Documentation
BK3xx0
Bus Coupler for PROFIBUS-DP
Version:
Date:
4.3.0
2019-04-03
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Product overview Bus Couplers for PROFIBUS DP..........................................................................5
1.2 Notes on the documentation..............................................................................................................5
1.3 Safety instructions .............................................................................................................................7
1.4 Documentation issue status ..............................................................................................................8
2 Product overview.......................................................................................................................................9
2.1 BK30x0, BK3100, BK3110, BK3120, LC3100 - Technical data ........................................................9
2.2 BK3150 - Technical data .................................................................................................................11
2.3 BK35x0 - Technical data (optical fibers)..........................................................................................13
2.4 The Beckhoff Bus Terminal system.................................................................................................14
2.5 PROFIBUS introduction...................................................................................................................15
2.5.1 PROFIBUS DP ................................................................................................................ 15
2.5.2 PROFIBUS DPV1 ............................................................................................................ 17
3 Mounting and wiring................................................................................................................................18
3.1 Instructions for ESD protection........................................................................................................18
3.2 Dimensions......................................................................................................................................18
3.3 Mounting..........................................................................................................................................19
3.4 Connection ......................................................................................................................................21
3.4.1 Connection system .......................................................................................................... 21
3.4.2 Wiring............................................................................................................................... 22
3.4.3 Potential groups, insulation testing and PE ..................................................................... 24
3.4.4 Power supply ................................................................................................................... 26
3.4.5 PROFIBUS cabling .......................................................................................................... 29
3.5 ATEX ...............................................................................................................................................33
3.5.1 ATEX - Special conditions (standard temperature range) ............................................... 33
3.5.2 ATEX - Special conditions (extended temperature range) .............................................. 34
3.5.3 ATEX Documentation ...................................................................................................... 34
4 Parameterization and commissioning...................................................................................................35
4.1 Start-up behaviour of the Bus Coupler ............................................................................................35
4.2 The Bus Coupler's UserPrmData ....................................................................................................35
4.3 Technical data - overview................................................................................................................38
4.4 Configuration ...................................................................................................................................38
4.4.1 Configuration - CfgData ................................................................................................... 38
4.4.2 Configuration of the Coupler Modules ............................................................................. 38
4.4.3 Configuration of Complex Modules.................................................................................. 39
4.4.4 Configuration of Digital Modules...................................................................................... 41
4.4.5 GSD Files ........................................................................................................................ 41
4.4.6 KS2000 - Introduction ...................................................................................................... 42
4.4.7 Configuration via TwinCAT .............................................................................................. 43
4.4.8 Configuration with Siemens S7 controller........................................................................ 46
5 PROFIBUS DP communication...............................................................................................................51
5.1 DataExchange - cyclic data exchange ............................................................................................51
5.1.1 Process data, process image .......................................................................................... 51
BK3xx0 3Version: 4.3.0
Table of contents
5.1.2 K-bus Cycle ..................................................................................................................... 53
5.2 DPV1 - acyclic data transfer ............................................................................................................56
5.2.1 DPV1 Interface ................................................................................................................ 56
5.2.2 Assignment of the DPV1 slot number.............................................................................. 57
5.2.3 DPV1 at the coupler......................................................................................................... 58
6 Diagnostics and error handling..............................................................................................................61
6.1 LEDs................................................................................................................................................61
6.2 DP diagnostics.................................................................................................................................64
6.2.1 DP Diagnostic Data (DiagData) ....................................................................................... 64
6.2.2 Errors during DP Start-up ................................................................................................ 67
6.2.3 Reaction to PROFIBUS Error .......................................................................................... 69
6.3 K-bus diagnosis ...............................................................................................................................69
6.3.1 K-bus interruption ............................................................................................................ 69
6.3.2 Terminal Diagnostics ....................................................................................................... 70
7 Extended functions .................................................................................................................................72
7.1 2-byte PLC Interface........................................................................................................................72
7.2 Word Alignment ...............................................................................................................................72
7.3 Deactivating the CfgData Check .....................................................................................................73
7.4 Multi-Configuration Mode ................................................................................................................73
7.5 Changing the Size of the Process Data...........................................................................................76
7.6 Bus Coupler versions in multi-configuration mode ..........................................................................77
8 Appendix ..................................................................................................................................................84
8.1 General operating conditions...........................................................................................................84
8.2 Approvals.........................................................................................................................................85
8.3 Bibliography.....................................................................................................................................86
8.4 List of Abbreviations ........................................................................................................................86
8.5 Support and Service ........................................................................................................................88
BK3xx04 Version: 4.3.0
Foreword
1 Foreword
1.1 Product overview Bus Couplers for PROFIBUS DP
BK3010, BK3110, BK3120, BK3150 [}9], BK3500, BK3520 [}13] and LC3100 [}9]
1.2 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®, EtherCATP®, SafetyoverEtherCAT®, 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.
BK3xx0 5Version: 4.3.0
Foreword
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.
BK3xx06 Version: 4.3.0
Foreword
1.3 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 instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.
BK3xx0 7Version: 4.3.0
Foreword
1.4 Documentation issue status
Version Stand
4.3.0 • Design of the safety instructions adapted to IEC 82079-1
• Technical data updated
• Chapter Instructions for ESD protection added
• ATEX added
• Update structure
4.2.0 • Mounting and wiring updated
4.1.0 • PROFIBUS-Connection corrected
4.0.0 • Migration
3.5.1 • Notes regarding compliance with UL requirements added.
3.5 • BK3150 with firmware version B0 added
3.03 • Corrections in English translation
3.02 • GSD files updated for BK3110, BK3120, BK3520
3.01 • Configuration examples for operation under Siemens S7 expanded.
3.0 • For BK3010 with firmware version B9
• For BK3110 with firmware version B9
• For BK3120 with firmware version B9
• For BK3500 with firmware version B9
• For BK3520 with firmware version B9
• For LC3100 with firmware version B9
BK3xx08 Version: 4.3.0
Product overview
2 Product overview
2.1 BK30x0, BK3100, BK3110, BK3120, LC3100 - Technical data
Fig.1: BK3120 and LC3100 - Bus Couplers for PROFIBUS DP
BK3xx0 9Version: 4.3.0
Product overview
Technical data
Type BK3000, BK3010 BK3100, BK3110 BK3120 LC3100
Number of Bus Terminals 64 64 (255 with K-bus exten-
Digital peripheral signals 512 inputs/outputs (BK3x00)
Analog peripheral signals 128 inputs/outputs (BK3x00) max. 64 inputs/outputs -
Configuration possibility Via the KS2000 configuration software or the controller
Max. number of bytes
(inputs and outputs)
Baud rate (automatic detection)
Bus connection 1 x D-sub plug, 9-pin with shielding spring-loaded terminals
Power supply 24VDC (-15 % /+20 %)
Input current 70mA + (total K-bus current)/4, 500mA max.
Starting current 2.5 x continuous current
Recommended fuse maximum 10A
K-bus current up to 1750mA (BK3x00)
Power contact voltage maximum 24 V
Power contact current
load
Electrical isolation Power contact / supply / fieldbus Power supply / fieldbus
Dielectric strength 500V (power contact/ supply/ fieldbus) 500 V (supply / fieldbus)
Weight approx. 170 g approx. 150 g approx. 170 g approx. 100 g
Permissible ambient temperature (operation)
Permissible ambient temperature (storage)
Permissible relative humidity
Vibration/shock resistance
EMC immunity / emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP20
Installation position variable
Approvals
256 inputs/outputs (BK3x10)
BK3000: 244bytes BK3100:
BK3010: 32bytes BK3110: 32bytes
up to max. 1.5
Mbaud
(BK3x00)
70mA + (total K-bus current)/4, 200mA max.
