Hardware and Engineering

PS 416-TCS-200
Telecontrol Card

08/97 AWB 27-1298 GB

1st published 1997, edition 08/97

Author:

Thomas Dahmen

Editors:

Klaus Krüger, Thomas Kracht

Translators: Christopher Baker, Terence Osborn

1298u1g.fm Seite 1 Dienstag, 23. Februar 1999 12:54 12

Caution!

Dangerous electrical voltage!

Before commencing the installation

●

Disconnect the power supply of the
device.

●

Ensure that the device cannot be
accidentally restarted.

●

Verify isolation from the supply.

●

Earth and short circuit.

●

Cover or enclose neighbouring units that
are live.

●

Follow the engineering instructions
(AWA) of the device concerned.

●

Only suitably qualified personnel may
work on this device/system.

●

Before installation and before touching
the device ensure that you are free of
electrostatic charge.

●

Connecting cables and signal lines
should be installed so that inductive or
capacitive interference do not impair the
automation functions.

●

Install automation devices and related
operating elements in such a way that
they are well protected against
unintentional operation.

●

Suitable safety hardware and software
measures should be implemented for
the I/O interface so that a line or wire
breakage on the signal side does not
result in undefined states in the
automation devices.

●

Ensure a reliable electrical isolation of
the low voltage for the 24 volt supply.
Only use power supply units complying
with IEC 60 364-4-41 or HD 384.4.41 S2.

●

Deviations of the mains voltage from the
rated value must not exceed the
tolerance limits given in the
specifications, otherwise this may cause
malfunction and dangerous operation.

●

Emergency stop devices complying with
IEC/EN 60 204-1 must be effective in all
operating modes of the automation
devices. Unlatching the emergency-stop
devices must not cause uncontrolled
operation or restart.

●

Devices that are designed for mounting
in housings or control cabinets must only
be operated and controlled after they
have been installed with the housing
closed. Desktop or portable units must
only be operated and controlled in
enclosed housings.

●

Measures should be taken to ensure the
proper restart of programs interrupted
after a voltage dip or failure. This should
not cause dangerous operating states
even for a short time. If necessary,
emergency-stop devices should be
implemented.

IBM is a registered trademark of International
Business Machines Corporation.

All other brand and product names are
trademarks or registered trademarks of the
owner concerned.

No part of this manual may be reproduced in
any form (printed, photocopy, microfilm or
any otherprocess) or processed, duplicated
or distributed by means of electronic
systems without written permission of
Moeller GmbH, Bonn.

Subject to alterations without notice.

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Contents

About This Manual

Other manuals (AWBs)

Setting Up A Telecontrol Station With
The PS 416 Controller

Procedure 8

About The Card

Task of the PS 416-TCS-200

Hardware and software requirements

Construction of the PS 416-TCS-200

Communication layers model

Engineering

Number of PS 416-TCS-200 cards in
the rack

Power supply

Terminal assignments

Selection of modem

Electromagnetic compatibility

Configuration

Installation

Installing the PS 416-TCS-200 in the rack

Operation

Function of the PS 416-TCS-200 card

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About This Manual

This card has been developed for remote metering,
remote indication and remote control and supports
the data security protocols FT 1.2 and FT 3
(asynchronous) as per the IEC 870-5 standard for
telecontrol equipment and systems.

This manual describes the structure, planning,
configuration, installation, operation and also the
testing and diagnostics of the PS 416-TCS-200
communication processor. The PS 416-TCS-200 is a
communication processor for PS 416 programmable
logic controller. With the aid of the PS 416-TCS-200
communication processor the PS 416 can be
connected as telecontrol station to a telecontrol
network.

This documentation is intended for the project
planner, programmer and commissioning engineer.
This documentation will enable such users to
connect the PS 416 to a telecontrol system.

A general knowledge of control and communication
engineering is required for a good comprehension of
this technical documentation.

Other manuals (AWBs)

The fundamentals of remote control using compact
PLCs are described in a separate manual. Each of
the individual components also has its own manual.

