Documentation
BC8050 und BC8150
Bus Terminal Controller with RS485 or RS232 Interface
Version:
Date:
3.0.0
2017-07-18
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation........................................................................................................... 5
1.2 Safety instructions .......................................................................................................................... 6
1.3 Documentation issue status............................................................................................................ 7
2 Product overview.......................................................................................................................................8
2.1 BCxx50 Overview ........................................................................................................................... 8
2.2 The principle of the Bus Terminal ................................................................................................... 9
2.3 The Beckhoff Bus Terminal system ................................................................................................ 9
2.4 Technical data .............................................................................................................................. 11
2.4.1 Technical Data - BCxx50 ................................................................................................11
2.4.2 Technical data - RS485 ...................................................................................................13
2.4.3 Technical Data - RS232...................................................................................................14
2.4.4 Technical Data - PLC.......................................................................................................15
3 Mounting and wiring ...............................................................................................................................16
3.1 Mounting ....................................................................................................................................... 16
3.1.1 Dimensions ......................................................................................................................16
3.1.2 Installation........................................................................................................................17
3.2 Wiring............................................................................................................................................ 18
3.2.1 Potential groups, insulation testing and PE .....................................................................18
3.2.2 Power supply....................................................................................................................19
3.2.3 Programming cable..........................................................................................................21
3.2.4 RS232 Connection...........................................................................................................22
3.2.5 RS485 connection............................................................................................................23
4 Parameterization and Commissioning ..................................................................................................24
4.1 Start-up behavior of the Bus Terminal Controller ......................................................................... 24
4.2 Setting the Address ...................................................................................................................... 25
4.3 Baud rate ...................................................................................................................................... 26
4.4 Configuration ................................................................................................................................ 26
4.4.1 Overview ..........................................................................................................................26
4.4.2 Creating a TwinCAT configuration ...................................................................................28
4.4.3 Downloading a TwinCAT configuration............................................................................28
4.4.4 Uploading a TwinCAT configuration ................................................................................30
4.4.5 Resources in the Bus Terminal Controller .......................................................................32
4.4.6 ADS connection via serial interface .................................................................................34
4.5 RS232 interface ............................................................................................................................ 36
4.5.1 TwinCAT Configuration - RS232 Interface.......................................................................36
4.6 K-bus ............................................................................................................................................ 38
4.7 Configuration software KS2000 .................................................................................................... 40
5 Programming ...........................................................................................................................................41
5.1 BCxx50 PLC features ................................................................................................................... 41
5.2 TwinCAT PLC ............................................................................................................................... 41
5.3 TwinCAT PLC - Error codes ......................................................................................................... 42
5.4 Remanent data ............................................................................................................................. 45
5.5 Allocated flags .............................................................................................................................. 46
5.6 Local process image in delivery state........................................................................................... 46
5.7 Mapping the Bus Terminals .......................................................................................................... 48
BC8050 und BC8150 3Version: 3.0.0
Table of contents
5.8 Local process image in the TwinCAT configuration...................................................................... 49
5.9 Creating a boot project ................................................................................................................. 50
5.10 Communication between TwinCAT and BX/BCxx50 .................................................................... 50
5.11 Up- and downloading of programs................................................................................................ 52
5.12 Libraries ........................................................................................................................................ 55
5.12.1 Libraries overview ............................................................................................................55
5.12.2 Seriell_Set data structure.................................................................................................56
5.12.3 TcBaseBCxx50 ................................................................................................................58
5.13 Program transfer........................................................................................................................... 61
