BECKHOFF BC3150 User Manual
BC3150 - Bus Terminal
Controller for PROFIBUS
Version: 1.1.0
Date: 2006-02-10
Contents
Contents
BC3150 - Bus Terminal Controller for PROFIBUS
1. Foreword 4
Notes on the Documentation 4
Safety Instructions 5
Documentation Issue Status 6
2. Product Overview 7
BCxx50 - Overview 7
The Principle of the Bus Terminal 8
The Beckhoff Bus Terminal System 9
Technical Data 11
Technical Data - BCxx50 11
Technical Data - PROFIBUS DP 13
Technical Data - PLC 14
3. Mounting and Wiring 15
Mounting 15
Dimensions 15
Installation 16
Wiring 17
Potential Groups, Insulation Testing and PE 17
Power supply 19
Programming cable 20
PROFIBUS Connection 21
PROFIBUS Cabling 23
Fieldbus Components 1
Contents
4. Parameterization and Commissioning 25
Start-up Behavior of the Bus Terminal Controller 25
Setting the slave address 26
Configuration 27
Overview 27
Creating a BX File 29
Downloading a BX Configuration 30
Uploading a BX Configuration 32
Bus Terminal Controller resources 34
ADS via Serial 36
ADS Connection via Serial Interface 36
PROFIBUS 37
PROFIBUS Settings 37
Master Configuration 38
Basic Device File (GSD) 38
Creating a TwinCAT PC File 39
Variable Mapping - PROFIBUS DP 41
BC3150 at 3rd party controller 42
SIEMENS S7 42
Configuration - Siemens S7 Controller 42
Configuration: Siemens S7 Controller with BX3100 43
K-Bus 46
K-Bus 46
PLC 48
Inserting a PLC project 48
Measuring the PLC Cycle Time 49
KS2000 50
KS2000 50
5. Programming 51
BCxx50 PLC features 51
TwinCAT PLC 52
TwinCAT PLC Error Codes 53
Remanent data 55
Allocated Flags 56
Local process image in delivery state 57
Mapping of the Bus Terminals 59
Local process image in the TwinCAT configuration 60
Creating a boot project 61
Communication between TwinCAT and BX/BCxx50 62
Up- and downloading of programs 63
2 Fieldbus Components
Contents
Libraries 67
Übersicht 67
TcBaseBX 69
System Task Info 69
System Task Info Type 70
System Info 71
System Info Type 72
ADS 73
Local ADS Port Numbers 73
ADS Services 74
BX Debug Function 75
Overview 75
Program Transmission 76
Transmission via Serial Interface 76
Transmission via PROFIBUS 78
Process Image 80
PROFIBUS Process Image 80
6. PROFIBUS 81
System Introduction 81
Fieldbus Overview 81
PROFIBUS DP 85
PROFIBUS DPV1 87
Cables, Plugs and Switches 88
Topology 91
7. Error handling and diagnosis 92
Diagnostics 92
Diagnostic LEDs 94
8. Appendix 97
First steps with the BC3150 97
Moving from BC to BX 99
Firmware Update 102
General Operating Conditions 105
Standards for Device Testing 107
Bibliography 108
List of Abbreviations 109
Support and Service 110
Fieldbus Components 3
Notes on the Documentation
1. Foreword
Notes on the Documentation
This description is only intended for the use of trained specialists in control and automation engineering who are
familiar with the applicable national standards. It is essential that the following notes and explanations are followed
when installing and commissioning these components.
Liability Conditions
The responsible staff must ensure that the application or use of the products described satisfy all the requirements for
safety, including all the relevant laws, regulations, guidelines and standards.
The documentation has been prepared with care. The products described are, however, constantly under
development. For that reason the documentation is not in every case checked for consistency with performance data,
standards or other characteristics. None of the statements of this manual represents a guarantee (Garantie) in the
meaning of § 443 BGB of the German Civil Code or a statement about the contractually expected fitness for a
particular purpose in the meaning of § 434 par. 1 sentence 1 BGB. In the event that it contains technical or editorial
errors, we retain the right to make alterations at any time and without warning. No claims for the modification of
products that have already been supplied may be made on the basis of the data, diagrams and descriptions in this
documentation.
