted
Residual ripple < 5%
Backup min. 20 ms
24 V DC non-switched (24 V S)
Output voltage 24 V DC (20.4 V to 28.8 V)
Output current 10 A DC 10 A DC 10 A DC 10 A DC
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 — 30 V DC
(29.5 V to 31.6 V)
—30 V DC
(29.5 V to 31.6 V)
Output current — 2.4 A DC — 2.4 A DC
Residual ripple — < 300 mVpp — < 300 mVpp
Backup — min. 20 ms — min. 20 ms
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
Certificates and approvals
(in preparation)
CE, UL, CSA
Safety class I
Power & Control Module (PCM)
ECOFAST System Manual
GWA 4NEB 950 5060-02
2-15
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 (no condensation)
Air pressure 700 to 1060 hPa
Mechanical environmental conditions
Transport
Vibratory load 3g
Shock 15 g with 11 ms
Operation
Vibratory load f = 10 to 58 Hz, d = 0,075 mm/58 to 100 Hz, 10g
Shock 10 g with 6 ms/6 g with 10 ms
Connections/feed-throughs
Input connections Cage Clamp max. 2 x 16 mm2 max. current carrying capacity
Throughfeeds 2 x M40 x 1.5
Output connections
Main circuit
2 x HAN Q8 socket (DESINA)
Output connections
Auxiliary circuits/field bus
2 x HAN Brid socket/socket (DESINA)
Output connections
AS-Interface —
Cage Clamp,
2.5 mm2
Throughfeed
4 x AS-i seal
Cage Clamp,
2.5 mm2
Throughfeed
4 x AS-i seal
—
Output connections
EMERGENCY STOP
Cage Clamp,
2.5 mm2
Throughfeed via
cable through-
feed flange
Cage Clamp,
2.5 mm2
Throughfeed via
cable through-
feed flange
Cage Clamp,
2.5 mm2
Throughfeed via
cable through-
feed flange
Cage Clamp,
2.5 mm2
Throughfeed via
cable through-
feed 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
Order number 4FB2111-2AE01-
0AA0
4FB2121-2AE01-
0AA0
4FB2111-2AE01-
0AA1
4FB2112-2AC0. -
0AA0
Power & Control Module (PCM)
ECOFAST System Manual
2-16 GWA 4NEB 950 5060-02
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 200B
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 4FB2111-2AE01-
0AA0
4FB2121-2AE01-
0AA0
4FB2111-2AE01-
0AA1
4FB2112-2AC0. -
0AA0
ECOFAST System Manual
GWA 4NEB 950 5060-02
3-1
Power & Control Module (PCM),
Cabinet Installation 3
Section Topic Page
3.1 Description 3-2
3.2 Connections of the Cabinet Installation Version 3-4
3.3 Installation and Wiring of the Cabinet Installation Version 3-6
3.3.1 Installation 3-6
3.3.2 Wiring 3-7
3.3.3 Commissioning 3-9
3.4 Diagnostics 3-10
3.5 Dimension Drawings 3-12
3.6 Technical Specifications 3-13
Power & Control Module (PCM), Cabinet Installation
ECOFAST System Manual
3-2 GWA 4NEB 950 5060-02
3.1 Description
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 Q8/0 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 fac-
tory. 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
Power & Control Module (PCM),
ECOFAST System Manual
GWA 4NEB 950 5060-02
3-3
Set-up
Depending on the device version, the PCM comprises the following
components:
– PLC (DP master, DP slave, AS-i master)
– 24 V DC (switched) (DC24V-S) and 24 V DC (non-switched) (DC24V-NS)
– 24 V DC switched (AUX PWR) and non-switched (AS-i) for AS-Interface
– 3TK28 (SIGUARD) safety combination or AS-i monitor
Fig. 3-1: Power & control module (PCM) IP65
24 V DC power supplies
The 24 V DC power supplies (switched (24 V DC-S) and non-switched (24 V
DC-NS)) are available in two different variants. Features you can consider
during configuration:
•Variant 1: SIDAC power supply
– Contains a safety isolating transformer
– Very high EMC resistance
– Very robust
•Variant 2: SITOP power supply
– Very high control accuracy for output voltage
– Settable voltage level
– Lightweight
Power & control module
for cabinet installation
with 24 V DC SITOP power supply
Power & Control Module (PCM), Cabinet Installation
ECOFAST System Manual
3-4 GWA 4NEB 950 5060-02
Device versions
Power & control modules for cabinet installation are currently available in
the following versions:
Table 3-1: PCMl 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
Device version Order No.
Power and Control Module (PCM), cabinet installation version
Housing dimensions (W x H x D) in mm: 550 x 850 x 255
Overall dimensions
without external connector (W x H x D) in mm: 600 x 920 x 310
Main power supply Safety system Generation
of auxiliary 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
1-0AA0
PROFIBUS master
with S7-300 CPU 313C-2 DP
plus AS-Interface bus master
with 2.4 A AS-Interface
power supply
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- 2A
1-0AA1
SITOP DC 24 V, 10 A (NS),
10 A (S)
4FB2 111- 2A
2-0AA1
Main power supply Breaking capacity External back-up fuse*)
16 A 50 KA 100 A A 0
20 A 50 KA 125 A B 0
25 A 50 KA 125 A C 0
32 A 50 KA 125 A D 0
40 A 50 KA 160 A E 0
Unregulated
Regulated
1
2
Power & Control Module (PCM),
ECOFAST System Manual
GWA 4NEB 950 5060-02
3-5
3.2 Connections of the Cabinet Installation Version
Connections and feed-throughs on the underside
Fig. 3-2: Connections and throughfeeds on the underside of the PCM
Power supply X01
Supplying and looping through the main power.
Terminal block N/L1/L2/L3/PE
Caution
All 5 conductors (N/L1/L2/L3/PE) must be wired.
Main circuit output X2/X3
To supply the power bus
2 x terminal block N/L1/L2/L3/PE
Start, EMERGENCY STOP, field bus AS-Interface X08
AS-i interface(s) for AS-Interface profile line(s)
• Yellow
•Black
Assignment page 3-8
24 V DC geschaltet und nicht geschaltet X10
PROFIBUS-DP field bus:
2 x 9-pin SUB-D socket directly on PLC
X08
X01
X2/X3X10
PROFIBUS-DP
2 x 9-pin
SUB-D socket
Terminal block X10
2 x 24 V DC
(switched and
non-switched)
Terminal block X2/X3
Output
Main circuit
400 V AC
X08 terminal block
for start, EMERGENCY
STOP, AS-Interface
X01 terminal block
(N/L1/L2/L3/PE)
Power supply
Power & Control Module (PCM), Cabinet Installation
ECOFAST System Manual
3-6 GWA 4NEB 950 5060-02
3.3 Installation and Wiring of the Cabinet Installation
Version
Note
Warning
Hazardous electrical voltages! These may cause electric shock and burns.
Disconnect the system and device from the power supply before starting work.
Caution
Refer to the information in the operating instructions.
3.3.1 Installation
To install the PCM, carry out the following steps:
Table 3-2: Installing the PCM, Cabinet Installation Version
Step Description
1
2
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.
The PCM is designed to be installed in
control cabinets. The degree of protection
of the control cabinet must be at least
IP32.
Drill 4 holes for the screws.
8
4 x
809
350
Power & Control Module (PCM),
ECOFAST System Manual
GWA 4NEB 950 5060-02
3-7
3.3.2 Wiring
To wire the PCM, carry out the following steps:
Table 3-3: Wiring of the PCM
Step Description
1Strip the lines. For more information about the stripped lengths, cross-
sections, and terminal assignments, refer to the table on the next page.
2Insert the lines for start, EMERGENCY STOP and, if necessary, the AS-Interface
into the control cabinet and use cage clamps to connect them to terminal
block X08.
3Insert the lines for 24 V DC (switched) and 24 V DC (non-switched) into the
control cabinet and use cage clamps to connect them to terminal block X10.
4Insert the lines for the power supply into the control cabinet and use cage
clamps to connect them to terminal block X01.
5Insert the lines for the main circuit outputs into the control cabinet and use
cage clamps to connect them to terminal block X2/X3.
6Connect the PROFIBUS-DP to the 9-pin SUB-D socket on the front of the CPU.
7This completes wiring. Close the F1 circuit-breaker.
8Close the cabinet door.
Power & Control Module (PCM), Cabinet Installation
ECOFAST System Manual
3-8 GWA 4NEB 950 5060-02
Stripped lengths, cross sections, terminal assignment
Table 3-4: Stripped lengths, cross sections, terminal assignment
IP00 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 mm
2
AWG 28...12 AWG 28...12 AWG 24...6
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
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 ... 10mm
2
AWG 28...12 AWG 28...12 AWG 24...8
9
Start
17
917
917
912
912
912
2
31
X01 Cage Clamp
X08
Power & Control Module (PCM),
ECOFAST System Manual
GWA 4NEB 950 5060-02
3-9
3.3.3 Commissioning
Sequence of steps
After installing and wiring the PCM, you must commission it.
To commission the PCM, and thus also the connected field bus(es) and
power bus (sub-)segments, carry out the following steps:
Table 3-5: Sequence of steps for commissioning the PCM
Caution
The AS-i monitor "measures" the connected cables and saves the configura-
tion. During commissioning, the factory-side configuration is still stored. For
this reason, the system displays a prompt after you have entered your pass-
word because the system has to be reconfigured.
Step Description
1If you are using motor starters without a thermal motor model and with a
motor supply lead (installation near motor), also observe the line protection
guidelines in
8.5.6 on page 8-16.
2Switch on the 400 V AC main power supply.
3If necessary, reset the external EMERGENCY STOP function and press the
external start switch. The power bus(es) and the field bus(es) are now
supplied with power.
4Configure the AS-i monitor if necessary. The password assigned in the factory
is "ECOFAST". Note the information below.
Power & Control Module (PCM), Cabinet Installation
ECOFAST System Manual
3-10 GWA 4NEB 950 5060-02
3.4 Diagnostics
Missing voltages
Table 3-6: Diagnostics - missing voltages
Voltage missing Shown by Potential fault Cause
400 V AC 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 OFF 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
Power & Control Module (PCM),
ECOFAST System Manual
GWA 4NEB 950 5060-02
3-11
Signal states
Table 3-7: Diagnostics - signal states
Signal What’s wrong? Potential fault Cause
D1/D2 E 0.0 OFF All OFF Q1 OFF ---
D1/D2 E 0.1 OFF All OFF Q1 overloaded ---
D1/D2 E 0.2 OFF All OFF Q1 short circuit ---
D1/D2 E 0.3 OFF 400 V AC K1, K2 OFF D5 (K5), emergency
stop, 24 V internal
D1/D2 E 0.4 OFF 24 V switched, 24 V
AS-i
K3, K4 OFF D5 (K5), emergency
stop, 24 V internal, F2/
channel 1
D1/D2 E 0.5 OFF 400 V, 24 V switched,
24 V AS-i
K1, K2, K3, K4 Emergency stop
D1/D2 E 0.6 OFF 24 V non-switched F2/channel 3 F2/channel 3
overloaded
D1/D2 E 0.7 OFF 24 V switched F2/channel 1 F2/channel 2
overloaded
D1/D2 E 1.0 OFF All OFF F1 OFF Overload, short circuit
D1/D2 E 1.1 OFF 24 V AS-i F2/channel 2 Overload, short circuit
F2/channel 1 red ON 24 V switched F2/channel 1 Overload, short circuit
F2/channel 2 red ON 24 V AS-i F2/channel 2 Overload, short circuit
F2/channel 3 red ON 24 V non-switched F2/channel 3 Overload, short circuit
F2/channel 4 red ON All OFF F2/channel 4 Overload, short circuit
Power & Control Module (PCM), Cabinet Installation
ECOFAST System Manual
3-12 GWA 4NEB 950 5060-02
3.5 Dimension Drawings
Fig. 3-3: Dimension drawings of the power & control module
520
350
830
809
Ø 9
2 x
224
2 x
Ø 9
809
350
8
4 x
Power & Control Module (PCM),
ECOFAST System Manual
GWA 4NEB 950 5060-02
3-13
3.6 Technical Specifications
Order number 4FB2111-2AE01-
0AA0
4FB2121-2AE01-
0AA0
4FB2111-2AE01-
0AA1
4FB2112-2AC0. -
0AA0
Version
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 3 AC 400 V/–10% +6%
System frequencyIrange 50, 60 Hz ± 5%
Main power supply See table page 2-4
Output/main circuit 3 AC 400 V
24 V switched (24 V S)
Output voltage 24 V DC (20.4 V to 28.8 V)
Output current DC 5 A when AS-Interface fitted
DC 10 A when AS-Interface not fitted
Residual ripple < 5%
Backup min. 20 ms
24 V DC non-switched (24 V S)
Output voltage 24 V DC (20.4 V to 28.8 V)
Output current 10 A DC 10 A DC 10 A DC 10 A DC
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 — 30 V DC
(29.5 V to 31.6 V)
—30 V DC
(29.5 V to 31.6 V)
Output current — 2.4 A DC — 2.4 A DC
Residual ripple — < 300 mVpp — < 300 mVpp
Backup min. 20 ms min. 20 ms min. 20 ms min. 20 ms
Protection and monitoring
Short circuit protection
Main circuit Built-in circuit breaker
Auxiliary circuits Built-in SDM
Signaling devices Green (ready for operation)
Yellow (power connected)
Red (internal fault)
Safety
Degree of protection IP65
Certificates and approvals
(in preparation)
CE, UL, CSA
Safety class I
Power & Control Module (PCM), Cabinet Installation
ECOFAST System Manual
3-14 GWA 4NEB 950 5060-02
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 (no condensation)
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, 10g
Schock 10 g with 6 ms/6 g with 10 ms
Connections/feed-throughs
Input connections Cage Clamp max. 2 x 16 mm2 max. current carrying capacity
Output connections
Main circuit
Cage Clamp,
2,5 mm2
Cage Clamp,
2,5 mm2
Cage Clamp,
2,5 mm2
Cage Clamp,
2,5 mm2
Output connections
Auxiliary circuits/field bus
Cage Clamp,
2,5 mm2
Cage Clamp,
2,5 mm2
Cage Clamp,
2,5 mm2
Cage Clamp,
2,5 mm2
Output connections
AS-Interface —
Cage Clamp,
2.5 mm2
Throughfeed
4 x AS-i seal
Cage Clamp,
2.5 mm2
Throughfeed
4 x AS-i seal
—
Output connections
EMERGENCY STOP
Cage Clamp,
2.5 mm2
Cage Clamp,
2.5 mm2
Cage Clamp,
2.5 mm2
Cage Clamp,
2.5 mm2
SIMATIC connections Cage Clamp, 1.5 mm2
Dimensions/weight
Housing dimensions (WxHxD) 520 x 830 x 240
Fixing dimensions (WxH) 350 x 809
Fixing holes 4 x M8
Weight max. 55 kg
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 200B
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 4FB2111-2AE01-
0AA0
4FB2121-2AE01-
0AA0
4FB2111-2AE01-
0AA1
4FB2112-2AC0. -
0AA0
ECOFAST Systemhandbuch
GWA 4NEB 950 5060-01
4-1
Power Tee Connectors 4
Section Topic Page
4.1 Description 4-2
4.2 Connections 4-5
4.3 Installation and Wiring 4-6
4.4 Dimension Drawings 4-8
4.5 Technical Data 4-9
Power Tee Connectors
ECOFAST Systemhandbuch
4-2 GWA 4NEB 950 5060-01
4.1 Description
Ta s k s
Power tee connectors connect ECOFAST components with the power bus.