(BK3x10)
500mA (BK3x10)
maximum 10A
0°C … +55°C -25°C … +60°C 0°C … +55°C
-25°C … +85°C
95% (no condensation)
conforms to EN 60068-2-6 / EN 60068-2-27
CE, ATEX [}33], cULus, GL CE, ATEX [}33], cULus,
64 bytes (DP and FMS operation)
128 bytes (DP operation
only)
up to max. 12 Mbaud
DC
sion)
max. 1020 inputs/outputs 256 inputs/outputs
128bytes 32bytes
70 mA + (total K bus current)/4, max. 500 mA
1750mA 500mA
GL, IECEx
64
70 mA + (total K bus current)/4, max. 200 mA
CE, ATEX [}33], cULus
BK3xx010 Version: 4.3.0
2.2 BK3150 - Technical data
Product overview
Fig.2: BK3150 - Bus Coupler for PROFIBUS DP
BK3xx0 11Version: 4.3.0
Product overview
Technical data BK3150
Type BK3150
Number of Bus Terminals 64 (255 with K-bus extension)
Digital peripheral signals 256 inputs/outputs (BK3x10)
Analog peripheral signals 128 inputs/outputs (BK3x00)
Configuration possibility Via the KS2000 configuration software or the
controller
Max. number of bytes
128 bytes (DP operation only)
(inputs and outputs)
Baud rate (automatic detection) up to max. 12 Mbaud
Bus connection 1 x D-sub plug, 9-pin with shielding
Power supply (Us) 24VDC (-15% /+20%) Use a 4A fuse or an NEC
Class2 power supply to meet the UL requirements!
Input current (Us) 70 mA + (total K bus current)/4, max. 320 mA
Starting current (Us) 2.5 x continuous current
K-bus current (5 V) up to hardware version 04: 1000mA
from hardware version 05: 1750mA
Power contact voltage (Up) maximum 24V
DC
Power contacts current load (Up) maximum 10A
Recommended backup fuse (Up) maximum 10A
Electrical isolation Power contact / supply / fieldbus
Dielectric strength 500V (power contact/ supply/ fieldbus)
Weight approx. 100 g
Permissible ambient temperature (operation) -25°C … +60°C
Permissible ambient temperature (storage) -25°C … +85°C
Permissible relative humidity 95% (no condensation)
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27
EMC immunity / emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP20
Installation position variable
Approvals
CE, ATEX [}33], cULus
BK3xx012 Version: 4.3.0
2.3 BK35x0 - Technical data (optical fibers)
Fig.3: BK3500 and BK3520 - Bus Couplers with optical fiber connection for PROFIBUS DP
Product overview
Technical data
Type BK3500 BK3520
Number of Bus Terminals 64 64 (255 with K-bus extension)
Digital peripheral signals max. 512 inputs/outputs max. 1020 inputs/outputs
Analog peripheral signals max. 64 inputs/outputs max. 64 inputs/outputs
Configuration possibility Via the KS2000 configuration software or the controller
Max. number of bytes
(inputs and outputs)
Baud rates up to max. 1.5Mbaud (manual setting) up to max. 12Mbaud (automatic detec-
Bus connection 1 x optical fiber with 2 HP Simplex con-
Power supply 24VDC (-15% /+20%)
Input current 70mA + (total K-bus current)/4, 500mA, 500mA max.
Starting current 2.5 x continuous current
Recommended fuse maximum 10A
K-bus power supply up to 1750mA
Power contact voltage maximum 24 V
Power contact current load maximum 10A
Electrical isolation Power contact / supply / fieldbus
Dielectric strength 500V (power contact/ supply/ fieldbus)
Weight approx. 170g approx. 170g
Permissible ambient temperature (operation) 0°C … +55°C
Permissible ambient temperature (storage) -25°C … +85°C
Permissible relative humidity 95% (no condensation)
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27
EMC immunity / emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP20
Installation position variable
Approvals
128bytes 128bytes
tion)
nectors
DC
CE, ATEX [}33], cULus
2 x optical fibers with 2 HP Simplex connectors each
BK3xx0 13Version: 4.3.0
Product overview
2.4 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.
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.
BK3xx014 Version: 4.3.0
Product overview
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.
The interfaces
A Bus Coupler has six different methods of connection. These interfaces are designed as plug connectors
and as spring-loaded terminals.
2.5 PROFIBUS introduction
2.5.1 PROFIBUS DP
In PROFIBUS DP systems a master (PLC, PC, etc.) usually communicates with many slaves (I/Os, drives,
etc.); only the master actively accesses the bus (by sending unsolicited telegrams), while a DP slave only
sends telegrams when requested by the master.
DP StartUp
Before the master and slave can cyclically exchange data, the parameter and configuration data is
transmitted from the master to the slaves during the DP StartUp phase. After the parameter and
configuration data has been sent, the master interrogates the slave's diagnostic data until the slave indicates
that it is ready for data exchange. Depending on the scope of the calculations the slave has to carry out as a
result of receiving parameter and configuration data, it may take several seconds before it is ready for data
exchange. For this reason the slave possesses the following states.
Parameter data
The parameter data is sent from the master to the slave in the SetPrmLock request telegram. The
SetPrmLock response telegram does not contain any data, and therefore consists of a single byte, the short
acknowledgement. The parameter data consists of DP parameters (e.g. the setting of the DP watchdog or
BK3xx0 15Version: 4.3.0
Product overview
checking the IdentNumber (unique to each DP device)), of DPV1-/DPV2 parameters and of applicationspecific parameters that only have to be transmitted once during the StartUp. If an error is found in the
parameter data, this is indicated in the diagnostic data, and the slave either remains in or enters the WAITPRM state.
Configuration data
The configuration data is sent from the master to the slave in the ChkCfg request telegram. The ChkCfg
response telegram does not contain any data, and therefore consists of a single byte, the short
acknowledgement. The configuration data describes the assignment of the DP modules to the cyclic I/O data
that is to be exchanged between the master and slave via the Data_Exchange telegram in the cyclic data
exchange phase. The sequence of the DP modules added to a slave in the DP configuration tool determines
the sequence of the associated I/O data in the Data_Exchange telegram.
Diagnostic data
The diagnostic data is requested by the master using a SlaveDiag request telegram without any data. The
slave replies with the diagnostic data in a SlaveDiag response telegram. The diagnostic data consists of the
standard DP diagnostics (e.g. the state of the slave, the IdentNumber) and of application-specific diagnostic
data.
Cyclic data exchange
At the core of the PROFIBUS DP protocol is the cyclic data exchange, during which the master exchanges I/
O data with each slave within a PROFIBUS DP cycle. This involves the master sending the outputs to each
slave with a DataExchange request telegram, while the slave replies with the inputs in a DataExchange
response telegram. This means that all the output and/or input data is transmitted in one telegram, in which
the DP configuration (the sequence of DP modules) specifies the assignment of the output and/or input data
to the slave's actual process data.
Diagnosis during cyclic data exchange
A slave can send a diagnostics signal to the master during cyclic data exchange. In this case, the slave sets
a flag in the DataExchange response telegram, whereby the master recognizes that there is new diagnostic
data in the slave. It then fetches that data in the SlaveDiag telegram. The diagnostic data is therefore not
available at the same time as the cyclic I/O data, but always delayed by at least one DP cycle.
Synchronisation with Sync and Freeze
The Sync and Freeze commands in the GlobalControl request telegram (broadcast telegram) allow the
master to synchronise the activation of the outputs (Sync) or the reading of the inputs (Freeze) in a number
of slaves. When the Sync command is used, the slaves are first switched into Sync mode (a process that is
acknowledged in the diagnostic data). The I/O data is then exchanged sequentially with the slaves in the
DataExchange telegram. Transmitting the Sync command in the GlobalControl telegram then has the effect
of causing the slaves to generate the most recently received outputs. In Freeze operation a Freeze
command is first sent in the GlobalControl telegram, in response to which all the slaves latch their
inputs.These are then fetched sequentially by the master in the DataExchange telegram.
States in the master
The master distinguishes between the CLEAR state (all outputs are set to the Fail_Safe value) and the
OPERATE state (all outputs have the process value). The Master is usually switched into the CLEAR mode
when, for instance, the PLC enters STOP.
Class 1 and Class 2 DP Masters
The Class 1 master refers to the controller that carries out cyclic I/O data exchange with the slaves, while a
Class 2 master is a B&B device that generally only has read access to the slaves' I/O data.
BK3xx016 Version: 4.3.0
Product overview
2.5.2 PROFIBUS DPV1
PROFIBUS DPV1 refers primarily to the read and write telegrams, with which data sets in the slave are
acyclically accessed. A distinction between a Class 1 (C1) and a Class 2 (C2) master is also made for DPV1.