5.13.1 Program transfer via the serial interface ..........................................................................61
5.14 Process image .............................................................................................................................. 62
5.14.1 Modbus Process Image ...................................................................................................62
5.14.2 KS8000 Process Image ...................................................................................................62
6 RS232 - Interface .....................................................................................................................................64
6.1 Protocol......................................................................................................................................... 64
6.1.1 Modbus ............................................................................................................................64
6.1.2 Protocol Overview............................................................................................................74
6.1.3 KS8000 protocol ..............................................................................................................74
6.2 Introduction to the system............................................................................................................. 77
6.2.1 Overview of the physical structure of RS232 ...................................................................77
6.2.2 Topology of the physical RS232 structure .......................................................................78
7 Error handling and diagnosis.................................................................................................................79
7.1 Diagnostics ................................................................................................................................... 79
7.2 Diagnostic LEDs ........................................................................................................................... 80
8 Appendix ..................................................................................................................................................82
8.1 First steps with the BC8150.......................................................................................................... 82
8.2 Switching between controllers ...................................................................................................... 82
8.3 Example programs for serial communication................................................................................ 84
8.4 Firmware Update .......................................................................................................................... 85
8.5 General operating conditions........................................................................................................ 87
8.6 Test standards for device testing.................................................................................................. 90
8.7 Bibliography .................................................................................................................................. 90
8.8 List of Abbreviations ..................................................................................................................... 90
8.9 Support and Service ..................................................................................................................... 91
BC8050 und BC81504 Version: 3.0.0
Foreword
1 Foreword
1.1 Notes on the documentation
Intended audience
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 documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
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.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
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.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registered
trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or
registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
BC8050 und BC8150 5Version: 3.0.0
Foreword
1.2 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
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 & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
DANGER
WARNING
CAUTION
Attention
Note
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
life and health of persons.
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
health of persons.
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
persons.
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the environment or equipment.
Tip or pointer
This symbol indicates information that contributes to better understanding.
BC8050 und BC81506 Version: 3.0.0
Foreword
1.3 Documentation issue status
Version Comment
3.0.0 • Migration
2.0.0 • BC8050 added
1.1.1
1.1.0 • Notes to meet the UL requirements added.
1.0.1 • Minor routine corrections
1.0.0 • First public issue (only available in German)
BC8150 firmware
For updating your firmware you need a serial cable, the KS2000 configuration software, or the firmware
update program.
Document version BC8050 BC8150
Firmware version Hardware version Firmware version Hardware version
3.0.0 B0 04 B1 08
2.0.0 B0 00 B1 04
1.1.1 - - B0 00
1.1.0 - - B0 00
1.0.1 - - B0 00
1.0.0 - - B0 00
• ADS communication example added [}84]
The firmware and hardware versions (delivery state) can be found on the sticker on the underside of the Bus
Terminal Controller.
BC8050 und BC8150 7Version: 3.0.0
Product overview
2 Product overview
2.1 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 decentralized 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 255Bus 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.
Various versions cover the most important fieldbus systems:
• BC3150: PROFIBUS DP
• BC5150: CANopen
• BC5250: DeviceNet
• BC8050: RS485, various protocols
• BC8150: RS232, various protocols
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 interface (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.
BC8050 und BC81508 Version: 3.0.0
2.2 The principle of the Bus Terminal
Product overview
Fig.1: The principle of the Bus Terminal
2.3 The Beckhoff Bus Terminal system
Up to 256 Bus Terminals, with 1 to 16I/O channels per 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. Up to 255 Bus Terminals can be connected via the K-bus extension. For each
technical signal form, terminals are available with one, two, four or eight I/O channels, which can be mixed
as required. 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.
Decentralised 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 decentralised 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.
BC8050 und BC8150 9Version: 3.0.0
Product overview
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.
Mounting on standardized mounting rails
The installation is standardized thanks to the simple and space-saving mounting on a standardized mounting
rail (EN60715, 35mm) and the direct wiring of actuators and sensors, without cross connections between
the terminals. The consistent labelling scheme also contributes.
The small physical size and the great flexibility of the Bus Terminal system allow 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.
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 64Bus Terminals can be used in a terminal block, with optional K-bus extension for up to 256Bus
Terminals. 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.
BC8050 und BC815010 Version: 3.0.0
Product overview
The interfaces
A Bus Coupler has six different methods of connection. These interfaces are designed as plug connectors
and as spring-loaded terminals.