The power bus is not interrupted when the ECOFAST components are
unplugged.
Three different versions are available:
• Power tee connectors: this version connects the "incoming" power cable to
the consumer using a Han Q8 mating connector. To conduct the main power,
a power cable with free ends must be connected to the screw-type terminals.
Scopes of supply:
– Individually, including cable gland and Han Q8 plug housing for screw-
type terminals.
– Prefabricated, with cable in different lengths for conducting the main
power. This supply type will not be described in this chapter.
• Power tee clamping connector with Han Q8 socket. This version connects
standard round cables to the consumer. The round cable is contacted using
the insulation displacement method.
• Power tee clamping connector with Han Q8 pin. This version connects stan-
dard round cables to the power & control module, for example. The round
cable is contacted using the insulation displacement method.
Power Tee Connectors
ECOFAST Systemhandbuch
GWA 4NEB 950 5060-01
4-3
Versions
The following versions are currently available:
Table 4-1: Power tee connector versions
Sealing Sets for Power Tee Clamping Connectors
Suitable seal sets are required for the power tee clamping connectors to
attain degree of protection IP65/67. A seal set contains two seals, which are
available with different internal diameters depending on the external diame-
ter 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.
Caution
Sealing sets are not supplied with the power tee clamping connector. They
must be ordered separately.
The following sealing sets are currently available:
Table 4-2: Sealing sets for power tee clamping connectors
Order number Version Function
3RK1 911-2BG00 Power tee connector Connect consumer
3RK1 911-2BF00 Power tee clamping connector Connect consumer
3RK1 911-2BE00 Power tee clamping connector Connect power supply
(e.g. PCM)
Order number External diameter of round
cable/mm
3RK1911-5BA00 10 to 13
3RK1911-5BA10 13 to 16
3RK1911-5BA20 16 to 19
3RK1911-5BA30 19 to 22
Power Tee Connectors
ECOFAST Systemhandbuch
4-4 GWA 4NEB 950 5060-01
Installation
Fig. 4-1: Power tee connectors
Sealing for
round cable*)
Sealing for
round cable*)
Cover
Fixing lug
Cover
Fixing lug
Han Q8 socket
To
consumer
Direction of
power
Power tee connector
Han Q8 plug housing
with seal and PG screwed gland
Screw-type terminals
Power tee clamping connector
Han Q8 socket
to power supply (e.g. PCM)
Sealing for
round cable *)
Han Q8 pin
to power supply (e.g. PCM)
Power tee clamping connector with round cable inserted
and cover open
Terminal block with clamping screws
*) not supplied
Power Tee Connectors
ECOFAST Systemhandbuch
GWA 4NEB 950 5060-01
4-5
4.2 Connections
Fig. 4-2: Terminal assignment for power tee connectors
Terminal Assignment Core no.*
1 Phase L1
2 Phase L2
3 Phase L3
PE
4 Neutral conductor N
5Brake
6 Brake (reference potential)
222
333
444
111
555
666
1
2
3
4
5
6
Terminal Assignment Core no.*
1 Neutral conductor N
2 Phase L2
4Brake
PE
5 Brake (reference potential)
6 Phase L3
8 Phase L1
111
333
555
666
444
222
128456
1
2
4
5
11
22
44
333
55
Caution
Note that core numbers and terminal numbers are not
identical for prefabricated power cables.
Please read the information in "Installation and
Wiring" as of page 4-6.
* Core no.
Power tee connector
Terminal numbers and Han Q8 pin numbers
have the same assignment
Power tee clamping connector
Terminal numbers and Han Q8 pin numbers
do not have the same assignment
Power Tee Connectors
ECOFAST Systemhandbuch
4-6 GWA 4NEB 950 5060-01
4.3 Installation and Wiring
Warning
Hazardous electrical voltages! These may cause electric shock and burns.
Disconnect the system and device from the power supply before starting work.
Caution
Refer to the information in the operating instructions.
Procedure for installing and wiring the power tee connector
To install and connect the power tee connector, carry out the following
steps:
Table 4-3: Installing and connecting the power tee connector
Wiring
Fig. 4-3: Power tee connector wiring
Step Procedure
1Strip the power cable.
2Route the power cable through the PG screwed gland on the seal provi-
ded and the plug housing.
3If necessary, unscrew the clamping screws.
4Insert the individual wires into the screw-type terminals and secure the
clamping screw. Make sure the terminals are assigned correctly.
5Push the plug housing onto the power tee connector until you hear it
engage.
6Push the seal onto the plug housing and secure the PG screwed gland.
7The power tee connector is now installed and connected.
The core numbers and their
assignments are valid for
power cables prefabricated at
one end.
Note that the core numbers
and terminal numbers are not
identical.
Terminal Core no. Assignment
1 Neutral conductor N
2Phase L2
4Brake
PE
5 Brake (referencepotential)
6Phase L3
8Phase L1
111
333
555
666
444
222
Power Tee Connectors
ECOFAST Systemhandbuch
GWA 4NEB 950 5060-01
4-7
Procedure for installing and wiring the power tee clamping connector
Table 4-4: Installing and connecting the power tee clamping connector
Wiring
Fig. 4-4: Power tee clamping connector wiring
Step Procedure
1Connect the power tee clamping connector to the Han Q8 power termi-
nal on the matching mating component (e.g. the consumer or the power
supply). Secure the connection with the locking device
2If required, you can screw the fixing lugs on the power tee clamping con-
nector onto a flat surface using screws with a diameter of 5 mm.
3Loosen the four screws in the cover. Open the cover.
4Unscrew the clamping screws.
5Strip the insulation from the power cable over a length of approximately
130 mm. Take care not to damage the insulation of the individual wires.
6Place 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.
7Insert the individual wires in the insulation displacement terminations.
Make sure the terminals are assigned correctly.
8Insert the throughfeeds with the round cable. Align the stripped part of
the cable centrally inside the housing.
9Firmly secure the clamping screws. The individual wires are bonded via
the insulation displacement terminations.
10 Close the cover. The power tee clamping connector is now installed and
connected.
1111 1111
1
222
22
222
2
333
33333
3
4444 444
44
130
~
~
Terminal Core no. Assignment
1 Phase L1
2 Phase L2
3 Phase L3
PE
4 Neutral conductor N
5Brake
6 Brake (reference potential)
222
333
444
111
555
666
The core numbers and their
assignments are valid for
power cables prefabricated at
one end.
Note that the core numbers
and terminal numbers are not
identical.
Power Tee Connectors
ECOFAST Systemhandbuch
4-8 GWA 4NEB 950 5060-01
4.4 Dimension Drawings
Fig. 4-5: Dimension drawings of power tee connectors
112,6
158
130 55
142,5
78,5
Ø5,5
Ø5,5
35
102
107
57,1
104 24
PG 16
Power tee connector
Power tee clamping connector
Power Tee Connectors
ECOFAST Systemhandbuch
GWA 4NEB 950 5060-01
4-9
4.5 Technical Data
Table 4-5: Technical data for power tee connectors
Location On the system • Wall mounting
• Mounted directly on the
ECOFAST consumer
Suitable cables
Power tee connector 7 x 4 mm2Power bus
7 x 2.5 mm2Consumer
Power tee clamping connector 5 x 4 mm2External dia.: approx. 14 mm
Throughfeed dia.:approx. 13 to 16
mm
7 x 2.5 mm2External dia.: approx. 14.5 mm
Throughfeed dia.:approx. 13 to 16
mm
Rated current 32 A
Installation position Any
Degree of protection IP65/67 Watertight acc. to
IEC 529 (DIN 40050)
Enclosure dimensions: H x W x D 1
Power tee connector 107 x 104 x 35
Power tee clamping connector 112.6 x 158 x 55
Weight Approx. 0.3 kg
Installation temperature -10°C to +40°C Establish bonding
Operating temperature -25°C to +40°C
Storage/transport temperature -40°C to +80°C
Number of poles 7
Vibratory load 5 g
Rated insulation voltage 500 V
600 V
according to EN 61 984
according to UL 1977
Standards, approvals DIN VDE 0627 UL 1977, CSA
Power Tee Connectors
ECOFAST Systemhandbuch
4-10 GWA 4NEB 950 5060-01
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-1
Hybrid Field Bus Connections 5
Section Topic Page
5.1 Description 5-2
5.2 Connections 5-4
5.3 Installation, Wiring and Commissioning 5-7
5.3.1 Installation 5-7
5.3.2 Wiring 5-8
5.3.3 Commissioning 5-10
5.4 Diagnostics 5-11
5.5 Dimension Drawings 5-12
5.6 Technical Specifications 5-13
5.7 Applications 5-14
5.7.1 Passive Hybrid Field Bus Connection for Supply 5-14
5.7.2 Passive Hybrid Field Bus Connection for Conducting 5-15
5.7.3 Active Hybrid Field Bus Connection for Supply 5-16
5.7.4 Active Hybrid Field Bus Connection for Conducting 5-17
5.7.5 Active Hybrid Field Bus Connection for Supply 5-18
5.7.6 Active Hybrid Field Bus Connection for Conducting 5-19
5.7.7 Active Hybrid Field Bus Connection for Supply 5-20
5.7.8 Active Hybrid Field Bus Connection for Supply 5-21
5.7.9 Conveyor Section with Hybrid Field Bus Connections for
Supply and Conducting
5-22
5.7.10 Installation Method with PROFIBUS-DP – Cu 5-23
5.7.11 PROFIBUS-DP -Optical-Fiber Cables 5-24
5.7.12 PROFIBUS-DP (Cu) and passive Hybrid Field Bus
Connections with 2 Separate Power Supplies
5-25
5.7.13 PROFIBUS-DP (Cu) and active Hybrid Field Bus Connections
with 2 Separate Power Supplies
5-26
5.7.14 PROFIBUS-DP (LWL) and passive Hybrid Field Bus Connec-
tions with 2 Separate Power Supplies
5-27
Hybrid Field Bus Connections
ECOFAST System Manual
5-2 GWA 4NEB 950 5060-02
5.1 Description
Ta s k s
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 optical-fiber cable.
– 2 x 24 V DC, switched (S) and non-switched (NS).
• Conduct:
– data via RS 485, shielded copper cable (Cu) or optical-fiber cable.
– 2 x 24 V DC, switched (S) and non-switched (NS).
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 sok-
ket (9-pin).
Fig. 5-1: Hybrid field bus connections
3RK1911-1AB32
IP65 side (field bus level, external) IP20 side (in control cabinet)
Example:
Conducting
optical-fiber
cable
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-3
Versions
The following versions are currently available:
Table 5-1: Hybrid field bus connection versions
Passive and active
• Passive means that the signals are not regenerated. The IP20 and IP65 sides
are electrically connected.
• Active means that the signals are regenerated (repeater function). The IP20
and IP65 sides are electrically isolated for versions with an optical-fiber cable.
24 V DC non-switched supply voltage (NS)
This voltage is required for:
• supplying the electronics
• interrogating the auxiliary contacts
24 V DC switched supply voltage (S)
This voltage is required for:
• controlling the switching elements (e.g. contactor)
Order number 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
(optical-fiber cable)
SUB-D socket
3RK1911-1AB32 Conducting
(active)
Pin/socket
(optical-fiber cable)
SUB-D socket
3RK1911-1AE22 Supply
(active)
Socket/socket
(copper)
SUB-D socket
3RK1911-1AE32 Conducting
(active)
Pin/socket
(copper)
SUB-D socket
Hybrid Field Bus Connections
ECOFAST System Manual
5-4 GWA 4NEB 950 5060-02
5.2 Connections
IP65-side connections
Fig. 5-2: Hybrid field bus connections (IP65 side)
IP20-side connections
Fig. 5-3: Hybrid field bus connections (IP20 side)
Pin Socket
Cu
Han-Brid
Socket Socket
Han-Brid
Supply
Cu
Supply
optical-fiber
cable
Conducting
Conducting
optical-fiber
cable
Terminal block for 2 x 24 V DC (S and NS)
Shielded terminals
Terminals A1 (green)/B1 (red)
for PROFIBUS-DP
Channel 1
Terminals A2 (green)/B2 (red)
for PROFIBUS-DP
Channel 2
Terminal block for 2 x 24 V DC (S
and NS)
SUB-D socket
for PROFIBUS-DP
IP65 side (field bus level, external)
IP20 side (in control cabinet)
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-5
Connections for PROFIBUS-DP and 2 x 24 V DC (IP65 Side)
2 x Han-Brid socket/socket or pin/socket
Pin assignment to DESINA:
Table 5-2: Pin assignment for hybrid field bus connection (IP65 side)
$ %
$ %
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)
—
5[' 7['
5[' 7['
Copper
Optical-fiber 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
sender
Optical-fiber cable
field bus
RxD Field bus
receiver
Optical-fiber cable
field bus
Pin Socket
Hybrid Field Bus Connections
ECOFAST System Manual
5-6 GWA 4NEB 950 5060-02
Connections for passive hybrid field bus connection (IP20 side)
Table 5-3: Connections for passive hybrid field bus connection (IP20 side)
Connections for Active Hybrid Field Bus Connection (IP20 Side)
Table 5-4: Connections for passive hybrid field bus connection (IP20 side)
Connection Assignment Comment
24 V terminal block
+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
Terminals A/B for PROFIBUS-DP
A1/A2 Line A (field bus)
B1/B2 Line B (field bus)
Shield (field bus)
Connection Assignment Comment
24 V terminal block
+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
1Shield
2 —
3RxD/TxD-P (+)
4CNTR-P
5DGND
6VP
7 —
8RxD/TxD-N (–)
AB
green
red
1
6.
