Overvoltage Protection of The S7-200 Analog Input Module

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show the entry list S7-200 Digital/analog expansion modules -- Setting up and parameterizing hardware -Connecting and wiring modules Overvoltage protection of the S7-200 analog input module How do you interconnect unused inputs on the EM 231 RTD expansion module? How do you realize a sensor range of 4mA to 20mA with an analog module EM231 or EM235? How do you connect a sensor to an analog module EM 231 or EM 235 of an S7-200 and what should you watch out for? Overvoltage protection of the S7-200 analog input module Display part number QUESTION: What options do you have for protecting the analog input module against overvoltage? ANSWER: In order to protect the analog input module against overvoltage damage we recommend using a controlled power supply (SITOP power supply). If you use an uncontrolled power supply you can use a suppressor diode (very fast Z diode) as overvoltage protection. This diode has to be connected in reverse direction parallel to the incoming terminals. Under certain circumstances it might be necessary to have a series resistor placed in series to the plus pole for current limiting (protection of the suppressor diode). The diodes listed below support a peak current of 20A (load capacity 600W) and 50A (load capacity 1500W). Note: The maximum input voltage on the analog module must not exceed 30V. Load capacity 600W / 1ms 600W / 1ms 1500W / 1ms 1500W / 1ms Voltage range 25.7V to 28.4V (nom. 27V) 28.5V to 31.5V (nom. 30V) 25.7V to 28.4V (nom. 27V) 28.5V to 31.5V (nom. 30V) Type (SGS-Thomsen) P6KE27A P6KE30A 1N5634A 1N5644A
Table 1: List of usable suppressor diodes The main point in protecting analog inputs is that the analog inputs of the expansion module have the same reference potential as the power supply of the analog module. This guarantees that the analog input signals are not exposed to any common-mode voltage (see Entry ID: 2415890).
How do you interconnect unused inputs on the EM 231 RTD expansion module? Display part number Instructions: If only one input channel of the EM 231 RTD Module is used, the unconnected channel has to be either connected parallel to the used channel or to be short-circuited with a resistor. If the unused channel remains unconnected, the SF Error LED of the EM 231 RTD module is lit and in CPU information "Area overflow" is displayed on module status. The SF LED serves for recognizing of "wire breakage" on the connected inputs. If inputs are unconnected, this is shown as "wire breakage" by the SF LED on the module.
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Parallel connection of channel A and B Fig. 1 shows a EM 231 RTD, at which only the channel A is used. The inputs of channel B are placed 1:1 to channel A.
Fig. 1: Parallel Connection of Channel A and B "Short-circuiting" Channel B with Resistor Fig. 2 shows an EM 231 RTD, of which only channel A is used. As displayed in the figure, channel B is wired as 2 wire sensor.
Fig. 2: Bridging Channel B For Resistor R, a resistor value has to be selected depending onthe sensor type that is set at the DIP switches.
Fig. 3: Resistor Values Note: Wire the module in the voltage-free status only. Modifications regarding the DIP switches take only effect after power off/on of CPU. Keywords: Group Error
How do you realize a sensor range of 4mA to 20mA with an analog module EM231 or EM235? Display part number Instructions: Use the DIP switches to configure a sensor range of 0mA to 20mA. Wire the sensor as shown in Fig. A-12 (Channel D) in Appendix A of the SIMATIC S7-200 Programmable Controller System Manual
(Entry ID 1109582). Connect L+ of the power supply to the sensor's plus connection. Connect the sensor's minus connection to RD and D+. Connect all of the ground connections M together and connect them to D-. Note: When using a 4mA to 20mA sensor, you must convert the measured value accordingly. A sample program with explanations is available as Tip 38a in "Tips&Tricks S7-200" in Entry ID 1232912.
How do you connect a sensor to an analog module EM 231 or EM 235 of an S7-200 and what should you watch out for? Display part number Instructions: The analog input modules can be adjusted to various measuring methods with DIP switches. The settings for these switches apply to the entire module - different measurement ranges cannot be measured within the same module at the same time. The switch configuration is only read when the power supply is switched on. The switch settings needed for the required measurement range are given in Appendix A of the SIMATIC S7-200 Programmable Controller System Manual (Entry ID 1109582). The size of the module's input resistance depends on the type of connection. When measuring the voltage the input resistance is high at 10 MOhm. If the inputs Rx and x are bridged, as is necessary for measuring the current, then the input resistance drops to 250 Ohm. Note: In order to prevent common-mode voltage occurring, please refer to the information in Entry ID 2415890. Below are sample connections for various types of encoder on an analog module of the S7-200.
Fig. 1: 4-wire current measurement
Fig. 2: 3-wire current measurement
Fig. 3: 2-wire current measurement In order to protect the analog module against a short circuit of the current sensor you can connect another 750 Ohm resistance in series to the current sensor. This resistance - connected in series to the 250 Ohm resistance - limits the current to under 32 mA (at 20.4 V to 20.4 mA and at 28.8 V to 28.8 mA).
Fig. 4: 4-wire voltage measurement
Fig. 5: 3-wire voltage measurement Note: When using a 4mA to 20mA sensor, you must convert the measured value accordingly. A sample program with explanations is available as Tip 38a in "Tips&Tricks S7-200" in Entry ID 1232912. Entry ID:22148598 Date:2007-03-16 as helpful I regard this article.... Copy link
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Overvoltage Protection of The S7-200 Analog Input Module

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Fig. 1: 4-wire current measurement

Fig. 2: 3-wire current measurement

Fig. 4: 4-wire voltage measurement

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