2.4 Technical data
2.4.1 Technical Data - BCxx50
Technical data BCxx5x
Processor 16bit micro-controller
Diagnostics LEDs 2 x power supply, 2 x K-Bus
Configuration and programming software TwinCAT PLC
Fieldbus interface BC8050 BC8150
Fieldbus RS485:
- KS8000 protocol
- ModbusRTU
- ModbusASCII
RS232
- Serial ADS
- KS8000 protocol
- ModbusRTU
- ModbusASCII
Interfaces
Serial interface COM1 (RS232 for configuration and programming, automatic baud rate
detection 9600/19200/38400 baud)
Terminal Bus (K-Bus) 64 (255 with K-bus extension)
BC8050 und BC8150 11Version: 3.0.0
Product overview
Technical data BC8050/BC8150
Digital peripheral signals 2040 inputs/outputs
Analog peripheral signals 1024 inputs/outputs
Configuration possibility via TwinCAT or the controller
Maximum fieldbus byte
depending on fieldbus
number
Maximum number of bytes -
2048bytes of input data, 2048bytes of output data
PLC
Bus connection D-sub,9-pin
Power supply (Us) 24VDC (-15% /+20%) Use a 4A fuse or an NEC Class2 power supply to
meet the UL requirements!
Input current (Us) 60mA + (total K-bus current)/4
Starting current approx. 2.5 x continuous current
K-bus current (5V) maximum 1000mA
Power contact voltage (Up) maximum 24V
Power contact current load
maximum 10A
DC
(Up)
Recomm. back-up fuse (Up) ≤10A
Dielectric strength 500V (power contact/supply voltage/fieldbus)
Weight approx. 100g
Dimensions (W x H x D) approx. 44mm x 100mm x 68mm
Permissible ambient
-25°C ... +60°C
temperature range during
operation
Permissible ambient
-40°C ... +85°C
temperature range during
storage
Relative humidity 95% no condensation
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Installation position variable
Protection class IP20
BC8050 und BC815012 Version: 3.0.0
2.4.2 Technical data - RS485
Product overview
Fig.2: BC8050
System data RS485 (BC8050)
Protocols • Address 1-39 serial ADS)*, KS8000 protocol (automatic recognition of
the protocol and the baud rate (9600, 19200, 38400 baud, fixed data
frame, 8 data bits, even parity, one stop bit)
• Address 40-59 ModbusRTU (fixed baud rate 1200, 2400, 4800, 9600,
19200, 38400, DEFAULT 9600 baud, 8 bit data, optionally even, odd, no
default no parity)
Number of I/O modules 32 (99 with repeater)
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 50 170
Segment length up to 1200m
Data transfer rate 1200 - 38400baud
Topology RS485 line
Transmission time depending on protocol and baud rate
)* only via the configuration interfaces, not via RS485.
BC8050 und BC8150 13Version: 3.0.0
Product overview
2.4.3 Technical Data - RS232
Fig.3: BC8150
System data RS232 (BC8150)
Protocols • Address 1-39 serial ADS, KS8000 protocol (automatic recognition of the
protocol and the baud rate (9600, 19200, 38400 baud, fixed data frame, 8
data bits, even parity, one stop bit)
• Address 40-59 ModbusRTU (fixed baud rate 1200, 2400, 4800, 9600,
19200, 38400, DEFAULT 9600 baud, 8 bit data, optionally even, odd, no
default no parity)
Number of I/O modules 1
Number of I/O points depending on controller
Data transfer medium shielded copper cable, 3 x 0.25 mm²
Segment length up to 15m
Data transfer rate 1200 - 38400baud
Topology RS232 peer to peer
Transmission time depending on protocol and baud rate
BC8050 und BC815014 Version: 3.0.0
Product overview
2.4.4 Technical Data - PLC
PLC data BCxx5x
Programmability via serial programming interface or via the fieldbus
Program memory 48kbyte
Source code memory 128kbyte
Data memory 32kbyte
Remanent flags 2kbyte
PLC cycle time Approx. 3.0ms for 1000 IL commands (without I/O cycle)
Programming languages IEC 6-1131-3 (IL, LD, FBD, ST, SFC)
Runtime 1 SPS Task
Online Change Yes
Up/Down Load Code Yes/Yes
BC8050 und BC8150 15Version: 3.0.0
Mounting and wiring
3 Mounting and wiring
3.1 Mounting
3.1.1 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.4: BCxx50
The total width of the fieldbus station is the width of the Bus Coupler/Bus TerminalController plus the width
of the Bus Terminals being used (incl. KL9010 bus end terminal). Depending on design, the Bus Terminals
are 12mm or24mm wide. The height is 100mm.