9.
5
Pin
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-7
5.3 Installation, Wiring, and Commissioning
Note
Warning
Hazardous electrical voltages! These may cause electric shock and
burns. Disconnect the system and device from the power supply before starting
work.
Caution
Refer to the information in the operating instructions.
5.3.1 Installation
Caution
Note that it may be more convenient to wire the IP20 side before installation
(see next page for description).
Procedure
Table 5-5: Installing the hybrid field bus connection
Step Description
1
2
3
80
90
Cut out the required section (90 mm x 80 mm) on
the control cabinet.
Note that the wall strength must not exceed 5 mm.
Place the hybrid field bus connection into the cut-
out section.
S
ecure t
h
e
h
y
b
r
id
fi
e
ld
b
us connect
i
on
using the quick-clamping devices by
tightening the four screws.
4 x
Hybrid Field Bus Connections
ECOFAST System Manual
5-8 GWA 4NEB 950 5060-02
5.3.2 Wiring
Procedure
Table 5-6: Wiring the hybrid field bus connection
Diagram
Fig. 5-4: Wiring the hybrid field bus connection
Step Description
1Strip the lines. For more information on stripped lengths, cross-sections, and
terminal assignments, refer to the table on the next page.
2Use 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
3Use 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.
4Connect the shield to the shield
terminals.
—
5If 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).
6This completes the wiring.
Passive hybrid field bus connection Active hybrid field bus connection
2 x 24 V DC 2 x 24 V DC
9-pin
SUB-D socket
Shielded terminals
A1 B1 A2 B2
+NS –NS –S +S
S1
S2
Jumpers for supplying
24 V DC NS
24 V DC S
S1 with 2 x 24 V DC
24 V DC wiring:
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-9
Stripped lengths, cross sections, terminal assignments
Table 5-7: Stripped lengths, cross-sections, terminal assignments
2 x 24 V DC
+NS –NS – S + S
PROFIBUS-DP
A1 B1 A2 B2
PROFIBUS-DP
9-pol. SUB-D
3RK1911-1AA22
xx
3RK1911-1AA32
xx
3RK1911-1AB22
xx
3RK1911-1AB32
xx
3RK1911-1AE22
xx
3RK1911-1AE32
xx
9
1,5 mm²
AWG 15
999
AB
grün
rot
Cage Clamp
2
3
1
A1 B1
A2 B2
S1
S2
1
2
+NS–NS –S +S
S1
S2
Cage Clamp
Hybrid Field Bus Connections
ECOFAST System Manual
5-10 GWA 4NEB 950 5060-02
5.3.3 Commissioning
Procedure
After installing and wiring the hybrid field bus connection, you must
commission it.
Carry out the following steps:
Table 5-8: Procedure for commissioning the hybrid field bus connection
Step Description
1Connect up to 2 hybrid field bus cables.
2Close the control cabinet.
3Attach bus terminating connectors or screw caps to any unused connections.
4Switch on the main power.
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-11
5.4 Diagnostics
LEDs for diagnosis
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. 5-5: Diagnosis LEDs for active hybrid field bus connections
Ta b l e
Table 5-9: Diagnosis for active hybrid field bus connections
Fault Display/LED Remedy
No supply voltage from 24
V DC (NS)
Green LED: OFF Connect 24 V DC (NS)
supply voltage
No supply voltage from 24
V DC (NS)
Yellow LED: OFF
Connect 24 V DC (NS)
supply voltage
No signal from master Check signal cable from
master for interruption
Baud rate not recognized Plug in bus terminating
connector
Baud rate not recognized
Yellow LED flickers
Plug in bus terminating
connector
Check bus station in
direction of master for fault
Ye l l o w L E D
Green LED
Hybrid Field Bus Connections
ECOFAST System Manual
5-12 GWA 4NEB 950 5060-02
5.5 Dimension Drawings
Fig. 5-6: Dimension drawing of the hybrid field bus connection
93
103
5 max.
65
IP20 IP65
80
90
Cut-out section on control cabinet:
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-13
5.6 Technical Data
General Technical Data
Electrical data
Table 5-10: Technical data for hybrid field bus connections
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:
H x W x D
103 x 93 x 65
Weight Approx. 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)
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
Hybrid Field Bus Connections
ECOFAST System Manual
5-14 GWA 4NEB 950 5060-02
5.7 Applications
5.7.1 Passive Hybrid Field Bus Connection for Supply
Fig. 5-7: Passive hybrid field bus connection 3RK1911-1AA22 (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
HanBrid Hybrid fIeld bus connection Bus terminating
Right
Slave 4
Left
Slave 3
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 (Bu/Bu)connector
e. g. 6XV1830-7BH30
Bus terminating
connectors are
plugged directly
onto the data tee
e. g. CPU 315-2 DP
Power supply
connector
segment segment
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-15
5.7.2 Passive Hybrid Field Bus Connection for Conducting
Fig. 5-8: Passive hybrid field bus connection 3RK1911-1AA32 (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
Station 1
3~
Bus plug
e. g. 6ES7972-0BA50-0XA0
PROFIBUS
standard cable
Slave 4
e. g. OP 27
Non-switched (NS)
Cage clamp
Cage clamp
PROFIBUS DP
RS 485
IP20 (inside)
IP65 (in the field) Hybrid field bus connection
Conducting: 3RK1911-1AA32 (pin/socket)
Han Brid
2 x 24 V DC
Slave 3 Slave 5
Hybrid field bus cable RS 485
e. g. 6XV1830-7BH30
e. g. Power & Control Module (P&CM)
Note:
Bus terminating
connectors are
plugged directly
onto the data tee
connector
Hybrid Field Bus Connections
ECOFAST System Manual
5-16 GWA 4NEB 950 5060-02
5.7.3 Active Hybrid Field Bus Connection for Supply
Fig. 5-9: Active hybrid field bus connection 3RK1911-1AB22 (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)
– Segement 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
HanBrid
IP65 (in the field)
IP20 (inside)
PROFIBUS standard cable
PROFIBUS-DP
RS 485
Sub-D
Switched (S)
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-17
5.7.4 Active Hybrid Field Bus Connection for Conducting
Fig. 5-10: Active hybrid field bus connection 3RK1911-1AB32 (pin/socket)
Typical set-up: integrating an operator panel (OP)
IP20 (inside)
– Active hybrid field bus connection for separating PROFIBUS-DP and
converting optical-fiber cable to RS 485 + power supplies (NS + S) for the
components.
– Standard PROFIBUS-DP cable connected to hybrid field bus connection
with 9-pin SUB-D socket.
– PROFIBUS-DP cable connected to the component with 9-pin SUB-D bus
plug.
– Component power supply (e.g. for operator panel) connected to hybrid
field bus connection with cage clamp (NS + S).
– Standard IP20 component (e.g. operator panel)
IP65 (in the field):
– Supply to PROFIBUS-DP with optical-fiber 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
3~
e. g. Power & Control Module (PCM)
Hybrid Field Bus Connections
ECOFAST System Manual
5-18 GWA 4NEB 950 5060-02
5.7.5 Active Hybrid Field Bus Connection for Supply
Fig. 5-11: Active hybrid field bus connection 3RK1911-1AD22 (socket/socket)
Typical set-up:
IP20 (inside):
– PLC/DP master/PROFIBUS-DP via RS 485 or optical-fiber cable
– Power supply for switched/non-switched voltage
– Active hybrid field bus connection for combining PROFIBUS-DP 9-pin
SUB-D socket or optical-fiber cable + power supplies (terminals)
– Segment divided left and right
IP65 (in the field):
– Supply to PROFIBUS-DP with optical-fiber cables in segment (left/right)
via Han-Brid (sockets)
– Screw caps (left and right) on the last data tee connector
– Power supply (NS + S) via Han-Brid (sockets)
Non-switched (NS)
Cage Clamp
Hybrid field bus connection
Cap
Slave 4Slave 3
Cap
IP65 (in the field)
IP20 (inside)
PROFIBUS-DP
Switched (S)
RS 485 Sub-D
Hybrid field bus fiber-optic cable
e. g. 6XV1830-6DH30
PROFIBUS standard cable
+ fiber-optic cable
Power supply
SIMATIC
e. g. CPU 315-2 DP
Supply: 3RK1911-1AD22 (socket/socket))
Han-Brid
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-19
5.7.6 Active Hybrid Field Bus Connection for Conducting
Fig. 5-12: Active hybrid field bus connection 3RK1911-1AD32 (pin/socket)
Typical set-up: integrating an operator panel (OP)
IP20 (inside):
– Active hybrid field bus connection for separating PROFIBUS-DP and
converting optical-fiber 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) or optical-fiber cable.
– PROFIBUS-DP cable connected to the component with 9-pin SUB-D bus
plug or FO.
– Component power supply (e.g. for operator panel) connected to hybrid
field bus connection with cage clamp (NS + S).
– Standard IP20 component (e.g. operator panel)
IP65 (in the field):
– Supply to PROFIBUS-DP with optical-fiber 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
RS 485 Sub-D
Conducting: 3RK1911-1AD32 (pin/socket))
Hybrid field bus fiber-optic cable
e. g. 6XV1830-6DH30
PROFIBUS standard cable
e. g. OP 27
Slave 4
Station 1
2 x 24 V DC
3~
e. g. Power & Control Module (PCM)
+ fiber-optic cable
RS 485 or/and fiber-optic cable
Hybrid Field Bus Connections
ECOFAST System Manual
5-20 GWA 4NEB 950 5060-02
5.7.7 Active Hybrid Field Bus Connection for Supply
Fig. 5-13: Active hybrid field bus connection 3RK1911-1AE22 (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
PROFIBUS standard cable
RS 485
Non-switched (NS)
Stromversorgung
Bus terminating
connector
Hybrid field bus connection
Supply: 3RK1911-1AE22 (socket/socket)
SIMATIC
e. g. CPU 315-2 DP
PROFIBUS-DP
RS 485
Note:
Bus terminating
connectors are
plugged directly
onto the data tee
connector
Switched (S)
SUB-D
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-21
5.7.8 Active Hybrid Field Bus Connection for Supply
Fig. 5-14: Active hybrid field bus connection 3RK1911-1AE22 (socket/socket)
Typical set-up:
IP20 (inside):
– PLC/DP master with PROFIBUS-DP via RS 485
– Power supply for several non-switched and independently-switched
voltages (creation of several emergency stop circuits, disconnection of
individual segments) via cage clamp
– Linear design of PROFIBUS DP on the inside (IP20) of the hybrid field bus
connections with terminating resistors for the last 9-pin SUB-D connector
of the hybrid field bus connection and on the CP of SIMATIC S7
IP65 (in the field):
– PROFIBUS-DP supply with RS 485 in three segments (left/right) via Han-
Brid (sockets)
– Bus terminating connector (left/right) on the last data tee connector
– Power supply (NS + S) via Han-Brid (sockets)
Power supply
SIMATIC S7
Switched (S)
segment 1/2/3
Non-
switched (NS)
segment
1-3
3RK1911-1AE22 (socket/socket)
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-pol. SUB-D
e. g. 6ES7972-0BA50-0AA0
PROFIBUS-DP
RS 485
Hybrid Field Bus Connections
ECOFAST System Manual
5-22 GWA 4NEB 950 5060-02
5.7.9 Conveyor Section With Hybrid Field Bus Connections for Supply and
Conducting
Fig. 5-15: Conveyor section with hybrid field bus connections for supply and conducting
Slave 6
Slave 5
Slave 4
Slave 3
PROFIBUS standard cable
Internal bus station
Non-switched
Hybrid field bus connection
Supply: 3RK1911-1AA22
Socket/socket
Bus terminating connector
Conducting: 3RK1911-1AA32
Switched
PROFIBUS-DP
e.g. ET 200S/M
2 x 24 V DC
Hybrid field bus connection
Pin/socket
Slave 7
OP in local box ET 200S in local box
Bus terminating connector
Hybrid field bus cable RS 485
PS
FC
ET 200X-RS 485
OP 27
SIMATIC S7
RS 485 RS 485
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-23
5.7.10 Installation Method with PROFIBUS-DP - Cu
Fig. 5-16: Installation system with PROFIBUS-DP in Cu
Slave 3 Slave 4 Slave 5
Slave 11
Slave 10 Slave 12
Slave 9
Slave 32
e.g CPU 315-2DP
2 x 24 V cc
Typical application: Installation system with PROFIBUS DP in Cu
Power & control module (PCM) with
- PLC
- 2 x 24 V DC supply
- 400 V AC main power supply
Terminating resistor
PROFIBUS CONNECTOR
connected internally
or left segment
Bus terminating
connector
or left
Power cable
400 V AC
Hybrid field bus cable RS 485
Screw
Right segment
Data tee
Left segment
segment cap
connector
Right segment
Left segment
3/PE-50/60 Hz
connector
PROFIBUS
Order numbers:
PCM:
Data tee connector:
Bus terminating connector:
Hybrid field bus cable RS 485:
Hybrid Field Bus Connections
ECOFAST System Manual
5-24 GWA 4NEB 950 5060-02
5.7.11 PROFIBUS-DP – Optical-Fiber Cable
Fig. 5-17: 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
Order numbers:
PCM:
Screw cap
Power cable
Hybrid field bus fiber-optic cable
Screw cap
Right segment
Data tee
Left segment
connector
Right segment
Left segment
PROFIBUS
4FB ...
3RK1911-2AH00
???
