Nexgen 5000 System Overview

SYSTEM OVERVIEW
TM
PLC
AN ICON OF THE FUTURE
TM
AUTOMATION PEOPLE
CONTENTS
Introduction : Nexgen 5000 PLC............................................................................1

Product Highlights
SaIient Features : Nexgen 5000 CPU...................................................... 2-3
CoDeSys : PLC Program Development Suite......................................... 4-6
Nexgen CPU 521x & 522x : Application Schemes
Modbus Connectivity .............................................................................. 7-8
Data Exchange via Modem......................................................................... 9
Fault Message Alert ................................................................................. 10
Servo Connectivity .............................................................................. 10-11
Nexgen Slave .......................................................................................... 12
Micro PLCs in Multidrop Connectivity ....................................................... 12
Variable Frequency Drives in Multidrop .................................................... 13
Specifications : Nexgen 521x & 522x Series of CPUs ...................................14-15
Detailed CPU Information
Nexgen 522x Series of CPU ................................................................ 16-19
Nexgen 521x Series of CPU ................................................................ 20-23
CoDeSys : Programming Software for Nexgen 5000 Series
Ladder Diagram (LD) ............................................................................ 25
Instruction List (IL)...................................................................................25
Structured Text (ST) .............................................................................. 26
Function Block Diagram (FBD) ............................................................. 26
Sequential Function Chart (SFC) .......................................................... 26
Continuous Function Chart (CFC) ......................................................... 27
Dynamic Data Exchange ........................................................................ 28
Sample Trace Function with Graphical Display ..................................... 29
Process Visualisation for On Line Testing .............................................. 30
POUs & Data Types .......................................................................... 30-31
CoDeSys: Instructions & Libraries .............................................................. 32
Communication Basics ................................................................................ 32-35
Base & Expansion Plates ................................................................................. 36
Power Supply Modules ..................................................................................... 36
Digital I/O Modules ....................................................................................... 37-38
Analog I/O Modules ..................................................................................... 38-41
Counter Modules ............................................................................. 42
Smartline Jr. & Sr. ............................................................................................. 43
E-Series Operator Terminals ....................................................................... 44-45
Ordering Information
HMI Connectivity ................................................................................ 46
Nexgen CPU 5000 Series .................................................................... 47
Base & Expansion Plates ..................................................................... 48
Input / Output Modules ..........................................................................48
Power Supply Modules ......................................................................... 48
Introduction
INTRODUCTION
IEC 61131-3 AN ICON OF THE FUTURE
PLC
Messung Systems, a leading pioneer in indigenous PLC in India, has constantly innovated to achieve global
standards in designing and manufacturing PLC products. With pride, it has now launched a high performance
series of world class CPUs viz. Nexgen 5000; coupled with basic building blocks of its earlier launched and
established Nexgen 4000 PLC. This Nexgen 5000 PLC family offers a wide range of CPU variants, with
®
IEC 61131-3 compatibility, having performance excellence and Windows based programming software.
Evolution Of PLCs on IEC 61131-3 Platform

In the earlier days of industrial automation, application specific machines or process plants were designed with
huge control panels having Relay Contactor Logic and Hardware Timers, Counters, Thumbwheels. These were
very bulky in size, complex for fault finding, less reliable with limited and unpredictable life. Similarly these
systems were very rigid in terms of any up-gradation.
This has evolved concept of Programmable Logic Controllers (PLC) which were compact in size, having better
edge over earlier electro-mechanical devices. PLC implementation has resulted in several benefits like:
minimized panel and wiring volume, expedited program development, reliability of operations with an improved
life, PLC re-usability across the applications (conditionally), easy and quick fault finding, and ease of interface
with HMIs, SCADA like external devices.
Over the time, only application specific hardware and software products were developed by various vendors,
which addressed the problem of compatibility and portability. This has initiated necessity of products
standardization in terms of hardware as well as software.
Similarly, with the growing Industrial Automation, industry has started facing typical problems of PLC
processing speed, memory, handling of a complex or very big program, logic re-usability, avoiding
duplicate variables in programming, choice of programming language selection as per application, user
friendly software along with documentation, standardized program interface.
Subsequently, International Electro-technical Commission worked upon complete design of PLC, which
comprised of hardware design, installation, testing, programming and documentation. Several inputs from
various machine manufacturers, end-users and research institutes has evolved five part IEC 61131 standard.
This international standard IEC 61131-3 is the first substantial endeavor to standardize programming languages
for industrial automation. It emphasizes on consistent method of PLC programming which encourages the
development of quality software. IEC 61131-3 provides tools to improve intrinsic quality of software in terms of its
persistent correctness, integrity, reliability, robustness, modularity, flexibility and safety. It also deals with
programming, installation and maintenance phases of software development projects in industrial control.
IEC 61131-3 compatible programming yields Rapid Application Development.
Nexgen 5000 series of CPU family is programmed with CoDeSys, the Windows® based, IEC 61131-3
compatible programming software.
1
Nexgen 5000 PLC : Product Highlights
NEXGEN 5000 PLC : AN ICON OF THE FUTURE Max. 32
l A truly modular PLC modules
an icon of the future
NEXGEN
l More I/O Capacity - 1024 Inputs / 1024 Outputs

l Enhanced Data Memory - 160 KB
64 KB - Data Memory (Selectively retainable)
32 KB - Marker Memory (Selectively retainable)
64 KB - File Marker Memory (Super retainable)
l Better processing speed - Boolean - 0.4 µsec max.
Word - 1.2 µsec upto
9 mtrs.
l Higher program memory -
Application Program Code - 256 KB
Application Source Code - 1 MB
l Wide assortment of Analog modules - Thermocouple,
RTD, Fast Analog Input and Output Modules
Nexgen 5000 PLC with full capacity
IMPROVED PG PORT OPERATION

l Supports RS-232C interface
l Dual operation - Program mode or Open Protocol
l Auto detect programming cable plug in & switch
to program mode
l User memory cassette interface
l Supports all protocol FBs
ENHANCED FILE MARKER MEMORY

l Super retained battery backed up memory
l Not cleared by cold start or even after program change
l Large capacity of 64K bytes
PLUGGABLE KEYBOARD DISPLAY UNIT (OPTIONAL)

The Keyboard Display interface is a extremely user & maintenance
friendly tool, which provides 4-character alpha-numeric display
with 6 keys key-pad.
Highlights :
l User has an optional choice of pluggable keyboard display
l It has built-in freely programmable 6 functions keys &
4 character alphanumeric display
l The keyboard display can be used as a self diagnostic tool.
This is helpful for assistance in :
n Displaying fault messages
n Displaying systems messages
n Viewing / modifying PLC variables
n Redirection of Digital I/O points
2
Nexgen 5000 PLC : Product Highlights
l The display and keyboard are freely programmable for application specific functionality. Display and
keyboard is accessible in the application program through the system variables. Using these system
variables, the user can develop their own function blocks to handle display and keypad as per the
application need.
l Standard FB library for I/O/M Monitoring, Redirection of Digital I/O points are also available.
l The Keyboard Display Unit can be fixed to / removed from, the Processor module during the
module powered ON condition.
COMPACT & HANDY MEMORY CASSETTE :

The memory cassette is used to store an application program code and
source code. It is a flash PROM type of intelligent memory cassette.
The cassette is compatible with all the Nexgen 522x series CPUs and it
is available in various memory sizes. The application program code
and source code can be downloaded to processor module (Nexgen
CPU) from the cassette.
Application Program Transfer : CoDeSys to Memory Cassette
The front side provides a push button and two LED indications for user
interface. The backside provides 9-pin D female connector for the
interface with PC or processor module.
APPLICATION PROGRAM DOWNLOADING

l First, cassette needs to be set using PC based software 'Bootstrap Loader Tool'.
l For transferring a program, memory cassette is plugged in to serial port-1 of PLC. Now pressing a
push button twice, initiates the 'Program Transfer'.
l If an application program code is valid, green LED will be ON. If the application program code
is blank, green LED blinks with 1Hz frequency. In case of invalid application program, red LED will
be ON.
Bootstrap
Loader Tool / CoDeSys
Memory PC COM
Cassette Programming cable 9910 Port
Cassette adapter
30 VAC to 5 VDC
power supply
5 VDC Power supply
To 230 VAC power supply
Fig : Set Up to download the Program to Memory Cassette
3
CoDeSys PLC Program Development Suite
Windows Based IEC Programming Software
IEC 61131-3 : A GLOBAL STANDARD
l Better Structuring of large programs
l High Reusability
l Combination of ladder program and high level programming language
VARIETY OF PROGRAM EDITORS

l LD : Ladder Diagram ST : Structured Text
l ST : Structured Text
l FBD : Function Block
Diagram
l IL : Instruction List
l SFC : Sequential
Function Chart
l CFC : Continuous
Function Chart
LD : Ladder Diagram
IEC 61131-3
FBD :
Function
Block Diagram
HIGH PERFORMANCE EVENT TASK SUPPORT

l Execution of POU on an event occurrence (Immediate action, as per priority)
l Dynamic attach / detach POUs to events
l Global masking via application program
INCREASED PROGRAMMING FUNCTIONALITY

l Online functionality : Program modifications, Monitoring of all
variables, Power flow monitoring
l Offline simulation now possible (limited)
l Variable trace function with graphical display
l Visualization (Limited for process monitoring)
ADVANTAGE - BUILT IN PROTOCOL FUNCTION BLOCKS

l Modbus RTU Slave / RTU Master
l Nexgen Slave
l XMP8-10 Micro PLC Master
l Frequrol - Inverter
l Printer
4
New Possibilities of Remote Operation
REMOTE PROGRAMMING VIA MODEM
PSTN
Network PC
Port - 1,
RS-232 C CoDeSys
Dial-up modem Dial-up modem

remote operation
Remote programming / on-line monitoring of Nexgen-5000

PLC via dial-up modem is possible on PG port. The PLC
programming software- CoDeSys can communicate with
Nexgen-5000 PLC via modem.
Highlights :
l Users can remote Login via dial-up modems.
l Project, source upload/download extended via modem
l On-line project modification is possible
Configuration : Communication Parameters
l Remote on-line debugging via modem support
The modem used at PC end could be internal modem or it
could be external modem. The communication speed
depends upon the line conditions and the link may establish
at lower Baud-Rate than default setting of 38.4kB.
5
New Possibilities of Remote Operation
REMOTE PROGRAMMING VIA LAN :
Nexgen 522x CPU

The PLC programming software-CoDeSys can
P : PG Port, RS 232C communicate with Nexgen-5000 PLC via TCP/IP
connection.
P TCP/IP (LAN)
PC2 PC1
COM Port
In this setup, the programming software 'CoDeSys' is running on PC1 and the gateway server is
remote operation
running on PC 2. The link between CoDeSys & Gateway Server is established via TCP/IP bus. The
Nexgen-5000 PLC is connected to COM port of PC2, the link between Gateway Server & PLC is
established via RS-232 bus. Or otherwise the PC2 can be directly interfaced with PLC via
programming cable.
Gateway Icon
6
Nexgen 5000 PLC Based Application Schemes
MODBUS CONNECTIVITY MADE EASIER
l MODBUS Master and MODBUS Slave

l Nexgen 5000 series PLC provides MODBUS connectivity as software feature rather than any
hardware module. This is quite fascinating feature for every application developer.
modbus connectivity
l While communicating with SCADA or other Nexgen 5000 PLC, one may implement MODBUS Slave.
l Similarly, while communicating with the field devices like relays, energy meters (which implement
MODBUS), PLC implements MODBUS Master.
MODBUS MASTER
Master
Master : Nexgen 5000 PLC
Slave : Enercon Energy Meter
P : Port - 2 / 3, RS 485
Slave-1 Slave-2 Slave-31
Network having 31 nos. of Enercon Energy Meters as slave connected to one Master Nexgen-522x CPU, using MODBUS Master.
Master FB : This FB handles serial communication with MODBUS RTU Protocol as master device. It is
useful to interface HMI, SCADA as a slave with Nexgen 5000 PLC. PLC communication can be
established with one PLC as Master and other(s) as slave(s). It can also be used to have CPU as data
logger to collect the data from Energy meters, VFDs etc.
Highlights :
l User need not know the MODBUS protocol.
l Protocol implementation is physical layer independent i.e. it can be used with RS232C, RS422 or
RS485.
l Communicates with any third party MODBUS RTU slaves inclusive of Messung PLCs with the
MODBUS RTU_Slave FB
l Easy interface with various SCADA and HMI packages as slaves is possible with appropriate FBs. No
need to develop any special driver.
l Easy connection to multiple Beijer E-terminals with it's MODBUS Slave driver
l Easy application interface by defining data exchange records with various stations
l Allows exchanging data via I, Q and M devices in Nexgen 5000 with MODBUS devices in various
stations
l Data exchange records can be grouped and called in manual, auto-cyclic and super cyclic modes.
l Flexibility in data exchange records programming.
l Programmable Retry and Time-out facility if a station fails to respond.
l Supports variety of baud rates to suit the application needs.
7
These FBs are useful -

l To interface Beijer make E terminals as master or slave with MODBUS RTU Driver.
l To interface any SCADA software as master or slave which supports MODBUS RTU protocol.
modbus connectivity
l For PLC to PLC communication in Nexgen 5000 PLC. One PLC can be a Master PLC and other/s can
be slave/s.
MODBUS MASTER AND MODBUS SLAVE