© This documentation is copyrighted. Any reproduction or third party use of this publication, whether in whole or in
part, without the written permission of Beckhoff Automation GmbH, is forbidden.
4 Fieldbus Components
Safety Instructions
Safety Instructions
Safety Rules
The responsible staff must ensure that the application or use of the products described satisfy all the requirements for
safety, including all the relevant laws, regulations, guidelines and standards.
State at Delivery
All the components are supplied in particular hardware and software configurations appropriate for the application.
Modifications to hardware or software configurations other than those described in the documentation are not
permitted, and nullify the liability of Beckhoff Automation GmbH.
Personnel Qualification
This description is only intended for the use of trained specialists in control and automation engineering who are
familiar with the applicable national standards.
Description of safety symbols
The following safety symbols are used in this operating manual. They are intended to alert the reader to the
associated safety instructions.
This symbol is intended to highlight risks for the life or health of personnel.
Danger
This symbol is intended to highlight risks for equipment, materials or the environment.
Warning
This symbol indicates information that contributes to better understanding.
Note
Fieldbus Components 5
Safety Instructions
Documentation Issue Status
Version Comment
1.1.0 Notes to meet the UL requirements added.
•
1.0.1
1.0.0 First release (only German version available)
Chapter Creating a boot project corrected
•
minor routine corrections (typing errors, orthography etc.)
•
English version available
Firmware BC3150
To make a firmware update, you need a serial cable and the KS2000 Configuration Software or the firmware update
program.
Firmware Comment
0xB0 Firmware Version 0xB0
The firmware and hardware version (delivery status) can be found on the label at the bottom of the Bus Terminal
Controller.
6 Fieldbus Components
Safety Instructions
2. Product Overview
BCxx50 - Overview
Bus Terminal Controllers are Bus Couplers with integrated PLC functionality. The BCxx50 Bus Terminal Controllers
have a fieldbus interface, are intelligent slaves and can be used as remote intelligence within the system. They are
located in a cost-optimized and compact housing. In contrast to the BCxx00 range, the BCxx50 range supports up to
255 Bus Terminals via the K-Bus extension.
The Bus Terminal Controller is programmed using the TwinCAT programming system according to IEC 61131-3. The
BCxx50 configuration/programming interface is used for loading the PLC program. If the TwinCAT software PLC is in
use, the PLC program can also be loaded via the fieldbus.
The inputs and outputs of the connected Bus Terminals are assigned in the default setting of the mini-PLC. Each
individual Bus Terminal can be configured in such a way that it exchanges data directly through the fieldbus with the
higher-level automation device. Similarly, pre-processed data can be exchanged between the Bus Terminal
Controller and the higher-level controller via the fieldbus.
Fieldbus interface
The variants of the BCxx50 series Bus Terminal Controllers differ in terms of their fieldbus interfaces. Five different
versions cover the main fieldbus systems:
•
BC3150: PROFIBUS DP
•
BC5150: CANopen
•
BC5250: DeviceNet
•
BC8150: RS232 or RS485 (without fieldbus interface)
Programming
The BCxx50 devices are programmed according to the powerful IEC 61131-3 standard. Like for all other BECKHOFF
controllers, the TwinCAT automation software is the basis for parameterization and programming. Users therefore
have the familiar TwinCAT tools available, e.g. PLC programming interface, System Manager and TwinCAT Scope.
Data is exchanged optionally via the serial port (COM1) or via the fieldbus through BECKHOFF PC FCxxxx fieldbus
cards.
Configuration
The configuration is also carried out using TwinCAT. The fieldbus interface can be configured and parameterized via
the System Manager. The System Manager can read all connected devices and Bus Terminals. After the
parameterization, the configuration is saved on the BCxx50 via the serial interface. The configuration thus created
can be accessed again later.
Fieldbus Components 7
Safety Instructions
The Principle of the Bus Terminal
8 Fieldbus Components
Safety Instructions
The Beckhoff Bus Terminal System
Up to 64 Bus Terminals each having 2 I/O channels for each signal form
The Bus Terminal system is the universal interface between a fieldbus system and the sensor / actuator level. A unit
consists of a Bus Coupler as the head station, and up to 64 electronic series terminals, the last one being an end
terminal. For each technical signal form, terminals are available each having two I/O channels, and these can be
mixed in any order. All the terminal types have the same mechanical construction, so that difficulties of planning and
design are minimized. The height and depth match the dimensions of compact terminal boxes.