6XV1830-6DH15 (1.5 m)
6XV1830-6DH30 (3 m)
6XV1830-6DH50 (5 m)
6XV1830-6DN10 (10 m)
6XV1830-6DN15 (15 m)
Data tee connector:
Screw cap:
Hybrid field bus fiber-optic cable:
- PLC
- 2 x 24 V DC supply
- 400 V AC main power supply
or left segment
or left
segment
3/PE-50/60 Hz
400 V AC
connector
PROFIBUS connector
connected internally
3~
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-25
5.7.12 PROFIBUS-DP (Cu) and Passive Hybrid Field Bus Connections with 2
Separate Power Supplies
Fig. 5-18: PROFIBUS-DP (Cu) and passive hybrid field bus connectionswith 2 separate power
supplies
Slave 5 Slave 6 Slave 8 Slave 9
e. g. CPU 315-2 DP 2 x 24 V DC
Switched
Non-switched
e. g. OP 27
Power supply
Slave 7
Bus terminating
Hybrid field bus cable RS 485
Switched
Non switched
Slave 3 Slave 4
2 x 24 V DC
connector
MMMMM
M
K1 K2
K1K2
BBAA
+S -NS +NS
K1 K2
K1K2
BBAA
+S -S -NS +NS
IP20
IP65
IP20
IP65
-S
+S -S -NS +NS
+S -NS +NS-S
The power supply is not jumpered
on the hybrid field bus connection
=> Channel 1 supplies the OP (Slave 7)
=> Channel 2 of the hybrid field bus
connection on slave 7 is supplied
by the second power supply
with power
Typical application: installation system with PROFIBUS DP (Cu) and passive hybrid field bus connections with 2 separate power supplies
Power supply
Hybrid Field Bus Connections
ECOFAST System Manual
5-26 GWA 4NEB 950 5060-02
5.7.13 PROFIBUS-DP (Cu) and Active Hybrid Field Bus Connections with 2
Separate Power Supplies
Fig. 5-19: PROFIBUS-DP (Cu) and active hybrid field bus connections with 2 separate power
supplies
Typical application: Installation system with PROFIBUS DP (Cu) and active hybrid field bus connections with 2 separate power supplies
Power supply
Cap
Switched
Non-switched
2 x 24 V cc
Slave 8
e. g. CPU 315-2 DP
2 x 24 V DC
Switched
Non switched
e. g. OP 27
Hybrid field bus cable
9-pin SUB-D
HP Versatile Link
IP20
IP65
IP20
IP65
Slave 5 Slave 6 Slave 7 Slave 9Slave 3 Slave 4
MMM
M
MM
+S
+S
-S
-S -NS
-NS
+NS
+NS
K1K2
+S
-S -NS
-NS
+NS
+NS
K1
+S
K2
-S
K2
The power supply is not jumpered
on the hybrid field bus connection on
on slave 8
=> Channel 1 supplies the OP (slave 8)
=> Channel 2 of the hybrid field bus connection
on slave 8 is supplied by the second
power supply
with power
Power supply
Hybrid Field Bus Connections
ECOFAST System Manual
GWA 4NEB 950 5060-02
5-27
5.7.14 PROFIBUS-DP (Optical-Fiber Cable) and Passive Hybrid Field Bus
Connections with 2 Separate Power Supplies
Fig. 5-20: PROFIBUS-DP (optical-fiber cable) and passive hybrid field bus connections with 2
separate power supplies
Typical application: Installation system with PROFIBUS DP (optical-fiber cable) with 2 separate data supply lines
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
e. g. CPU 315-2 DP
Hybrid field bus
HP Versatile Link
IP20
IP65
IP20
IP65
MMM M MM
-NS
-NS
+NS
+NS
K1
+S
-S
K2
-NS
-NS
+NS
+NS
K1
+S
-S
K2
-NS
-NS
+NS
+NS
K1
+S
-S
K2
+S
-S
+S
-S
+S
-S
fiber-optic cable
In the active hybrid field bus
connection, data is
jumpered as standard.
=> A 2nd hybrid field bus connection
data segment
(data segment 2).
is required in station 2
to supply a new
Data segment 2Data segment 1
Hybrid Field Bus Connections
ECOFAST System Manual
5-28 GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
6-1
Data Tee Plug Connector 6
Section Topic Page
6.1 Description 6-2
6.1.1 Pin assignment 6-3
6.2 Dimension Drawing 6-4
6.2.1 Technical Data 6-5
Data Tee Plug Connector
ECOFAST System Manual
6-2 GWA 4NEB 950 5060-02
6.1 Description
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:
– With copper cable (PROFIBUS-DP Cu)
– With optical-fiber cable (PROFIBUS-DP optical-fiber cable)
• 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)
Data Tee Plug Connector
ECOFAST System Manual
GWA 4NEB 950 5060-02 6-3
6.1.1 Pin assignment
Fig. 6-1: Pin assignment for the data tee plug connector/core assignment Hybrid field bus cable
Pin Assignment Colour*)
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
$%
$%
5' 7'
5' 7'
Pin Assignment Colour*)
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 optical-fiber cable field bus -
transmitter
see Fig.
below
RD optical-fiber cable field bus -
receiver
see Fig.
below
Data tee plug connector PROFIBUS-DP optical-fiber cable
On the motor starter:
Pin Socket
Input Output
SUB-D female connector, 25-pole
OF field bus
Data plug
connector
(Socket)
Data plug
connector
(Pin)
*) Core colours of the DESINA
Hybrid field bus cable
5' 7'
5' 7' 5' 7' 5' 7'
Pin Socket
Input Output
Assignment optical fiber field bus
Data Tee Plug Connector
ECOFAST System Manual
6-4 GWA 4NEB 950 5060-02
6.2 Dimension Drawing
Bild 6-2: Dimension drawing of the data tee connector
Data Tee Plug Connector
ECOFAST System Manual
GWA 4NEB 950 5060-02 6-5
6.2.1 Technical Data
Location On the system Connected to motor starter
Installation position Any
Degree of protection IP65/67 Watertight according to
IEC 529 (DIN 40050)
Cooling Convection No additional cooling required
Weight 105 g
100 g
Copper variant
Optical-fiber cable variant
Operating temperature –20 °C to +40 °C Do not allow condensation to
form!
Max. 55 °C with reduction of
IDC24V-NS and IDC24V-S
each with 0.3 A per K
Storage/transport temperature –40 °C to +80 °C
Relative humidity 5% to 95% Do not allow condensation to
form!
Site altitude 2,000 m No restrictions
Vibratory load f = 5 to 26 Hz; d = 0.75 mm
f = 26 to 150 Hz; a = 2 g
10 cycles
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
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
Data Tee Plug Connector
ECOFAST System Manual
6-6 GWA 4NEB 950 5060-02
Electrical data for auxiliary power
Electrical data for communication
Table 6-1: Technical data for the data tee connectors
*)
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.
Non-switched voltage
24 V DC-NS
Switched
voltage
24 V DC-S
Voltage range 20.4 V DC to 28.8 V DC Standard power supply to DIN
19240
Maximum current-carrying
capacity from Han Brid to Han Brid
10 A 10 A
Polarity protection No No
Short-circuit protection/overload
protection
No No
Insulation voltage 500 V DC between auxiliary voltages and PE
Copper variant Optical-fiber cable variant
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
ECOFAST System Manual
GWA 4NEB 950 5060-02
7-1
Discriminating Module 7
Section Topic Page
7.1 Description 7-2
7.2 Connections 7-3
7.3 Installation and Wiring 7-4
7.3.1 Setting the Address 7-4
7.3.2 Required Components 7-5
7.3.3 Installation 7-6
7.4 Commissioning 7-7
7.5 Messages 7-7
7.6 Dimension Drawing 7-8
7.7 Technical Specifications 7-9
Discriminating Module
ECOFAST System Manual
7-2 GWA 4NEB 950 5060-02
7. 1 D e s c ri p t i o n
Tasks of the 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 pad-
locks
Set-up
The discriminating module comprises a circuit-breaker, mains switch, and
alarm switch.
The discriminating module has the following connections:
• Han Q8 pin for supplying the power
• Han Q8 socket for conducting the power
• AS-Interface to enable the yellow AS-Interface profile line to communicate
Fig. 7-1: Set-up of the discriminating module
Device versions
Discriminating modules are available in three different device versions:
Table 7-1: Discriminating module versions
Device
version
Current Order number
125 A 3RK1 911-4AA25
216 A 3RK1 911-4AA16
38 A 3RK1 911-4AA08
Han Q8 pin
Han Q8 socket
AS-i nterface
AS-Interface
Profile line
Discriminating Module
ECOFAST System Manual
GWA 4NEB 950 5060-02
7-3
7.2 Connections
Power
Input: Han Q8/0 pin
Output: Han Q8/0 socket
Pin assignment acc. to DESINA:
Table 7-2: Pin assignment of the Han Q8 pin/socket
Communication
AS-Interface for the yellow AS-Interface profile line.
Pin Assignment Comment
1 Neutral conductor N Looped through
2 Phase L2 Switched
3— —
4 Brake 24 V DC Looped through
5 Brake 0 V DC Looped through
6 Phase L3 Switched
7— —
8 Phase L1 Switched
9 PE, ground Looped through
Discriminating Module
ECOFAST System Manual
7-4 GWA 4NEB 950 5060-02
7.3 Installation and Wiring
7.3.1 Setting the Address
AS-i slave profile
Table 7-3: AS-i slave profile
Prerequisites
To set the address, you need - among other things - the addressing and dia-
gnostic unit (order no.: 3RK1904-2AB00).
Addresses 1 to 31 are valid addresses. Each address can only be assigned
once.
Note
The address of the discriminating module can only be changed 15 times. If
you attempt to set the address a sixteenth time, the last valid address will
remain set.
Discriminating module
Order no.
I/O
configuration
(hex)
ID code (hex) ID1 code
(hex)
ID2 code
(hex)
3RK1 911-4AA.. 0 F F F
Discriminating Module
ECOFAST System Manual
GWA 4NEB 950 5060-02
7-5
7.3.2 Required Components
The table below lists the required components:
Table 7-4: Required components
Item Ordering data Order number
1 Discriminating module 3RK1 911-4AA..
depending on the
version
2 2 fixing screws (dia. 4 mm), if necessary nuts,
spring washers, plain washers
3 Power line with Han Q8 socket
(discriminating module at input)
prefabricated or prepared by customer
3RK1 911-0.. depending
on the length and cross-
section
4 Power line with Han Q8 pin
(discriminating module at output)
prefabricated or prepared by customer
3RK1 911-0.. depending
on the length and cross-
section
5 Optional: Yellow AS-Interface profile line
for communication
3RX9 0.... depending on
the length and material
6 Optional: Line end covers for sealing open ends of
lines (1 set = 10 pieces)
3RK1 901-1MN00
Discriminating Module
ECOFAST System Manual
7-6 GWA 4NEB 950 5060-02
7.3.3 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.
To install the discriminating module, carry out the following steps:
Table 7-5: Installing the discriminating module
Step Description
1 Choose a flat surface for installation. You can choose any mounting position.
2
3 Screw the discriminating module onto the flat surface.
4Optional:
Connect the AS-Interface profile line to the discriminating module.
Caution
If the discriminating module is the last station in the AS-Interface line, you
must seal the ends of the AS-i lines with line end covers (Order No. 3RK1 901-
1MN00)
in order to achieve the IP67 degree of protection. Leave the ends of the lines
protruding approximately 10 cm beyond the AS-Interface for this purpose.
5 Connect the discriminating module to the power line with the Han Q8 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 Q8 socket
(discriminating module at the input).
Secure the connections with the locking devices.
105
Drill 2 holes for the screws.
145
250
4
2 x
3RK1 901-1MN00
AS
-
i
Discriminating Module
ECOFAST System Manual
GWA 4NEB 950 5060-02
7-7
7.4 Commissioning
To commission the discriminating module, and thus also the downstream
power bus (sub-)segment, carry out the following steps:
Table 7-6: Sequence of steps for commissioning the discriminating module
7.5 Messages
The following messages are transmitted via the AS-i field bus:
Table 7-7: Messages of the discriminating module
Step Activity
1 If you are using motor starters without a thermal motor model and
with a motor supply lead (installation near motor), also observe the
line protection guidelines in 8.5.6 on page 8-16.
2 Switch on the 400 V AC main power supply
3 Switch on the discriminating module
Data bit Message Signal:
[1]: HIGH
[0]: LOW
D0 Main circuit on [1]: Yes
[0]: No
D1 Tripped [1]: Yes
[0]: No
D2 —
D3 —
Discriminating Module
ECOFAST System Manual
7-8 GWA 4NEB 950 5060-02
7.6 Dimension Drawing
Fig. 7-2: Dimension drawing of the discriminating module
105
250
230
135
155
Discriminating Module
ECOFAST System Manual
GWA 4NEB 950 5060-02
7-9
7.7 Technical Specifications
Table 7-8: Technical specifications of the discriminating module
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:
H x W x D
205 x 105 x 140
Weight 1. 5 k g
Operating temperature –20 °C to +40 °C
Storage/transport
temperature
–40 °C to +80 °C
Vibration strain 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
Discriminating Module
ECOFAST System Manual
7-10 GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-1
Installation Guidelines 8
Section Topic Page
8.1 Installation Guidelines for PROFIBUS-DPwith
ECOFAST Hybrid Field Bus Cable
8-2
8.2 Installation Guidelines for PROFIBUS-DPwith
DESINA Hybrid Field Bus Cable
8-3
8.3 Installation Guidelines for Standard PROFIBUS-DP Cables 8-6
8.3.1 Potential equalization 8-6
8.3.2 Cable Shielding 8-7
8.4 PNO Installation Guideline 8-9
8.5 Power Bus Installation Variants 8-10
8.5.1 Installation with Power Tee Connector and Power Cable
(Prefabricated)
8-10
8.5.2 Installation with Power Tee Clamping Connector and
Power Cable (Not Prefabricated)
8-11
8.5.3 Sub-Segments 8-12
8.5.4 ET 200X Sub-Segments with EM300 Motor Starter 8-13
Installation Guidelines
ECOFAST System Manual
8-2 GWA 4NEB 950 5060-02
8.1 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 start and end of the
bus.
Fig. 8-1: Set-up of a bus segment with RS 485
Power & Control Module (P&CM) with
Terminating resistor
ECOFAST hybrid field bus cable Bus terminating connector
Order numbers:
4FB2..