Master
Master : Nexgen 5000 PLC
Slave : Nexgen 5000 PLC
OR P : Port - 2 / 3, RS 485
P
P P P
Converter for
RS 232C to RS 485
Network having 31 Nos. of Nexgen 522x PLCs as slave connected to one Master Nexgen 5222-B0 CPU, using MODBUS Master and
MODBUS Slave.
MODBUS Slave FB :
It emulates MODBUS slave functionality. This FB handles serial communication with MODBUS RTU
Protocol as slave device. The RTU slave FB is useful to communicate with any external master PLC,
SCADA or DCS systems. Communication speed can be up to 56Kbps.
Highlights :
l User need not know the MODBUS protocol
l Protocol implementation is physical layer independent i.e. it can be used with RS232C, RS422 or
RS485.
l Communicates with any third party MODBUS RTU master or Messung PLC with MODBUS
RTU_Master FB Easy connection to various SCADA and HMI packages. No need to develop any
special driver.
l Easy connection to Beijer E-terminals with it's MODBUS Master driver
l Allows to exchange data via I, Q and M devices in Nexgen.
l Ready to use FB with few parameters to define to go
l Flexibility in station number programming.
l Supports variety of baud rates to suit the application needs.
8
DATA EXCHANGE VIA MODEM

Multiple PLC Data Collection Via Modem
PLC : Nexgen with 522x CPU

PLC 1
modem connectivity
PLC 2
Dial-up modem
Dial-up modem
PSTN
PLC 3 Network
PC
SCADA package with
SCADA protocol driver and
modem connectivity
Dial-up modem
Dial-up modem
Multiple PLCs can be connected to PSTN network via modem. Multiple PLCs can communicate with one
or more PC/PLC at a time through modem. Either of PLC / PC or both can initiate a communication.
Once the communication is established, Protocol FB like MODBUS, Nexgen or Micro can take over a
control for Data Exchange.
PLC to PLC Connection Via Modem
PLC 4 PLC : Nexgen with 522x CPU
PLC 1

PSTN
PLC 3 Network
PLC 2
PLC initiates a call via modem FB. Now, modem FBs establish a communication between any of the two
Nexgen-522x PLCs ( As shown in above figure ). Once the connection is established, the control is
passed to protocol FBs like MODBUS, Nexgen protocol.
The calling line / connection status can be monitored and failure of the link can be detected. In case of
lines getting busy or unreachable auto redial, auto retry is possible. Dial-In facility with auto connect
modems & Dial-Out predefined number is also feasible. Various communication speeds can be gained
based on line conditions. Connect, Initialize and Hang-up sequence for the modem can be also
controlled.
Nexgen-522x PLC, which initiates a call will implement Dial-Out FB. While PLC at other end i.e.the
responding PLC, will implement Dial-In FB.
Note : The calling PLC ( i.e. PLC which has initiated a communication call ) can be a Master or Slave.
9
CONVENIENT FAULT MESSAGE ALERT
PLC : Nexgen 522x PLC : Nexgen 522x

P : Port 1 / 2 / 3 , RS-232C P : Port 1 / 2 / 3 , RS-232C
PLC Pager PLC

Mobile Mobile
Numeric
Message
P PSTN P
Network
ser vo connectivity
Dial-up modem
GSM modem
with SIM card
Dial up modem connected to Nexgen 522x CPU , sends GSM modem connected to Nexgen 522x CPU, sends
Numeric Messages on pager, or only Ring Alert on mobile. SMS (text messages )
The relevant FBs can be implemented, as per application requirement.
SERVOS NOW CONNECTABLE
PLC : Nexgen 5000, with 5214 or 522x - P4

PLC
Interface Cable 4944
Patch Panel
4960
MRJ2-A AC Servo Motor
A Typical Nexgen 5000 PLC Set-up with CPU-5214
Special CPU varieties with HSC/PTO and motion control :

The special features offered are High-speed counter (HSC) & Pulse train output (PTO). Processor
modules with following extensions support added functionalities. These functionalities are
summarized as below.
10
CP522x P2 : 1 HSC + 1 PTO + 2 Interrupt I/Ps (Under Development)

CP522x P3 : 2 PTO channels + 2 Interrupt I/Ps (Under Development)
CP522x P4 : 2 ch HSC + 2 ch PTO + 2 Interrupt I/Ps
There are two variants in the patch panel
a. PNP type ( 4960 ) : The output of PTO is PNP type & can be interfaced to 24V signal level.
b. Differential type ( 4962) : The output of PTO is differential type & can be interfaced to
Rs422 differential signal level
HSC-PTO Function Library :
ser vo connectivity
Nexgen 5000 CPU provides 2 channels of HSC I/P and 2 channels of PTO O/P. To handle these
hardware resources the OS of Nexgen 5000 CPU supports external FB library PTO lib.
MC-MoveAbsolute
HSC MC-MoveRelative Analog
MFIP MC-MoveVelocity Out
Axis1 MC-Stop
Analog MC-ReadActualPosition
MC-ReadParameter PWM
Pot MC-ReadBoolParameter
Data Data
In MC-WriteParameter Out
MC-WriteBoolParameter
PTO PTO
MC-MoveHome
Under Development
Axis2 2 Axis_Interpolation
Electronic_Gearing
CANbus Phasing CANbus
CAM_Control
H/W Axis_Ref PLC open H/W

Driver Data Motion Control Driver Schematic diagram
FBs FBs FBs depicting motion control
Its based on PLC open motion control FB guidelines. It's a universal method of motion control
irrespective of front-end interface.
HSC PTO features supported in Motion Control applications :

l HSC, Potentiometer position input, Infrared position input
l Pulse Train Output, Analog output, PWM output, Motorised potentiometer control
l (PTO) features supported in Motion Control
l Point To Point Positioning
l Absolute and Relative Positioning
l Acceleration / Deceleration control
l Emergency stop with controlled deceleration
l Velocity Control FBs
l Positioning Profile Handling
l Co-ordination Interrupts
These special modules can be used in variety of applications like Packaging, Printing, Cut to length,
Bottling, M/C tools etc.
11
NEXGEN SLAVE
Nexgen slave FB is provided in FB library. By defining input parameters of FB, user can select
communication port and communication parameters to establish communication with HMI. This FB
handles serial communication with Nexgen 5000 as slave device and interfaces HMI, SCADA as a
Master.
This FB is useful to interface -
l Messung make HMIs SMARTLINESr and SMARTLINEJr
l Beijer make E terminals with NEXGEN 4000 Driver
l SCADA software which supports Nexgen protocol
HMI & E TERMINAL CONNECTIVITY

Master
HMI connectivity
l It emulates Nexgen 4000 HMI port protocol F 940

F 930
l Allows connection to Smartline, E-Terminals
and SCADA with Nexgen Drivers
Sr. HMI
l The HMIs or E-Terminal can be attached to any E-Series Mitsubishi Make
Operator Terminal Graphic Operator
Com port and can be instantiated as desired Terminals
l Communication speed can be set, up to
56K for connecting E-Terminals or SCADA
Slave
Graphic Operator Terminal ( GOT ) Connectivity

l GOT-F Series and A Series are supported
l Modbus RTU is used for serial Communication
l Nexgen 5000 CPU works as Modbus Slave
l Memory mapping of I(X), Q(Y), M(M&D) supported
MICRO PLCs IN MULTIDROP CONNECTIVITY
PC Master Master : Nexgen 5000 PLC or PC

Slave : Micro PLC
P : Port - 2 / 3, RS 485
OR
Converter for
RS 232C to RS 485
Network having 31 Micro PLCs (XMP81x Series i.e. XMP-8 11/12/13/15/16/17) are connected to a Master Nexgen 5000 PLC, where PLC
implements XMP8_10 Master block.
Here, 31 Micro PLCs are networked with one master, where master can be :
- Nexgen 5000 PLC using RS 485 port
- PC with SCADA
Here, FB used is XMP8_10Master.
12
VARIABLE FREQUENCY DRIVES IN MUTIDROP
Master HMI Master : Nexgen 5000 PLC or PC

Slave : Freqrol (Mitsubishi make Inverter)
P : Port - 2 / 3, RS 485
combining strengths
Slave 1 Slave 2 Slave 3 Slave 31
Nexgen5222- BO interfaced with Beijer HMI E-Terminal on 2'nd port and network of Mitsubishi make Inverter is interfaced with 3'rd port.
l User need not know the Inverter interface protocol. It Reads/Writes data to multiple inverters.
It can have direct serial inverter control from user program
l Transfer data to central SCADA / HMI on other port
l Extendible to serial connection up to 31 inverters
l Fast response to set point changes
l Direct Inch, On/Off control
l Cyclic updation of actual data from inverters
l Individual Inverter Error handling
l Automatic communication recovery as soon as Inverter is switched ON
l Inverter data may be modified or controlled from HMI, SCADA or result of application program
l Communication on 9.6K or 19.2K baud
l Easy access to parameters via structured data for each inverter.
l Support some On-demand command execution such as initialisations etc.
l Predefined Parameters Handling (selectable)
- Write control : Start, Stop, Reset, Set Frequency.
- Read info : Frequency, Voltage, Current, Inv-status.
13
CPU Specifications
SPECIFICATIONS :
NEXGEN 521x & 522x SERIES OF CPUs
Attributes Specifications Remarks
CPU 521x CPU 522x
Processor 16 bit Micro controller -
Processing Boolean ( Move ) 0.6 µSec 0.4 µSec

Time -
Word ( Move ) 1.2 µSec 1.2 µSec
Maximum Permissible up to 1 Sec User can modify

Scan Time Default setting 250 mSec with System variable _wLimitMaxScan
Standard IEC 61131-3 -

Software CoDeSys Windows ® based
(Version) All available Version 2.3* * Recommended Version 2.3 or onwards
LD Ladder Diagram
Programming IL Instruction List

Language ST Structured Text
FBD Function Block Diagram
SFC Sequential Function Chart
CFC Continuous Function Chart
Remote Programming - Supported Supported, using dial-up modem
Application Memory 64 KB 256 KB For run time execution
Data 32 KB 64 KB Used as application data memory.

(Retainable) Essentially consumed by instances of
Memory FBs (e.g.Timers,Counters etc.)
Configuration
Data Marker Memory available for HMI / SCADA
(RAM) 15,872 bytes 32,256 bytes
Memory (Retainable) Connectivity
File Marker Memory Retains after cold start or
- 64 KB
(Super even after a program change.
Retainable)
Memory Application Program
Code 64 KB 256 KB -
Configuration
( Flash : Application Program Can be uploaded along with
On-board ) Source Code 192 KB 1 MB comments, with password protection
Automatic program transfer takes
Program Execution Program Execution is through RAM place from Flash to RAM, at
every power on.
Bootstrap Loader is a PC based
Operating System 128 KB utility for downloading OS
Marker bits Supported Except MB0 to MB127
Retentivity Data Memory Supported
I/O Not Applicable
Memory Used for storing an application program
Not Applicable 256 KB
Cassette code and an application source code.
Type Lithium, Ni-MH, 3.6 V 521x has plugaable battery
3 V DC DC, 800 mAH 522x has on-board battery
Battery
Back-up Re-Chargeable No Yes * If powered on, battery starts charging
Life 2 Years 6 Months** ** If PLC is not powered on,
battery gets discharged
Source code Supported
Modifications
On-line Write / Force Supported -
Features Variables
Watch-Receipt Supported
for PLC Variables
14
CPU Specifications
Attributes Specifications Remarks
CPU 521x CPU 522x
Project File
Application
Program POU Password Facility Read / Write Password available
Security Source Code
Uploading
Cyclic Available Available
Task -
Supported Periodic Event - Available
Interrupt Event - Available
Numbers Unlimited * *Limited by available data memory.

Resolution 1 ms TON, TOFF,TP
Timers
Max. Range 24.855 Days
Retentivity User Selectable
Numbers Unlimited * *Limited by available data memory.
CUP, CDN, CUD
Counters Max. Count 65536
Retentivity User Selectable
Input points 1024 Presently supported 1024 I/O points

I/O Capacity
Output points 1024 ( Free Mix )
Rack Basic 1 Racks are available accommodating

Capacity Expansion 3 3 I/O / 5 I/O or 8 I/O Modules
Keyboard 8 Keys 6 Keys Keyboard & Display are programmable

Diagnostic through an application program
User Configurable
Tools * 522x series has Pluggable Display-
Display 4 Character Alpha-numeric Keyboard, as against 521x series.
Operating Modes Run , Stop ,Single Cycle -

Run Green
CPU Red
Diagnostic
LED I/O Red
Indications
MEM Red
LOW BAT Red
Communica- Port 1 RS 232C Default as programming port(PG)
tion Ports
(All ports are Port 2 RS 422 RS 232C/
CPU 522x has
with Open RS 422/485
RS 232 C Or identical ports (2'nd/3'rd)
Protocol ) Port 3 (Identical Ports)
RS 422/RS 485
Communica- Up to 57.6 Kbps User selectable
tion Baud Rate
Communica- For Transmission 256 Bytes
-
tion Buffer
Memory For Reception 256 Bytes
Noise Power Supply As per 2 KV conductive noise

Immunity
Serial Ports IEC 1000 - 4 - 4 1 KV capacitive coupled noise
Current
Consumption At 5V DC 600 mA -
15
CPU Specifications
NEXGEN 522x SERIES OF CPUs
Nexgen 521x and 522x series of PLCs is an outcome of fundamental thought of modular PLC with IEC 61131-3 compatible CPU
and windows based programming software. This definitely has widened the scope of communication and interfacing multiple, as
well as variety of third party devices.
To reinforce the standardization, not only in programming techniques, but in hardware also, Messung Systems has launched a
step ahead, Nexgen 522x series of CPUs, with further faster and memory efficient CPU.
In nutshell, Nexgen 522x series of CPUs has an edge over existing Nexgen 521x series of CPUs in terms of ports standardization
and enhanced memory..
Nexgen 522x : CPU Variants And Communication Ports