The acyclic Class 1 or Class 2 connections differ in that the acyclic C1 connection is established with the DP
startup of the cyclic DP mode. Acyclic DPV1 C1 read and write telegrams can be sent from the master to the
slave from the state WAIT-CFG of the slave. In contrast, the C2 connection is established separately, usually
by a second C2 master. For example, a manufacturer-specific project configuration and diagnostics tool can
access the slave data independent of the cyclic DP connection.
When two masters are used, however, is must always be borne in mind that these share bus access (a
token is exchanged), so that time relationships are less favorable than in the case of a single master system.
BK3xx0 17Version: 4.3.0
Mounting and wiring
3 Mounting and wiring
3.1 Instructions for ESD protection
NOTE
Destruction of the devices by electrostatic discharge possible!
The devices contain components at risk from electrostatic discharge caused by improper handling.
• Please ensure you are electrostatically discharged and avoid touching the contacts of the device directly.
• Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).
• Surroundings (working place, packaging and personnel) should by grounded probably, when handling
with the devices.
• Each assembly must be terminated at the right hand end with an EL9011 or EL9012 bus end cap, to ensure the protection class and ESD protection.
Fig.4: Spring contacts of the Beckhoff I/O components
3.2 Dimensions
The BeckhoffBus 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 dimensions of the Bus Couplers are independent of the fieldbus system.
BK3xx018 Version: 4.3.0
Mounting and wiring
Fig.5: Dimensions, using BK3120 and LC3100 as examples
The total width in practical cases is composed of the width of the Bus Coupler with the KL9010 Bus End
Terminal and the width of the Bus Terminals in use. Depending on function, the Bus Terminals are 12mm or
24mm wide. The front wiring increases the total height of 68mm by about 5mm to 10mm, depending on
the wire thickness.
Mechanical
data
Material polycarbonate, polyamide (PA 6.6)
Dimensions
(W x H x D)
Mounting on 35 mm mounting rail according to EN60715 with locking mechanism
Stackable by double groove-tongue connection
Labelling Standard terminal block labelling and text slide (8 mm x 47 mm, not BK3150)
BK30x0, BK35x0, KL3110,
BK3120
50mm x 100mm x 68mm 44mm x 100mm x 68mm 21mm x 100mm x 68mm
BK3150 LC3100
3.3 Mounting
The Bus Coupler and all the Bus Terminals can be clipped, with a light press, onto a 35mm 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.
BK3xx0 19Version: 4.3.0
Mounting and wiring
Fig.6: 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.7: Groove and tongue of the housings
NOTE
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 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.
BK3xx020 Version: 4.3.0
Mounting and wiring
3.4 Connection
3.4.1 Connection system
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
Overview
The Bus Terminal system offers different connection options for optimum adaptation to the respective
application:
• The terminals of ELxxxx and KLxxxx series with standard wiring include electronics and connection
level in a single enclosure.
• The terminals of ESxxxx and KSxxxx series feature a pluggable connection level and enable steady
wiring while replacing.
• The High Density Terminals (HD Terminals) include electronics and connection level in a single
enclosure and have advanced packaging density.
Standard wiring (ELxxxx / KLxxxx)
Fig.8: Standard wiring
The terminals of ELxxxx and KLxxxx series have been tried and tested for years.
They feature integrated screwless spring force technology for fast and simple assembly.
Pluggable wiring (ESxxxx / KSxxxx)
Fig.9: Pluggable wiring
The terminals of ESxxxx and KSxxxx series feature a pluggable connection level.
The assembly and wiring procedure is the same as for the ELxxxx and KLxxxx series.
The pluggable connection level enables the complete wiring to be removed as a plug connector from the top
of the housing for servicing.
The lower section can be removed from the terminal block by pulling the unlocking tab.
Insert the new component and plug in the connector with the wiring. This reduces the installation time and
eliminates the risk of wires being mixed up.
The familiar dimensions of the terminal only had to be changed slightly. The new connector adds about 3
mm. The maximum height of the terminal remains unchanged.
BK3xx0 21Version: 4.3.0
Mounting and wiring
A tab for strain relief of the cable simplifies assembly in many applications and prevents tangling of individual
connection wires when the connector is removed.
Conductor cross sections between 0.08mm2 and 2.5mm2 can continue to be used with the proven spring
force technology.
The overview and nomenclature of the product names for ESxxxx and KSxxxx series has been retained as
known from ELxxxx and KLxxxx series.
High Density Terminals (HD Terminals)
Fig.10: High Density Terminals
The Bus Terminals from these series with 16 terminal points are distinguished by a particularly compact
design, as the packaging density is twice as large as that of the standard 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.
Wiring HD Terminals
The High Density (HD) Terminals of the ELx8xx and KLx8xx series doesn't support pluggable
wiring.
Ultrasonically "bonded" (ultrasonically welded) conductors
Ultrasonically “bonded" conductors
It is also possible to connect the Standard and High Density Terminals with ultrasonically
"bonded" (ultrasonically welded) conductors. In this case, please note the tables concerning the
wire-size width below!
3.4.2 Wiring
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the Bus Terminals!
BK3xx022 Version: 4.3.0
Mounting and wiring
Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx
Fig.11: Connecting a cable on a terminal point
Up to eight terminal points enable the connection of solid or finely stranded cables to the Bus Terminal. The
terminal points are implemented in spring force technology. Connect the cables as follows:
1. Open a terminal point by pushing a screwdriver straight against the stop into the square opening
above the terminal point. Do not turn the screwdriver or move it alternately (don't toggle).
2. The wire can now be inserted into the round terminal opening without any force.
3. The terminal point closes automatically when the pressure is released, holding the wire securely and
permanently.
See the following table for the suitable wire size width.
Terminal housing ELxxxx, KLxxxx ESxxxx, KSxxxx
Wire size width (single core wires) 0.08 ... 2.5mm
Wire size width (fine-wire conductors) 0.08 ... 2.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm
2
2
2
0.08 ... 2.5mm
0,08 ... 2.5mm
0.14 ... 1.5mm
2
2
2
Wire stripping length 8 ... 9mm 9 ... 10mm
High Density Terminals (HD Terminals [}22]) with 16 terminal points
The conductors of the HD Terminals are connected without tools for single-wire conductors using the direct
plug-in technique, i.e. after stripping the wire is simply plugged into the terminal point. The cables are
released, as usual, using the contact release with the aid of a screwdriver. See the following table for the
suitable wire size width.
Terminal housing High Density Housing
Wire size width (single core wires) 0.08 ... 1.5mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm
Wire size width (ultrasonically “bonded" conductors) only 1.5mm
2
2
2
2
Wire stripping length 8 ... 9mm
BK3xx0 23Version: 4.3.0
Mounting and wiring
3.4.3 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.12: 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.
BK3xx024 Version: 4.3.0
Mounting and wiring
Fig.13: 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.
BK3xx0 25Version: 4.3.0
Mounting and wiring
3.4.4 Power supply
Supply of Bus Coupler/Bus Terminal Controller and Bus Terminals (Us)
3.4.4.1 BKxx00, BKxx10, BKxx20 and LCxxxx
The Bus Couplers/Bus Terminal Controllers require an operating voltage of 24VDC.
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 and Bus Terminal Controllers and (via the
K-bus) the electronic components of the Bus Terminals. It is galvanically separated from the field level
voltage.
Fig.14: Power supply connections for BKxx00, BKxx10, BKxx20 and LCxxxx
BK3xx026 Version: 4.3.0
Mounting and wiring
3.4.4.2 BKxx50 and BKxx51
The Bus Couplers/Bus Terminal Controllers require an operating voltage of 24VDC. Use a 4A fuse or a
Class2 power supply to comply with the UL requirements.
The connection is made by means of the upper spring-loaded terminals labelled Us and GNDs. This supply
voltage is used for the electronic components of the Bus Coupler and Bus Terminal Controllers and (via the
K-bus) the electronic components of the Bus Terminals. It is galvanically separated from the field level
voltage.
Fig.15: Power supply connections for BKxx50 and BKxx51
Fig.16: UL identification
DANGER
Note the UL requirements for the power supply.