Guide to telecontrol, AWB 27-1299-GB

ZB 4-501-TC1:
Hardware and engineering, telecontrol card
ZB 4-501-TC1, AWB 27-1297-GB

About This Manual

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PS 416-TCS-200:
Hardware and engineering, telecontrol card PS 416-
TCS-200, AWB 27-1298-GB

Leased line S 40-AM-TL:
Telecontrol via leased line, application module S 40-
AM-TL, AWB 27-1301-GB

Dial-up line S 40-AM-TD:
Telecontrol via dial-up line, application module
S 40-AM-TD, AWB 27-1300-GB

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Setting Up A Telecontrol Station With
The PS 416 Controller

The PS 416-TCS-200 communication processor
forms part of the PS 416 modular control system.
With the PS 416-TCS-200 the individual controller
can be integrated into a telecontrol system. Here the
controller can be the central station or a substation.

Communication with the telecontrol network is
effected via modem and modem cable.
Communication is supported by task-specific
application modules (function blocks).

Figure 1: Layout of a telecontrol station with the PS 416
programmable controller

a Central station
b Modem

Either a dial-up line or a leased line can be used as the
transmission medium.

In the case of the dial-up line existing telephone
networks are used as transmission medium. All of the
modems in the central station and substations must
be modems with dialling capability. At the request of

S 40-AM-TD/TL

ZB 4-254-KB1

CPU PS 416

PS 416-TCS-200

Setting Up A Telecontrol
Station With The PS 416
Controller

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the central station or the substation the modems set
up a connection with a specified telephone number.

In the case of the dial-up line both the central and also
the substation can take over the function of a primary
station or the function of a secondary station:

Primary station:
Station which initiates data transport

Secondary station:
Station which replies to a data request

Communication of one station with several stations
simultaneously is not possible.

Figure 2: Telecontrol system with PS 416 components and
dial-up line configuration

a Central station – primary station / secondary station
b Dial-up modem
c Dial-up line
d Substation – primary station / secondary station

S 40-AM-TD

ZB 4-254-KB1

PS 4-200

ZB 4-501-TC1

S 40-AM-TD

CPU PS 416

PS 416-TCS-200

PS 416-CPU-400

PS 416-TCS-200

Other manuals (AWBs)

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In the case of the leased line all substations are
permanently connected to the central station.

If more than one secondary station is addressed via
the leased line only point-to-point leased modems
(party line) may be used. The central station will in
this case always be a primary station and the
substations always secondary stations. This makes it
possible for the central station to send messages to
all substations simultaneously.

Only the central station can initiate communication.
A substation cannot autonomously initiate
communication with the central station or with
another substation.

Figure 3: Telecontrol system with PS 416 components and
leased line configuration

a Central station – primary station
b Modem (party line)
c Substation – secondary station

S 40-AM-TL

PS 4-200

ZB 4-501-TC1

S 40-AM-TL

PS 416-TCS-200

CPU PS 416

PS 416-TCS-200

CPU PS 416

ZB 4-254-KB1

Setting Up A Telecontrol
Station With The PS 416
Controller

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Procedure

The following procedure is recommended for
connecting the PS 416 to a telecontrol system.

E Define all requirements made on the telecontrol

system – for example, data security, number of
stations, and so on. A detailed description will be
found in the “Guide to telecontrol” manual.

E Select the application module which matches

your requirements. Relevant factors here include:
station type (modular – compact), station class
(primary – secondary), number of stations.

E Configure the interface parameters for the

PS 416-TCS-200 in the application module. See
Chapter 4, Configuration.

E Adjust the transmission parameters where

necessary to match the requirements of the data
integrity class. See the “Guide to telecontrol”
manual.

E Install the card in the rack. See Chapter 5,

Installation

E Connect the PS 416-TCS-200 to the modem via

the ZB 4-254-KB1 modem cable. See Chapter 5,
Installation

The card is now installed, programmed, configured
and is ready for operation.

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About The Card

Task of the
PS 416-TCS-200

The PS 416-TCS-200 communication processor is
used for connecting the PS 416 programmable
controller via a modem to a telecontrol system. It
communicates with other telecontrol stations via a
point-to-point modem or dial-up modem.

The card has its own microcontroller. This means that
it handles the communication process autonomously
without taking up any of the capacity of the PS 416
central processing unit.

Hardware and software
requirements

Table 1 provides an overview of the hardware and
software requirements for running the
PS 416-TCS-200 within the PS 416 PLC system.