The BCxx50 series Bus TerminalControllers are 68mm deep.
BC8050 und BC815016 Version: 3.0.0
Mounting and wiring
3.1.2 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.
Fig.5: Release the locking mechanism by pulling the orange tab
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 cannot be made by pushing the housings together on the mounting rail. When
correctly assembled, no significant gap can be seen between the attached housings.
Fig.6: Power contact on the left
Bus Terminals should only be pulled or plugged in switched-off state.
Insertion and removal of Bus Terminals is only permitted when switched off. The electron-
Attention
ics 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 safely and permanently.
BC8050 und BC8150 17Version: 3.0.0
Mounting and wiring
3.2 Wiring
3.2.1 Potential groups, insulation testing and PE
Potential groups
A Beckhoff Bus Terminal block usually has 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 electrically
isolated 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.
Fig.7: Potential groups of a Bus Terminal block
Insulation testing
The connection between Bus Coupler/ Bus Terminal Controller and Bus Terminals is realized automatically
by latching the components. 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 used for supplying the power contacts.
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 125A.
BC8050 und BC815018 Version: 3.0.0
Mounting and wiring
Fig.8: Power contact on the left
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 supply line at the Bus Coupler / Bus Terminal Controller must be disconnected for an
insulation test. 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 power contact with the label PE must not be used for other potentials.
3.2.2 Power supply
Risk of injury through electric shock and damage to the device!
Bring the Bus Terminals system into a safe, de-energized state
DANGER
Supply of Bus Terminal Controller and Bus Terminals (Us)
The Bus Terminal Controller requires a supply voltage of 24 VDC.
The connection is made by means of the upper spring-loaded terminals labelled 24V and 0V. This supply
voltage is used for the electronic components of the Bus Coupler/Bus Terminal Controllers and (via the Kbus) the electronic components of the Bus Terminals. It is galvanically separated from the field level voltage.
before starting mounting, disassembly or wiring of the components!
BC8050 und BC8150 19Version: 3.0.0
Mounting and wiring
Fig.9: Terminal points for the Bus Terminal Controller supply
Fig.10: UL identification
Note the UL requirements for the power supply.
To comply with the UL requirements, the 24VDC supply voltage for Us must originate
DANGER
• from an isolated source protected by a fuse of max. 4A (according to UL248) or
• from a voltage supply complying with NECclass2.
An NECclass2 voltage source must not be connected in series or parallel with another
NECclass2 corresponding voltage source!
No unlimited voltage sources!
To comply with the UL requirements, Us must not be connected with unlimited voltage
DANGER
sources.
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 0.08mm2 and 2,5mm2.
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 10A for long periods. The current carrying capacity between two spring-loaded terminals is identical
to that of the connecting wires.
BC8050 und BC815020 Version: 3.0.0
Mounting and wiring
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 cannot 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.
3.2.3 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 identifier
KS2000-Z2).
Fig.11: Programming cable KS2000-Z2
KS2000-Z2
The programming cable offers the option of programming the BCxx50 via the serial interface.
Do not interrupt the ground connection for the supply voltage
When the programming cable (between BCxx50 and PC) is connected, the ground connec-
Attention
tion of the Bus Terminal controller must not be interrupted or disconnected, since this may
destroy the programming cable.
BC8050 und BC8150 21Version: 3.0.0
Mounting and wiring
3.2.4 RS232 Connection
Nine-pin D sub
The cable is connected via a 9-pin D-Sub connector on the left side of the Bus Terminal Controller.
A three-core cable with shield should be used, with the shield being connected to the D-Sub connector
casing.