Nexgen 522x series itself has 6 CPU variants. This wide range of CPU empowers user to select a CPU as per application specific
requirement, with enhanced memory viz. feature wise as well as capacity wise.
This has a well defined ordering code system, which explains the complete portfolio of a Nexgen 522x series of CPUs.
This essentially has Standard CPU, 3 Port CPUs (2 No.), Low cost CPU and Special CPU.
CP 5220-P4 CP 5220-B0 CP 5221-P4 CP 5221-B0 CP 5222-P4 CP 5222-B0

Special CPU 1 port CPU Special CPU 2 port CPU Special CPU 3 port CPU
Ordering Code CP 5220 CP 5221 CP 5222

BO Port 1 Port1,Port2 Port1, Port2, Port3
P2 Port 1, Port1, Port2, Port1, Port2, Port3,
1 HSC + 1 PTO 1 HSC + 1 PTO 1 HSC + 1 PTO
P3 Port 1 Port1,Port2 Port1, Port2, Port3
2 PTO 2 PTO 2 PTO
P4 Port 1 Port1,Port2 Port1, Port2, Port3
2 HSC + 2 PTO 2 HSC + 2 PTO 2 HSC + 2 PTO
* CP 522x P2, CP 522x P3 and CP 522x P4 requires a patch panel and cables.
The processor module supports three independent serial communication ports with well defined availability criteria as :
Port-1 is RS 232C only (Applicable to 5220, 5221, 5222 CPUs)

Port-2 is RS 232C/422/485 (Applicable to 5221 and 5222 only)
Port-3 is RS 232C/422/485 (Applicable to 5222 only)
All the serial ports are provided on-board and are open for user to define communication parameters and handle serial
communication using function blocks as per requisite protocol.
The communication port-1 is RS 232C hardware interface port and it automatically gets assigned for programming through
programming software 'CoDeSys', if programming cable (having an ordering code 9910) is connected. Otherwise it is open for user
to define protocol and handle serial communication through application program. Port 1 is used to transfer an application program,
from memory cassette to PLC, when ever required.
16
CPU Specifications
The detailed pin configuration is illustrated in below diagram. For the communication port 1, 9-pin D male connector is provided on
the Processor module. The figure below shows front view of the connector.
5
9
GND : 5
9 : Modem Ring Indicator
5V:4
8 : Reserved for programming
TxD : 3
7 : No Connection
RxD : 2
6 : No Connection
Carrier Detect : 1 6
1
Nexgen 522x : Port 1
Pin-1 provides carrier detection status when modem is connected. This status is available in application program on activating
PORT_STATUS. Pin-9 provides ring indicator when modem is connected and if any controlling device is dialing. Pin-4 and Pin-5
provides 5 VDC and Ground, which is used for memory cassette operation.
This 5 V DC is strongly recommended only for restricted use. ( Not for driving the 5V DC operated external devices).
Communication Port 2 and Port 3

Communication Port-2 and Port-3 are open for RS 232C/422/485 hardware interface. The signals are terminated on different pins
on 9 pin D connector. The processor module provides requisite hardware for serial interface. The operating system provides driver
functions and function blocks which directly controls the hardware interface. For a serial port, processor provides system buffer of
256 bytes each for reception and transmission. The relevant driver function blocks like Nexgen_slave and RTU_Slave are
provided in the library Nexgen 522x.lib.
For the communication ports 2 and port 3, 9-pin D male connectors are provided on the Processor module. The figure below
shows front view of the connector. The connections for both ports are identical.
5
GND : 5 9
9 : Rx+ (RS 422)
Tx+(RS 422) : 4
8 : Rx- (RS 422)
TxD (RS 232C) : 3
7 : Tx- (RS 422)
RxD (RS 232C) : 2
6 : No Connection
Carrier Detect (RS 232C) : 1 6
1
Nexgen 522x : Port 2 / 3
The detailed pin configuration is illustrated in above diagram. Pin-1 provides carrier detection status when modem is connected.
This status is available in application program on activating PORT_STATUS.
Special Interfaces
Nexgen 522x series has specialized interfaces as :
CP 522x-P2 : 1 HSC Channel + 1 PTO Channel + 2 Interrupt inputs ( Under Development)

CP 522x-P3 : 2 PTO Channels + 2 Interrupt inputs (Under Development)
CP 522x-P4 : 2 HSC Channel + 2 PTO Channel + 2 Interrupt inputs
Interrupt feature is not available in Nexgen 5214.
17
CPU Specifications
MOST ADVANCED NEXGEN 522x SERIES OF CPUs
On-board Interrupt Inputs
Industrial automation applications are ever demanding with increased level of sophistication. Especially real-time systems
demand flexible and configurable control over the execution of different parts of program, which can be in response to any
Interrupt Event.
Interrupts suspend the current (normal) execution, completes the interrupt-linked POU execution and then returns back to
suspended point, to resume normal execution.
In case of multiple interrupt events, these event needs to be prioritized. System interrupt events like serial communication interrupt,
internal timer interrupt are executed at highest priority. Here scheduler manages the execution of queued events as per defined
priority.
The general specifications are as:
Two Maximum
Event Number Enum
2 EVENT_Z1_R_TRIG
No . of on-board inputs
3 EVENT_Z1_F_TRIG
5 EVENT_Z2_R_TRIG
6 EVENT_Z2_F_TRIG
Selectable by inputs at Open collector ( 18-30 V DC inclusive of ripple )

patch panel Differential ( 5V DC )
7 mA for open collector type input

Current
15 mA for differential type input
Min. ON time duration 5m s
Min. OFF time duration 5m s
Patch Ordering code 4960
Panel Ordering code 4962
Accessories Required
Interface Ordering code 4945
cable Ordering code 4946
Nexgen 522x : Memory & Configuration

Nexgen 522x series CPU has two on-board memory resources viz. RAM and Flash PROM. This is similar to Nexgen 521x, but it
has enhanced memory capacity and also has file marker memory.
RAM
Nexgen 522x series CPU has 256 KB RAM with battery back-up. This has various memory components like Input process image,
Output process image, Application program code memory, Data memory, Marker memory, File marker memory and system
variable memory.
Address Specifier In
Memory Type Application Program Size
Input process image %I 128 Bytes
Output process image %Q 128 Bytes

Marker %M 32768 Bytes
Data Addressable by Name 64 KB

File marker Addressable indirectly 64 KB
System Variables Addressable by Name System Area
Application program Memory Not Addressable 256 KB
18
CPU Specifications
Input Process Image and Output Process Image are input and output status respectively, for the configured IO modules.
These images are stored in global memory area, in every input and output scan. These images are accessible to external devices
like HMI and SCADA. Input and Output scan, can be executed on demand in a logic scan by calling Refresh_In and Refresh_Out
respectively.
Marker Memory is used to store the intermediate results and stored at addressable global memory area, accessible to external
devices like HMI, SCADA.
File Marker Memory is the data memory, which needs to retain after a PLC cold start or even after program change. Thus it is used
to store the reciepe, history and data logged. This memory is accessible to user only by using specific functions and function blocks
in application program. It is possible to access the file marker area for external devices also via serial communication by
MODBUS_RTU and Nexgen protocol.
Data Memory is used to store the intermediate results like instances of function blocks and variables used in application program.
Unlike marker memory, data memory addressing is not handled by application developer, but these addresses are generated by
compiler. Hence data memory is not accessible to external devices like HMI and SCADA.
System Variables are implicitly global and used to exchange the information with PLC operating system and its functionalities.
Flash PROM
Nexgen 522x series CPU has 512 KB Flash PROM. This serves as on-board backup memory.
Operating System
Operating System 198 KB
This contains core code of processor module which
handles various functions of the processor. Operating Application Program Code 256 KB
system code can be upgraded by a software tool Application Program Source
code memory 1 MB
'Bootstap loader’
Battery Back Up
PLC variables are stored in RAM, which is of volatile nature, demands a battery backup to retain its contents. This battery
also serves as a backup to on-board RTC. Nexgen 522x CPUs use 3.6V Ni-MH (Nickel Metal Hydride) rechargeable battery,
which is mounted on board. The battery provides backup period around 6 months, from its fully charge status.
Keypad and Display Unit
Optional pluggable keyboard display unit can be used as diagnostic tool. It provides 4-character alpha-numeric display with
6 keys keypad. This is helpful for:
l Displaying fault messages l Displaying system messages
l Viewing / modifying PLC Variables l Redirection of I/O points

l This display and keypad are accessible to application program and its information is available in form of system variables.
Application developer can develop customised function blocks to handle the display and keypad routines as per required
by application.
l _BKEYSTATUS is the system variable associated with keypad. This is a byte & its six bits are accessible corresponding to
each of the key.
l _ADISPLAY is the system variable associated for four character alphanumeric display. This is a array of 4 bytes & each of
the byte represents individual characters corresponding to display position
19
CPU Specifications
NEXGEN 521x SERIES OF CPUs
Nexgen 521x : CPU Variants And Communication Ports
Nexgen 521x series itself has 5 CPU variants. This wide range of CPU empowers user to select a CPU as per application specific
rd
requirement. This essentially has Standard CPU, 3 Port CPUs (2 Nos.), Low-cost CPU and Special CPU.
CPU 5210 (Standard) CPU 5213 (Low Cost) CPU 5211 CPU 5214 (Specially made
(CPU with 3 Serial Ports) with Motion Control Features)
CPU Communication (Connector Type) Keyboard /

Display HSC / PTO
Code Name Port 1 Port 2 Port 3
5210 Standard Not Available Yes Not Available
5213 Economy Not Available Not Available Not Available
RS 232C, RS 422 / 485
5214 Special 8 pin 8 pin Not Available Yes Yes *
Mini Din Mini Din RS232C,9 Pin D
5211 CPU with 3’rd Female Female Yes No
port as RS-232C Male
5212 CPU with 3’rd RS 422/485 9 Pin D Yes No

port as RS 422/485 Female
* CPU 5214 : Requires a patch panel and an interface cable.
8 5 2 8 5 2
+12 V +12 V
Rx RxD+
TxD+ TxD-
GND Tx GND RxD-
GND GND
6 3 1 6 3 1
Communication Port 1 : RS 232C Communication Port 2 : RS 422

( 8 pin mini DIN female connector ) ( 8 pin mini DIN female connector )
1 5
6 9 Rx-
RTS-
RTS Rx RTS+ Rx+
CTS Tx CTS+ Tx+
GND CTS- Tx-
9 6 GND
5 1
Communication Port 3 (RS 232) Communication Port 3 (RS 422)

(9 pin D male connector, CPU 5211) (9 pin D female connector, CPU 5212)
20
CPU Specifications
Nexgen CPU 521x : Faster Instruction Execution
Nexgen 521x series CPUs are faster in execution, which makes it suitable for any sophisticated application, where processing
speed and computation matters.
Execution Speed for Various Instructions and Data Types
INSTRUCTION DATA TYPE BOOLEAN BYTE WORD DWORD REAL

LOAD 00.75 -- -- -- --
MOVE (Load & Store) 01.20 01.20 01.20 02.00 02.00
ADD / SUB -- 02.10 02.10 03.50 12.60
MUL / DIV -- 02.50 02.50 12.00 12.80
Square Root -- -- -- -- 19.50
Logical AND / OR / XOR -- 02.10 02.10 03.50 --
Compare -- 02.50 02.50 03.40 15.40
Above execution time is in micro seconds (µsec)
Nexgen CPU 521x : Memory & Configuration

Nexgen 521x series CPU has two on-board memory resources viz. RAM and Flash PROM.
RAM
Nexgen 521x series CPU has 256 KB RAM with battery back-up. This has various memory components like Input process image,
Output process image, Application source code memory, Data memory, Marker bits memory and other for system variables.
Input Process Image (%I) 128 Bytes

Output Process Image (%Q) 128 Bytes
Marker (%M) 15872 Bytes
Data 32 KB
Application Program (for RUN time execution) 64 KB
Application Program (storage for on-line change) 64 KB
System Variables, Communication port buffer area, etc Remaining RAM utilised
Flash PROM
Nexgen 521x series CPU has 512 KB Flash PROM. This serves as on-board back-up memory.
Operating System 128 KB

Application Program Code 64 KB
Application Program Source code memory 192 KB
Nexgen CPU 521x : Run-time Execution, Downloading and Boot Project

PLC run-time execution takes place through RAM only. PLC programming software downloads executable binary code in RAM
and the same is optionally transferred to Flash PROM, creating Boot Project.
Programming software (CoDeSys) facilitates user to select source code downloading option. Unless specified explicitly,
Executable Binary code will get transferred to RAM.
21
Motion Control
NEXGEN CPU 5214
WITH MOTION CONTROL FEATURES
For every power ON operation, program gets transferred from Flash PROM to RAM. In case of no program in Flash PROM,
'MEMR' gets displayed on CPU Display.
In case boot project is not created, RAM and Flash PROM will have two different programs. On next power ON, this will cause
copying of old program from Flash PROM to RAM.
On-Line Application Program Change

During run-time, program executes from RAM. When on-line change in an application program occurs, modified application
program is transferred to additional memory space in RAM. During this download, PLC continues to execute the earlier program
from standard memory location of RAM. When downloading is completed, from immediate next scan, latest (modified) program
gets executed.
Application Program Source Code

PLC programming software (CoDeSys) generates application program project file in a compressed format. This file gets
downloaded to Flash PROM as source code download occurs. This project file contains all project related data like ladder,
comments, variable name, variable declaration, password, libraries (optional).
Source Code Uploading