Table 1: Hardware and software requirements

Software
Programming software
Operating system

Application modules

Sucosoft S 40 Manager, Version 2.0 and
higher for PS 416-CPU-400 Version 1.13 and
higher
S 40-AM-TD Version 1.0 (dial-up line)
S 40-AM-TL Version 1.0 (leased line)

Hardware
Central processing unit
Power supply card:

Subrack

Modem cable

PS 416-CPU-400
PS 416-POW-400
PS 416-POW-410
PS 416-POW-420
PS 416-BGT-400/410/420 or 421 with
PS 416-ZBX-401/402/403 potential
equalisation rail
ZB 4-254-KB1

About The Card

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Construction of the
PS 416-TCS-200

Figure 4: Elements of the PS 416-TCS-200

a Switches S1 / S2
b RS 232 – modem port
c LED (error)
d LED (RxD / TxD)
e Interface module
f System EPROM

rxd/

txd

error

TCS-

200

d
c

Communication layers
model

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Switches S1 / S2

These switches must be left switched off at all times.

Port

The 9-pole Sub-D connector is used for connecting
the modem cable. The modem cable is not supplied.
Pin assignments are described in Chapter 3,
Engineering.

LED (error)

The LED indicates error messages. See Chapter 7,
Diagnostics

LED (RxD / TxD)

The LED indicates the operating status of the card.
See Chapter 7, Diagnostics

Interface

In order to ensure interference immunity the data
lines are optocoupled and the interface is supplied
with power via DC / DC converter with electrical
isolation.

Communication layers
model

The communication layers model describes the
relationships between programming software,
function blocks and the requisite hardware.

About The Card

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Figure 5: Communication layers model

Application layer
The program data are processed in the application
layer.

Link layer
This layer generates the line telegrams in accordance
with the IEC 870-5 standard and synchronises data
traffic between the station and the telecontrol system.

Physical layer
The electrical signals are formed in this layer in
accordance with the transmission medium used.

plica

tion layer

Sucosoft S 40

ppli

ca-

tion

Routing data

Event control

Data type conversion

modules

nk layer

S 40-AM-TL

S 40-AM-TD

lecont

rol function

blocks

ppl

ica

tion modules

Handling services

Address evaluation

Life control

Time-out monitoring

PS 416 programmable controller

PS 416-TCS-200 card

Card

IEC 870-5 primary station point-to-point modem

IEC 870-5 secondary station point-to-point modem

IEC 870-5 dial-up modem

Phys

ical

laye

Integrated RS-232 interface

SUB D, 9-pole

Dial-up modem
Primary / secondary
Type 1

Point-to-point modem
Primary

Secondary

Type 2

Type 3

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Engineering

Number of PS 416-
TCS-200 cards in the
rack

The communication processor works in all PS 416
basic units. The maximum number of
PS 416-TCS-200 cards which can be operated in a
single rack depends on the power consumption. For
this reason a power requirements calculation must
be made in all cases .

Power supply

The card is supplied internally with power at 5 V DC
from the PS 416-POW-400/410/420 power supply
card via the PS 416-rack. For further information
please refer to the Appendix, Technical data.

Terminal assignments

The communication processor is classed as data
terminal equipment (DTE).

The interface has full duplex capability – in other
words, data can be sent and received
simultaneously.

For the connection to the modem use the
ZB 4-254-KB1 modem cable.

Figure 6 shows:

interconnections and the pin assignments for the
9-pole Sub-D front connector

signal numbering as per CCITT recommendation
V24/V28

signal designations as per RS 232C

signal flow

Engineering

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Figure 6: Connections of the ZB 4-254-KB1 modem cable

Table 2: Meaning of the signals

Modem
D connector
25-pole plug

PS 416-TCS-200
D connector
9-pole plug

Pin

Protective ground (screening)

—

Not connected

DCD

(Data Carrier Detect)

1 DCD (Data

Carrier

Detect)

TxD

(Transmit Data)

2 RxD (Receive

Data)

RxD (Receive

Data)

3 TxD

(Transmit Data)

20 DSR (Data

Set

Ready)

4 DTR

(Data Terminal Ready)

SGND

(Signal Ground)

—

5 SGND

(Signal Ground)

DTR

(Data Terminal Ready)

6 DSR (Data

Set

Ready)

CTS

(Clear To Send)

7 RTS

(Request To Send)

RTS

(Request To Send)