Pin assignment of the RS232 D-Sub socket
Fig.12: RS232 pin assignment
Cable
The cable must be crossed type. GND is connected 1:1. Only use assigned and described pins.
Fig.13: Three-core cable with shield, crossed
BC8050 und BC815022 Version: 3.0.0
Mounting and wiring
3.2.5 RS485 connection
Nine-pin D sub
The cable is connected via a 9-pin D-Sub connector on the left side of the Bus Terminal Controller.
A two-core cable with shielding should be used. The shielding should be connected to signal ground (GND).
Pin assignment of the RS485 D-sub socket
Fig.14: RS485 pin assignment
Cable
The BC8050 can establish connections to several devices; the maximum permitted cable length is 1200m.
Fig.15: Two-core cable with shield
BC8050 und BC8150 23Version: 3.0.0
Parameterization and Commissioning
4 Parameterization and Commissioning
4.1 Start-up behavior of the Bus Terminal Controller
When the Bus Terminal Controller is switched on it checks its state, configures the K-bus, creates a
configuration list based on the connected Bus Terminals and starts its local PLC.
The I/O LEDs flash when the Bus Terminal Controller starts up. If the system is in an error-free state, the I/O
LEDs should stop flashing after approx. 2-3 seconds. In the event of a fault the error type determines which
LED flashes (see chapter Diagnostic LEDs).
Fig.16: Start-up behavior of the Bus Terminal Controller
BC8050 und BC815024 Version: 3.0.0
Parameterization and Commissioning
4.2 Setting the Address
The address must be set via the two rotary selection switches. The default setting is 11.
The BC8150 Bus Terminal Controller supports different protocols.
Address 1 to 39
Automatic recognition of the following protocols
• Serial ADS, automatic baud rate detection, default 38400 baud, fixed data frame (8,e,1)
• KS8000 protocol, automatic baud rate detection, default 38400 baud, fixed data frame (8,e,1)
• KS2000 protocol, automatic baud rate detection, default 38400 baud, fixed data frame (8,e,1)
• ModbusASCII protocol, automatic baud rate detection, default 38400 baud, fixed data frame (8,e,1)
• TwinCAT PLC, protocol automatic baud rate detection default 38400 baud, fixed data frame (8,e,1)
Address 40 to 59
• ModbusRTU, configurable baud rate, default 9600, configurable data frame default 8,n,1
Changing the address
The switches can be set to the required position using a screwdriver. Ensure that the switches engage
correctly. The lower switch is the ten-multiplier, the upper switch is the one-multiplier. The address change
becomes active immediately.
Example
You want to set address 34:
• Lower rotary selection switch Sx11: 3
• Upper rotary selection switch Sx10:4
Fig.17: Setting the node ID
Special functions using the address switch
In addition, the address switch can be used for following functions. To this end the associated address has to
be set (as long as the coupler is switched off), only the end terminal may be connected (KL9010), and the
coupler must then be connected to the supply voltage.
Address 99: Factory setting
Address 98: Delete boot project
Address 97: Delete TwinCAT configuration
BC8050 und BC8150 25Version: 3.0.0
Parameterization and Commissioning
4.3 Baud rate
The Bus Coupler features automatic baud rate detection. When the supply voltage is switched on, the Bus
Coupler searches for the current baud rate and stores it as long as the supply voltage is present.
Restarts the bus coupler for automatic baud rate detection
If the master baud rate is changed, the Bus Coupler has to be switched off and on again in
Note
Linear extension of RS 232
Baud rate in kbit/sec 9,6 19,2 38,4
Permissible cable length in m 15 15 15
order to restart automatic baud rate detection.
4.4 Configuration
4.4.1 Overview
Configuration types
The Bus Terminal controllers of the BCxx50, BCxx20 and BXxx00 series can be configured in two different
ways: DEFAULT CONFIG or TwinCAT CONFIG.
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 process image depends on the connected terminals!
The process image changes when a terminal is added or removed!