This uploads the complete project from CPU to PC. Usually this should be password protected to restrict the source code
uploading.
Nexgen CPU 5214 :

Specially Developed with Motion Control Features
Special CPU 5214 has a provision for two independent channels for High Speed Counters (HSC) and Pulse Train Outputs (PTO).
For external interface, a cable with 25-pin D connector at both ends is provided. One end of cable is to be connected to 25-pin male
D connector provided at bottom side of CPU module. Other end of cable is to be connected to 25 pin female D connector on patch
panel for field interface. On this patch panel, connectors are provided where HSC inputs and PTO outputs can be connected. The
technical specifications are as per page 23.
Depending upon type of pulse output interface two varieties of patch panel are provided
for wiring. These are 2 HSC & 2 PTO (PNP type) and 2 HSC & 2 PTO (RS 422 type)
CPU 5214 (Specially developed for

Motion Control)
22
Motion Control
High Speed Counters
5214 processor module provides 2 independent channels for high speed counters. Each channel provides three input interfaces
as A, B and Z. This channel provides hardware interface for open collector (PNP/NPN) inputs of 24 VDC or differential 5 V inputs.
To configure for its use, processor 5214 provides driver function blocks for each channel in library PTO.lib. This facilitates
application developer to set the mode of operation and fetch the accumulated count and status of Z input. Counter provides pulse
count in double integer format.
High Speed Counter Input

Channels 2 nos.
Inputs A, B and Z
Frequency 100 KHz Maximum
Counting Range -2147483648 to 2147483647
Type (Selectable by input Open Collector* (18-30 VDC inclusive of ripple)
connections at Patch Panel) Differential / TTL (5V DC)
7 mA For open collector type of Input.
Current
15 mA For differential type of Input.
Min. ON time duration 5 µs
Min. OFF time duration 5 µs
Pulse input,
Mode 0 Counts at rising edge of input
Direction input and
(100 kHz) depending upon Direction.
Reset input
Mode of Operation Pulse input,
Mode 1 Counts at rising and falling edge
(Software Selectable) Direction input and
(100 kHz) of input depending upon Direction.
Reset input
Phase A input,
Mode 2 Counts at rising and falling edge
Phase B input and
(50 kHz) of phase A input and phase B input.
Zero Marker input
* Open collector : PNP / NPN
Pulse Train Output

5214 processor module provides 2 independent channels for pulse train outputs. This channel provides two output interfaces
where output functionality depends on mode of operation selected. Relevant function blocks are located in PTO.lib. The driver
function block selects mode of operation, number of pulses, output frequency and direction.
Pulse Train Output

Channels 2 Nos.
Outputs FP and RP
100 KHz, ±1% maximum for differential output with patch panel 4962.
Frequency
5 KHz, ±1% maximum for open collector (PNP) output with patch panel 4960.
Duty Cycle 50 %
Pulse output range 0 to 4294967296 with Direction
Open collector With patch panel 2 HSC & 2 PNP type PTO
(18-30 VDC including ripple) (Ordering Code-4960)
Type (Selectable by
type of patch panel) With patch panel 2 HSC & 2 RS 422 type PTO
Differential
(Ordering Code-4962)
60 mA maximum for differential output with patch panel 4962.
Current
1.5 Amp maximum for open collector (PNP) output with patch panel 4960.
Mode of Operation Mode 0 Pulses and Direction

(Software selectable)
Mode 1 Forward Pulses and Reverse Pulses
External Power For pulse output driving circuit.
Supply
24 VDC ( 18-30 VDC including ripple), 100 mA
23
CoDeSys
CoDeSys PLC PROGRAM DEVELOPMENT
SUITE FOR NEXGEN-5000 PLC SERIES
IEC 61131-3 CoDeSys is a Windows ® based, an
international quality software which is IEC
61131-3 compatible.
CoDeSys is Controlled Development System

for Nexgen 5000 series of programmable logic
controllers. It is a PLC program developer's
suite.
®
Microsoft Windows (32 bit) Platform
With the Windows® based platform, application developer can avail the inherent benefits like Copy, Cut, Paste
and Delete operations. Using Import-Export facility developer can copy/re-use the Program Organisation Unit
(POU) across the applications. Global Search and Global Replace are features for the ease of program
modifications.
Modular Programming
CoDeSys encourages use of modular programming. Developed application is called as project, which has .pro as
file extension. Every CoDeSys project must have at least one POU. POU stands for program organisation unit
which either could be a program, function-block (FB) or function. One project can have many POUs.
PLC_PRG is a program, which is mandatory POU in every project. This PLC_PRG is a master routine where from
all the other POUs (sub-routines) are called. In a way, PLC_PRG can be viewed as main function in C language.
Hence, rather than dumping the complete logic into one POU (PLC_PRG), multiple POUs are developed, as per
objectives. Thus any project can be developed into split components. This approach resembles with object
oriented programming in higher level languages like C++ or Java.
Powerful Library Management

CoDeSys provides a powerful way of library management. Modular programming facilitates having multiple
POUs in the same project. But it sensed more to have a provision of external storage of POUs, which are
application specific or required frequently i.e. just develop a POU once and for all, store it in application specific
library and implement it,as and when/where required.
This reduces development time for a machine manufacturer or end-user. Simply write it once and implement
many times. Password protection facility conceals the application logic in POUs (function & function blocks).
Modular programming and library management has indeed eased the task of application program development,
to a great extent.
Powerful Program Editor

CoDeSys has powerful program editor which facilitates a user set of six programming languages: two textual
languages and four graphical languages.
24
CoDeSys
LADDER DIAGRAM & INSTRUCTION LIST
Ladder Diagram (LD)
It is the simplest graphical method of PLC
programming comprised of normally open and
normally closed contacts and coils, widely used in
discrete control applications. IEC ladder program
encourages, use of other program organization
units (POU) i.e. functions, function blocks and
programs. This has enhanced its wide acceptance
to process control applications also.
As per IEC 61131-3, symbolic addressing is

implemented rather than absolute addressing. IEC
ladder can deploy function, function block or
program, in a ladder irrespective of IEC
programming language, in which the POU is written.
Typical example of ladder programming comprised of normally open

contacts, normally closed contacts, coil outputs and Function Block.
Instruction List (IL)

It is a textual language which follows simple
microprocessor assembler level instructions, similar
to mnemonics used in earlier PLC program
development language. It is the most primitive and
fundamental level programming language; hence
every PLC programming language can be converted
to Instruction List. It is comprised of sequence of
instructions and operates single instruction per line.
It is a bit tricky and tedious for novice to implement. It
has its own unique grace and glory, especially while
dealing with compact and crucial applications, where
performance and optimization are of prime
importance.
Its program editor is characterized with line numbers

- visible for quick reference error messages and
comment mode to have programs translated by
non-programmers.
In a nutshell, Instruction List has a series of

instructions, where each instruction begins with new
line and contains an operator and one or more Example narrating series of instructions in a typical Instruction List Program
operands separated by comma.
25
STRUCTURED TEXT, FUNCTION BLOCK DIAGRAM
SEQUENTIAL FUNCTION CHART
Structured Text (ST)
It is a textual language resembling with high level
programming language like Ada, Pascal or C. It exhibits
its suitability for logic with complex algorithms or
mathematical computations. It can be used to build
POUs i.e. functions, function blocks or programs.
This can be very well harmonized with ladder.
ST supports powerful control structures like IF ELSE -

THEN, DO - WHILE, REPEAT, FOR and many more.
It eases use of data structures like ARRAY,
STRUCTURE and User Defined Data Types. It also
supports SIZEOF operator and Pointers for memory Snapshot for typical POU with Structured Text (ST) as programming language
optimization.
Function Block Diagram (FBD)

It provides graphical development of a program using
the basic building block from IEC Function Block
Library. It has wide acceptance in process control
application development as it expresses behavior of
functions, function blocks and the programs as a set of
interconnected graphical blocks.
In a nutshell, FBD works with a list of networks whereby

each network having a structure which represents
either a logical or an arithmetic expression, the call of
function block and the return instruction.
Typical network in function block diagram
Sequential Function Chart (SFC)

It is a graphic language which provides the
diagrammatic representation of a process. It provides
fragmenting of a program into manageable logical
sequences. This function chart is made up of steps and
transitions which are interconnected with directed links.
Steps are linked with action blocks and transitions.
Each state represents a particular state of system being
controlled. A transition is associated with a condition,
activating or deactivating an earlier and next step as per
status of condition. Steps are linked with action blocks,
which are performing a certain control action. Each
element can be programmed with IEC language,
including SFC itself.
This snippet explains a program with various steps and,
an action for the 'init' step.
26
CoDeSys
CONTINUOUS FUNCTION CHART
OFF LINE SIMULATION, ONLINE FUNCTIONALITY
A simplified step consists of an action and flag to indicate whether the step is active. An IEC step has a flag and one or more
associated actions or Booleans. An action has series of instructions in either of IEC language. In addition to step action, there can
be an entry action and/or an exit action. These entry and exit steps get executed once only, right after the step is activated or just
before step is deactivated, respectively.
Continuous Function Chart (CFC)

Apart from these five programming languages,
CoDeSys also supports Continuous Function Chart
(CFC), which is of graphical type. In operates with freely
placeable elements, rather then network like in FBD.
This allows a feedback. The elements of sequential
process list includes boxes, input, output, jump, return,
label and comment. Inputs and outputs of the element
can be connected by dragging a connection with
mouse. The connection lines are automatically drawn
and automatically adjusted when elements are moved.
Graphical flexibility and ease of feedback makes it

suitable to use it in any process application or
application where SFC or FBD can be used. CoDeSys
has powerful program editors where toolbar icons,
menu items are automatically adjusted as per IEC
language selected.
Sample for CFC programming displays freely placed
blocks rather than a grid.
Off-line Simulation
CoDeSys has an off-line simulation facility. This is very vital utility for an application program developer, as one can develop
complete program logic independent of PLC. This feature helps the developer to complete the application program development
on or before scheduled time. Off-line simulation is built-in* feature of CoDeSys.
Please note that offline simulation does not support some of the CPU resource specific function / function blocks.
(e.g. it does not support RTC related, System variable related functions and function blocks.
*In case of some PLC vendors, Application program development software and simulation software are different.
On-line Functionality
CoDeSys has on-line program monitoring and on-line
program modifications features. This makes it suitable
for continuous process application, where program
modifications without process interrupt may be
required. Watch and Receipt window facilitates to
monitor multiple variables, simultaneously from
multiple program organization units (POUs). On-line
power flow monitoring serves as ready tool for fault
Watch & Receipt window, shows, different variables from, various POUs.
diagnostics.
27
CoDeSys
DYNAMIC DATA EXCHANGE
PLC I/O Configuration
Hierarchical and Graphical method of PLC rack
configuration and module configuration minimises the
chance of errors in I/O addresses.
Once, user selects the module, I/O addresses are

automatically assigned to the selected module. Hence
the user is not required to calculate or memorise the I/O
addresses.
PLC configuration for 3 IO Rack System with module details
PLC Browser
CoDeSys facilitates use of PLC Browser for viewing or
setting certain PLC parameters. PLC Browser is textual
command monitor which is a analogous to DOS prompt.
It has command entry line cum result display window,
which is like a combo-box.
It has smart history of latest executed commands, which Sample for using PLC browser, a handy and quick tool for developer
displays it without repetition of command. User can
check /set RTC from PLC browser.
Dynamic Data Exchange

CoDeSys facilitates Dynamic Data Exchange utility. This
makes user to fetch the PLC variable information in
® ®
Microsoft Excel Sheet or Microsoft Word. The
concurrent and continual data logging is possible by
devising advanced programming techniques in
Microsoft Excel spreadsheet.
CoDeSys is responsible only for the displaying dynamic

®
values of PLC variables in Microsoft Excel spreadsheet
cells. These values in Excel spreadsheet sheet cells get
overwritten, on very next pre-defined time interval in
CoDeSys project. This assists the handling and storing,
these dynamic values, with advanced programming
The above snippet depicts implementation of DDE, where a current value
®
techniques in Microsoft Excel. of a counter in PLC project is monitored.
In case direct DDE Server is used, which works with symbols rather than addresses, CoDeSys is not required to read the variables
from PLC and transfer them to application with DDE interface. Direct Addresses are not read with DDE Server. One needs to use
symbolic variables.
®
CoDeSys has assured and tested DDE interface, with Microsoft® Excel 97 and Microsoft Word 97, only with Microsoft
®
Windows NT 4.0
28
CoDeSys
SAMPLE TRACE FUNCTION
Sample Trace Function with Graphical Display
This on-line feature of CoDeSys enables user to
monitor progression of maximum eight different
analog or digital variables, simultaneously in trace
window (graphical format). This sampling rate is user
settable. The sampled values are stored in internal
trace buffer. If this ring buffer gets full, data purging
takes place i.e. older values are overwritten with
newer ones.
Trace configuration facilitates user to set various

parameters for sample trace. The trace configuration
settings can be saved to a file, which can be reloaded
with option load trace feature. Similarly, sampled
data can be saved in text file. The detailed
parameters description for trace configuration is as
explained here.
Other features like stretch, compress, Y Scaling Typical example of sampled temperature and pressure,
in a process application
allows user to adjust the trace window for the
requisite visibility. Enabled show grid option makes
grid as well as X-Y axis values to be visible.
Parameter Description
Trigger Variable This terminates sampling activity. (Trigger OFF)
Trigger Level This initiates sampling activity. (Trigger ON)
This decides percentage of measured values, which will be recorded