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~
3RK1911-2AG00
6GK1905-6DA00
6ES7194-1JB10-0XA0
6XV1830-7BH15 (1,5 m)
6XV1830-7BH30 (3 m)
6XV1830-7BH50 (5 m)
6XV1830-7BN10 (10 m)
6XV1830-7BN15 (15 m)
P&CM:
Data tee plug connector:
Bus terminating connector:
Screw cap (cover plate):
ECOFAST hybrid field bus cable:
- PLC
- 2 x 24 V DC Supply
- 400 V AC Main Power Supply
connected internally
or segment 2!
or
segment 2
3/PE-50/60 Hz;
400 V AC connector
2 x 24 V DC and data
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-3
Key data of a bus segment
The maximum line length of a bus segment depends on the baud rate that is
used.
8.2 Installation Guidelines for PROFIBUS-DP with
DESINA Hybrid Field Bus Cable
DESINA hybrid field bus cable
DESINA hybrid field bus cables are suitable for trailing. They have two
plastic optical-fiber conductors for PROFIBUS-DP and four 1.5 mm2 copper
cores for 24 V DC switched (DC24V-S) and 24 V DC non-switched (DC24V-
NS).
Connection to PROFIBUS-DP
If you want to bridge long distances with the field bus regardless of the
baud rate, or if disturbance fields must not be allowed to interfere with data
traffic on the bus, you should use optical-fiber cables instead of copper
cables.
The PROFIBUS-DP stations are connected to the PROFIBUS-DP by means
of
• separate data tee plug connectors with optical-fiber cables
(PROFIBUS-DP LWL)
• integrated plug connectors, e.g. ET 200X base module BM143
Advantages and applications
Optical-fiber 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 M b a u d 2 0 0
3 to 12 Mbaud 100
Table 8-1: Permissible line length of a bus segment as a function of the baud rate
Installation Guidelines
ECOFAST System Manual
8-4 GWA 4NEB 950 5060-02
Optical PROFIBUS-DP network with line topology
The optical PROFIBUS-DP network is designed with a line topology. The
PROFIBUS-DP stations are connected together in pairs by means of
DESINA hybrid field bus cables. If one PROFIBUS-DP station fails, the line
topology means that all downstream DP slaves are no longer accessible to
the DP master. Faults can thus be localized easily.
Fig. 8-2: Optical PROFIBUS-DP network with line topology
Power & Control Module (P&CM) with
DESINA hybrid field bus cable Screw cap
Order numbers:
4AV9..
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~
3RK1911-2AH00
6ES7194-1JB10-0XA0
6XV1830-6DH15 (1,5 m)
6XV1830-6DH30 (3 m)
6XV1830-6DH50 (5 m)
6XV1830-6DN10 (10 m)
6XV1830-6DN15 (15 m)
P&CM:
Data tee plug connector:
Screw cap (cover plate):
ECOFAST hybrid field bus cable:
- PLC
- 2 x 24 V DC supply
- 400 V AC main power supply
or
segment 2
3/PE-50/60 Hz;
400 V AC connector
2 x 24 V DC and data
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-5
Baud rate
The optical PROFIBUS-DP network with a line topology can be operated
with the following baud rates:
9.6 kbaud, 19.2 kbaud, 45.45 kbaud, 93.75 kbaud, 187.5 kbaud, 500 kbaud,
1.5 Mbaud and 12 Mbaud.
Line lengths
If optical-fiber cables are used, the length of the transmission link is
independent of the baud rate.
Every PROFIBUS-DP station connected to the optical PROFIBUS-DP
network has a repeater functionality. The distances specified below
therefore refer to the distance between two neighboring PROFIBUS-DP
stations in the line topology.
The maximum line length between two PROFIBUS-DP stations is
dependent on the type of optical-fiber cable that is used.
Table 8-2: Permissible line lengths in the optical PROFIBUS-DP network
Optical-fiber cable Max. line length
between
2 stations [m]
Projection
to 1 network
(= 32 stations) [m]
DESINA
hybrid field bus
cable
50 1550
Installation Guidelines
ECOFAST System Manual
8-6 GWA 4NEB 950 5060-02
8.3 Guidelines for PROFIBUS-DP standard cables
8.3.1 Potential equalization
When do differences in potential occur?
Differences in potential can occur, for example, when different mains
supplies are used. Damage may be caused to the system as a result of
potential differences between various system parts if:
• programmable controllers and inputs/outputs are connected by
potentialbonded couplings,
or
• cable shields are connected at both ends and grounded to different parts of a
system.
Avoiding potential differences
It is important to install potential equalization lines in order to minimize
potential differences and ensure the functionality of the electronic
components.
When and why do you need potential equalization?
Potential equalization has the following advantages:
• Devices with a grounded interface may be destroyed as a result of potential
differences.
• The shielding of the PROFIBUS cable must not be used for potential
equalization. This is the case, however, with any parts of the system that are
linked together via the cable shield, but 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 connected at both ends to ground/protective conductors, it is important
to ensure that the impedance of the additional potential equalization line is
not in excess of 10% of the shield impedance.
• Use connectors with large contact areas to connect the potential equalization
conductors to the ground/protective conductor.
• Protect the potential equalization conductors against corrosion.
• Use potential equalization conductors made of copper or galvanized steel.
• Route the potential equalization conductors in such a way that the areas
bounded by the potential conductor and the signal lines are as small as
possible.
• Use equipotential bonding conductors made of copper or galvanized steel.
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-7
Note
Equipotental bonding conductors are not necessary if the parts of the
system are connected to each other exclusively by means of fiber-optic cables.
8.3.2 Cable Shielding
Definition
Shielding is a means of weakening (attenuating) magnetic, electric and
electromagnetic interference fields.
Interference currents on cable shields are diverted to ground via the shield
busbar, which forms a conductive connection with the housing. It is
particularly important to ensure a low-ohmic connection to the protective
conductor, as otherwise the interference currents themselves may become
a source of interference.
Measures for cable shielding
Note the following points:
• If possible, use only cables with braided shields. The shield density should be
more than 80%. Avoid using cables with foil shielding, because tensile and
compressive loads at the attachments can easily damage the foil. The result
is a reduction in shield efficiency.
• Always connect the cable shields at both ends. It is only when the shielding is
connected at both ends that interference suppression is effective at the high
end of the frequency range.
Exceptions: It may be better to connect the shield at one end only, if
– for some reason it is not possible to install potential equalization
lines,
–analog signals (in the low mV or A range) are transmitted, or
–foil shielding (static shields) is used.
Note, however, that if the shield is connected at one end only it can
suppress only 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/protective conductor busbar.
Note
If a potential difference occurs between the grounding points, an equaliza-
tion current can flow through a shield connected at both ends.
In this case, install an additional potential equalization line.
u
Installation Guidelines
ECOFAST System Manual
8-12 GWA 4NEB 950 5060-02
8.5.3 Sub-Segments
Installation
With sub-segments, the consumers (not ET200X with EM 300 motor
starter) are connected to the power bus using a sub-segment cable and a
power tee clamping connector or power tee connector.
The sub-segment cable can be ordered prefabricated.
Diagram
Bild 8-6: Sub-segment configuration
Caution
ET 200X sub-segments fitted with EM148-FC frequency converters only
must be used here (see diagram).
EM 148-FC
ET 200X
Power tee clamping connector
with Han Q8/0 socket Power tee connector
Sub-segment cable
(prefabricated)
Sub-segment cable
(prefabricated)
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-9
8.4 PNO Installation Guideline
PNO installation guideline
Please comply with the PROFIBUS-DP/FMS Installation Guideline of the
PROFIBUS-Nutzerorganistation (user organization) when using electrical
networks. It describes important measures to be taken as regards the
wiring, cabling and commissioning of PROFIBUS networks.
Publisher
PROFIBUS-Nutzerorganisation e. V.
Haid-und-Neu-Straße 7
D-76131 Karlsruhe
Tel: ++49 721 / 9658 590
Fax: ++49 721 / 9658 589
Internet: http//www.profibus.com
Guideline order number: 2.111
Installation Guidelines
ECOFAST System Manual
8-10 GWA 4NEB 950 5060-02
8.5 Power Bus Installation Variants
8.5.1 Installation with Power Tee Connector and Power Cable (Prefabricated)
Installation
With this variant, the consumers are connected to the power bus using
power tee connectors. The power cables can be:
• Ordered prefabricated with different configurations and lengths
• Prepared by the customer himself.
The power cables can be either plugged in to the power tee connector or
connected directly to the last consumer on the power bus.
Benefits
• Quicker connection (plug and play), no wiring
• No risk of wiring errors with prefabricated power cables
Diagram
Bild 8-4: Installation with power tee connector and power cable (prefabricated)
PCM
Supply
Main power
Power tee connector with
Han Q8 socket for consumer
Power cable (prefabricated
or prepared by customer)
Possible components:
Prefabricated with Han Q8/0 pin
and power tee connector
Prefabricated with Han Q8/0 pin
and Han Q8/0 socket
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-11
8.5.2 Installation with Power Tee Clamping Connector and Power Cable (Not
Prefabricated)
Installation
With this variant, the consumers are connected to the power bus using
power tee clamping connectors. The power cable is routed through the
system in one piece. In the configuration shown in the diagram below, you
merely have to prepare a Han Q8 connector set at the beginning and end of
the power cable.
Benefits
• In principle, any cable with a diameter of between 10 mm and 22 mm can be
used in accordance with requirements.
• The power tee clamping connector can be connected at any point.
Diagram
Bild 8-5: Configuration with power tee clamping connector
PCM
Supply
Main power
Power tee clamping connector with
Han Q8/0 socket for consumer
Power cable
(sold by the meter)
Possible components:
Connector set
with pins
for connecting
the PCM
Power cable
(sold by the meter)
Power tee clamping connector
Suitable seals
Connector set
with sockets
for connecting the
last consumer
Installation Guidelines
ECOFAST System Manual
8-12 GWA 4NEB 950 5060-02
8.5.3 Sub-Segments
Installation
With sub-segments, the consumers (not ET200X with EM 300 motor
starter) are connected to the power bus using a sub-segment cable and a
power tee clamping connector or power tee connector.
The sub-segment cable can be ordered prefabricated.
Diagram
Bild 8-6: Sub-segment configuration
CautionET 200X sub-segments fitted with EM 148-FC frequency converters
only must be used here (see diagram).
EM 148-FC
ET 200X
Power tee clamping connector
with Han Q8/0 socket Power tee connector
Sub-segment cable
(prefabricated)
Sub-segment cable
(prefabricated)
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-13
8.5.4 ET 200X Sub-Segments with EM300 Motor Starter
Installation
With ET 200X sub-segments with the EM300 motor starter, an ET 200X is
connected to the power bus using an ET 200X sub-segment cable and a
power tee clamping connector or power tee connector.
The ET 200X sub-segment cable can be ordered prefabricated.
Diagram
Bild 8-7: Sub-segment configuration
Caution
The ET 200X sub-segment cable must only be used for ET 200X sub-seg-
ments 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.
EM300 EM300 EM148-FC
Power tee clamping connector
with Han Q8/0 socket Power tee connector
Power bus
ET 200X
sub-segment cable
(prefabricated)
Installation Guidelines
ECOFAST System Manual
8-14 GWA 4NEB 950 5060-02
Guidelines for the ET 200X Sub-Segment
Distributed ET 200X peripheral devices can be integrated in the ECOFAST
system. The following rules, however, must be followed:
• An ET 200X sub-segment comprises the ET 200X sub-segment cable and a
distributed ET 200X peripheral device with at least one feeder.
• A maximum of 6 motor starters or frequency converters can be used in one
ET 200X 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 prefabricated
line (line type: ET 200X motor).
• The EM148-FC frequency converters are connected to the motor with a
prefabricated line (line type: ET 200X FU motor).
• The prefabricated ET 200X power cables must be used for connecting the
ET 200X sub-segment to the power bus and for transferring the power.
Caution
The ET 200X sub-segment cable and the power cable for transferring the
power are different. They must only be used for their intended purpose.
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-15
8.5.5 Possible power distribution with discriminating modules
Diagram
The diagram below shows the possible power distribution arrangements
with discriminating modules:
Bild 8-8: Possible power distribution with discriminating modules
1ECOFAST consumer without a discriminating module directly in the
power bus segment backbone.
2The ECOFAST consumer and the discriminating module form a power
bus sub-segment. They are connected to the power cable using the Han
Q8/0 pin/socket. The discriminating module connects the power bus sub-
segment to the power bus segment backbone.
3The ECOFAST consumer and the discriminating module form a power
bus sub-segment. They are connected directly without a cable. The
power cable with the Han Q8/0 pin/socket connects the power bus sub-
segment to the power bus segment backbone.
ECOFAST
Consumer
ECOFAST
Consumer
ECOFAST
Consumer
ECOFAST
Consumer
123 4
Power cable
3/PE-50/60 Hz
400 V AC
Discriminating module
Input:
Han Q8/0 pin
Output:
Han Q8/0 socket
Caution
The discriminating module cannot be connected without a cable if
ECOFAST motor starters are operated with the PROFIBUS-DP field bus.
Installation Guidelines
ECOFAST System Manual
8-16 GWA 4NEB 950 5060-02
8.5.6 Line Protection in Power Bus Segment for Motor Starters Without
Thermal Motor Model (Installation Near 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 near 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:
Bild 8-9: Line protection for motor starters without thermal motor model
Variant A
Variant B
Power cable
3/PE-50/60 Hz
400 V AC
Motor starter
Motor supply lead
Motor
Motor protection:
Temperature sensor
No thermal motor model
No full motor protection
Discriminating module
PCM
Supply
Main power
Motor starter
Motor supply lead
Motor
Motor protection:
Temperature sensor
No thermal motor model
No full motor protection
Installation Guidelines
ECOFAST System Manual
GWA 4NEB 950 5060-02
8-17
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)
Laying type: E (Reduction factor: 0.650 at 30°C)
Setting value: 12 A.
Variant A: 16 A and 25 A discriminating modules must be
opened
so that they can be set.
The 8 A discriminating module limits the current
to 8 A
(nothing is set).
Variant B: The PCM must be opened so that it can be set.