8 CTS

(Clear To Send)

22 RI (Ring

Indicator)

9 (Signal not supported)

Signal

Meaning

TxD output

Transmit data, in idle state

m 3 V

RxD input

Receive data

SGND

Signal ground

RTS output

The modem is switched to the transmission state and remains in this
state for as long as the On state exists.
RTS is active M 3 V (Request To Send)

CTS input

The modem is ready to send data signals or to receive data for setting up
the connection.
CTS is active

M 3 V (Clear to send)

DTR output

The telecontrol card is ready for operation:
DTR is active

M +3 V, CPU in RUN MODE (Data Terminal Ready)

DSR input

The modem is ready for operation:
DSR is active

M +3 V (Data Set Ready)

DCD input

The modem reports that the transmission link is ready to receive data
(modem carrier frequency is stable).
DCD is active

M 3 V (Data Carrier Detection)

Selection of modem

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Selection of modem

You should select modems which have electrical
isolation between the RS 232 and the dial-up or
leased line. This prevents potential equalisation
currents occuring.

Electromagnetic
compatibility

You should note the following engineering
instructions in order to comply with the requirements
of EMC legislation:

E If the inductive and capacitive effects of

electromagnetic fields are to be reduced you will
need to fit the screen in a thorough and careful
manner.

E Connect the screen of the data line to the

protective ground by connecting each end of the
screen to a potential equalisation rail.

E Fit an RF ferrite ring of type PS 416-ZBX-405 to

the lead wire to the data line before the screen
connection.

The RF ferrite sleeve is not supplied with the card. It
can be ordered under type designation
PS 416-ZBX-405.

For the designation of the potential equalisation rail
appropriate for the rack please refer to
AWB 27-1208, PS 416 system.

The modems must also support the 11-bit
signalling format (8E1)

Engineering

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Figure 7: Grounding the signal line of the PS 416-TCS-200

a Signal line of the PS 416-TCS-200
b Screen

PS 416-BGT-4xx

PS 416-ZBX-40x

PS 416-ZBX-404

The screen braid must not be interrupted.

Electromagnetic
compatibility

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Figure 8: Grounding the signal lines of the modem

a Top-hat rail
b Snap fastener
c Contact clamp
d Screw
e Modem

The screen braid must not be interrupted.
Items

, and

are constituent parts of the

ZB 4-102-KS1 screen earth kit.

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Configuration

Before you can exchange data over the telecontrol
system for the first time with the PS 416 you will need
to configure each communication processor with the
aid of the device configurator.

E Access the Sucosoft S 40 Topology

Configurator.

E In order to configure the telecontrol card, key a

“0” into the boxes “Line” and “Rack / Station”
since the card can only be operated in the basic
unit of the PS 416.

E Next, in the “Slot / module” box you should

specify which slot the card is occupying.

E In the “Selectable Types” selection box you

should select the option “Card”. From the list of
available cards select the PS 416-TCS-200.

Interface parameters for data transmission
Parameter sets for communication have been
provided in the telecontrol card for the various
modes (leased or dial-up lines). When a service is
called via the application module the appropriate
parameters are used automatically. If these settings are
not the same as the parameters you want you can
change the settings via the application module.

The modified settings are saved in the controller and
when the controller is switched on they are
transferred automatically to the card.

Configuration

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Table 3: Default settings for the various modes

Baud rate

You can select from the following baud rates:

300 baud

4800 baud

600 baud

9600 baud

1200 baud

19200 baud

2400 baud

The better the signal quality (the transmission link)
the higher the baud rate you can select for faster data
transmission.

Parity

For additional data security a parity bit can also be
transmitted. Here at the transmitting end it is
possible to expand the character to an even or odd
value. Agreement with the parity setting must be
aimed at with all stations. Note that here not every
combination of data format, number of stop bits and
parity bit is possible – see Table 4

Handshaking RTS/CTS/DSR/DTR/DCD

The handshake lines RTS/CTS/DSR/DTR/DCD are
supported in order to ensure trouble-free
communication between two telecontrol stations via
modem.

Interface parameters (default settings)

Mode

Baud rate

Start bit (fixed value)

Data bit

Parity bit

Stop bit

Dial-up modem

9600

even

Point-to-point modem

1200

even

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Data format

7 bit / 8 bit: With 7-bit selection 128 different bit
combinations are available. If you wish to transmit
the entire character set with 256 bit combinations
you will need to select the 8-bit format.