Decentralized wiring of each I/O level
Fieldbus technology allows more compact forms of controller to be used. The I/O level does not have to be brought to
the controller. The sensors and actuators can be wired decentrally, using minimum cable lengths. The controller can
be installed at any location within the plant.
Industrial PCs as controllers
The use of an Industrial PC as the controller means that the operating and observing element can be implemented in
the controller’s hardware. The controller can therefore be located at an operating panel, in a control room, or at some
similar place. The Bus Terminals form the decentralized input/output level of the controller in the control cabinet and
the subsidiary terminal boxes. The power sector of the plant is also controlled over the bus system in addition to the
sensor/actuator level. The Bus Terminal replaces the conventional series terminal as the wiring level in the control
cabinet. The control cabinet can have smaller dimensions.
Bus Couplers for all usual bus systems
The Beckhoff Bus Terminal system unites the advantages of a bus system with the possibilities of the compact series
terminal. Bus Terminals can be driven within all the usual bus systems, thus reducing the controller parts count. The
Bus Terminals then behave like conventional connections for that bus system. All the performance features of the
particular bus system are supported.
Assembly on standardized C mounting rails
The easy, space-saving, assembly on a standardized C-rail, and the direct wiring of actuators and sensors, without
cross-connections between the terminals, standardizes the installation. The consistent labelling scheme also
contributes.
The small physical size and the great flexibility of the Bus Terminal system allows it to be used wherever a series
terminal is also used. Every type of connection, such as analog, digital, serial or the direct connection of sensors can
be implemented.
Modularity
The modular assembly of the terminal strip with Bus Terminals of various functions limits the number of unused
channels to a maximum of one per function. The presence of two channels in one terminal is the optimum
compromise of unused channels and the cost of each channel. The possibility of electrical isolation through potential
feed terminals also helps to keep the number of unused channels low.
Display of the channel state
The integrated LEDs show the state of the channel at a location close to the sensors and actuators.
K-Bus
The K-Bus is the data path within a terminal strip. The K-Bus is led through from the Bus Coupler through all the
terminals via six contacts on the terminals’ side walls. The end terminal terminates the K-Bus. The user does not
have to learn anything about the function of the K-Bus or about the internal workings of the terminals and the Bus
Coupler. Many software tools that can be supplied make project planning, configuration and operation easy.
Fieldbus Components 9
Safety Instructions
Potential feed terminals for isolated groups
The operating voltage is passed on to following terminals via three power contacts. You can divide the terminal strip
into arbitrary isolated groups by means of potential feed terminals. The potential feed terminals play no part in the
control of the terminals, and can be inserted at any locations within the terminal strip.
Up to 64 terminals can be used within one terminal strip. This count does include potential feed terminals, but not the
end terminal.
Bus Couplers for various fieldbus systems
Various Bus Couplers can be used to couple the electronic terminal strip quickly and easily to different fieldbus
systems. It is also possible to convert to another fieldbus system at a later time. The bus coupler performs all the
monitoring and control tasks that are necessary for operation of the connected Bus Terminals. The operation and
configuration of the Bus Terminals is carried out exclusively by the Bus Coupler. Nevertheless, the parameters that
have been set are stored in each Bus Terminal, and are retained in the event of voltage drop-out. Fieldbus, K-Bus
and I/O level are electrically isolated.
If the exchange of data over the fieldbus is prone to errors or fails for a period of time, register contents (such as
counter states) are retained, digital outputs are cleared, and analog outputs take a value that can be configured for
each output when commissioning. The default setting for analog outputs is 0 V or 0 mA. Digital outputs return in the
inactive state. The timeout periods for the Bus Couplers correspond to the usual settings for the fieldbus system.
When converting to a different bus system it is necessary to bear in mind the need to change the timeout periods if
the bus cycle time is longer.
The interfaces
A Bus Coupler has six different methods of connection. These interfaces are designed as plug connectors and as
spring-loaded terminals.