CAUTION
The data of the fieldbus slaves interface are referred to as PLC variables. The PLC variables have
addresses from %QB1000 and %IB1000
The DEFAULT CONFIG (without PLC program) can also be used for writing and testing of the Connected
Bus Terminals. To this end, the Bus Terminal Controller must be scanned in the System Manager, and
FreeRun mode must be enabled (to use this function, no PLC program may be active on the Bus Terminal
Controller).
TWINCAT-CONFIG
In the TwinCAT CONFIG the Bus Terminals and PLC variables can be freely linked as required (TwinCAT
System Manager file required). The configuration is transferred to the coupler via the System Manager
andADS.
The following is required for the TwinCAT configuration (TC file):
• Via the fieldbus (PROFIBUS, CANopen, Ethernet)
PROFIBUS: (BC3150, BX3100)
◦ PC with FC310x from version 2.0 and TwinCAT 2.9 build 1000
◦ BX3100 with CIF60 or CP5412
BC8050 und BC815026 Version: 3.0.0
Parameterization and Commissioning
◦ TwinCAT 2.9 build 946
(NOTE: with PROFIBUS cards from Hilscher only one ADS communication is permitted, i.e.
either System Manager or PLC Control)
CANopen: (BC5150, BX5100)
◦ PC with FC510x from version 1.76 TwinCAT build 1030
DeviceNet: (BC5250, BX5200)
◦ on request
Ethernet: (BC9050, BC9020, BC9120, BX9000)
◦ PC with TwinCAT 2.10 build 1322
• Via the serial ADS TwinCAT 2.9 build 1010
◦ BX3100 version 1.00
◦ BX5100 version 1.00
◦ BX5200 version 1.10
◦ BX8000 version 1.00
◦ BC3150, BC5150, BC5250, BC9050, BC9020, BC9120 from firmware B0
◦ For BC8150 from TwinCAT 2.10 build 1243
BCxx50 and BXxx00 can be parameterized via the System Manager of the TwinCAT program.
• Variable I/O mapping
• Type-specific PROFIBUS data (BC3150 and BX3100 only)
• RTC (real-time clock) (BX series only)
• SSB (Smart System Bus) (BX series only)
• PLC settings
• K-Bus settings
The configuration can be transferred to the BCxx50 or BXxx00 via fieldbus ADS protocol or serial ADS
protocol.
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 to PLC)
• K-bus fieldbus (only for BX controllers)
• Support for TwinSAFE terminals (only BX controllers from firmware 1.17)
In addition, the TwinCAT configuration can be used to parameterize special behavior, 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.
Work steps
1. Setting the fieldbus address
2. Open the System Manager and create a TC file
3. Configure fieldbus data in the TC file
4. Save the TC file
5. Opening a new system manager, creating a PC file and reading in saved TX file
6. Creating a link to a PLC task
7. Saving the configuration
8. Starting the TwinCAT system
9. Open the TC file in the System Manager, complete the configuration and transfer it to the BCxx50,
BCxx20 or BXxx00
10. Transfer the program to BCxx50, BCxx20 or BXxx00
11. Creating a boot project
BC8050 und BC8150 27Version: 3.0.0
Parameterization and Commissioning
4.4.2 Creating a TwinCAT configuration
In order to configure a Bus Terminal Controller of the BCxx50, BCxx20 or BXxx00 series, create a BX file in
the System Manager. To simplify matters, files for the basic units have already been prepared. Open the
corresponding Bus Terminal Controller with New from Template.
Fig.18: Creating a TwinCAT configuration
Select the corresponding Bus Terminal Controller.
Fig.19: Selecting the Bus Terminal Controller
All Bus Terminal Controller components are now available:
• Fieldbus interface
• K-bus interface [}38]
• PLC Program
• SSB (only Bus Terminal Controllers of the BX series)
Please refer to the relevant chapter for device configuration.
4.4.3 Downloading a TwinCAT configuration
The TwinCAT configuration is loaded into the Bus Terminal Controller via ADS protocol.
Serial ADS protocol
(all Bus Terminal Controllers of the BXxx00 and BCxx50 series)
Enter the serial ADS connection, as described in the chapter Serial ADS [}34].
BC8050 und BC815028 Version: 3.0.0
Loading...