To comply with the UL requirements, the 24VDC supply voltage for Us must originate
• from an isolated source protected by a fuse of max. 4A (according to UL248) or
• from a voltage supply complying with NEC class 2.
An NEC class 2 voltage source must not be connected in series or parallel with another NEC class 2
voltage source!
DANGER
No unlimited voltage sources!
To comply with the UL requirements, Us must not be connected with unlimited voltage sources.
BK3xx0 27Version: 4.3.0
Mounting and wiring
3.4.4.3 Configuration and Programming Interface
The standard Bus Couplers have an RS232 interface at the bottom of the front face. The miniature plug
connector can be connected to a PC using a connecting cable and the KS2000 configuration software. The
interface permits the Bus Terminals to be configured, for example adjusting the amplification factors of the
analog channels. The interface can also be used to change the assignments of the bus terminal data to the
process image in the Bus Coupler. The functionality of the configuration interface can also be reached via
the fieldbus using string communication facility.
3.4.4.4 Electrical isolation
The Bus Couplers/ Bus Terminal Controllers operate with three independent potential groups. The supply
voltage feeds the K-bus electronics and the K-bus itself. The supply voltage is also used to generate the
operating voltage for the fieldbus interface.
Note: All the Bus Terminals are electrically isolated from the K-bus. The K-bus is thus electrically isolated
from everything else.
Fig.17: Potential connection diagram of an EKxxxx
3.4.4.5 Power contacts
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 power supply for the power contacts
has no connection to the power supply for the Bus Couplers/ Bus Terminal Controllers.
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 10A for long periods. The current carrying capacity between two spring-loaded terminals is identical
to that of the connecting wires.
Power contacts
Three spring contacts of the power contact connections can be found on the right of the Bus Coupler/ Bus
Terminal Controller. 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 & groove design of the top and bottom of the Bus Coupler/ Bus Terminal
Controller and Bus Terminals enables secure fitting of the power contacts.
BK3xx028 Version: 4.3.0
3.4.5 PROFIBUS cabling
3.4.5.1 PROFIBUS Connection
M12 round connector
Mounting and wiring
The M12 socket is inverse-coded and has five pins. Pin 1 transfers 5V
pin 3 transfers GND for the active
DC,
termination resistor. These must never be misused for other functions, as this can lead to destruction of the
device.
Pins 2 and 4 transfer the PROFIBUS signals. These must never be swapped over, as this will prevent
communication. Pin 5 transfers the shield, which is capacitively connected to the base of the Fieldbus Box.
Pin assignment M12 socket (-B310)
Fig.18: Pin assignment M12 socket (-B310)
Pin assignment M12 socket/plug connector (-B318)
Fig.19: Pin assignment M12 socket/plug connector (-B318)
Nine-pin D-Sub
Pin 6 transfers 5V
pin 5 transfers GND for the active termination resistor. These must never be misused
DC,
for other functions, as this can lead to destruction of the device.
Pins 3 and 8 transfer the PROFIBUS signals. These must never be swapped over, as this will prevent
communication.
Pin assignment of the PROFIBUS D-sub socket
Fig.20: Pin assignment of the PROFIBUS D-sub socket
PROFIBUS wire colors
PROFIBUS line M12 D-Sub
B red Pin 4 Pin 3
A green Pin 2 Pin 8
BK3xx0 29Version: 4.3.0
Mounting and wiring
Connection of the FieldbusBoxmodules
The FieldbusBoxmodules are connected either directly or via a T-piece (or Y-piece).
The B318 series features a socket and a plug connector, i.e. this is where the PROFIBUS is routed in the
module. The supply voltage (+5VDC) for the termination resistor is only present at the socket. The termination
resistor ZS1000-1610 is only available as a plug connector.
The incoming PROFIBUS line should always end with a socket.
Fig.21: Pin assignment socket/plug connector Fieldbus Box modules
Two T-pieces are available:
• ZS1031-2600 with +5VDC transfer for supplying the termination resistor
• ZS1031-2610 without +5VDC transfer
3.4.5.2 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).
BK3xx030 Version: 4.3.0
Mounting and wiring
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 100 m at 12 Mbit/s
200 m at 1500 Kbit/s, up to 1.2 km at 93.75 kbit/s
Max. bus length with repeater 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.
Transmission speed (adjustable in
steps)
Connector 9-pin D-Sub connector for IP20
Cabling for PROFIBUS DP and PROFIBUS FMS
Note the special requirements on the data cable for baud rates greater than 1.5Mbaud. The correct cable is
a basic requirement for correct operation of the bus system. If a simple 1.5Mbaud 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 (<93.75kbaud)
corrects this faulty behavior.
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
If reducing the baud rate does not correct the error, then in many cases this can indicate a wiring fault. The
two data lines may be crossed over at one or more connectors, or the termination resistors may not be
active, or they may be active at the wrong locations.
Recommended cables
Installation is made a great deal more straightforward if preassembled cables from 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 termination
resistors and T-pieces. Connectors and cables for field assembly are nevertheless also available.
Fig.22: PROFIBUS cable assignment
Termination resistors
In systems with more than two stations all devices are wired in parallel. The PROFIBUS cable must
be terminated with resistances at both ends, in order to avoid reflections and associated transfer
problems.
Distances
The bus cable is specified in EN 50170. This yields the following lengths for a bus segment.
BK3xx0 31Version: 4.3.0
Mounting and wiring
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.de).
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).
BK3xx032 Version: 4.3.0
Mounting and wiring
3.5 ATEX
3.5.1 ATEX - Special conditions (standard temperature range)
WARNING
Observe the special conditions for the intended use of Beckhoff fieldbus components with
standard temperature range in potentially explosive areas (directive 94/9/EU)!
• The certified components are to be installed in a suitable housing that guarantees a protection class of at
least IP54 in accordance with EN 60529! The environmental conditions during use are thereby to be
taken into account!
• If the temperatures during rated operation are higher than 70°C at the feed-in points of cables, lines or
pipes, or higher than 80°C at the wire branching points, then cables must be selected whose temperature data correspond to the actual measured temperature values!
• Observe the permissible ambient temperature range of 0 to 55°C for the use of Beckhoff fieldbus components standard temperature range in potentially explosive areas!
• Measures must be taken to protect against the rated operating voltage being exceeded by more than
40% due to short-term interference voltages!
• The individual terminals may only be unplugged or removed from the Bus Terminal system if the supply
voltage has been switched off or if a non-explosive atmosphere is ensured!
• The connections of the certified components may only be connected or disconnected if the supply voltage has been switched off or if a non-explosive atmosphere is ensured!
• The fuses of the KL92xx/EL92xx power feed terminals may only be exchanged if the supply voltage has
been switched off or if a non-explosive atmosphere is ensured!
• Address selectors and ID switches may only be adjusted if the supply voltage has been switched off or if
a non-explosive atmosphere is ensured!
Standards
The fundamental health and safety requirements are fulfilled by compliance with the following standards:
• EN 60079-0:2012+A11:2013
• EN 60079-15:2010
Marking
The Beckhoff fieldbus components with standard temperature range certified for potentially explosive areas
bear one of the following markings:
II 3GKEMA 10ATEX0075 X Ex nA IIC T4 GcTa: 0…55°C
or
II 3GKEMA 10ATEX0075 X Ex nC IIC T4 GcTa: 0…55°C
BK3xx0 33Version: 4.3.0
Mounting and wiring
3.5.2 ATEX - Special conditions (extended temperature range)
WARNING
Observe the special conditions for the intended use of Beckhoff fieldbus components with
extended temperature range (ET) in potentially explosive areas (directive 94/9/EU)!
• The certified components are to be installed in a suitable housing that guarantees a protection class of at
least IP54 in accordance with EN 60529! The environmental conditions during use are thereby to be
taken into account!
• If the temperatures during rated operation are higher than 70°C at the feed-in points of cables, lines or
pipes, or higher than 80°C at the wire branching points, then cables must be selected whose temperature data correspond to the actual measured temperature values!
• Observe the permissible ambient temperature range of -25 to 60°C for the use of Beckhoff fieldbus components with extended temperature range (ET) in potentially explosive areas!