Trigger Position
before Trigger On event occurs.
Positive Triggering occurs after the rising edge of Boolean

Negative Triggering occurs after the falling edge of Boolean
Triggering Edge
Both Triggering occurs both at, rising and falling edge of Boolean
None Triggering does not occur at all.
Number Minimum 32
of Samples Maximum 1024
Sampling Minimum 1 ms
Rate (ms) Maximum 20000 ms
Single Displays only once the samples 'Number of samples'
Recording Continuous Displays continuously selects 'Number of samples'
Manual Used to read trace recording with 'Read Trace' from ‘Extras'
Variables These are variable for sampling ( Maximum 8 )
This is a navigator to locate/select 'Variable' from the entire project,

Help Manager
for sample tracing.
Similarly the saved text file for sampled data can be readily transported to Microsoft Excel, where user can take further
analytical and database storage actions.
29
CoDeSys
PROCESS VISUALISATION &
POUs AND DATA TYPES
Process Visualisation for On-Line Testing
This on-line feature of CoDeSys facilitates a user for
designing interactive graphic user interface or screens.
This allows user to design application specific screens,
using various GUI elements or visualisation elements like:
rectangles, rounded rectangles, ellipse, polygon, polyline,
curves, BMP images, buttons (with limited events) and the
other visualisation itself. It also facilitates a user to have a
regular configuration of these elements. e.g. rectangle has
shape, text, line-width, color, motion-absolute, motion-
relative, variables, input and tool-tip. These configuration
parameters vary as per visualisation element.
This makes Visualisation as very handy tool for viewing the

dynamically changing data in textual or even graphical
form. User can simulate a mimic or even a process using
these visualisation elements.
Also user can force PLC outputs from this interactive

screen. Sample for Visualisation for PLC output and
PLC display scrolling speed control
In comparison with other front end tools (Visual Basic, Power Builder, Oracle Forms), this has limited capacity and features.
Even though it is comparable to SCADA, one should not use this feature as SCADA, as its response and performance are not
assured. It is strongly recommended to use this tool for test and monitoring purpose rather than control action.
POUs and Data Types

POU stands for Program Organising Unit and it can be either a program, function or a function block. Hierarchy of POU
entities is as :
i) Program ii) Function Block iii) Function
As a general rule, any POU (calling POU) can call other POU (called POU), which is hierarchically at equal or lower level of calling
POU. A POU can not call other POU, which is hierarchically above the calling POU. Thus, a function block can call other function
block or function and cannot call program.
CoDeSys supports standard data types, which are as:
Type Range Memory

BOOL TRUE or FALSE 8 Bit
BYTE 0 to 255 8 Bit
WORD 0 to 65535 16 Bit
DWORD 0 to 4294967295 32 Bit
SINT -128 to 127 8 Bit
USINT 0 to 255 8 Bit
INT -32768 to 32767 16 Bit
UINT 0 to 65535 16 Bit
DINT -2147483648 to 2147483647 32 Bit
UDINT 0 to 4294967295 32 Bit
+38 -38
-3.4 E to -1.176 E
REAL ±0 32 bit (IEEE floating point)
+1.176 E-38 to +3.4 E+38
It is a set of characters.
String ( '/0' is the termination character, User defined size ( default 80 Bytes )
automatically added by system )
30
CoDeSys
CoDeSys supports other data types, which are specific to date and time.
Type Resolution Remark Example Memory
TIME 1 ms 25 Days ( Max Value ) t#23h02m12s247ms 32 Bit
DATE 1 sec Counts from 1'st Jan.1970 d#2003-05-23 32 Bit
DATE_AND_TIME 1 sec Counts from 1'st Jan.1970 dt#2003-05-12-15:36:57 32 Bit
TIME_OF_DAY 1 ms Counts from 12.00 am, everyday tod#14:27:09.986 32 Bit
CoDeSys supports special data types, which are as:

Type Remark
ARRAYS It is sequential storage of same type of data
STRUCTURE It is collection of different types of data in a record type approach
Similarly, an application developer can have, User defined Data Types.
Class
Class defines the scope of the variable viz. local and global. Global elements are accessible to all the POUs in a project. CoDeSys
compiler forcibly insists data type declaration for an every variable used in the project, except PLC addresses.
Local Variables:
These variables are declared & defined specifically for the POU, thus the scope is valid only for the declared POU.
Global Variables:
These variables are declared and defined for a POU, with its widen accessibility. Thus these variables can be referred in other
POUs of the same project.
VAR
These are the local variables, necessarily meant for storing intermittent results of any POU. VAR variables restrict their
accessibility to the POU itself.
VAR_IN
These are read only type local variables, acting as inputs to POU (e.g. function block). Value of the variable can be given along with
the call, in calling POU.
VAR_OUT
These are local variables, acting as output to POU (e.g. function block). Value of these variables are returned back at the calling
POU. These variables can be used further, in the POU.
VAR_IN_OUT
These are local variables, acting as input as well as output of any POU. Value of such a variable is always passed by reference
rather than value. These variables are not applicable to the function.
31
CoDeSys
CoDeSys : INSTRUCTIONS & LIBRARIES
COMMUNICATION BASICS
Nexgen 5000 Series of CPUs supports extensive instruction set to built the control logic across variety of applications, from
machine tools to process industry. The CPU is capable of handling various data types.
Data types supported are
l Boolean l String of sequential ASCII characters
l 8, 16, 32 bit signed / unsigned numbers l 1-, 2-, 3- dimensional arrays
l Real numbers (32 bit IEEE floating point format) l Structures (User Defined Data Types)
l Date, Time, Date and Time.
The CPU can handle various instructions like:

l Boolean instructions l String handling instructions compare, search, left,
l Timer instructions right etc.
l Counter instructions l Real time clock handling instructions
l Comparison instructions l I/O module handling instructions
l Data type conversion instructions l Event interrupt handling instructions
l Logical instructions like AND, OR, XOR, NOT l Serial communication handling instructions
l Application specific instructions like SHL, SHR, ROL, ROR l High Speed Counter handling instructions
l Arithmetic instructions like ADD, SUB, MUL, DIV, MOD, SQRT l Pulse Train Output handling instructions
l Trigonometric instructions like SIN COS, TAN, ASIN, ACOS, ATAN
l Statistical instructions like MIN, MAX, MOD, variance etc.
l Logarithmic instructions like EXP, LN
Variety of application specific libraries

l Process FB libraries like P, PI, PID
l Communication FB's like MODBUS RTU master, RTU slave, Mitsubishi Frequrol master, Mitsubishi UC24 slave, printer
and many more
l FBs for data exchange via. modem interface, sending SMS via GSM modem etc.
l Motion control FBs as per IEC61131 guidelines
Communication is handled with seven layers. But, still most of the time communication is handled with Application Layer, Protocol
Layer, Data Link Layer and Physical Layer.
Physical Layer
Physical layer is comprised of several elements viz. media of transmission (like wires, fiber optics, wire-less), signal drivers, method
of transmission, inter connections, connectors and inter signal converters. Most commonly employed physical layer protocols are
RS 232C, RS 422 and RS 485.
RS 232C RS 422 RS 485

Basic Signals 3 Wires TXD,RXD,GND 4 Wires TX+,TX-,RX+,RX- 2 Wires Data +, Data -
Signal Voltage -12 V / +12 V 5 V Differential 5 V Differential
Distance 15 Feet Up to 1 KM * Up to 1 KM *
Communication 1:1 1:1, 1:N 1:1, 1:N, N:N
At Both ends, At Both ends,

Termination No resistor reqd.
4* 120 ohm RX,TX 4* 120 ohm (Data +, Data -)
* Isolator drivers are required for a distance more than 50 m. ( Maximum supported distance is 1 KM )
32
CommunicationBasics
RS 422 to RS 485 Conversion
As a common practice, RX+ is shorted to TX+ and RX- is shorted to TX-. The RS 485 connected station is called as Half
Duplex as it either receives or transmits the signal. In some cases, TX needs to put to tri-state when receiving starts. Such
convertible ports are marked as RS 422 / RS 485.
Nexgen 521x series having serial 2'nd and 3'rd port, are convertible from RS 422 to RS 485 and vice versa.
Signal Converters Used in various Interface Schemes

RS 422 / RS 485 To RS 422 / RS 485 Isolator Conversions
These are used in high speed long distance serial communication as an isolated signal repeater, RS 422 ( 4 wire ) to RS 485
( 2 wire ) converter and vice versa conversion.
This is characterized by :
l Optical isolation between input and output signals l Auto detection of direction, in case of RS 485
l Can be used as RS 422 isolated repeater l Supports 3 baud rates viz. 9600,19.2,38.4 Kbps
l Can be used as RS 485 isolated repeater l Provides diagnostic LED indications
l Operates directly on 85-260 V AC range l DIN rail mountings
l Does signal level correction l Provides output signal short circuit protection
l Provides auxiliary output power supply for local device connection
Item Description
Function RS 422(4 Wire) to RS 485(2 Wire) Conversion or Vice versa
Input supply voltage 85-260 VAC,15VA, 50/60Hz
Operating modes RS 422 (4-wire) or RS 485(2 wire ), set by switch settings
Auto direction sensing Facility available for RS 485(2-wire) interface
Baud rates supported 9600, 19200 and 38400 ( set by DIP Switch setting )
Signal isolation 1.5 KV optical isolation
Signal short circuit protection Applicable
Auxiliary power output Model 6012 24 V DC, 250 mA

Model 6013 12 V DC, 250 mA
Model 6014 5 V DC, 500 mA
Supply protection 2 Amp miniature glass fuse protection at input supply
Diagnostics Diagnostics LEDs for communication signals
TX ( Down Arrow ) , RX ( Up Arrow )
Mounting DIN rail
Dimensions (H x W x D) 100 mm X 60 mm X 75mm
RS 232 to RS 422 / RS 485 Conversions
These are used in various networking schemes where PC (RS 232) side is interfaced with RS 422 / RS 485
or vice versa.
This is characterized by:
l Optical isolation between input and output signals l Auto detection of direction, in case of RS 485
l Operates directly on 85-260 V range l Supports 3 baud rates viz. 9600,19.2,38.4 Kbps
l Does signal level correction l Provides diagnostic LED indications
l Provides auxiliary output power supply for l DIN rail mountings

local device connection
l Provides output signal short circuit protection
33
Communication Basics
Item Description
Function RS 232(3 Wire) to RS 422/485(4/2 Wire) Conversion or Vice versa
Input supply voltage 85 260 VAC,15VA, 50/60Hz
Operating modes RS 422 (4-wire) or RS 485(2 wire ), set by DIP switch settings
Auto direction sensing Facility available for RS 485(2-wire) interface
Baud rates supported 9600, 19200 and 38400 ( set by DIP Switch setting )
Signal isolation 1.5 KV optical isolation
Signal short circuit protection Applicable
Model 6010 24 V DC, 250 mA
Auxiliary power output
Model 6015 12 V DC, 250 mA
Model 6016 5 V DC, 500 mA
Supply protection 2 Amp miniature glass fuse protection at input supply
Diagnostics Diagnostics LEDs for communication signals

TX ( Down Arrow ) , RX ( Up Arrow )
Mounting DIN rail
Dimensions (H x W x D) 100 mm X 60 mm X 75mm
Protocol
Protocol is synonymous to language as both the devices should communicate and understand the same language. It is predefined
sequence of codes for data exchange. By using protocol converter, two devices having un-identical protocols can communicate.
A protocol is command and response having, header, body and a trailer. Header is indicative of a new message begin, body is
comprised of command number, data and any other information need to communicate. Trailer has error checking checksum and
end of transmission character. Protocols work independent of physical layer.
MODBUS is a widely used protocol in industry being established and open for use. Messung Protocols are specific to Messung
products and are not open for its use. To communicate with Messung products, application developer has to write a protocol
converter like SCADA driver.
Typical communication string has Header, Station ID, Length, Command/Response byte, Data, Checksum and Trailer.
Communication parameters are Baud rate, Data bits, Parity bits and Number of stop bits. Typically one byte frame consumes 11
bits and at 9600 bits per seconds, it takes 1ms per byte frame.
Nexgen 5000 has an Application Layer and Protocol Layer, which are open to user, Data Link Layer which is implicitly handled by
PLC operating system and Physical Layer which is hardware dependent.
Function blocks for MODBUS master and slave are developed by Messung, for Nexgen 5000 PLCs.
Nexgen5000 has two buffers viz. RX buffer and TX buffer which simultaneously handle transmission and reception, functions
independently and in parallel to PLC scan. Data Link Layer handles conversion of Data Frame to Byte Frame.
Protocol Function Blocks

Protocol Purpose
MODBUS RTU
Master FB SCADA, E-series HMIs Connectivity, Compatible Field Devices
Slave FB Nexgen 5000 to Nexgen 5000 Network, SCADA Connectivity
Nexgen 4000
Slave FB HMI Connectivity Messung Smartline Sr, Jr and Beijer E Series
XMP8-10 PLC
Micro Master FB Network of Micro PLC Slaves with Nexgen 5000 Master PLC
Mitsubishi UC-24
Slave FB Mitsubishi GOT Connectivity
Freqrol
Freqrol Master FB Read/Write Data to Multiple Inverter, Serial control for inverter.
Transfer data to HMI/ SCADA on other port
34
CommunicationBasics
Protocol FB get executed in logic scan and consumes application as well as data memory. It delivers same throughput, facilitates
variety of communication speeds and exerts complete control on communication scheme.
MODBUS Protocol
MODBUS protocol, introduced by MODICON, is open to 01 Read Coil Status ( 1 bit )
everybody for use, which has MODBUS RTU (binary),
03 Read Holding Register ( 16 bit )
MODBUS ASCII and MODBUS TCP protocols. Presently
Messung supports MODBUS RTU protocol, which is efficient 04 Read Input Register ( 16 bit )
being in binary format. Messung FB has MODBUS Master
05 Write Single Coil / Preset single holding register
and MODBUS Slave which support various commands as :
15 Write Multiple Coils / Preset multiple holding register
MODBUS RTU_Slave
It emulates MODBUS Slave functionality. User can create only single instance of the block and can be attached to any port . It is
interface able with SCADA, DCS, E Terminals, Nexgen PLC with MODBUS Master FB.
MODBUS RTU_Master RTU-MAST