Installation Guidelines
ECOFAST System Manual
8-18 GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
9-1
Wiring and Interfaces 9
Section Topic Page
9.1 Securing Plug in Connections that are not Safe Against Finger
To u ch When Using Frequency Converters
9-3
9.2 Wiring Rules 9-4
9.2.1 Selecting the power leads 9-4
9.2.2 Unused Connections 9-5
9.3 Power Cables Prefabricated at One End 9-6
9.3.1 Power Cables Prefabricated at One End with Han Q8 Pin 9-6
9.3.2 Motor Supply Leads Prefabricated at One End with Han 10E
Pin
9-7
9.3.3 Prefabricating Power Cables 9-8
9.4 AS Interface 9-10
9.4.1 Connection Techniques 9-10
Wiring and Interfaces
ECOFAST System Manual
9-2 GWA 4NEB 950 5060-02
Warning
Hazardous voltages! These may cause electric shock and burns.
Disconnect the system and device from the supply before starting work.
Danger
Ensure that the wiring is carried out carefully and correctly. Otherwise
motor starters may be destroyed. There is potentially lethal danger!
Wiring and Interfaces
ECOFAST System Manual
GWA 4NEB 950 5060-02 9-3
9.1 Securing Plug in Connections that are not Safe Against
Finger Touch When Using Frequency Converters
Danger
Hazardous voltage caused by frequency converters!
Discharge time: 5 minutes
Protect plug connection after locking with enclosed cable fastener against
unauthorized access!
The Capacitors of the frequency converter DC Link and EMC Filter remain
charged for a period of 5 minutes after switching off of the power supply.
During this period, DO NOT disconnect the frequency converter power con-
nector, as there is a danger of electric shock from contact with the connec-
tor pins.
The power connectors must therefore be interlocked to prevent inadvertent
disconnection and contact with the connector pins.
If the frequency converter is used in systems incorporating multiple connec-
tors, it must also be ensured that ALL connector positions are protected
against inadvertent disconnection and contact and hold a label warning of
transmission of dangerous voltages across the power cable network.
Securing the plug-in connections
Secure the plug-in connections as shown in the diagram below:
Fig. 9-1: Securing the plug-in connections against unauthorized access
Cable ties are enclosed with all prefabricated power cables and a warning
label is affixed to the connectors.
Note on power cables prepared by the customer
Note
Please note that you must also secure the plug-in connections of customer-
prepared power cables in an appropriate way!
Cable ties and warning labels are not included in the delivery package of
individual power connectors!
Cable ties
Locking devices
Wiring and Interfaces
ECOFAST System Manual
9-4 GWA 4NEB 950 5060-02
9.2 Wiring Rules
Warning
Hazardous voltages! These may cause electric shock and burns.
Disconnect the system and device from the supply before starting work.
9.2.1 Selecting the power leads
The core cross-section of the power leads must be matched to the respec-
tive ambient conditions. The decisive factors for choosing the core cross-
section are as follows:
• set current on the device
• method of installation
• 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:
Observe the following rules when carrying out wiring:
Table 9-1: Rules for wiring
30 °C 40 °C 45 °C 50 °C 55 °C
1,5 mm214 A 12.2 A 11.1 A 9.9 A 8.5 A
2,5 mm219 A 16.5 A 15.0 A 13.5 A 11.6 A
4,0 mm226 A 22.6 A 20.5 A 18.5 A 15.9 A
Rules for flexible cables Data
Current carrying capacity of the plug connection as a
function of the connectable core cross-sections and ambi-
ent temperature
Tu =
55 °C 40 °C
1,5 mm2
2,5 mm2
4,0 mm2
12 A
20 A
30 A
15 A
25 A
35 A
Permissible outer diameter of the cable
sealing insert green
red
white
7.0 ... 10.5 mm
9.0 ... 13.0 mm
11.5 ... 15.5 mm
Length of insulation to strip from cores 8 mm
Length of insulation to strip from cable sheath 20 mm
TU
Ø
Wiring and Interfaces
ECOFAST System Manual
GWA 4NEB 950 5060-02 9-5
9.2.2 Unused Connections
Close off unused connections with screw caps; this is the only way of ensu-
ring degree of protection IP65. Order number 3 RK1 902-0CJ00 (10 screw
caps) or 3 RK1 902-0CK00 (1 screw cap).
Wiring and Interfaces
ECOFAST System Manual
9-6 GWA 4NEB 950 5060-02
9.3 Power Cables Prefabricated at One End
Description
Power cables prefabricated at one end are available in different lengths (see
appendix for order numbers). One end of the cable is fitted with a power
plug connector with pins. The other end is free. Here, you can strip the
cores and, for example, attach a plug connector or terminal block.
Fig. 9-2: Numbers printed on the power cable cores
9.3.1 Power Cables Prefabricated at One End with Han Q8 Pin
Fig. 9-3: Power cables prefabricated at one end with Han Q8 pin
Numbers are printed on the cores for identification
purposes.
The core number/pin assignments are specified in
the following two sections.
Pin Core
no.
Assignment
1 1 Neutral N
23Phase L2
3——
45Brake
5 6 Brake (reference potential)
64Phase L3
7——
82Phase L1
PE (yellow/green)
Wiring and Interfaces
ECOFAST System Manual
GWA 4NEB 950 5060-02 9-7
9.3.2 Power Cables Prefabricated at One End with Han 10E Pin
Fig. 9-4: Motor supply leads prefabricated at one end with Han 10E pin
Caution
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)
Wiring and Interfaces
ECOFAST System Manual
9-8 GWA 4NEB 950 5060-02
9.3.3 Prefabricating Power Cables
Accessories
When you are preparing power cables, you need a crimping tool (soldering is
possible as an alternative) and the accessories listed in the table.
Power cables with Han Q8/0
Table 9-2: Preparing connecting leads with Han Q8
You need ...
for connecting the main power on the
motor starter/
power tee connector:
for looping through
the main power from the
power tee connector:
A flexible Cu cable
4 x 2.5 mm2/4 mm2 (3 conductors + PE)
6 x 2.5 mm2/4 mm2 (3 conductors + PE + brake)
Power connector
Han Q8 socket
• 2.5 mm2: 3RK1 902-0CA00
• 4.0 mm2: 3RK1 902-0CB00
Power connector
Han Q8 pin
•2.5 mm
2: 3RK1 902-0CC00
•4.0 mm
2: 3RK1 902-0CD00
Wiring and Interfaces
ECOFAST System Manual
GWA 4NEB 950 5060-02 9-9
Han Q8/0 power connectors
The power connectors belonging to a power tee connector and to the motor
starter consist of the following components:
Fig. 9-5: Han Q8 power connector
Assembling and wiring power connectors
Assemble and wire the power connectors according to the following instruc-
tions:
Table 9-3: Assembling and wiring power connectors
Step Procedure
1Guide the cable through the heavy-gauge threaded joint, the matching
enclosed sealing ring in each case and the connector housing.
2Attach the jacks/contact pins to the strands
3Push the jacks/contact pins into the socket insert/pin insert until they snap
into place.
4Pull the cable back and screw the insert in place in the connector housing
with the enclosed screws.
5Screw the heavy-gauge threaded joint tight.
Connector housing Connector housing
Socket insert
Jacks Contact pins
Pin insert
Han Q8/0 socket Han Q8/0 pin
for looping through the main power
for connecting the main power
Wiring and Interfaces
ECOFAST System Manual
9-10 GWA 4NEB 950 5060-02
9.4 AS Interface
9.4.1 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
Schematic arrangement
The diagram below shows the position and coding of the AS-i cables on the
motor starter:
Fig. 9-6: AS interface
Contacting
The AS-i cables are contacted automatically using the insulation piercing
method when the AS-i cover is screwed on.
Fig. 9-7: Contacting the AS-i cables
AS-i
AUX PWR
AS-i cable
Communication and
non-switched auxiliary power
Switched auxiliary power
Han Q8 main power feed
Motor starter
AS-i cover
AS-i (–)
AUX PWR (–)
AUX PWR (+)
AS-i (+)
AS-i
AUX PWR
AS-i cover
Wiring and Interfaces
ECOFAST System Manual
GWA 4NEB 950 5060-02 9-11
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 emergency 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 swit-
ching elements and the brake output are disconnected.
• When the supply is restored, the disconnection command and the associated
signal bits and error bits are acknowledged automatically.
Wiring and Interfaces
ECOFAST System Manual
9-12 GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
A-1
Questions and Answers A
Section Topic Page
A.1 Frequently asked Questions A-2
Questions and Answers
ECOFAST System Manual
A-2 GWA 4NEB 950 5060-02
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, however,
e.g.
ECOFAST also includes Cu transmission technology for
PROFIBUS-DP and takes account of AS-Interface. In
addition, ECOFAST can optionally be supplied with special
configuring software.
2 Can components
from other
manufacturers also
be integrated in
ECOFAST?
Ye s -
ECOFAST is designed as an open system.
ECOFAST is based on open bus systems (PROFIBUS-DP,
AS-Interface), and its interfaces (connections) are both
standardized and open (in accordance with DESINA). Any
manufacturer offering devices that comply with these
specifications can thus easily be integrated in an ECOFAST
system.
3 Can connectors
from other
manufacturers be
used as well?
Ye s -
ECOFAST is an open system with standardized interfaces.
Siemens currently cooperates with Harting as a connector
manufacturer and supplier on 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?
Ye s -
SIMOCODE must be installed in a local switchbox. It is
integrated in ECOFAST by means of the switch cabinet
throughfeeds (hybrid field bus connections)
If the maximum permissible current of the power bus (40 A)
is exceeded, this feeder must be started separately on the
power side.
5 Is ECOFAST suitable
for sub-zero
temperatures
(outdoor
applications, cold
stores)?
No -
ECOFAST is designed for ambient temperatures between 0
and 60 degrees Celsius.
6 Can ECOFAST be
used in potentially
explosive areas?
No -
ECOFAST is not designed for use in potentially explosive
areas.
Questions and Answers
ECOFAST System Manual
GWA 4NEB 950 5060-02
A-3
7 How is the PLC
integrated in
ECOFAST?
The power & control module can optionally be supplied with
an integrated PLC for ECOFAST. The S7 315-2 DP is planned
in the
first stage. The PLC can of course also be accommodated
in a conventional switch cabinet. In this case it is integrated
into the system by means of switch cabinet throughfeeds
(hybrid field bus connections).
8 Are frequency
converters available
for ECOFAST?
Ye s -
A frequency converter up to 750 W is available in
conjunction with the ET 200X and a standalone ECOFAST
converter is planned for mid-2003. Like the ECOFAST
starter, it will be integrated in the motor and it will also be
possible to install it near the motor (e.g. Combimaster with
ECOFAST connection method).
9 If ECOFAST is based
on DESINA, how
can it be connected
to a SINUMERIK?
It is connected by means of the switch cabinet
throughfeeds (hybrid field bus connections), i.e. the switch
cabinet can be factory-wired (interface to SINUMERIK) and
the peripheral devices (I/Os and starter) are then connected
externally.
10 If ECOFAST is based
on DESINA, does
this mean that it is
only designed for
machine tools?
No -
Machine tools are only one target industry. Since DESINA
pursues the same objective of cutting overall costs and has
already standardized interfaces, we decided to use it as a
basis for ECOFAST. ECOFAST is more versatile than
DESINA, however, being designed for use across industry
boundaries. Conveyor systems and production machines
are among our other target markets.
11 What about the
safety technology
interface via bus
systems (Profisafe,
Safety at work)?
Emergency stop circuits can be connected to the power &
control module. The AS-I motor for Safety at work can also
be installed in this module. Safety-oriented (two-channel)
modules are required to transmit safety-oriented signals via
Profibus-DP.
They will be integrated depending on availability (e.g. in the
ET 200X). We are unable to provide a definite date at the
present time.
Compatible with Safety/Profisafe.
12 Can components
with the IP20
degree of protection
(e.g. SIMOCODE or
ET 200S) also be
integrated into
ECOFAST?
Ye s -
These components can also be connected to ECOFAST. The
switchbox can be factory-wired with plug-in switch cabinet
throughfeeds (hybrid field bus connections). The switchbox
can be factory-wired on the inside; the plug-in connections
are located on the outside. Integration into the complete
system is thus very straightforward.
13 How can the bus
and the power
supplies (24 V
auxiliary voltages)
be combined in the
hybrid cable?
The bus (PROFIBUS-DP) and the 24 V power supplies are
combined by means of the hybrid field bus connections
(switch cabinet throughfeeds). These are available in several
different versions (for copper, optical fiber, active and
passive), in other words no additional terminal blocks are
required in the cabinet or the switchbox.
Questions and Answers
ECOFAST System Manual
A-4 GWA 4NEB 950 5060-02
14 How can an OP be
integrated for
visualization
purposes?
OPs are normally designed with the IP20 degree of
protection and are therefore installed either in a cabinet or
in a local box. They can be integrated in an ECOFAST
system by means of the switch cabinet throughfeeds
(hybrid field bus connections)
15 How many feeders
fit into one
segment?
This depends on the power of the connected feeders/
motors. ECOFAST installations are not star-shaped but
linear ("power bus"). Up to 40 A (approx. 14 kW) is possible
per segment or connection, depending on the type of laying
and the ambient temperature. When this value is reached, a
new segment must be opened.
The ECOFAST ES configuration tool calculates and checks
the power-engineering design.
16 How can switching
devices with a
higher power than
ECOFAST starters (4
kW) be integrated?
Switching devices of this kind can be integrated in local
boxes as IP20 components by means of the switch cabinet
throughfeeds (hybrid field bus connections).
If the maximum permissible current of the "power bus" (40
A) is exceeded, this feeder must be started separately on
the power side.
17 Is a repair switch
provided? Do the
starters have a
repair switch?
There is a lockable repair switch on the power & control
module, in other words the connected segment is
disconnected. The starters themselves are not fitted with a
repair switch.
A lockable variant is planned for the connector on the
motors (discriminating module in preparation).
The discriminating module can be used as a repair switch.
18 How can a system
built with ECOFAST
be extended?
Very easily.
The communication and power components are simply
hooked onto the PROFIBUS or the power bus. The
communication components must of course be configured
with STEP7 or COM PROFIBUS (software integration).