• Measures must be taken to protect against the rated operating voltage being exceeded by more than
40% due to short-term interference voltages!
• The individual terminals may only be unplugged or removed from the Bus Terminal system if the supply
voltage has been switched off or if a non-explosive atmosphere is ensured!
• The connections of the certified components may only be connected or disconnected if the supply voltage has been switched off or if a non-explosive atmosphere is ensured!
• The fuses of the KL92xx/EL92xx power feed terminals may only be exchanged if the supply voltage has
been switched off or if a non-explosive atmosphere is ensured!
• Address selectors and ID switches may only be adjusted if the supply voltage has been switched off or if
a non-explosive atmosphere is ensured!
Standards
The fundamental health and safety requirements are fulfilled by compliance with the following standards:
• EN 60079-0:2012+A11:2013
• EN 60079-15:2010
Marking
The Beckhoff fieldbus components with extended temperature range (ET) certified for potentially explosive
areas bear the following marking:
II 3GKEMA 10ATEX0075 X Ex nA IIC T4 GcTa: -25…60°C
or
II 3GKEMA 10ATEX0075 X Ex nC IIC T4 GcTa: -25…60°C
3.5.3 ATEX Documentation
Notes about operation of the Beckhoff terminal systems in potentially explosive areas (ATEX)
Pay also attention to the continuative documentation
Notes about operation of the Beckhoff terminal systems in potentially explosive areas (ATEX)
that is available in the download area of the Beckhoff homepage http:\\www.beckhoff.com!
BK3xx034 Version: 4.3.0
Parameterization and commissioning
4 Parameterization and commissioning
4.1 Start-up behaviour of the Bus Coupler
Immediately after being switched on, the Bus Coupler checks, in the course of a self-test, all the functions of
its components and the communication on the K-bus/E-bus. The red I/O LED blinks while this is happening.
After completion of the self-test, the Bus Coupler starts to test the attached Bus Terminals (the "Bus
Terminal Test"), and reads in the configuration. The Bus Terminal configuration is used to generate an
internal structure list, which is not accessible from outside. In case of an error, the Bus Coupler enters the
Stop state. Once the start-up has completed without error, the Bus Coupler enters the fieldbus start state.
Fig.23: Start-up behaviour of the Bus Coupler
The Bus Coupler can be made to enter the normal operating state by switching it on again once the fault has
been rectified.
4.2 The Bus Coupler's UserPrmData
The following settings can be made in the Bus Coupler's UserPrmData. So that a more easily understood
GSD file [}41] is obtained in 90% of applications, some of the settings are only contained in text form in the
Extended GSD file [}41], and these are indicated in the last column by Extended. The standard settings are
contained both in the standard and the extended GSD file [}41].
BK3xx0 35Version: 4.3.0
Parameterization and commissioning
Byte Bit Value Description GSD file
0 7 0
1
1 0 0
1
MSAC_C1 connection is not active (default) Standard
bin
MSAC_C1 connection is active (see DPV1 [}56])
bin
CfgData checking is active (default) Extended
bin
CfgData checking deactivated (see Deactivating the CfgData checking
bin
[}73])
2 3 0
1
3 3 0
1
3 4 0
1
Diagnostic data is transferred in a form compatible with the BK3100 Extended
bin
Diagnostic data is transferred in a form compatible with DPV1 (default)
bin
K-bus cycle counter is not active (default) Extended
bin
K-bus cycle counter is active (see K-bus cycle [}53])
bin
Multi-configuration mode is not active (default) Extended
bin
Multi-configuration mode is active (see Multi-configuration mode
bin
[}73])
3 5 0
1
3 6 0
Dummy output byte not active (default) Extended
bin
Dummy output byte is active (see K-bus cycle [}53])
bin
MCM startup "Static diagnostics"
bin
Extended
In multi-configuration mode, the coupler sets the Stat_Diag bit in the
diagnostic data if the configuration is not consistent, and does not yet
enter data exchange (default).
1
MCM startup "Data exchange without K-bus"
bin
In multi-configuration mode the coupler also enters data exchange
even when the configuration is not consistent, although K-bus cycles
are not yet executed (see Multi-configuration mode [}73])
5 0 0
1
7 0 0
2-byte PLC interface not activated (default) Extended
bin
2-byte PLC interface is active (see 2-byte PLC interface [}72])
bin
Response to K-bus error: Manual K-bus reset (default) (see K-bus
bin
Standard
interruption [}69])
1
7 1 0
Response to K-bus error: automatic K-bus reset
bin
Terminal diagnosis is not active (default) (see Terminal diagnosis
bin
Standard
[}70])
1
7 4 0
Terminal diagnosis is active
bin
Diagnostic data for digital terminals included in process image (default)
bin
Standard
(see Terminal diagnosis [}70])
1
9 2 0
Diagnostic data of digital terminals not in the process image (default)
bin
Analog modules are mapped in compact form (only showing the input
bin
Extended
and/or output user data) (this is the default, only relevant when
CfgData checking has been deactivated, otherwise the terminals are
set by means of the CfgData) (see Deactivation of CfgData checking
[}73])
1
Analog modules are mapped in complex form (with control/status for
bin
register access and with the same data length in inputs and outputs)
(only relevant when CfgData checking has been deactivated,
otherwise the terminals are set by means of the CfgData)
9 3 0
1
9 4 0
1
9 5 0
1
9 6 0
1
Representation in INTEL format Standard
bin
Representation in Motorola format (default)
bin
K-bus mode slow FreeRun (default) (see K-bus cycle [}53])
bin
K-bus mode fast FreeRun
bin
WORD alignment inactive (default) Extended
bin
WORD alignment active (see WORD alignment [}72])
bin
K-bus mode is synchronous (see K-bus cycle [}53])
bin
K-bus mode FreeRun (default)
bin
Standard
Standard
BK3xx036 Version: 4.3.0
Parameterization and commissioning
Byte Bit Value Description GSD file
10 0-1 00
Reaction to PROFIBUS error: K-bus cycle is abandoned (default,
bin
Standard
digital outputs become 0, complex outputs are set to a configured
substitute value) (see Reaction to PROFIBUS errors [}69])
01
10
10 2-3 00
Reaction to PROFIBUS error: K-bus outputs become 0
bin
Reaction to PROFIBUS error: K-bus outputs remain unchanged
bin
Reaction to K-bus error: DP data exchange is abandoned (default)
bin
Standard
(see K-bus interruption [}69])
01
10
11 3-6 X Maximum length of the diagnostic data. Allowed values: 16, 24, 32, 40,
Reaction to K-bus error: DP inputs set to 0
bin
Reaction to K-bus error: DP inputs remain unchanged
bin
Extended
48, 56, 64 (see Terminal diagnosis [}70])
12 0-1 0
If K-bus mode is synchronous: Standard synchronous mode (default)
bin
Extended
(see K-bus cycle [}53])
01
If K-bus mode is synchronous: synchronous mode with optimized input
bin
update (one cycle)
10
If K-bus mode is synchronous: synchronous mode with optimized input
bin
update (two cycles)
12 4-7 0
12 4-7 15 The maximum DP buffer lengths are changed using the values from
Maximum DP buffer lengths not changed Extended
bin
Extended
UserPrmData 37-40 (see Multi-configuration mode [}73])
13 0-7 X
14 0-7 X
15-30 0-7 X
Delay time (in µs) high byte (see K-bus cycle [}53])
Delay time (in µs) low byte (see K-bus cycle [}53])
Assignment of Bus Terminals 1 to 64 (see Multi-configuration mode
Extended
Extended
Extended
[}73])
31-36 0-7 - Reserved Extended
37 0-7 X
Maximum length of the input data (see Multi-configuration mode
Extended
[}73])
38 0-7 X
Maximum length of the output data (see Multi-configuration mode
Extended
[}73])
39 0-7 X
Maximum length of the diagnostic data (see Multi-configuration mode
Extended
[}73])
40 0-7 X
Maximum length of the configuration data (see Multi-configuration
Extended
mode [}73])
41-56 0-7 X
Assignment of terminals 65 to 128 (see Multi-configuration mode
Extended
[}73])
BK3xx0 37Version: 4.3.0
Parameterization and commissioning
4.3 Technical data - overview
Description BK3010 BK3110 BK3120 BK3150 BK3500 BK3520 LC3100 BC3100
Number of Bus
Terminals
Baud rate [Mbaud] 1,5 12 12 12 1,5 12 12 12
Physical basis RS 485 RS 485 RS 485 RS 485 Optical
UserPrm Data
DPV1 Services x x x x x x x x
Multi-configuration
mode
Word Align x x x x
Byte oriented Bus
Terminals
Distributed control
PLC IEC 6 1131-3 x
64 64 255 255 64 255 64 64
Optical
fibers
x x x x x x x
x x x x x
fibers
RS 485 RS 485
4.4 Configuration
4.4.1 Configuration - CfgData
The CfgData is generated from the modules inserted in the DP configuration tool. When modules are added,
the following rules are to be observed:
Sequence of DP modules to be added in the DP configuration tool
Modules for the coupler's functions [}38]
Complex function modules [}39]
Digital function modules [}41]
For TwinCAT applications, these rules are followed by the TwinCAT system manager. It adds the terminals
or IE modules in the sequence in which they are plugged in, and the modules for functions are added
automatically if the corresponding function is activated in the UserPrmData [}35].