EN Status
Its design is characterized by its facility to handle Cyclic, Super Cyclic and
Port LastRec
On-demand data updates, User defined exchange requirements in source
Init Set LastResult
as well as destination formats of records and Error reporting with record
Mode Sel
number. RecNo
AutoRestart
AddRecTable
MaxRec
ModeSel can have values as 0, 1 or greater than 1. Its 0 value stands for on-demand or manual updation, only once but in
overriding mode. Its value 1 stands for cyclic execution but only once per network scan. When ModeSel has value greater than 1,
it can be grouped and gets executed along with cyclic.
MODBUS supporting devices may not support all the MODBUS commands, this emphasizes due care while putting such a device
to network. Nexgen 5000 to Nexgen 5000 communication can be established with MODBUS Master function block.
Nexgen_Slave
It emulates Nexgen 4000 HMI port protocol, facilitating connectivity for Smartline Sr., Smartline Jr., E-Series HMIs and SCADA
with Nexgen Drivers. Communication speed is selectable up to 56 Kbps, incase of E-series HMIs and SCADA only. This can be
attached to any of the Nexgen 5000 communication port.
Freqrol Inverter FB
This block facilitates a user to connect 31 freqrol Inverters and user need not know Inverter interface protocol. User can have
control over Direct Inch, ON/OFF operations, Cyclic data updation, Individual error handling and automatic communication
recover on Inverter switched ON. It reflects fast changes to set point changes. Communication speed is settable to 9.6 Kbps or
19.2 Kbps.
35
Power Supply
BASE AND EXPANSION PLATE &
POWER SUPPLY MODULE
Base Plate
The base plate holds Power Supply, CPU and I/O modules. It is available in varieties to suit I/O and expansion requirement. The
base plate is available with or without expansion connector to offer economic solution. Both the base plates are available in 3 I/O, 5
I/O and 8 I/O slots. x mm
NEXGEN
Expansion Plate
161.5mm
190mm
In multi-rack system, the expansion plate can be mounted
next to each other or one below other. The expansion
plate is available in varieties to suit I/O and power supply
requirement. It is available with or without power supply
connection facility. Both the expansion plates are
available in 3 I/O, 5 I/O and 8 I/O slots. At the most 3 3 I/O Base Plate (248 mm) (Depth 145 mm)
expansion plates can be connected to the base plate. 5 I/O Base Plate (332 mm)
8 I/O Base Plate (458 mm)
(Base plate and Expansion plate are of the same size)

Base & Expansion Plate Pin Hole to Pin Hole Length
Plate 3 I/O 5 I/O 8 I/O
x mm 230 mm 314 mm 440 mm
POWER SUPPLY MODULE

Power Supply Module, with 220VAC Supply Input
The power supply provides 5 V DC power to the processor, I/O modules and 12 V DC power for interfacing HMI Jr to HMI port. In
multi-rack system, additional power supplies can be connected into expansion plates.
Input supply 220VAC, ± 15 %,

50 Hz, ± 6%, 50VA
Inrush current 8A for 2 msec
Output voltages 5V DC - 5A, 12V DC - 0.5A
Fuse protection for 3A / 20 mm glass fuse
incoming mains
l MOV for incoming over voltage

Protections
l Output short circuit protection
Connector 8 pin (removable)

Ordering Code 4110
Power Supply Module, with 24VDC Supply Input

2
2 24VDC (18 TO 30 VDC including ripple)
24 VDC
24 VDC
Input supply
45 Watt
Inrush current 25A for 10 msec
Output voltages 5V DC - 5A, 12V DC - 0.5A
Fuse protection for 5A / 20 mm glass fuse
R1
NC
incoming supply
R2
Protections provided l Reverse polarity diode protection

+
24 V
NC DC
-
l Output short circuit protection
250V 5A Connector 8 Pin (removable)
Ordering Code 4112
36
Digital Modules
DIGITAL I/O MODULES
Digital Input Modules
32 pt DC Input Module 16 pt DC Input Module 16 pt AC Input Module
Inputs Response Operating

Inputs Input Time (ms) Voltage (V) Backplane Ordering
Type Current(mA) Current Code
Total Per On Off On Off (mA)
Common
DC Sink/Source 32 8 6 @ 24V DC 15-20 15-20 18-30 0-5 110 4632
selectable
DC Sink/Source 16 8 6 @ 24V DC 15-20 15-20 18-30 0-5 110 4616
selectable
8 @ 230V AC
AC 16 8 4 @ 120V AC 15-35 15-35 79-265 0-40 90 4617
Digital Output Modules
16 pt DC Output 32 pt DC Output 16 pt Relay (Potential Free) 8 pt AC Output

Module Module Output Module Module
Output Load Current (A) Response

Back-
Time (ms)
plane Ordering
Output Type Per Max per Off State Current Code
Total Common Output Group Leakage On Off (mA)
DC Source 16 8 1.5 4.0 10m A 0.1 0.4 200 4716

DC Source 32 8 0.2 1.5 10m A 0.1 0.4 315 4732
AC 8 1 1.5 1.5 3mA 1.0 10.0 210 4711
Relay 16 1 0.75 Nil 3mA 10.0 5.0 185 4721
(Potential free) type
To use 16pt. Relay (Potential free) type module "4721" with "2 independent commons" arrangement,
we recommend to use Prewired Terminal Block, 38 pin 4910
37
MIXED
DIGITALDIGITAL I/O MODULES
& ANALOG
DIGITAL I/O MODULES
I/O MODULES
16 pt DC Input 16 pt DC Input
8 pt DC Output Module 8 pt Relay Output Module
Input Configuration Back- Order-

plane ing
Inputs Input Response Time (ms) Operating Voltage (V) Current Code
Current (mA) (mA)
Inputs Type Total Per Common On Off On Off
DC Sink/ 16 8 6 @ 24V DC 15-20
Source selectable 15-20 18-30 0-5
Output Configuration
Output Load Current(A) Response Time (ms)
Outputs Type Off state
Max Per
Leakage
Total Per Common Output Group On Off
DC Source 8 4 1.5 4.0 10m A 0.1 0.4 220 4425

Relay (Potential free) 8 1 0.75 NA 3mA 10 5 220 4424
8 Channel Non-isolated Analog Input Module

The module incorporates microprocessor for carrying No. of Input Channels 8
out scaling and on-board diagnostic operations. High -10 to +10VDC
resolution - 16 bit provides accurate control. Input Voltage 0 to 10VDC
0 to 5VDC
channel filtering rejects high frequency noise coupled Types 1 to 5VDC
with signal. Current 0 to 20 mA
4 to 20 mA
Voltage/Current Resolution
Range Significant Bits per LSB
-10 to +10VDC 16 Bits 305.176 m V
Resolution 0 to 10VDC 15 Bits 305.176 m V
0 to 5VDC 14 Bits 305.176 m V
1 to 5VDC 13.67 Bits 305.176 m V
0 to 20 mA 14 Bits 1.2207 mA
4 to 20 mA 13.67 Bits 1.2207 mA
Analog to Digital Filter frequencyChannel Update
conversion time (mSec) time
50 Hz 60 ms
60 Hz 50 ms
250 Hz 12 ms
500 Hz 6 ms
Channel to Channel No
Isolation
Channel to internal circuit 1.5 KV optical
External voltage requirement 24 V DC, 200 mA
Indications lNo 24 VDC
lCPU Error
lConfiguration Error
l8 Channel Status
Back-plane current 400 mA
I/O points consumed 8 Input Bits & 8 Output Bits
Terminal / Connection Removable 38 pin Terminal Block
Ordering Code 4308
38
ANALOG I/O MODULES
8 Channel Thermocouple Input Module
The module converts thermocouple input mV values No. of Input Channels 8

o
into equivalent temperature values of 0.1 C resolution Conversion Method Sigma Delta with digital filter
with Cold Junction Compensation and Linearisation. From (°C) To (°C)
Thermocouple J -210.0 760.0
Input Types And K -270.0 1370.0
Output Range T -270.0 400.0
E -270.0 1000.0
R 0.0 1760.0
S 0.0 1760.0
B 0.0 1820.0
N -270.0 1300.0
Temperature Resolution 0.1°C
Thermocouple Linearization In Steps Of 10°C
Cold Junction Compensation LM 35 IC Sensor Mounted On
Terminal Block Itself
Analog to Digital 60 mSec per channel
Conversion Time
Isolation Channel to Channel Nil
Input Impedance 1 M Ohms
External Supply 24 V DC, 100 mA
Requirement (18-30 VDC Including Ripple)
External Supply Protection l 315 mA miniature glass fuse on module.
l Reverse polarity protection.
l No 24 V Supply
l CPU Fault
Indications l CJC Fault
l Channel Status(8)
I/O points consumed 8 Input Bits And 8 Output Bits
Terminal/Connection Removable 38 Pin Terminal Block
Ordering Code 4310
8 Channel RTD Input Module

The module converts RTD input resistance values into No. of Input Channels 8
o
equivalent temperature values of 0.1 C resolution with Conversion Method Sigma Delta with digital filter
Lead Compensation. RTD Input Type
And 3 Wire
PT 100 -200°C To 850°C
Output Range
Temperature Resolution 0.1°C
Analog To Digital 60 mS per Channel

Conversion Time

Excitation Current 1 mA
External Supply Requirement 24 V DC, 100 mA
(18-30 VDC Including Ripple)
External Supply Protection l 315 mA miniature glass fuse on module.
l Reverse polarity protection.
l No 24 V Supply
Indications l CPU Fault
l Channel Status (8)
Ordering Code 4311
39
ANALOG I/O MODULES
2 Channel Isolated Analog Output Module (Voltage/Current)
The module provides 2 isolated channels with 12-bit
No. Of Output Channels 2 Isolated, 12 Bit
resolution. Output type can be Voltage/Current. Conversion Method R-2R Ladder
Voltage -10 to +10 VDC
Types
Current 4 to 20 mA
Voltage / Current Significant Resolution
Range Bits per LSB
Resolution
-10 to +10 VDC 12 Bits 4.88 mV
4 to 20 mA 11 Bits 7.8 m A
Voltage > 1 K Ohms
Load Resistance 500 Ohms
Current
Conversion Time 20 m S
Isolation Channel to Channel 1.5 KV optical
Channel to internal circuit
External Power Requirement 24 V DC, 500 mA
External Supply Protection Reverse Polarity Protection
Indications No 24 V Supply
I/O points consumed 32 Input Bits and 32 Output Bits
Ordering Code 4332
2 Channel Isolated Voltage Analog Output Module.

The module provides 2 isolated channels with 12 bit
No. Of Output Channels 2 Isolated, 12 Bit
resolution. Output type is Voltage only.
Conversion Method R-2R Ladder
OutputVoltageRange -10 V To +10 V
Resolution 12 Bits (11 Bits + 1 Sign Bit)
Load Resistance > 1 K Ohm

Load Current 10 mA
Conversion Time 20 m S
Isolation Channel to Channel 1.5 KV optical

Channel to internal circuit
External Supply Protection Reverse Polarity Protection
Indications No 24 V Supply
I/O points consumed 32 Input Bits and 32 Output Bits
Ordering Code 4333
40
ANALOG I/O MODULES
4 Channel Non Isolated Analog Output Module
The module converts digital values data from CPU to
No. Of Output Channels 4 Non Isolated, 16 Bit
equivalent analog output voltage.It provides 4 non-
isolated channels with 16 bit resolution.
Input Range -32,000 To +32,000
Output Voltage Range -10 To +10 V DC
Resolution 312.5 m V
Load Current 10 mA Maximum
Output Protection Infinite Short Circuit Protection.
Accuracy 0.5 % of Full Scale Reading.
50 m S (Irrespective of
Conversion Time
No. of ON Channels)

18-30 VDC, Including Ripple)
External Supply Protection 315 mA miniature glass
fuse on module
Indications l No 24 V Supply
l Channel On (For Each Channel)
Ordering Code 4334
Fast Analog I/O Module No. Of Input Channels 4 Differential

Conversion Method Sigma Delta with digital filter
Input Range 0 - 10 VDC, 0 - 20 mA
This module converts 4 differential analog voltage inputs
Output Range 0 - 32000 (unipolar)
to equivalent binary numbers with ADC, 16 bit resolution. ADC Resolution 312.5 m V (15 bit)
Similarly it converts binary data from CPU to analog 625 m A (15 bit)
voltage output with DAC, 12 bit resolution. Analog To Digital Conversion Time 1 mS per Channel
Isolation Channel to Channel
(Input Channel to internal Nil
Channels) circuit 1.5 KV optical
Voltage 1 M Ohms
Input Impedance
Current 500 Ohms
No. Of Analog
Output Channels 2 Non-Isolated