10 Fieldbus Components
Safety Instructions
Technical Data
Technical Data - BCxx50
Technical data BCxx5x
Processor 16 bit micro-controller
Diagnostic LEDs 2 x power supply, 2 x K-Bus
Configuration and programming software TwinCAT PLC
Fieldbus
interface BC3150 BC5150 BC5250 BC8150 -
Fieldbus PROFIBUS DP CANopen DeviceNet - Serial ADS
- KS8000 Protocol
- ModbusRTU
- ModbusASCII
Interfaces
Serial interface COM1 (RS232 for configuration and programming, automatic baud rate detection
9600/19200/38400/57600 baud)
Terminal Bus (KBus)
Technical data BC3150 BC5150 BC5250 BC8150 -
Digital peripheral signals 2040 inputs/outputs
Analog peripheral signals 1024 inputs/outputs
Configuration possibility via TwinCAT or the controller
Maximum fieldbus byte
number
Maximum number of bytes
- PLC
Bus connection D-sub, 9-pin Open Style Connector, 5 pin D-sub, 9-pin -
64 (255 with K-Bus extension)
depending on fieldbus
2048 bytes of input data, 2048 bytes of output data
-
Power supply (Us)
Input current (Us) 60 mA + (total K-Bus current)/4
Starting current approx. 2.5 x continuous current
K-Bus current (5 V) maximum 1000 mA
Power contact voltage
(Up)
Power contact current load
(Up)
Recommended fuse (Up) ≤ 10 A
Dielectric strength 500 V
Weight approx. 100 g
Dimensions (W x H x D) approx. 44 mm x 100 mm x 68 mm
24 VDC (-15%/+20%) To meet the UL requirements use a 4 A fuse or a power
supply that has to satisfy NEC class 2!
maximum 24 VDC
maximum 10 A
(power contact / supply voltage / fieldbus)
rms
Fieldbus Components 11
Safety Instructions
Technical data BC3150 BC5150 BC5250 BC8150 -
Operating temperature 0°C... +55°C
Storage temperature -25°C... +85°C
Relative humidity 95 % no condensation
Vibration / shock resistance conforms to EN 60068-2-6 / EN 60068-2-27, EN 60068-2-29
EMC resistance burst / ESD conforms to EN 61000-6-2 / EN 61000-6-4
Installation pos. Variable
Protection class IP20
12 Fieldbus Components
Safety Instructions
Technical Data - PROFIBUS DP
System data PROFIBUS (BC3150)
Number of I/O modules 126 (BC3150 max. 99 devices)
Number of I/O points depending on controller
Data transfer medium shielded copper cable 2 x 0.25 mm², cable type A according to EN 50170
Segment length up to 1200 m
Number of segments 3
Data transfer rate up to 12 MBaud
Topology RS485 line, optical fiber ring
Transmission time approx. 0.5 ms with 10 stations for 32 bits input/output at 12 MBaud
Fieldbus Components 13
Safety Instructions
Technical Data - PLC
PLC data BCxx5x
Programmability via serial programming interface or via the fieldbus
Program memory 48 kbyte
Source code memory 128 kbyte
Data memory 32 kbyte
Remanent flags 2 kbyte
PLC cycle time Approx. 3,0 ms for 1000 IL commands (without I/O cycle)
Programming languages IEC 6-1131-3 (IL, LD, FBD, ST, SFC)
Run time 1 PLC task
Online Change Yes
Up/Down Load Code Yes/Yes
14 Fieldbus Components
Safety Instructions
3. Mounting and Wiring
Mounting
Dimensions
The Beckhoff Bus Terminal system is characterized by low physical volume and high modularity. When planning a
project it must be assumed that at least one Bus Coupler and a number of Bus Terminals will be used. The
mechanical dimensions of the Bus Couplers are independent of the fieldbus system.
Fig. 1.0 BCxx50
The total width of the fieldbus station is the width of the Bus Coupler/Bus Terminal Controller plus the width of the
Bus Terminals being used (incl. KL9010 bus end terminal). Depending on design, the Bus Terminals are 12 or 24 mm
wide. The height is 100 mm.
The BCxx50 series Bus Terminal Controllers are 68 mm deep.
Fieldbus Components 15
Safety Instructions
Installation
The Bus Coupler and all the Bus Terminals can be clipped, with a light press, onto a 35 mm mounting rail. A locking
mechanism prevents the individual housings from being pulled off again. For removal from the mounting rail the
orange colored tension strap releases the latching mechanism, allowing the housing to be pulled off the rail without
any force.