4.4.2 Configuration of the Coupler Modules
The DP modules for the following Bus Coupler functions are to be added first in the DP configuration tool if
the associated function is activated (if the function is not activated, the corresponding DP module is not to be
added):
Function module Activation of the function
2-byte PLC Interface
K-bus cycle counter
Dummy output byte
The 2-byte PLC interface is activated via the UserPrmData [}35] (byte 5, bit 0). By
default it is not active.
The K-bus cycle counter [}53] is activated via the UserPrmData [}35] (byte 3, bit 3).
By default it is not active.
The dummy output byte [}53] is activated via the UserPrmData [}35] (byte 3, bit 5).
By default it is not active.
BK3xx038 Version: 4.3.0
Parameterization and commissioning
4.4.3 Configuration of Complex Modules
After the DP modules for the activated functions of the Bus Coupler have been added to the Bus Coupler in
the DP configuration tool, the next step is for the complex terminals (KL15xx, KL25xx, KL3xxx, KL4xxx,
KL5xxx, KL6xxx, KL8xxx) to be added in the sequence in which they are plugged in, regardless of whether
digital terminals are plugged in between the complex terminals, or of how many there may be:
Complex function
module
KL1501 KL1501 0xB4 (in GSD file)
KL2502 KL2502 0xB5 (in GSD file)
KL2521 KL2521 0xB2 (in GSD file)
KL3351 compact KL3351 - only the 16 bit input value is transmitted 0x51 (in GSD file)
KL3351 complex KL3351 - 24 bits of input/output are transmitted, so that
KL3361 KL3361 0xFB (in GSD file)
KL3xx2 compact All KL3xx2 - only the 16 bit input value of each channel is
KL3xx2 complex Old KL3xx2 - 24 bits of input/output are transmitted for each
KL3xx4 compact All KL3xx4 - only the 16 bit input value of each channel is
KL3xx4 complex Old KL3xx4 - 24 bits of input/output are transmitted for each
KL4xx2 compact All KL4xx2 - only the 16 bit output value of each channel is
KL4xx2 complex Old KL4xx2 - 24 bits of input/output are transmitted for each
KL4xx4 compact All KL4xx4 - only the 16 bit output value of each channel is
KL4xx4 complex Old KL4xx4 - 24 bits of input/output are transmitted for each
Description Associated CfgData (as
hex code)
0xB5 (alternatively)
0xF2 (alternatively)
0xB2, 0xB2 (alternatively)
0xF2 (alternatively)
0xF1 (alternatively)
0x50, 0x50 (alternatively)
0xB5 (in GSD file)
access can be had to the terminal's registers in addition to
transmission of the 16 bit input value
transmitted
channel, so that access can be had to the terminal's
registers in addition to transmission of the 16 bit input value
transmitted
channel, so that access can be had to the terminal's
registers in addition to transmission of the 16 bit input value
transmitted
channel, so that access can be had to the terminal's
registers in addition to transmission of the 16 bit input value
transmitted
channel, so that access can be had to the terminal's
registers in addition to transmission of the 16 bit input value
0xB2, 0xB2 (alternatively)
0xF2 (alternatively)
0x51 (in GSD file)
0x50, 0x50 (alternatively)
0xB5 (in GSD file)
0xB2, 0xB2 (alternatively)
0xF2 (alternatively)
0x53 (in GSD file)
0x51, 0x51(alternatively)
0x50, 0x50, 0x50, 0x50
(alternatively)
0xBB (in GSD file)
0xB5, 0xB5 (alternatively)
0xB2, 0xB2, 0xB2, 0xB2
(alternatively)
0xF5 (alternatively)
0x61 (in GSD file)
0x60, 0x60 (alternatively)
0xB5 (in GSD file)
0xB2, 0xB2 (alternatively)
0xF2 (alternatively)
0x63 (in GSD file)
0x61, 0x61 (alternatively)
0x60, 0x60, 0x60, 0x60
(alternatively)
0xBB (in GSD file)
0xB5, 0xB5 (alternatively)
0xB2, 0xB2, 0xB2, 0xB2
(alternatively)
0xF5 (alternatively)
BK3xx0 39Version: 4.3.0
Parameterization and commissioning
Complex function
module
KL5001 compact KL5001 - only the 32 bit input value is transmitted 0x93 (in GSD file)
KL5001 complex KL5001 - 40 bits of input/output are transmitted, so that
KL5051 KL5051 0xB5 (in GSD file)
KL5101 KL5101 0xB5 (in GSD file)
KL5111 KL5111 0xB5 (in GSD file)
KL5121 KL5121 0xB5 (in GSD file)
KL5151 KL5151 0xB5 (in GSD file)
KL5302 KL5302 0xB5 (in GSD file)
KL6001 KL6001 0xB5 (in GSD file)
KL6011 KL6011 0xB5 (in GSD file)
KL6021 KL6021 0xB5 (in GSD file)
KL6051 compact KL6051 - only the 32 input bits and 32 output bits are
KL6051 complex KL6051 - 48 input bits and 48 output bits are transmitted, so
KL6061 KL6061 0xBA (in GSD file)
KL6201 (PAB 6) KL6201 - 6 bytes input and output process data is
KL6201 (PRM PAB6)KL6201 - 6 bytes parameter interface and 6 bytes input and
KL6201 (PAB 16) KL6201 - 16 bytes input and output process data is
KL6201 (PRM PAB
16)
KL6801 KL6801 0xB5 (in GSD file)
KL8001 KL8001 0xBB (in GSD file)
Description Associated CfgData (as
hex code)
0xD1 (alternatively)
0xB4 (in GSD file)
access can be had to the terminal's registers in addition to
transmission of the 40 bit input value
transmitted
that in addition to the 40 input bits and the 40 output bits,
access can also be had to the terminal's registers
transferred (ASI slaves 1-11)
output process data is transferred (ASI slaves 1-11)
transferred (ASI slaves 1-31)
KL6201 - 6 bytes parameter interface and 16 bytes input
and output process data is transferred (ASI slaves 1-31)
0xB5 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xF2 (alternatively)
0xB3 (in GSD file)
0xF1 (alternatively)
0xB5 (in GSD file)
0xF2 (alternatively)
0xF5 (alternatively)
0x35 (in GSD file)
0xF2,0x35 (in GSD file)
0x3F (in GSD file)
0xF2,0x3F (in GSD file)
0xF2 (alternatively)
0xF5 (alternatively)
BK3xx040 Version: 4.3.0
Parameterization and commissioning
4.4.4 Configuration of Digital Modules
After the DP modules for the activated functions of the Bus Coupler and the complex terminals (KL15xx,
KL25xx, KL3xxx, KL4xxx, KL5xxx, KL6xxx, KL8xxx) have been added to the Bus Coupler in the DP
configuration tool in the sequence in which they are plugged in, the digital terminals follow. In the case of
digital terminals, it is only necessary for the total of the digital inputs and outputs of the modules that have
been added to agree with the number of digital inputs and outputs that are plugged in:
Sample
4 x KL1408 = 32 digital input bits
2 x KL2408 = 16 digital output bits
3 x KL1114 = 12 digital input bits
2 x KL2114 = 8 digital output bits
4 x KL1012 = 8 digital input bits
1 x KL2012 = 2 digital output bits
=> 52 digital input bits and 26 digital output bits
The following combinations of DP modules could, for instance, now be added in the DP configuration tool to
the Bus Coupler:
Alternative 1
8 digital input bits
8 digital input bits
8 digital input bits
8 digital input bits
8 digital input bits
8 digital input bits
8 digital input bits
8 digital output bits
8 digital output bits
8 digital output bits
8 digital output bits
Alternative 2
56 digital input bits
32 digital output bits
Other alternatives are possible, provided the total of digital inputs is 56 bits (the next number larger than 52
divisible by 8) and that the sum of the digital inputs is 32 bits (the next number larger than 26 divisible by 8).