OutputVoltage 0 To 10 V DC
OutputVoltageRange 0 - 32000 (unipolar)
Resolution 2.50 mV (12 bit)
Load Current 10 mA Maximum
Output Short Circuit Protection Yes
Maximum Conversion Time 200 m S
Input Channel To
Isolation Output Channel Nil
Indications l No 5 V Supply
l CPU Fault
l Analog Input Channel Status (8)
Note: This module does not require any external power supply. Terminal/Connection Removable 38 Pin Terminal Block
Ordering Code 4366
41
COUNTER INPUT MODULE
4 Channel Counter Input Module
4 Channel Counter Input Modul provides: 4 channels for

counter inputs as A, B & Z. Four Z inputs can be
Inputs 12
configured individually either as normal inputs (with Type of Inputs Sink/source/differential selectable by
minium 10 mS pulse width) or as pulse catch input (with type of connections to module
minimum 10 mS pulse width) or reset to computer Counter Input Channels 4 maximum
Filter 10 m S
Minimum Pulse Width 10 m S for pulse catch type of input &
reset type of input
Maximum frequency 50 Khz in Counter Mode of Operation
25 Khz in Encoder Mode of Operation
ON time minimum 10 m S for counter inputs
OFF time minimum 10 m S for counter inputs
Indications l GREEN LED for each input
l Yellow LED for Error
Current l 7 mA for Sink/source input
l 17 mA for Differential input
Isolation Optical (1.5KV from internal bus)
Back Plane Current 205 mA
IO points consumed 16 Input bits and 8 output bits
Terminal Connections Removable 38 pin terminal block
Ordering code 4634
Multifunction Input Module
The Multifunction Input module provides mix of inputs with programmable filter
time, pulse catch input, interrupt input and counters with programmable 16 bit
operational mode. Programmable filter (10ms) and up counter is the default
configuration. In such case, the inputs are not available as normal inputs.
The pulse having minimum 500 m sec ON time can be detected. Upon detection of
interrupt signal, the operating system of PLC branches to predefined interrupt
task.
The counters can be configured for :

i) 4 up counters or ii) 2 up/down counters or iii) 2 up & 1 up/down counter
The counters can be programmed for external reset using normal inputs.
Counting direction for up/down counter can be selected by external inputs
Input type Filter Time /

Channels Remark
Max freq.
100 m sec
Programmable Delay 12 (max) 1ms, 10 ms
24 V field interface. These inputs
Discrete can be selected in groups of 4.
Programmable Delay
Pulse catch 2 500 m sec
Up Counter with 10 m sec / 12 / 24 V field interface. These are accumulating type

programmable reset 4 counters. The count is added to predefined register
10 Khz
Counter
Up-Down counter with direction 10 m sec / 12 / 24 V field interface. The counter has external direction
input and programmable reset 2 10 Khz input. This count is available in predefined register.
Back plane current : 205 mA

I/O points consumed : 16 Input Bits and 16 Output Bits
Ordering code 4633
42
HMIs
MESSUNG MAKE HMIs
Human-Machine Interfaces (HMI) are panel mounted devices that provide effective dialogue between the operator and machine.
Equipped with programmable display and keys, HMIs allow easy operation and monitoring in the production area. HMIs display
operational and fault messages, enable machine specific parameters to be monitored and modified in suitable format. HMI keeps
the operator fully informed of the current status of operations at all times.
Benefits of using Human Machine Interface along with PLC
! Replaces conventional push button panel (and related wiring), indicating lamps etc.
! Connects to PLC via serial interface. So easy and quick installation
! Simple operation and control
! Clear display of information
! Fault messages and instructions help reduce down time thereby improving productivity directly
The table summarises key features of Smartline series of Human Machine Interfaces.
Item HMI - Jr HMI - Sr

Display 16 charaters X 2 lines 20 characters X 4 lines
Display type LCD with back-lit LCD with back-lit / VFD
LEDs 4 bicolour LEDs with 2 flash frequencies 28 LEDs
User Configurable Keys 4 (+ fixed function keypad) 28
Buzzer - Potential free contact
Password - 3 levels
Memory 8 K EEPROM 16 K EEPROM
Maximum screens 256 256
Power Derives power from PLC External 24 V DC
Dimensions W X H X D mm 125 X 75 X 45 200 X 180 X 55
Item Description Ordering Code

Jr
SMARTLINE HMI with 16 Ch. X 2 Lines LCD (Backlit) SL JR 1602 LN
Sr
SMARTLINE HMI with 20 Ch. X 4 Lines LCD (Backlit) SL 2004 LN
Sr
SMARTLINE HMI with 20 Ch. X 4 Lines VFD SL 2004 VN
PC Based Software Package
SOFTLINE V4.02, DOS based HMI configuration software on IBM compatible PC-XT/AT SFL V4.02
Serial Link Cable
l From HMI Jr to IBM compatible PC-XT/AT & Link Adapter/Power Supply Unit SL JR CAB 0300
(Length 3 Mtrs.)
l From HMI Sr to IBM compatible PC-XT/AT (Length 3 Mtrs.)
SL CAB 0300
E CAB 0300
l From E-Series operator terminal to IBM compatible PC-XT/AT (length 3 Mtrs.)
Serial Port Converter

For Port conversion of IBM compatible PC-XT/AT XMP8 SPC 2010
Product development is a continuous process. Consequently specifications are subject to change without prior notice.
For latest information please contact our nearest sales office.
43
E Series
A COMPLETE FAMILY OF
BEIJER MAKE E-SERIES OPERATOR TERMINALS
E50 E100 E150 E200 E300 E600

Display type LCD Backlit STN Backlit STN Backlit STN Backlit STN Backlit STN Backlit STN,
black / white
Presentation form Text Text Text Text Graphic + Text Graphic + Text
Display size 2 rows x 2 rows x 2 rows x 4 rows x 240 x 64 pixels 240 x 128 pixels
16 characters 20 characters 20 characters 20 characters
Active area of display
W x H (mm) 55.7 x 11.0 73.5 X 11.5 73.5 X 11.5 70.4 x 20.8 127.2 x 33.9 (5.2”) 120 x 64 (5.3”)
Backlight Lifetime (h) 50,000 50,000 50,000 50,000 50,000 15,000

Text height (mm) 5 5 5 5 Variable Variable
LEDs - - - 5 (two colors) 16 (two colors) 16 (two colors)
Function keys 4 4 6 (text strip) 5 (text strip) 8 (text strip) 16 ( 8 with text strip)
Dual drivers - · · · · ·
Transparent mode (1) - · · · · ·
Passthrough mode - · · · · ·
Web functionality - - - - · ·
Terminal reflection - - - -
via Internet · ·
Multi Language / Unicode - · /- · /- · /- · ·/ · ·/
Recipe handler - · · · · ·
Alarm management - - - 1 group Up to 4 groups Up to 4 groups
Time channels - · · · · ·
Real-time clock - · · · · ·
Trend graphs - - - - Real time Historic
Report printouts - · · · · ·
Password for security - 8 levels 8 levels 8 levels 8 levels 8 levels
Buzzer - - - - - -
400 kb Flash / 400 kb Flash /
Memory for application 16 kb Flash 64 kb Flash 64 kb Flash 64 kb Flash 8 Mb expansion 8 Mb expansion
Number of expansion - - - - 1 1
card positions
Communication interfaces RS422 or RS 232C RS422 and RS 232C RS422 and RS 232C RS422 and RS 232C RS422 and RS 232C RS422 and RS 232C
· · · · · ·
TM
Support for Palm handhelds
Support for extended - - - - · ·
keyboard
Ambient temperature 0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC
Waterproof front IP65, NEMA 4X (2) IP65, NEMA 4X (2) IP65, NEMA 4X (2) IP65, NEMA 4X (2) IP65, NEMA 4X (2) IP65, NEMA 4X (2)
EN 50081 -1, EN 50081 -1, EN 50081 -1, EN 50081 -1, EN 50081 -1, EN 50081 -1,
EMC
EN 61000-6-2 EN 61000-6-2 EN 61000-6-2 EN 61000-6-2 EN 61000-6-2 EN 61000-6-2
LVD - - - - - -
UL UL 508, UL 1604 (3) UL 508, UL 1604 (3) UL 508, UL 1604 (3) UL 508, UL 1604 (3) UL 508, UL 1604 (3) UL 508, UL 1604 (3)
DNV · · · · · ·
Power supply + 5 V DC ± 5 % + 5 V DC ± 5 % + 5 V DC ± 5 % +24 V DC, 20-30 V +24 V DC, 20-30 V +24 V DC, 20-30 V
Power consumption 200 mA (5 V) 200 mA (5 V) 200 mA (5 V) 150 mA (24 V) 450 mA (24 V) 450 mA (24 V)
104 X 69 X 38 142 X 100 X 29 142 X 100 X 29 147 X 163.5 X 38 211 X 198 X 69 214 X 232 X 879
Dimensions W x H x D (mm)
(401” X 2.7” X 1.5”) (5.6” X 3.5” X 1.1”) (5.6” X 3.5” X 1.1”) (5.8” X 6.4” X 1.5”) (8.3” X 7.8” X 2.7”) (8.4” X 9.1” X 3.4”)
Weight (kg) 0.2 0.5 0.5 0.7 1.5 1.4
44
E Series
E610 E615 / E615T E700 E710 E900T / E900TD E910T / E910TD
Backlit STN, Backlit STN / TFA Backlit STN colour,
Backlit STN colour Backlit TFT colour Backlit TFT colour, touch
16 grays, touch colour, touch touch
Graphic + Text Graphic + Text Graphic + Text Graphic + Text Graphic + Text Graphic + Text
320 x 240 pixels 320 x 240 pixels 320 x 240 pixels 320 x 240 pixels 640 x 480 pixels 640 x 480 pixels
115.2 x 86.4 (5.7”) 115.2 x 86.4 (5.7”) 115.2 x 86.4 (5.7”) 115.2 x 86.4 (5.7”) 211.25 x 158.4 (10.4”) 211.25 x 158.4 (10.4”)
25,000 40,000 / 50,000 40,000 40,000 50,000 50,000

Variable Variable Variable Variable Variable Variable
- - 14 (two colors) 8 (two colors) 20 (two colors) -
- - 16 ( 8 with text strip) 8 (text strip) 22 (10 with text strip) -
· · · · · ·
· · · · · ·
· · · · · ·
· · · · · ·
· · · · · ·
· ·/ · ·/ · ·/ · ·/ · ·/ · ·/
· · · · · ·
Uup to 5 groups Up to 5 groups Up to 16 groups Up to 5 groups Up to 16 groups Up to 11 groups
· · · · · ·
· · · · · ·
Historic Historic Historic Historic Historic Historic
· · · · · ·
8 levels 8 levels 8 levels 8 levels 8 levels 8 levels
- - - - - -
400 kb Flash / 400 kb Flash / 400 kb Flash / 400 kb Flash / 1,600 kb Flash / 1,600 kb Flash /
8 Mb expansion 8 Mb expansion 8 Mb expansion 8 Mb expansion 8 Mb expansion 8 Mb expansion
1 1 2 2 2 2
RS485, RS422, RS485, RS422,
RS 232C (4) RS 232C (4) RS422 and RS232C RS422 and RS232C RS422 and RS232C RS422 and RS232C
· · · · · ·
· · · · · ·
0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC 0 ºC - + 50 ºC
IP65, NEMA 4X (2) IP65, NEMA 4X (2) IP65, NEMA 4X (2) IP65, NEMA 4X (2) IP65, NEMA 4 / IP65, NEMA 4 /
IP 65, NEMA 4X (2) IP 65, NEMA 4X (2)
EN 50081 -1, EN 50081-2, EN 61000-6-2 / EN 61000-6-3, EN 61000-6-3, EN 50081-2, EN 61000-6-2 / EN 50081-2, EN 61000-6-2 /
EN 61000-6-2 EN 50081-1, EN 61000-6-2 / EN 61000-6-2 EN 61000-6-2 EN 61000-6-4, EN 61000-6-2 EN 61000-6-4, EN 61000-6-2
- - - - EN 60950 / - EN 60950 / -
UL 508, UL 1604 (3) UL 508, UL 1604 (3) / - UL 508, UL 1604 (3) UL 508, UL 1604 (3) UL 1950, UL 1604 (3) / UL 1950, UL 1604 (3) /
UL 508, UL 1604 (3) UL 508, UL 1604 (3)
· · /- · · · ·
+24 V DC, 20-30 V +24 V DC, 20-30 V +24 V DC, 20-30 V +24 V DC, 20-30 V 100-240 V AC / 100-240 V AC /
24 V DC, 20-30 V 24 V DC, 20-30 V
400 mA (24 V) 450 mA (24 V) 550 mA (24 V) 550 mA (24 V) Max 0.35 A / 1A Max 0.35 A / 1A
200 X 150 X 69 200 X 150 X 69 276 X 198 X 89 276 X 198 X 89 367 X 274 X 90 290 X 250 X 105
(7.8” X 5.9” X 2.7”) (7.8” X 5.9” X 2.7”) (10.9” X 7.8” X 3.5”) (10.9” X 7.8” X 3.5”) (14.4” X 10.8” X 3.5”) (11.4” X 9.8” X 4.1”)
1.5 1.5 1.7 1.7 3.5 3.3
45
HMI Connectivity
ORDERING INFORMATION :
HMI CONNECTIVITY
Nexgen 5000 PLCs and HMI Interface
Note: When HMI Smartline Jr. CPU 521x Setup CPU 522x Setup
Master Master
is interfaced with Nexgen
521x Third port, operational
power for HMI, needs to be 24V 24V
Supply Supply
externally provided. P2 P3 P2 P3
12V
Supply
Nexgen 521x Series of CPU Connectivity to Messung HMI

5210 / 5213 / 5214 5211 5211
HMI Port 2 Port 3 Features
RS 422 RS 232C RS 232C
Jr. HMI SL JR CAB üü 07 NA U.D.