The power components can be integrated and tested with
ECOFAST ES. The wiring can be reoptimized, or the existing
wiring tested and documented, taking account of the newly
connected consumer.
19 What is the
maximum power
allowed for the
electronic starter
(soft starter)?
Soft starters in output classes of up to 1.1 kW and of up to
5.5 kW can be supplied.
Questions and Answers
ECOFAST System Manual
GWA 4NEB 950 5060-02
A-5
20 Is ECOFAST
UL-listed?
The individual components (devices) of ECOFAST are UL-
listed. As far as ECOFAST’s UL listing as a complete system
is concerned, we are still negotiating with the responsible
bodies, because the handling of acceptances and
certifications for complete systems varies considerably
from one system to another. Importance is attached, for
instance, to the definition of a self-contained unit (complete
machine or system?). The same applies to the cable laying
types (the cables do not necessarily have to be "piped" in
self-contained units), for example in concatenated units.
21 Is a metal version of
the connectors also
available?
Only molded-plastic versions of the bus and power
connectors are available at present. Metal versions of
motor feeder connectors are also available (for FUs, due to
shielded motor line). Metal versions of the plug cases can
be requested from Harting.
22 What is the situation
regarding Ethernet
communication?
The ECOFAST communication philosophy is based on
Profibus-DP and AS-Interface. With regard to Ethernet, a
considerable amount of work still needs to be invested in
industry-standard connection methods.
The ECOFAST devices, such as ECOFAST starters, have a
modular internal set-up, so that additional bus interfaces
can be implemented easily as and when necessary (which
is not the case with Ethernet).
23 Is it true that
ECOFAST starters
compete with the
starters of the ET
200X?
No -
Different ECOFAST solutions are offered intentionally, to
facilitate maximum adaptability to each particular
application.
The following solutions are possible:
• 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 ECOFAST, namely both material and
installation costs. The potential savings concern the costs
of installation and - from the point of view of the end
customer - servicing. If only the hardware costs of the
components are considered, the calculation is misleading.
Questions and Answers
ECOFAST System Manual
A-6 GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
B-1
ECOFAST Pilot Projects B
Section Topic Page
7.1 Production line for SIRIUS 2 - Siemens Cham 7-2
7.2 Configuration in the Automotive Industry - Production
Planning
7-7
7.2.1 Configuration with ECOFAST ES 7-8
ECOFAST Pilot Projects
ECOFAST System Manual
B-2 GWA 4NEB 950 5060-02
B.1 Production line for SIRIUS 2 - Siemens Cham
SIRIUS 2: 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 prefabricated connections.
Fig. B-1: SIRIUS 2 pilot system - production
Power & Control Modul
PROFIBUS-DP ECOFAST Hybrid Kabel
Energieleitung
Bandstrecke 2 Bandstrecke 3 Bandstrecke 4
Conveyor section 1 Conveyor section 2 Conveyor section 3
Power & Control Module
Hybrid cable
ECOFAST Pilot Projects
ECOFAST System Manual
GWA 4NEB 950 5060-02
B-3
SIRIUS 2 pilot system: Configuration with ECOFAST ES
Fig. B-2: SIRIUS 2 pilot system - configuration with ECOFAST ES
ECOFAST Pilot Projects
ECOFAST System Manual
B-4 GWA 4NEB 950 5060-02
Production
Fig. B-3: SIRIUS 2 pilot system - production
ECOFAST Pilot Projects
ECOFAST System Manual
GWA 4NEB 950 5060-02
B-5
B.2 Configuration in the Automotive Industry - Production
Planning
Production planning
Application: Production of wheel hubs
Task: Conveyor system with 4 cells
Set-up: Power & control module with S7-300 PLC,
PROFIBUS-DP, AS-interface and AS-interface monitor
(Safety at work)
Total of 6 motor starters for motors with 0.55 KW
Objective: To replace centrally controlled drive technology with a
distributed installation system.
To integrate pneumatics and EMERGENCY STOP
functionality in a single system technology.
ECOFAST Pilot Projects
ECOFAST System Manual
B-6 GWA 4NEB 950 5060-02
2.2.1 Configuration with ECOFAST ES
Fig. B-4: Configuration with ECOFAST ES
ECOFAST System Manual
GWA 4NEB 950 5060-02
C-1
Order numbers C
Section Topic Page
C.1 Motor Starters (Reversing starters) C-2
C.2 Motor Connection Cables and Power Cables C-3
C.3 Power & Control Modules (Infeed Modules) C-5
C.4 Discrimination Modules C-6
C.5 Hybrid Fieldbus Cables C-6
C.6 AS-Interface Shaped Cable C-7
C.7 Hybrid Fieldbus Interfaces C-7
C.8 Connectors C-8
C.9 Project engineering software and Documentation C-11
C.10 Tools, Connector Sets, Configuration C-12
Order numbers
ECOFAST System Manual
C-2 GWA 4NEB 950 5060-02
Order numbers
C.1 Motor Starters (Reversing starters)
*) Power descriptions are valid for 400 V AC
Setting Range*Motor Protection/
Switching
Technology
Brake Fieldbus Order No.
ECOFAST Motor Starters
0.3 A - 9 A (4 kW) Temperature
Sensor/
Mechanical
AS-Interface 3RK1 323-2AS51- 1AA0
400 V AC AS-Interface 3RK1 323-2AS51- 1AA3
ECOFAST Motor Starters High Feature
0.3 A - 9 A (4 kW) Temperatur-
Sensor/
Mechanical
PROFIBUS-DP 3RK1 303-2AS51- 1AA0
400 V AC PROFIBUS-DP 3RK1 303-2AS51- 1AA3
0.3 A - 3 A (1.1 kW) Thermal Motor
Model/
Mechanical
PROFIBUS-DP 3RK1 303-5BS41- 1AA0
2.4 A - 9 A (4 kW) PROFIBUS-DP 3RK1 303-5CS41- 1AA0
0.3 A - 3 A (1.1 kW) 400 V AC PROFIBUS-DP 3RK1 303-5BS41- 1AA3
2.4 A - 9 A (4 kW) 400 V AC PROFIBUS-DP 3RK1 303-5CS41- 1AA3
0.3 A - 3 A (1.1 kW) Thermal Motor
Model/
Mechanical
AS-Interface 3RK1 323-5BS41- 1AA0
2.4 A - 9 A (4 kW) AS-Interface 3RK1 323-5CS41- 1AA0
0.3 A - 3 A (1.1 kW) 400 V AC AS-Interface 3RK1 323-5BS41- 1AA3
2.4 A - 9 A (4 kW) 400 V AC AS-Interface 3RK1 323-5CS41- 1AA3
0.3 A - 3 A (1.1 kW) Full Motor
Protection/
Electronic Soft
PROFIBUS-DP 3RK1 303-6BS71- 1AA0
2.4 A - 12 A (5.5 kW) PROFIBUS-DP 3RK1 303-6DS71- 1AA0
0.3 A - 3 A (1.1 kW) 400 V AC PROFIBUS-DP 3RK1 303-6BS71- 1AA3
2.4 A - 12 A (5.5 kW) 400 V AC PROFIBUS-DP 3RK1 303-6DS71- 1AA3
0,3 A - 3 A (1,1 kW) Full Motor
Protection/
Electronic Soft
AS-Interface 3RK1 323-6BS71- 1AA0
2,4 A - 12 A (5,5 kW) AS-Interface 3RK1 323-6DS71- 1AA0
0.3 A - 3 A (1.1 kW) 400 V AC AS-Interface 3RK1 323-6BS71- 1AA3
2.4 A - 12 A (5.5 kW) 400 V AC AS-Interface 3RK1 323-6DS71- 1AA3
0.6 A - 4 A (1.5 kW) Full Motor
Protection/
Electronic Soft
(Duo-Reversing
Soft)
400 V AC AS-Interface 3RK1 323-6ES81- 3AA3
2.4 A - 8 A (3 kW) 400 V AC AS-Interface 3RK1 323-6FS82- 3AA3
0.6 A - 4 A (1.5 kW) 400 V AC PROFIBUS-DP 3RK1 303-6ES81- 3AA3
2.4 A - 8 A (3 kW) 400 V AC PROFIBUS-DP 3RK1 303-6FS82- 3AA3
Table C-1: Order numbers for Motor Starters
Order numbers
ECOFAST System Manual
GWA 4NEB 950 5060-02
C-3
Order numbers
C.2 Motor Connection Cables and Power 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
3RK1 911-0BG10
3RK1 911-0CG20
3RK1 911-0BG20
3RK1 911-0CG30
3RK1 911-0BG30
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
3RK1 911-0BJ10
3RK1 911-0CJ20
3RK1 911-0BJ20
3RK1 911-0CJ30
3RK1 911-0BJ30
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
3RK1 911-0BH10
3RK1 911-0CH20
3RK1 911-0BH20
3RK1 911-0CH30
3RK1 911-0BH30
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
3RK1 911-0BK10
3RK1 911-0CK20
3RK1 911-0BK20
3RK1 911-0CK30
3RK1 911-0BK30
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
3RK1 911-0CV10
3RK1 911-0BV10
3RK1 911-0CV20
3RK1 911-0BV20
3RK1 911-0CV30
3RK1 911-0BV30
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
3RK1 911-0CU10
3RK1 911-0BU10
3RK1 911-0CU20
3RK1 911-0BU20
3RK1 911-0CU30
3RK1 911-0BU30
Table C-2: Order numbers for Motor Connection Cables and Power Cables
Order numbers
ECOFAST System Manual
C-4 GWA 4NEB 950 5060-02
Order numbers
Unassembled
- 8 x 1.5 mm2 20 m
- 8 x 1.5 mm2 50 m
- 8 x 1.5 mm2 100 m
3RK1 911-0BW60
3RK1 911-0BW70
3RK1 911-0BW80
Power Cables
Han Q8 Pin/power tee connector for looping through power
- 5 x 4.0 mm2 1. 5 m
- 5 x 4.0 mm2 < 3 m, any length
- 5 x 4.0 mm2 3.0 m
- 5 x 4.0 mm2 > 3 m to < 5 m, any length
- 5 x 4.0 mm2 5.0 m
- 5 x 4.0 mm2 > 5 m to < 10 m, any length
- 5 x 4.0 mm2 10. 0 m
- 5 x 4.0 mm2 > 10 m to < 15 m, any length
3RK1 911-0BB10
3RK1 911-0CB20
3RK1 911-0BB20
3RK1 911-0CB30
3RK1 911-0BB30
3RK1 911-0CB40
3RK1 911-0BB40
3RK1 911-0CB50
Power cable Han Q8 Pin/power tee connector for looping through power
- 7 x 2.5 mm2 1. 5 m
- 7 x 2.5 mm2 < 3 m, any length
- 7 x 2.5 mm2 3.0 m
- 7 x 2.5 mm2 > 3 m to < 5 m, any length
- 7 x 2.5 mm2 5.0 m
- 7 x 2.5 mm2 > 5 m to < 10 m, any length
- 7 x 2.5 mm2 10. 0 m
- 7 x 2.5 mm2 > 10 m to < 15 m, any length
3RK1 911-0BE10
3RK1 911-0CE20
3RK1 911-0BE20
3RK1 911-0CE30
3RK1 911-0BE30
3RK1 911-0CE40
3RK1 911-0BE40
3RK1 911-0CE50
Han Q8 pin/Han Q8 Socket for looping through power
- 5 x 4.0 mm2 1. 5 m
- 5 x 4.0 mm2 < 3 m, any length
- 5 x 4.0 mm2 3.0 m
- 5 x 4.0 mm2 > 3 m to < 5 m, any length
- 5 x 4.0 mm2 5.0 m
- 5 x 4.0 mm2 > 5 m to < 10 m, any length
- 5 x 4.0 mm2 10. 0 m
- 5 x 4.0 mm2 > 10 m to < 15 m, any length
3RK1 911-0BC10
3RK1 911-0CC20
3RK1 911-0BC20
3RK1 911-0CC30
3RK1 911-0BC30
3RK1 911-0CC40
3RK1 911-0BC40
3RK1 911-0CC50
Han Q8 pin/Han Q8 Socket for looping through power
- 7 x 2.5 mm2 1. 5 m
- 7 x 2.5 mm2 < 3 m, any length
- 7 x 2.5 mm2 3.0 m
- 7 x 2.5 mm2 > 3 m to < 5 m, any length
- 7 x 2.5 mm2 5.0 m
- 7 x 2.5 mm2 > 5 m to < 10 m, any length
- 7 x 2.5 mm2 10. 0 m
- 7 x 2.5 mm2 > 10 m to < 15 m, any length
3RK1 911-0BF10
3RK1 911-0CF20
3RK1 911-0BF20
3RK1 911-0CF30
3RK1 911-0BF30
3RK1 911-0CF40
3RK1 911-0BF40
3RK1 911-0CF50
Han Q8 Pin/open end
- 5 x 4.0 mm2 1. 5 m
- 5 x 4.0 mm2 < 3 m, any length
- 5 x 4.0 mm2 3.0 m
- 5 x 4.0 mm2 > 3 m to < 5 m, any length
- 5 x 4.0 mm2 5.0 m
- 5 x 4.0 mm2 > 5 m to < 10 m, any length
- 5 x 4.0 mm2 10. 0 m
- 5 x 4.0 mm2 > 10 m to < 15 m, any length
3RK1 911-0BA10
3RK1 911-0CA20
3RK1 911-0BA20
3RK1 911-0CA30
3RK1 911-0BA30
3RK1 911-0CA40
3RK1 911-0BA40
3RK1 911-0CA50
Description Order No.
Table C-2: Order numbers for Motor Connection Cables and Power Cables
Order numbers
ECOFAST System Manual
GWA 4NEB 950 5060-02
C-5
Order numbers
Han Q8 Pin/open end
- 7 x 2.5 mm2 1. 5 m
- 7 x 2.5 mm2 < 3 m, any length
- 7 x 2.5 mm2 3.0 m
- 7 x 2.5 mm2 > 3 m to < 5 m, any length
- 7 x 2.5 mm2 5.0 m
- 7 x 2.5 mm2 > 5 m to < 10 m, any length
- 7 x 2.5 mm2 10. 0 m
- 7 x 2.5 mm2 > 10 m to < 15 m, any length
3RK1 911-0BD10
3RK1 911-0CD20
3RK1 911-0BD20
3RK1 911-0CD30
3RK1 911-0BD30
3RK1 911-0CD40
3RK1 911-0BD40
3RK1 911-0CD50
Description Order No.