4.4.5 GSD Files
GSD files are required for integrating the PROFIBUS couplers in DP configuration tools.
GSD files can be found online at http://www.beckhoff.com/english/download/bkconfg.htm
BK3xx0 41Version: 4.3.0
Parameterization and commissioning
Note regarding GSD file
The GSD file contains a maximum of 244 bytes of input, output and configuration data. These are
the maximum values. Below are the default of values and the setting options.
DP buffer Default Maximum size
Inputs 128 244
Outputs 128 244
Diagnostic Data 64 64
Configuration data 64 244
The sizes can be adjusted through the PrmData [}73]. The length is changed in 8-byte steps.
Sample
If it is desired to increase the size of the input data, other sizes must be reduced to compensate.
If we have 20 x 4 channel KL3314 thermocouples, then in compact mapping we find 20 Bus Terminals * 4
channels * 2 bytes per channel = 20 * 4 * 2 = 160 bytes
160 bytes is larger than the 128 byte default figure - settings must therefore be modified.
Set PrmData byte 12 bits 4-7 to 15
data).
or 0xF
dec
, set byte for 37 to 160 (input data) and byte 38 to 96 (output
hex
4.4.6 KS2000 - Introduction
The KS2000 configuration software permits configuration, commissioning and parameterization of bus
couplers, of the affiliated bus terminals and of Fieldbus Box Modules. The connection between bus coupler/
Fieldbus Box Module and the PC is established by means of the serial configuration cable or the fieldbus.
Fig.24: KS2000 configuration software
BK3xx042 Version: 4.3.0
Parameterization and commissioning
Configuration
You can configure the Fieldbus stations with the Configuration Software KS2000 offline. That means, setting
up a terminal station with all settings on the couplers and terminals resp. the Fieldbus Box Modules can be
prepared before the commissioning phase. Later on, this configuration can be transferred to the terminal
station in the commissioning phase by means of a download. For documentation purposes, you are provided
with the breakdown of the terminal station, a parts list of modules used and a list of the parameters you have
modified. After an upload, existing fieldbus stations are at your disposal for further editing.
Parameterization
KS2000 offers simple access to the parameters of a fieldbus station: specific high-level dialogs are available
for all bus couplers, all intelligent bus terminals and Fieldbus Box modules with the aid of which settings can
be modified easily. Alternatively, you have full access to all internal registers of the bus couplers and
intelligent terminals. Refer to the register description for the meanings of the registers.
Commissioning
The KS2000 software facilitates commissioning of machine components or their fieldbus stations: Configured
settings can be transferred to the fieldbus modules by means of a download. After a login to the terminal
station, it is possible to define settings in couplers, terminals and Fieldbus Box modules directly online. The
same high-level dialogs and register access are available for this purpose as in the configuration phase.
The KS2000 offers access to the process images of the bus couplers and Fieldbus Box modules.
• Thus, the coupler's input and output images can be observed by monitoring.
• Process values can be specified in the output image for commissioning of the output modules.
All possibilities in the online mode can be used in parallel with the actual fieldbus mode of the terminal
station. The fieldbus protocol always has the higher priority in this case.
4.4.7 Configuration via TwinCAT
The TwinCAT automation software is a complete automation solution for PC-compatible computers.
TwinCAT turns any compatible PC into a real-time controller, an IEC 61131-3 Multi-PLC, NC positioning
system, the corresponding programming environment and user interface. TwinCAT supports several different
PROFIBUS DP PC cards. Beckhoff recommends the PROFIBUS DP PCI master card FC3101, which can
also be obtained as a two-channel version (FC3102).
TwinCAT*System-Manager
The TwinCAT System Manager Tool is used to configure the FC310x PROFIBUS DP PCI card. The System
Manager provides a representation of the number of programs of the TwinCat PLC systems, the
configuration of the axis control and of the connected I/O channels as a structure, and organizes the
mapping of the data traffic.
BK3xx0 43Version: 4.3.0
Parameterization and commissioning
Fig.25: TwinCAT System Manager
For applications without TwinCAT PLC or NC, the TwinCAT System Manager configures the programming
interfaces for a wide range of application programs:
• ActiveX control (ADS-OCX) for e.g. Visual Basic, Visual C++, Delphi, etc.
• DLL interface (ADS-DLL) for e.g. Visual C++ projects
• Script interface (ADS script DLL) for e.g. VBScript, JScript, etc.
The TwinCAT System Manager has the following properties:
• Bit-wise connection between server process images and I/O channels
• Standard data formats such as arrays and structures
• User defined data formats
• Continuous variable linking
• Drag and Drop
• Import and export at all levels
Procedure when configuring the PROFIBUS DP input/output modules
1. The corresponding PROFIBUS DP master PC card is selected first, and inserted into the I/O configuration.
BK3xx044 Version: 4.3.0
Parameterization and commissioning
Fig.26: Configuration of the PROFIBUS DP I/O modules - selection of the PROFIBUS DP master PC card
2. Following the master card, the bus nodes are then inserted:
Fig.27: Configuration of the PROFIBUS DP I/O modules - inserting the bus nodes
3. The appropriate Bus Terminals are now inserted at the PROFIBUS DP Bus Coupler.
BK3xx0 45Version: 4.3.0
Parameterization and commissioning
Fig.28: Configuration of the PROFIBUS DP I/O modules - appending the Bus Terminals
4.4.8 Configuration with Siemens S7 controller
4.4.8.1 Configuration: Siemens S7 Controller
Inserting the images
In order to assign an image to the devices in the Siemens software, they must be copied into the
Step7\S7Data\NcBmp directory.
Fig.29: Busklemn.bmp
Fig.30: Busklems.bmp
Inserting the GSD files
• Go to Extras\Install new GSD in the hardware catalog for your Step7.
• Select the directory in which the Beckhoff GSD is located, and import the files.
• It can then be found in the hardware catalogue under PROFIBUS DP\Further field devices\I/O.
4.4.8.2 Configuration: Siemens S7 Controller BK3120
Parameter data for the BK3120
Settings
BK3xx046 Version: 4.3.0
Parameterization and commissioning
Fig.31: Parameter data for the BK3120
Parameter data Name
DPV1 service (class 1)
Reaction to Bus Terminal error
Terminal bus diagnostics
Digital terminal diagnostic data
Data format
K-Bus mode
Fast FreeRun mode
Reaction to DP errors
Reaction to K-bus errors
Configuration of the BK3120 module with digital inputs/outputs only
Sample 1:
1 x BK3120
10 x KL1xx4
1 x KL9100 (is not entered, as this Bus Terminal is entirely passive)
11 x KL2xx4
1 x KL9010 (is not entered, as this Bus Terminal is entirely passive)
The sum total of digital bytes must be added together and entered.
Digital inputs
10 x KL1xx4, i.e. 10 x 4 bits = 40 bits
40bit/8=5bytes,i.e. enter 5x8 bitor1x40bitor1x8bit+1x32bit, etc. (see Fig. Example for
entering individual bytes and Fig. Example for entering contiguous bytes)
DPV1 Services [}56]
Reaction to Bus Terminal error [}69]
PROFIBUS diagnosis [}70]
Digital Bus Terminal diagnostics [}70]
Data format [}35]
K-bus update [}53]
Fast FreeRun mode [}53]
Reaction to fieldbus error [}35]
Reaction to K-bus errors [}35]
BK3xx0 47Version: 4.3.0
Parameterization and commissioning
Digital outputs
11xKL2xx4,i.e.10x4bit=44bit
44bit /8=5.5bytes,rounded up to 6 bytes, i.e. enter 6x8 bitor1x48bitor1x8bit+1x40bit etc. (see
Fig. Example for entering individual bytes and Fig. Example for entering contiguous bytes)
Fig.32: Example for entering individual bytes.