Up to 64 Bus Terminals can be attached to the Bus Coupler on the right hand side. When plugging the components
together, be sure to assemble the housings with groove and tongue against each other. A properly working
connection can not be made by pushing the housings together on the mounting rail. When correctly assembled, no
significant gap can be seen between the attached housings.
Insertion and removal of Bus Terminals is only permitted when switched off. The
Warning
electronics in the Bus Terminals and in the Bus Coupler are protected to a large measure
against damage, but incorrect function and damage cannot be ruled out if they are plugged
in under power.
The right hand part of the Bus Coupler can be compared to a Bus Terminal. Eight connections at the top enable the
connection with solid or fine wires from 0.08 mm² to 2.5 mm². The connection is implemented with the aid of a spring
device. The spring-loaded terminal is opened with a screwdriver or rod, by exerting gentle pressure in the opening
above the terminal. The wire can be inserted into the terminal without any force. The terminal closes automatically
when the pressure is released, holding the wire securely and permanently.
16 Fieldbus Components
Safety Instructions
Wiring
Potential Groups, Insulation Testing and PE
Potential groups
The Beckhoff Bus Terminals stations usually have three different potential groups:
•
The fieldbus interface is electrically isolated (except for individual Low Cost couplers) and forms the first potential group
•
Bus Coupler / Bus Terminal Controller logic, K-Bus and terminal logic form a second galvanically separated
potential group
•
The inputs and outputs are supplied via the power contacts and form further potential groups.
Groups of I/O terminals can be consolidated to further potential groups via potential supply terminals or separation
terminals.
Insulation testing
The connection between the Bus Coupler / Bus Terminal Controller and the Bus Terminals is automatically realized
by pushing the components together. The transfer of the data and the supply voltage for the intelligent electronics in
the Bus Terminals is performed by the K-Bus. The supply of the field electronics is performed through the power
contacts. Plugging together the power contacts creates a supply rail. Since some Bus Terminals (e.g. analog Bus
Terminals or 4-channel digital Bus Terminals) are not looped through these power contacts (or not completely) the
Bus Terminal contact assignments must be considered.
The potential feed terminals interrupt the power contacts, and represent the start of a new supply rail. The Bus
Coupler / Bus Terminal Controller can also be made use of to feed the power contacts.
Fieldbus Components 17
Safety Instructions
PE power contacts
The power contact labelled PE can be used as a protective earth. For safety reasons this contact mates first when
plugging together, and can ground short-circuit currents of up to 125 A.
It should be noted that, for reasons of electromagnetic compatibility, the PE contacts are capacitively coupled to the
mounting rail. This can both lead to misleading results and to damaging the terminal during insulation testing (e.g.
breakdown of the insulation from a 230 V power consuming device to the PE conductor). The PE conductor to the
Bus Coupler / Bus Terminal Controller must be disconnected for the insulation testing. In order to uncouple further
feed locations for the purposes of testing, the feed terminals can be pulled at least 10 mm out from the connected
group of other terminals. In that case, the PE conductors do not have to be disconnected.
The PE power contact must not be used for other potentials.
18 Fieldbus Components
Safety Instructions
Power supply
Bus Terminal Controller and Bus Terminal supply (Us)
The Bus Terminal Controller requires a supply voltage of 24 VDC for its operation.
The connection is made by means of the upper spring-loaded terminals labelled 24 V and 0 V. This supply voltage
feeds the Bus Coupler / Bus Terminal Controller electronics and, over the K-Bus, the electronics of the Bus
Terminals. It is electrically separated from the potential of the field level.
UL requirements
For the compliance of the UL requirements Us should only be supplied
•
Danger
To meet the UL requirements, Us must not be connected to unlimited power sources!
Danger
by a 24 VDC supply voltage, supplied by an isolating source and protected by
means of a fuse (in accordance with UL248), rated maximum 4 Amp.
•
by a 24 VDC power source, that has to satisfy NEC class 2.
A NEC class 2 power supply shall not be connected in series or parallel with another (class 2) power source!