Stop bit

1/2, see Table 4

Character format combinations

The PS 416-TCS-200 carries out plausibility checks
and any incompatibilities arising from the character
format combinations will be signalled.

Table 4: Permissible character format combinations

* Default setting of the PS 416-TCS-200

Start bit (fixed value)

Data bit

Parity bit

Stop bit

none

even

none

even*

odd

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Installation

Installing the PS 416-
TCS-200 in the rack

E Make sure that the interface module is firmly

seated in the PS 416-TCS-200.

E Install the PS 416-TCS-200 in the basic unit from

slot 4 onwards.

E Connect the RS 232 interface on the front plate of

the card to the modem. You should use the
ZB 4-254-KB1 modem cable.

E Install the application module; in this regard see

AWB 27-1300-GB and AWB 27-1301-GB.

E Configure the PS 416-TCS-200 with the

application module; see Chapter 4, Configuration.

E Integrate the PC 416-TCS-200 into your

configuration with the aid of the Sucosoft S 40
Topology Configurator.

Operating instructions:
To protect the components from the discharge of
static electricity the operator must discharge
himself electrostatically before touching the
PS 416-TCS-200, its front plate components or
the card.

Warning!
The PS 416-TCS-200 must not be inserted or
removed unless the power supply has been
switched off.

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Operation

Function of the
PS 416-TCS-200 card

Figure 9: Function of card in a telecontrol station

The card functions in a telecontrol system as a
protocol generator or protocol evaluator. The
application module prepares the user and control
data for the PS 416-TCS-200 communication
processor. The card packs this user data (a
maximum of 220 bytes) into the telecontrol protocol
and sends it to the modem via the integrated RS-232
interface.

The received data is evaluated according to the
telegram protocol used. The application module in
the central processing unit evaluates this data and
makes it available to the user for further processing.

Programmable controller

User program

Application module

PS 416-TCS-200

Protocol

Data

generation

evaluation

interface

mission
equipment

PS 416

↔

Data trans-

(modem)

Data terminal equipment (DTE)

Operation

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Startup behaviour

Both cold starts and warm starts are possible.

Cold start
Once the PS 416 has been switched on or a cold
restart signal has been received from the PS 416, the
activities of the communication processor begin with
the self-test. Here the PS 416-TCS-200 checks the
functional readiness of the interface module and of
the RAM memory modules.

The operating system will enter an error message in
the DPRAM should one of the following errors occur:

faulty operating system EPROM (where
detectable)

faulty RAM

faulty DPRAM (where detectable)

interface module not plugged in

In the event of such an error the user will receive the
corresponding fault message via the red front panel
LED when the program starts.

If there is none such error, the program logic
assumes that a cold start has taken place and sets
up a configuration which corresponds to the
system’s own default parameters. This default
configuration (leased line) includes a transmission
rate of 1200 baud, a data format of 8 data bits, even
parity with one stop bit as well as the characteristics
of a secondary station with a FT 1.2 message format.
The PS 416-TCS-200 now waits for new parameters
or the command to exchange data using the existing
default parameters.

Shutdown behaviour

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Warm start
If the PS 416-TCS-200 receives a reset command
from the application card without a cold start signal
from the central processing unit of the PS 416, the
communication processor stops all jobs which have
started and re-initialises itself with the aid of the user
parameters.

If there is no parameter error, the operating system of
the PS 416-TCS-200 assumes a warm start.

Shutdown behaviour

A drop in the power supply is communicated to the
communication card via a control line. In this case
transmit and receive operation via the serial interface
is aborted. All data which still needs to be sent and
data which has already been received is discarded.

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Diagnostics

Once the power supply has been switched on and
the self-test has run successfully the green front
panel LED “TxD / RxD” comes on and stays on.

The current operating status can be read off from the
two LEDs; see table.

Table 5: LED function during operation

Green data transfer LED
’TxD / RxD’

Red error LED ’ERR’

Card and bus interconnection status

Off

PS 416-TCS-200 is in coupled operation
No data exchange

Flashing

Off

PS 416-TCS-200 is exchanging data
The flashing mirrors the rhythm of the incoming
and outgoing characters.