üü : 3, 5, 10, 15, 20, 25 Mtrs.
Sr. HMI SL CAB üü 07 U.D. U.D.
Nexgen 521x Series of CPU Connectivity to Beijer HMI & Mitsubishi GOT
5210 / 5213 / 5214 5211 5211

HMI Port 2 Port 3 Features
RS 422 RS 232C RS 422
Port 1 : RS 422 U.D. NA U.D.

Beijer
E100 - E50
Port 2 : RS 232 C NA U.D. NA
** : 5 Mtrs. Only available
Port 1 : RS 422 ECAB üü 07 NA U.D. üü : 3, 5, 10, 15, 20, 25 Mtrs.
Beijer E200
onwards
Port 2 : RS 232 C NA U.D. NA
Mitsubishi GOT 930 / 940 GOT CAB üü 08 02 NA GOT 05 08 03**
Nexgen 522x Series of CPU Connectivity to Messung HMI

5221-B0 / P4 & 5222-B0 / P4
HMI Features
Port 2 / Port 3
Jr. HMI SL JR CAB PS üü 09 23

üü : 3, 5, 10, 15, 20, 25 Mtrs.
Sr. HMI SL CAB üü 09 23
Nexgen 522x Series of CPU Connectivity to Beijer HMI & Mitsubishi GOT
5221-B0 / P4 & 5222-B0 / P4
HMI Features
Port 2 / Port 3
Port 1 : RS 422 U.D.

Beijer
E100 - E50
Port 2 : RS 232 C U.D.
Port 1 : RS 422 ECAB üü 09 23 üü : 3, 5, 10, 15, 20, 25 Mtrs.

Beijer E200
onwards
Port 2 : RS 232 C U.D.
Mitsubishi GOT 930 / 940 GOT CAB üü 08 23

U.D. : UNDER DEVELOPMENT
46
Nexgen 5000 CPU
NEXGEN CPU 5000 SERIES
Sr.
No.
Item Description Ordering
Code
* Back Plane
Current (mA) at 5 V DC
I Processor Series : 521x

1 Basic CPU 5210 600
2 CPU, with 3rd Port - RS 232 5211 600
3 CPU, with 3rd Port - RS 422 / 485 5212 600
4 Low-cost CPU 5213 600
5 CPU with 2 Ch. HSC + 2 Ch. PTO 5214 600
II Processor Series : 522x

1 Basic CPU with Only PG Port . CP 5220-B0 600
2 CPU with PG Port & 2HSC+2PTO. CP 5220-P4 600
3 Basic CPU with 1 AUX Port. CP 5221-B0 600
4 CPU with 1 AUX Port & 2HSC+2PTO. CP 5221-P4 600
5 Basic CPU with 2 AUX Ports. CP 5222-B0 600
6 CPU with 2 AUX Ports & 2HSC+2PTO. CP 5222-P4 600
7 Pluggable Keyboard + Display for CPU 522x Series. 5910
8 Blanking Module for CPU 522x Series. 5911
Accessories to be used along with CPU 5214 as well as with CP 522x-P4,

as per the application requirements...
1 Patch Panel, 2 Ch.,100 KHz Max. HSC & 2 Ch.,5 KHz Max. PNP Type PTO 4960
2 Patch Panel, 2 Ch.HSC,100 KHz Max. & 2 Ch.,100 KHz RS-422 Type PTO 4962
3 Interface Cable (0.5 Meter Length) 4944
4 Interface Cable (1 Meter Length) 4945
1 Program Memory Cassette - 256 KB 9904

2 Serial Communication Cable between 4806
CPU 521x series & PC, for programming purpose
3 Serial Communication Cable between 9910
CPU 522x series & PC, for programming purpose
4 Docking Station 9911
5 'CoDeSys' - Windows based Programming & Documentation Software 9920
Ordering Ordering
Item Description Code Item Description Code
BASE PLATES EXPANSION PLATES
8 I/0 without expansion connector 4906 8 I/0 without Slot for Aux Power Supply 4934
8 I/0 with expansion connector 4937 8 I/0 with Slot for Aux Power Supply 4907
The expansion cable is used in multi-rack system for connecting

base or expansion plate to expansion plate. These cables are
available in different lengths.
Expansion Cable (Length) Ordering Code
0.5 meter 4940
1 meter 4941
2 meters 4942
3 meters 4943
47
I/O Modules
PSU, I/O MODULES
POWER SUPPLY MODULE Ordering Code
PSU 220 V AC, 5 V DC - 5 A, TERMINAL BLOCKS Ordering Code

4110
12 V DC - 0.5 A Terminal blocks - 20 pin 4908
PSU 24 V DC, 5 V DC - 5 A, Terminal blocks - 38 pin 4909
4112 Prewired Terminal Block - 38 pin 4910
12 V DC - 0.5 A
Terminal
I/O MODULES
Ordering * Back Plane
Current (mA) Block
Code Required
at 5 V DC
DISCRETE INPUT MODULES

16 I/Ps 24 V DC, Source/Sink Selectable 4616 110 20 pin
16 I/Ps, 110/220 V AC: 4617 90 20 pin
32 l/Ps, 24 V DC, Source/Sink Selectable 4632 110 38 pin
16 Channels, Multifunction Input, Source/Sink Selectable 4633 205 38 pin
4 Channel Counter Input Module 4634 205 38 pin
DISCRETE OUTPUT MODULES

8 Triac O/Ps, 110/220 V AC @ 1.5 A with fuse protection 4711 210 20 pin
32 DC O/Ps, 24 V DC @ 0.2 A with short circuit protection, Source Type 4732 315 38 pin
16 DC O/PS 24 V DC @ 1.5 A with short circuit protection, Source Type 4716 200 20 pin
16 Relay O/Ps (Potential Free) 24-250 V AC @ 750 mA 4721 185 38 pin
MIXED DIGITAL INPUT-OUT MODULES

16 DC I/Ps, 24 V Source/Sink Selectable, 8 Relay O/Ps (Potential Free) 4424 220 38 pin
24-250 V AC @ 0.75 A
16 DC I/Ps, 24 V Source/Sink Selectable, 8 DC O/Ps 24 V @ 1.5 A 4425 220 38 pin
With shot circuit protection, source type
ANALOG INPUT MODULES

8 Channel, 16 bit, non-isolated Input Module 4308 400 38 pin
8 Channel, 16 bit, Thermocouple Input Module, 4310 250 38 pin
For Interfacing J,K,T,E,N,R,S,B type of thermocouples
8 Channel, 16 bit, RTD Input Module, For Interfacing PT-100 Sensors 4311 250 38 pin
ANALOG OUTPUT MODULES

2 Channel, 12 bit, Isolated Output Module (Voltage/Current Type) 4332 150 20 pin
2 Channel, 12 bit, Isolated Output Module (Voltage Type) 4333 150 20 pin
4 Channel, 16 bit, Non-Isolated Output Module 4334 300 20 pin
FAST ANALOG INPUT & OUTPUT MODULES

4 Channel, High Speed , Non-isolated, 16 Bit Analog Input (V / I) & 4366 1000 38 pin
2 Channel, Non-isolated, 12 Bit, Analog Output (Voltage type)
* Please note that if current consumption at 5 V DC of CPU, for all Digital & Analog Module I/O modules exceeds 5 A,
an additional power supply is required to be ordered.
48
UCING
D
RO
INT
CAN -Bus Based Automation Systems

" A STEP IN TO THE FUTURE "
IPC - Master / Slave PLC Configurator &
Network Monitor
GATEWAY
Nexgen CPU -
523x Series PLC - Master
PC
OPC Server
GATEWAY
"CANopen" - An Internationally Accepted Fieldbus System

GATEWAY GATEWAY
GATEWAY
GATEWAY
Graphic HMI
Mitsubishi
indiCAN - indiCAN - AC Servo System -
Remote Digital I/Os Remote Analog I/Os Mitsubishi Slave
Text HMI AC VFD / Inverter -
Slave
CANopen GATEWAYS
Under Development
Nexgen CPU -
523x Series PLC - Slave
Highlights
l Nexgen CPU 523x series supports CANbus connectivity
l Distributed configuration: Low cost, shielded, twisted cable
l Maximum of 31 stations of digital / analog remote I/Os over a
distance of 500 meters
l Network configuration through software
Benefits
l Reduced wiring leads to quick installation
l Network expansion by add on
l Easy diagnostics & troubleshooting
TM MESSUNG AREA OFFICES AREA DISTRIBUTORS
www.intericsdesigns.com
PUNE MUMBAI NEW DELHI BANGALORE CHENNAI

MESSUNG SYSTEMS MESSUNG SYSTEMS
TEL:+91(20)7110862 /
MESSUNG SYSTEMS
TEL:+91(22)26177700 /
MESSUNG SYSTEMS
TEL:+91(11)26385609 /
LEONARDO AUTOMATION
TEL:+91(80)3283030 /
C/MOS PROCESSORS
TEL:+91(44)26287653 /
MANUFACTURER OF PLCs & HMIs
7110865 56949564 26386128 3287161 26217942
EL-2, J BLOCK, M.I.D.C. BHOSARI, FAX:+91(20)7121402 FAX:+91(22)26177710 FAX:+91(11)26384389 FAX:+91(80)3282613 FAX:+91(44)26287653
PUNE - 411 026. INDIA
HYDERABAD BANGALORE BARODA NASIK KOLKATA
TEL : +91(20)27102000 MESSUNG SYSTEMS MESSUNG SYSTEMS MESSUNG SYSTEMS DIGILOG SYSTEMS TTS SYSTEMATIX PVT. LTD
FAX : +91(20)27102100 TEL:+91(40)27722519 / TEL:+91(80)5092119 / TEL:+91(265)2314699 / TEL:+91(253)2578834 / TEL:+91(33)24635645
email : corpgroup@ms.messung.com 27720308 5320480 2358137 2570085 FAX:+91(33)24635646
WEBSITE:www.messungautomation.com FAX:+91(40)27722519 FAX:+91(80)5320480 FAX:+91(265)2333307 FAX:+91(253)2573834
DOCUMENT NO. : 6317 (2000;10/2003)

Nexgen 5000 System Overview

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Nexgen 5000 System Overview

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SYSTEM OVERVIEW

Introduction : Nexgen 5000 PLC............................................................................1

Evolution Of PLCs on IEC 61131-3 Platform

IEC 61131-3 compatible programming yields Rapid Application Development.

l More I/O Capacity - 1024 Inputs / 1024 Outputs

Nexgen 5000 PLC with full capacity

IMPROVED PG PORT OPERATION

ENHANCED FILE MARKER MEMORY

PLUGGABLE KEYBOARD DISPLAY UNIT (OPTIONAL)

COMPACT & HANDY MEMORY CASSETTE :

APPLICATION PROGRAM DOWNLOADING

To 230 VAC power supply

Fig : Set Up to download the Program to Memory Cassette

VARIETY OF PROGRAM EDITORS

HIGH PERFORMANCE EVENT TASK SUPPORT

INCREASED PROGRAMMING FUNCTIONALITY

ADVANTAGE - BUILT IN PROTOCOL FUNCTION BLOCKS

Dial-up modem Dial-up modem

Remote programming / on-line monitoring of Nexgen-5000

REMOTE PROGRAMMING VIA LAN :

Nexgen 522x CPU

l MODBUS Master and MODBUS Slave

Slave-1 Slave-2 Slave-31

These FBs are useful -

MODBUS MASTER AND MODBUS SLAVE

Slave-1 Slave-2 Slave-31

DATA EXCHANGE VIA MODEM

PLC : Nexgen with 522x CPU

PLC to PLC Connection Via Modem

PLC 4 PLC : Nexgen with 522x CPU

Dial-up modem Dial-up modem

Dial-up modem Dial-up modem

CONVENIENT FAULT MESSAGE ALERT

PLC : Nexgen 522x PLC : Nexgen 522x

PLC Pager PLC

The relevant FBs can be implemented, as per application requirement.

SERVOS NOW CONNECTABLE

PLC : Nexgen 5000, with 5214 or 522x - P4

Interface Cable 4944

MRJ2-A AC Servo Motor

A Typical Nexgen 5000 PLC Set-up with CPU-5214

Special CPU varieties with HSC/PTO and motion control :

CP522x P2 : 1 HSC + 1 PTO + 2 Interrupt I/Ps (Under Development)

H/W Axis_Ref PLC open H/W

HSC PTO features supported in Motion Control applications :

HMI & E TERMINAL CONNECTIVITY

l It emulates Nexgen 4000 HMI port protocol F 940

Graphic Operator Terminal ( GOT ) Connectivity

MICRO PLCs IN MULTIDROP CONNECTIVITY

PC Master Master : Nexgen 5000 PLC or PC

Slave-1 Slave-2 Slave-31

VARIABLE FREQUENCY DRIVES IN MUTIDROP

Master HMI Master : Nexgen 5000 PLC or PC

Slave 1 Slave 2 Slave 3 Slave 31

Processing Boolean ( Move ) 0.6 µSec 0.4 µSec

Maximum Permissible up to 1 Sec User can modify

Standard IEC 61131-3 -

Programming IL Instruction List

Remote Programming - Supported Supported, using dial-up modem

Application Memory 64 KB 256 KB For run time execution

Data 32 KB 64 KB Used as application data memory.

Numbers Unlimited * *Limited by available data memory.

Input points 1024 Presently supported 1024 I/O points

Rack Basic 1 Racks are available accommodating