Power contacts supply (Up)
The bottom six connections with spring-loaded terminals can be used to feed the supply for the peripherals. The
spring-loaded terminals are joined in pairs to a power contact. The feed for the power contacts has no connection to
the voltage supply for the BC electronics.
The spring-loaded terminals are designed for wires with cross-sections between 0.08 mm2 and 2.5 mm2.
The assignment in pairs and the electrical connection between feed terminal contacts allows the connection wires to
be looped through to various terminal points. The current load from the power contact must not exceed 10 A for long
periods. The current carrying capacity between two spring-loaded terminals is identical to that of the connecting
wires.
Power contacts
On the right hand face of the Bus Terminal Controller there are three spring contacts for the power contact
connections. The spring contacts are hidden in slots so that they can not be accidentally touched. By attaching a Bus
Terminal the blade contacts on the left hand side of the Bus Terminal are connected to the spring contacts. The
tongue and groove guides on the top and bottom of the Bus Terminal Controllers and of the Bus Terminals
guarantees that the power contacts mate securely.
Fieldbus Components 19
Safety Instructions
Programming cable
Use the KS2000-Z2 programming cable for serial programming of the Bus Terminal Controller. This cable is included
in the scope of supply of the KS2000 software, or it can be ordered separately (order number KS2000-Z2).
KS2000-Z2
The programming cable offers the option of programming the BCxx50 via the serial interface.
When the programming cable (between BCxx50 and PC) is connected, the ground
Warning
connection of the Bus Terminal controller must not be interrupted or disconnected, since
this may destroy the programming cable.
20 Fieldbus Components
Safety Instructions
PROFIBUS Connection
M12 circular connector
The M12 socket is inverse coded, and has five pins. Pin 1 is 5 VDC and 3 is GND for the active termination resistor.
These must never be misused for other functions, as this can lead to destruction of the device. Pin 2 and pin 4 are
the Profibus signals. These must never be swapped over, as this will prevent communication. Pin 5 is the shield, and
this is capacitatively coupled to the Fieldbus Box chassis.
M12 socket pin assignment
Nine pole D-Sub
Pin 6 is 5 VDC und Pin 5 is GND for the active termination resistor. These must never be misused for other functions,
as this can lead to destruction of the device. Pin 3 and pin 8 are the Profibus signals. These must never be swapped
over, as this will prevent communication. Shield is connected to the D-Sub housing that is coupled with lowresistance to the mounting rail.
D-Sub socket pin assignment
Profibus conductor colors
Profibus conductors M12 D-Sub
B red Pin 4 Pin 3
A green Pin 2 Pin 8
Fieldbus Components 21
Safety Instructions
Connection of FieldbusBox modules
The connection of the Fieldbus Box modules is done direct or via a T-piece (or Y-piece).
The B318 series does have a male and female connector, that means no external T-piece is required. The supply
voltage (+5VDC) for the termination resistor is only supplied via the female M12 connector. The termination resistor
ZS1000-1610 is only available with male connector, therefore the incoming PROFIBUS line should end in a female
connector.
Two T-pieces are available:
•
ZS1031-2600 with +5VDC on male and female connector for the termination resistor
•
ZS1031-2610 with +5VDC only on the female connector
22 Fieldbus Components
Safety Instructions
PROFIBUS Cabling
Physical aspects of the data transmission are defined in the Profibus standard (see Profibus layer 1: Physical Layer).
The types of area where a fieldbus system can be used is largely determined by the choice of the transmission
medium and the physical bus interface. In addition to the requirements for transmission security, the expense and
work involved in acquiring and installing the bus cable is of crucial significance. The Profibus standard therefore
allows for a variety of implementations of the transmission technology while retaining a uniform bus protocol.
Cable-based transmission
This version, which accords with the American EIA RS-485 standard, was specified as a basic version for
applications in production engineering, building management and drive technology. A twisted copper cable with one
pair of conductors is used. Depending on the intended application area (EMC aspects should be considered) the
screening may be omitted.
Two types of conductor are available, with differing maximum conductor lengths (see the RS-485 table).
RS485 - Fundamental properties
RS-485 transmission according to the Profibus standard
Network topology Linear bus, active bus terminator at both ends, stubs are possible.
Medium Screened twisted cable, screening may be omitted, depending upon the
environmental conditions (EMC).