Table C-2: Order numbers for Motor Connection Cables and Power Cables
Order numbers
ECOFAST System Manual
C-6 GWA 4NEB 950 5060-02
Order numbers
C.3 Power & Control Modules (Infeed Modules)
Table C-3: Order numbers for Power & Control Modules (Infeed Modules)
C.4 Discriminating Modules
Table C-4: Order numbers for Discriminating Modules
Description Order No.
PROFIBUS S7-300 (Master)
Main power supply 3 AC 400 V, 40 A
Auxiliary power supply 2 x 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
4FB2 111-2AE01-
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 248C
4FB2 121-2AE01-
0AA0
PROFIBUS S7-300 (master) and AS-i bus (master)
Main power supply 3 AC 400 V, 25 A
Auxiliary power supply 2x DC 24 V, 1 x 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
4FB2 112-2AC01-
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
4FB2 111-2AE01-
0AA1
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 AC 400 V, 8 A
- for AC 400 V, 16 A
- for AC 400 V, 25 A
3RK1 911-4AA08
3RK1 911-4AA16
3RK1 911-4AA25
Order numbers
ECOFAST System Manual
GWA 4NEB 950 5060-02
C-7
Order numbers
C.5 Hybrid Fieldbus Cables
Description Order No.
PROFIBUS ECOFAST Hybrid Cable – fiber-optic
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 6XV1 830-7DH50
- 10 m 6XV1 830-7DN10
- 15 m 6XV1 830-7DN15
Unassembled cable
- 20 m 6XV1 830-7CN20
- 50 m 6XV1 830-7CN50
- 100 m 6XV1 830-7CT10
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 6XV1 830-7BH15
- 3 m 6XV1 830-7BH30
- 5 m 6XV1 830-7BH50
- 10 m 6XV1 830-7BN10
- 15 m 6XV1 830-7BN15
- 20 m 6XV1 830-7BN20
- 25 m 6XV1 830-7BN25
- 30 m 6XV1 830-7BN30
- 35 m 6XV1 830-7BN35
- 40 m 6XV1 830-7BN40
- 45 m 6XV1 830-7BN45
- 50 m 6XV1 830-7BN50
Table C-5: Order numbers for Hybrid Fieldbus Cables
Order numbers
ECOFAST System Manual
C-8 GWA 4NEB 950 5060-02
Order numbers
Unassembled cable
- material sold by meter 6XV1 830-7AH10
- 20 m 6XV1 830-7AN20
- 50 m 6XV1 830-7AN50
- 100 m 6XV1 830-7AT10
Table C-5: Order numbers for Hybrid Fieldbus Cables
Order numbers
ECOFAST System Manual
GWA 4NEB 950 5060-02
C-9
Order numbers
C.6 AS-Interface Shaped Cable
C.7 Hybrid Fieldbus Interfaces
Description Order No.
Material Colour Quantity
Rubber yellow (AS-Interface) 100 m roller 3RX9 010-0AA00
1 km drum 3RX9 012-0AA00
black (DC 24 V) 100 m roller 3RX9 020-0AA00
1 km drum 3RX9 022-0AA00
TPE yellow (AS-Interface) 100 m roller 3RX9 013-0AA00
1 km drum 3RX9 014-0AA00
black (DC 24 V) 100 m roller 3RX9 023-0AA00
1 km drum 3RX9 024-0AA00
TPE
Special design accor-
ding to UL Class2
yellow (AS-Interface) 100 m roller 3RX9 017-0AA00
black (DC 24 V) 100 m roller 3RX9 027-0AA00
PUR yellow (AS-Interface) 100 m roller 3RX9 015-0AA00
1 km drum 3RX9 016-0AA00
black (DC 24 V) 100 m roller 3RX9 025-0AA00
1 km drum 3RX9 026-0AA00
Table C-6: AS-Interface Shaped Cable
Description Order No.
Hybrid fieldbus interface
Interface between switchgear 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 Fieldbus Interface Copper/Copper, Socket/Socket for incoming supply
Hybrid Fieldbus Interface Copper/Copper, Pin/Socket for looping through
Hybrid Fieldbus Interface Copper/FO, Socket/Socket incoming supply
Hybrid Fieldbus Interface Copper/FO, Pin/Socket for looping through
Hybrid Fieldbus Interface Copper-FO/FO, Socket/Socket incoming supply
Hybrid Fieldbus Interface Copper-LWL/FO, Pin/Socket for looping through
Hybrid Fieldbus Interface Copper/Copper, Socket/Socket incoming supply
(active)
3RK1 911-1AA22
3RK1 911-1AA32
3RK1 911-1AB22
3RK1 911-1AB32
3RK1 911-1AD22
3RK1 911-1AD32
3RK1 911-1AE22
Table C-7: Order numbers for Hybrid Fieldbus Interfaces
Order numbers
ECOFAST System Manual
C-10 GWA 4NEB 950 5060-02
Order numbers
C.8 Connectors
Description Order No.
Data + 24 V
Data Tee Connector Cu
Data Tee Connector FO
ECOFAST Bus Terminating Connector for PROFIBUS-DP 1 piece
ECOFAST Bus Terminating Connector for PROFIBUS-DP 5 pieces
3RK1 911-2AG00
3RK1 911-2AH00
6GK1 905-0DA10
6GK1 905-0DA00
PROFIBUS FO plug connector FO, 5 pieces
with 2x plastic FO and 4x copper conductors 1.5 mm2
- with pin insert
- with socket insert
6GK1 905-0BA00
6GK1 905-0BB00
PROFIBUS copper-cable plug connector, 5 pieces
with 2x shielded copper and 4x copper conductors 1.5 mm2
- with pin insert
- with socket insert
6GK1 905-0CA00
6GK1 905-0CN00
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).
- for Feeders (e.g. Motor Starter)
- for Power supply (e.g. Power & Control Module)
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
3RK1 911-2BF00
3RK1 911-2BE00
3RK1 911-5BA00
3RK1 911-5BA10
3RK1 911-5BA20
3RK1 911-5BA30
Power Tee Connector Han Q8 individual mounting
Power Tee Connector Han Q8 lined up
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 thin funnel enclosure PG 16
Connector Set Han 10E Pin EMC
Connector Set Han 10E Socket EMC
3RK1 911-2BG00
3RK1 911-2BH00
3RK1 911-2BK00
3RK1 911-2BL00
3RK1 911-2BM00
3RK1 911-2BN00
3RK1 911-2BL10
3RK1 911-2BN10
Table C-8: Order numbers for Connectors
Order numbers
ECOFAST System Manual
C-11 GWA 4NEB 950 5060-02
Order numbers
C.9 Project engineering software and Documentation
Description Order No.
Project engineering software
ECOFAST ES
– Graphical power bus configuration
– Power bus dimensioning
– Operator prompting on selection of Siemens A&D products
– Norm-compliant power system design
– Documentation
Switch ES
• Switch ES Motor Starter V 2.0
– for parameterizing, visualizing, diagnosing and testing the
ECOFAST motor starters via PROFIBUS-DP
– with online help
– German/English selectable
– tested for execution under Windows 95/98/2000/NT System
System requirements:
– PROFIBUS-DP interface: CP5411 (ISA), CP5412 (ISA), CP5511 (PCMCIA)
P5611 (PCI), Smart Cable for serial communication via a serial interface and
Teleservice, CP5613 and CP5614 (new CP card) and MPI interface on PG7xx
and its driver software (view interactive catalog CA01)
– CD-ROM drive
• STEP7 object manager
– for integrating the ECOFAST starter as an S7 slave in SIMATIC S7
– for calling Switch ES from STEP7
System requirements:
– SIMATIC: S7, M7, C7, PCS7
– STEP7: Version 5.0 or higher
– CD-ROM drive
Upgrade Switch ES Motor Starter from version 1.0 up to 2.0
3ZS1 200-0CC11-
0YA0
3ZS1 310-0CC20-
0YA0
3ZS1 310-0CC20-
0YE0
Documentation
Manual for ECOFAST Motor Starters (German/English)
Manual for ECOFAST Motor Starters High Feature (German)
Manual for ECOFAST Motor Starters High Feature (English)
3RK1 702-2GB18-
0AA0
3RK1 702-3AB18-
1AA0
3RK1 702-3BB18-
1AA0
Table C-9: Project engineering software and Documentation
Order numbers
ECOFAST System Manual
C-12 GWA 4NEB 950 5060-02
Order numbers
C.10 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
1
1
3RK1 902-0AH00
3RK1 902-0CT00
Disassembling tool for contact pins and sockets 1 3RK1 902-0AJ00
Cover for power sockets 1
10
3RK1 902-0CK00
3RK1 902-0CJ00
Connector set for power infeed 2.5 mm2: 1 connector enclosure
with PG 16, 1 socket insert and 9 contact sockets 2,5 mm2
1 3RK1 902-0CA00
Connector set for power infeed 2.5 mm2: 1 connector enclosure
with PG 16, 1 socket insert and 9 contact socket 4.0 mm2
1 3RK1 902-0CB00
Connector set for looping through power 2.5 mm2: 1 connector
enclosure with PG 16, 1 pin insert and 9 contact pins 2.5 mm2
1 3RK1 902-0CC00
Connector set for looping through power 4.0 mm2: 1 connector
enclosure with PG 16, 1 pin insert and 9 contact pins 4.0 mm2
1 3RK1 902-0CD00
Mounting plate (for motor plugged in) 1 3RK1 911-3AA00
Identification Plug 1 6ES7 194-1KB00-0XA0
PC cable with memory submodule 1 3RK1 911-0BN20
Test connector set 1 3RK1 911-2AM00
Cable end covers for AS-Interface Shaped Cable 1 3RK1 901-1MN00
Addressing and diagnostic unit for AS-i 1 3RK1 904-2AB00
Table C-10: Order numbers for Tools, Connector Sets, Configuration
ECOFAST System Manual Glossary-1
GWA 4NEB 950 5060-02
Glossary
Terminating resistor Each bus line connecting the individual motor starters to each other must be
terminated with a resistor at the start and end. This prevents line reflections.
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 an optical-fiber
cable.
Bus segment see Segment
Bus system The bus system comprises all the stations that are physically connected via
a bus cable.
Data tee connector Data tee connectors connect the components of an automation system with
PROFIBUS-DP.
Two data tee connectors are available in the ECOFAST system:
• With a copper cable (PROFIBUS-DP Cu)
• With an optical-fiber cable (PROFIBUS-DP optical-fiber cable)
DESINA Decentralized and standardized installation system for machine tools:
Developed by the Association of Machine Tool Manufacturers with the aim
of defining a standard for the design and installation of machine tool com-
ponents.
DMD Device master data (DMD) contains DP slave descriptions in a standardized
format. The use of DMD makes configuring the master and the DP slave
easier.
DP-Master The DP Master is a master that functions in accordance with EN 50 170,
volume 2, PROFIBUS, and uses the DP protocol.
DP-Slave The DP Slave is a slave that is operated on the PROFIBUS bus with the PRO-
FIBUS-DP protocol and functions in accordance with EN 50 170 standard,
volume 2, PROFIBUS.
DP-Standard The DP Standard is the bus protocol of the ET 200 distributed I/O system
based on the EN 50 170 standard, Volume 2, PROFIBUS.
ECOFAST Energy and Communication Field Installation System:
A system that decentralizes and modularizes installation to a large extent
and permits extensive diagnostics on the component level.
ECOFAST certified Confirms that devices from different manufacturers are compatible with
ECOFAST specifications.
Glossary-2 ECOFAST System Manual
GWA 4NEB 950 5060-02
ECOFAST integrated In addition to Siemens components, devices from other manufacturers can
be integrated in this configuration tool. Their integration and conformity is
confirmed by the "ECOFAST integrated" certificate.
ECOFAST ES The ECOFAST ES configuration tool supports power-engineering system
design.
Host A host is a system or unit that contains at least one DP Master. For example,
the programmable controller with the CPU is the host, and the IM 308-C is
the DP Master.
Hybrid field bus
connector
The Hybrid field bus connector is the physical connection between the sta-
tion 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.
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-slave method A bus access method whereby only one station at a time is the master and
all other stations are slaves.
Master system All slaves that are assigned to a master with a reading and writing function
form a master system together with the master.
Power bus Linear, primary power distribution bus
Power tee connectors Power tee connectors connect motor starters to the power bus. The power
bus is not interrupted when the motor starter is unplugged.
PROFIBUS PROcess FIeld BUS, European process and fieldbus standard which is defi-
ned 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 automa-
tion systems and field devices at the cell and field levels.
PROFIBUS is available with the following protocols: DP (= Distributed Input/
Output), FMS (= Fieldbus Message Specification), PA (Process Automation)
and TF (= Technological Functions).
ECOFAST System Manual Glossary-3
GWA 4NEB 950 5060-02
PROFIBUS address Each station must be assigned a PROFIBUS address for the purpose of
unique identification.
The PC/PU or the ET 200 hand-held unit have the PROFIBUS address "0".
The master and slaves have a PROFIBUS address within the range from 1 to
125.
Process image An "image" of the states of all inputs (= PII) or all outputs (= PIO) at a particu-
lar instant in time. You can access the process image in the controller pro-
gram
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 star-
ters, 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
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 startup until the class time has elapsed (e.g. after 10 seconds for
class 10). If the current limits are violated, the motor starter responds with
either a shutdown or warning.
Setting range for lower current limit:
20%..0.100% of the rated operational current.
Setting range for upper current limit:
50%...150% of the rated operational current.
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).
Glossary-4 ECOFAST System Manual
GWA 4NEB 950 5060-02
ECOFAST System Manual
GWA 4NEB 950 5060-02
DeutschEnglish
SIEMENS AG
A&D CD MM 3
D-92220 Amberg
Fax: **49-9621-80-3337
ECOFAST System Manual
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ECOFAST System Manual
GWA 4NEB 950 5060-02
Siemens Aktiengesellschaft
Automation and Drives
Low Voltage Controls and Distribution
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w w w . s i e m e n s . c o m / e c o f a s t Order No. 3RK1703-0BB18-0AA0