Off

Hardware fault or defective initialization
No data exchange

Off

Flashes at a frequency of 2 Hz

Faulty or incorrectly initialised interface module

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Appendix

Technical data

Data interface

RS 232, V24/V28
9-pole SUB-D connector for modem connection

Handshake lines

RTS, CTS, DCD, DTR, DSR

Data transmission protocol

FT 1.2, FT 3 asynchronous

Maximum amount of user data in the
telecontrol transmission protocol

220 bytes

Maximum amount of user data in the
telecontrol transmission protocol

250 bytes

Electromagnetic compatibility (EMC)

See page 32

Transmission procedure

Asynchronous, choice of protocol

Data transmission rate

300, 600, 1200, 2400, 4800, 9600, 19 200 baud

Transmission link

RS 232, maximum cable length 2 m

Recommended cable

RS 232 with control lines: eight-conductor cable, screened;
max. cable length 2 m

Power consumption

0.83 A (5 V DC)

Power loss

Max. 4.2 W

Ambient temperature

0 to +55 °C

Transportation and storage temperature

–20 to +70 °C

Cards

4 space units (1 slot)

Format

Euroformat (160

u 100 mm)

Weight

approx. 180 g

Appendix

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Glossary

Application module
Application modules are programs or parts of
programs for the PLC or PC which support a function
in an application or which execute it entirely.
Application modules provide ready-made solutions
for the most varied applications.

Assymmetrical configuration
Configurations of telecontrol stations which consist
of primary and secondary stations are referred to as
asymmetrical configurations.

Asynchronous transmission
Each message character is synchronised
individually, usually by start and stop elements.

Central station
The station which remotely monitors substations
and / or remotely controls them.

Characters
Agreement regarding the data format, for example,
1 start bit, 8 data bits, 1 parity bit, 1 stop bit; i.e. 1
character = 11 bits.

General information on the electromagnetic compatibility (EMC) of programmable controllers

Emission

EN 55 011/22 Class A

Immunity

ESD

EN 61 000-4-2

Contact discharge
Air discharge

4 kV
8 kV

RFI

ENV 50 140

AM/PM

10 V/m

Burst

EN 61 000-4-4

Power supply/digital I/O
Analogue I/O, field bus

2 kV
1 kV

Surge

ENV 50 142

Digital I/O, assymmetrical
DC supply, assymmetrical
DC supply, symmetrical
AC supply, assymmetrical
AC supply, symmetrical

0.5 kV
1 kV
0.5 kV
2 kV
1 kV

Line-conducted
interference

ENV 50 141

10 V

Glossary

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Dial-up line
A transmission line which can be used after dialling.

DTE
Data Terminal Equipment may include computers,
terminals or other input or output devices. A DTE
which transmits data is referred to as a data source.
A DTE which receives data is referred to as a data
sink.

DTE
Data transmission equipment; see also Modem

Handshake
Defined sequence of signals for setting up and
checking a connection.

ISO / OSI
The ISO / OSI model describes a model for
classifying data transmission and processing
between two computers.

Leased line
A non-switched transmission line.

Modem
Abbreviation for “modulator-demodulator”. Device
which converts digital signals into analog signals and
vice versa.

Parity
Method of providing security for data – a check bit is
attached to every character.

Party line configuration
A configuration whereby the central station is
connected to more than one substation via a shared
transmission path in such a way that only one
substation at a time can send data to the central
station. The central station can send data either to
one or more substations. General messages can be
sent to all substations simultaneously.

Appendix

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Primary station
Station which initiates data transportation.

Secondary station
A station which replies to a data request from a
primary station.

Substation
A station which is monitored or monitored and
controlled by a central station.

Symmetrical configuration
Configurations of telecontrol stations which consist
of stations with equal rights are referred to as
symmetrical configurations. The stations in these
configurations combine the properties of primary
and secondary stations.

Telecontrol
Telecontrol is the monitoring and control of spatially
widely distributed processes by means of coded bit-
serial data transmission.

Telecontrol configuration
The combination of telecontrol stations and the
transmission paths between the stations.

Telecontrol station
Central station or substation within a telecontrol
system.

Telecontrol station
A telecontrol system is used for controlling and
monitoring processes which are spatially widely
distributed.

The system includes all equipment and functions for
data acquisition, processing, transmission and
display of the requisite process information.