Number of stations 32 stations in each segment with no repeater. Can be extended to 127 stations
with repeater
Max. bus length without
repeater
Max. bus length with
repeater
Transmission speed
(adjustable in steps)
Plug connector 9-pin D-Sub connector for IP20
100 m at 12 MBit/s
200 m at 1500 KBit/s, up to 1.2 km at 93.75 KBit/s
Line amplifiers, or repeaters, can increase the bus length up to 10 km. The
number of repeaters possible is at least 3, and, depending on the manufacturer,
may be up to 10.
9.6 kBit/s; 19.2 kBit/s; 93.75 kBit/s; 187.5 kBit/s; 500 kBit/s; 1500 kBit/s; 12 MBit/s
M12 round connector for IP65/67
Cabling for Profibus DP and Profibus FMS
Note the special requirements on the data cable for baud rates greater than 1.5 MBaud. The correct cable is a basic
requirement for correct operation of the bus system. If a simple 1.5 Mbaud cable is used, reflections and excessive
attenuation can lead to some surprising phenomena. It is possible, for instance, for a connected Profibus station not
to achieve a connection, but for it to be included again when the neighboring station is disconnected. Or there may be
transmission errors when a specific bit pattern is transmitted. The result of this can be that when the equipment is not
operating, Profibus works without faults, but that there are apparently random bus errors after start-up. Reducing the
baud rate (< 93,75 kBaud) corrects this faulty behavior.
If reducing the baud rate does not correct the error, then in many cases this can indicate a wiring fault. The two data
lines maybe crossed over at one or more connectors, or the termination resistors may not be active, or they may be
active at the wrong locations.
Installation is made a great deal more straightforward if pre-assembled cables from
Note
BECKHOFF are used! Wiring errors are avoided, and commissioning is more rapidly
completed. The BECKHOFF range includes fieldbus cables, power supply cables, sensor
cables and accessories such as terminating resistors and T-pieces. Connectors and cables
for field assembly are nevertheless also available.
Fieldbus Components 23
Safety Instructions
In systems with more than two stations all devices are wired in parallel. It is essential that
Note
the bus cables are terminated with resistors at the conductor ends in order to avoid
reflections and associated transmission problems.
Distances
The bus cable is specified in EN 50170. This yields the following lengths for a bus segment.
Baud rate in kbits/sec 9.6 19.2 93.75 187.5 500 1500 12000
Cable length in m 1200 1200 1200 1000 400 200 100
Stubs up to 1500 kbaud <6.6 m; at 12 Mbaud stub segments should not be used.
Bus segments
A bus segment consists of at most 32 devices. 126 devices are permitted in a Profibus network. Repeaters are
required to refresh the signal in order to achieve this number. Each repeater is counted as one device.
IP-Link is the subsidiary bus system for Fieldbus Boxes, whose topology is a ring structure. There is an IP master in
the coupler modules (IP230x-Bxxx or IP230x-Cxxx) to which up to 120 extension modules (IExxxx) may be
connected. The distance between two modules may not exceed 5 m. When planning and installing the modules,
remember that because of the ring structure the IP-Link master must be connected again to the last module.
Installation guidelines
When assembling the modules and laying the cables, observe the technical guidelines provided by the Profibus User
Organization (Profibus Nutzerorganisation e.V.) for Profibus DP/FMS (see www.profibus.com).
Checking the Profibus wiring
A Profibus cable (or a cable segment when using repeaters) can be checked with a few simple resistance
measurements. The cable should meanwhile be removed from all stations:
1. Resistance between A and B at the start of the lead: approx. 110 Ohm
2. Resistance between A and B at the end of the lead: approx. 110 Ohm
3. Resistance between A at the start and A at the end of the lead: approx. 0 Ohm
4. Resistance between B at the start and B at the end of the lead: approx. 0 Ohm
5. Resistance between screen at the start and screen at the end of the lead: approx. 0 Ohm
If these measurements are successful, the cable is okay. If, in spite of this, bus malfunctions still occur, this is usually
a result of EMC interference. Observe the installation notes from the Profibus User Organization (www.profibus.com).
24 Fieldbus Components
Safety Instructions
4. Parameterization and Commissioning
Start-up Behavior of the Bus Terminal Controller
After being switched on, the Bus Terminal Controller checks its state, configures the K-Bus, creates a structure list on
the basis of the inserted bus terminals and starts it's local PLC.
The I/O LEDs illuminate and flash as the Bus Coupler starts up. If there are no errors, the I/O LEDs should stop
flashing within about 2-3 seconds. In the case of an error, the flash code of the according LED depends on the error
type (see Diagnostic LEDs).
Fieldbus Components 25
Safety Instructions
Setting the slave address
The address must be set via the two rotary selection switches. The default setting is 11. All addresses are permitted,
although each address may only occur once within the network. For changing an address the Bus Coupler must be
switched off. The switches can be set to the required position using a screwdriver. Ensure that the switches engage
correctly. The lower switch is the 10-multiplier, the upper switch is the 1-multiplier. The change in address is active as
soon as the module is switched on.
Example
You want to set address 34:
•
lower rotary selection switch Sx11: 3
•
upper rotary selection switch Sx10: 4
26 Fieldbus Components
Safety Instructions
Configuration
Overview
Configuration types
DEFAULT-CONFIG
Bus Terminals are mapped in the order they are inserted, i.e. first the complex Bus Terminals followed by the digital
Bus Terminals.
The complex Bus Terminals are mapped as follows:
•
Word Alignment
•
complex representation
The fieldbus slave interface are the PLC variables. The PLC variables have addresses from %QB1000 and %IB1000.
TWINCAT-CONFIG
Bus Terminals and PLC variables can be linked freely in TWINCAT-CONFIG (TC-file required). The configuration is
transferred to the coupler via the System Manager and ADS.
The following is required for TwinCAT Config:
•
Via the fieldbus (PROFIBUS, CANopen, Ethernet)
PROFIBUS: (BC3150, BX3100)
- PC with FC310x from version 2.0 and TwinCAT 2.9 build 1000
- BX3100 with firmware from 0.28 with CIF60 or CP5412
- TwinCAT 2.9 build 946
(WARNING: only one ADS communication is permitted with the Hilscher cards, i.e. either System Manager
or PLC Control)
CANopen: (BC5150, BX5100)
PC with FC510x from version 1.76 or higher and TwinCAT 2.9 build 1030
DeviceNet: (BC5250, BX5200)
on request
Ethernet: (BX9000):
- TwinCAT 2.10 Build xxxx
•
Via serial ADS TwinCAT 2.9 build 1010 for NT4.0, 2000 or XP
- BX3100 version 1.00
- BX5100 version 1.00
- BX5200 version 1.10
- BX8000 version 1.00
- BC3150, BC5150, BC5250 Frimware B0
- BC8150 TwinCAT 2.10 Build 1244
The BX can be parameterised via the System Manager of the TwinCAT program.
•
Variable I/O mapping
•
Type-specific PROFIBUS data (only BC3150 or BX3100)
•
RTC (Real Time Clock) (only BX-controller)
•
SSB bus (Smart System Bus) (only BX-controller)
•
PLC settings
•
K-Bus settings
The configuration can be transferred to the BXxxxx or BCxx50 via fieldbus ADS protocol or with the serial ADS
protocol.
Fieldbus Components 27
Safety Instructions
The TwinCAT configuration can be used to link variables, I/Os and data. The following is possible:
•
PLC - K-BUS
•
PLC - fieldbus (e.g. PROFIBUS slave interface)
•
K-Bus - fieldbus (only the BX-Controller)
In addition, the TwinCAT configuration can be used to parameterise special behaviour, for example whether data are
preserved or set to "0" in the event of a fieldbus error.
The real-time clock can be set via a tab in the system manager.
Individual steps
1. Setting the fieldbus address
2. Opening the system manager and creating a TC-file
3. Configuring fieldbus data in the TC-file
4. Saving the TC-file
5. Opening a new system manager, creating a PC file and reading in saved TC-file
6. Creating a link to a PLC task
7. Saving the configuration
8. Starting the TwinCAT system
9. Opening the system manager for the TC-file, completing the configuration and transferring it to the BXxxxx
or BCxx50
10. Transferring the program to the BXxxxx or BCxx50
11. Creating a boot project
28 Fieldbus Components
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