Maximum config data
Each individual byte requires one byte of ConfigData. In the BK3120 a maximum of 64 bytes of configuration data is available.
BK3xx048 Version: 4.3.0
Parameterization and commissioning
Fig.33: Example for entering associated bytes.
Configuration of the BK3120 module with complex and digital input/outputs
Byte-oriented modules are the first to be mapped into the process image, and for this reason all the complex
modules must first be entered in the sequence in which they are plugged into the Bus Coupler. For some
byte-oriented Bus Terminals, it is possible to distinguish between compact and complex mapping.
Compact - only user data
Complex - user data plus status (for extended diagnosis) and control (for register communication)
Finally the digital signals are entered and rounded up to a whole byte.
Example 2.a:
1 x BK3120
2 x KL1012
1 x KL2022
1 x KL3312 compact mapping
1 x KL9010
BK3xx0 49Version: 4.3.0
Parameterization and commissioning
Fig.34: Example for compact representation of the Bus Terminal KL3312
Example 2.b:
1 x BK3120
2 x KL1012
1 x KL2022
1 x KL3312 complex mapping
1 x KL9010
Fig.35: Example for compact representation of the Bus Terminal KL3312
BK3xx050 Version: 4.3.0
PROFIBUS DP communication
5 PROFIBUS DP communication
5.1 DataExchange - cyclic data exchange
5.1.1 Process data, process image
The Bus Coupler includes different memory areas, each having a capacity of 256 words. Telegrams passing
over the Lightbus can specifically access any desired memory cell. The control and status bytes in the
Lightbus telegrams can be used to distinguish between two relevant regions of the memory and to address
them separately. In order to initiate a Bus Coupler update, the value in the control and status bytes must be
0x10, while the data byte must contain the constant 80hex. It is possible to access the Bus Coupler data
after this. For this purpose the control and status byte contains the value 0x30. Two bytes can be written and
two bytes can be read simultaneously with one access. The process is described in detail in the following
sections.
After being switched on, the Bus Coupler determines the configuration of the inserted input/output terminals.
The assignment of the physical slots for the input/output channels and the addresses in the process image is
carried out automatically by the Bus Coupler.
The Bus Coupler creates an internal assignment list, in which the input/output channels have a specific
position in the process image of the Bus Coupler. A distinction is made here according to inputs and outputs,
and according to bit-oriented (digital) and byte-oriented (analog or complex) signal processing.
Two groups are created, one for inputs and the other for outputs. Each group has the byte-oriented channels
in ascending sequence, starting from the lowest address, and these are followed by the bit-oriented
channels.
Digital signals (bit-oriented)
The digital signals are bit-oriented. This means that one bit in the process image is assigned to each
channel. The Bus Coupler creates a memory area containing the current input bits, and ensures that the bits
in a second (output) memory area dedicated to the output channels are written out immediately, following the
update command.
The details of the assignment of the input and output channels to the controller's process image is explained
fully with the aid of an example in the appendix.
Analog signals (byte-oriented)
The processing of analog signals is always byte-oriented. Analog input and output values are represented in
memory by two bytes each. Values are represented in SIGNED INTEGER format. The number 0 stands for
the input/output value 0 V, 0 mA or 4 mA. The maximum value of an output or input value is represented,
according to the standard settings, by 0x7FFF. The intermediate values are correspondingly proportional. A
range with a resolution of 15 bits is not achieved for all inputs and outputs. If the actual resolution is 12 bits,
the last three bits have no effect in outputs, while as inputs they are read as 0. Each channel also has a
control and status byte. The control and status byte is the most significant byte in the most significant word.
An analog channel is represented by 4 bytes in the process image, of which 3 bytes are used. In the BK3000
and BK4000 only 2 bytes are occupied in the process image of the corresponding bus system for each
analog channel. The Bus Terminal's control and status bytes can also be included through appropriate
configuration of the Bus Coupler and Bus Terminals.
Special signals and interfaces
The Bus Coupler supports Bus Terminals with other interfaces such as RS232, RS485, incremental encoder
and others. These signals can be considered similarly to the analog signals named above. For some special
signals the bit width of 16 is not sufficient. The Bus Coupler can support any byte width. It is necessary to
consider how data consistency is ensured when accessing these values. This means that update commands
must not be issued nor must the Bus Coupler be placed into the free running mode between the accesses.
BK3xx0 51Version: 4.3.0
PROFIBUS DP communication
Default assignment of the inputs and outputs to the process image
Once it has been switched on, the Bus Coupler finds out how many Bus Terminals are inserted, and creates
an assignment list. The analog and digital channels, divided into inputs and outputs, are assembled into
separate parts of this list. The assignment starts on the left next to the Bus Coupler. The software in the Bus
Coupler collects consecutively the individual entries for each of the channels in order to create the
assignment list counting from left to right. Four groups are distinguished in the assignment:
Group Functional type of the channel Assignment
1 analog outputs byte-wise
2 digital outputs bit-wise
3 analog inputs byte-wise
4 digital inputs bit-wise
All complex Bus Terminals are represented by analog inputs or outputs.
Overview of the distribution of the process image within the Bus Coupler
Output data in the Bus Coupler
Fig.36: Output data in the Bus Coupler
Input data in the Bus Coupler
Fig.37: Input data in the Bus Coupler
BK3xx052 Version: 4.3.0
PROFIBUS DP communication
5.1.2 K-bus Cycle
The K-bus cycle can be set to run freely (FreeRun mode [}53]) or synchronously (synchronous mode
[}54]) with respect to the DP cycle. The K-bus cycle for the DP coupler consists of the following parts:
Fig.38: Configuration of the K-bus cycle for the DP couplers
The K-bus cycle time can be calculated with a precision of around 10% using the following formula (4channel terminals or terminals with more than 6bytes data (exception: ASI terminal KL6201: more than 12
bytes of data) require two or more K-bus cycles).
Tcyc (in µs) = number of K-Bus cycles x (600 + number of digital channels x 2.5 + number of analog
input channels x 32 + number of analog output channels x 42)
The K-bus cycle time can be read via DPV1 [}60]. If TwinCAT is used, this is possible on the "Beckhoff" tab
of the DP coupler in the System Manager.
K-bus modes
The K-bus mode (the type of synchronisation between the K-bus cycles and the DP cycle) is set via the
UserPrmData [}35]:
Byte 9, bit 4 Byte 9, bit 6 Byte 12, bit 0 Byte 12, bit 1 K-bus mode
0
bin
1
bin
0
bin
0
bin
1
bin
1
bin
0
bin
0
bin
0
bin
0
bin
0
bin
1
bin
0
bin
0
bin
0
bin
0
bin
Slow FreeRun
Fast FreeRun
Synchronous
Synchronous with optimized input update,
one cycle
0
bin
0
bin
0
bin
1
bin
Synchronous with optimized input update,
two cycles
FreeRun mode
Slow FreeRun (default setting)
In the FreeRun mode there is no synchronisation between the K-bus cycle and the DP cycle. It is a
characteristic feature of the Slow FreeRun mode that the K-bus cycle is called from the main task. Acyclic
communication or events result in heavy jitter in the K-bus cycle (KS2000, DPV1, terminal diagnosis, etc.),
because all of these functions are also called from the main task.
Fig.39: K-bus - Slow FreeRun mode (default setting)
BK3xx0 53Version: 4.3.0
PROFIBUS DP communication
FastFreeRun
To avoid the jitter resulting from acyclic communication or events and to achieve fast K-bus update times,
the Fast FreeRun mode can be activated. The K-bus cycle is called by a higher priority task, controlled by a
timer. At the end of the K-bus cycle the low-priority tasks (DPV1, KS2000 interface, etc.) are assigned
computing time corresponding to 12.5% of the preceding K-bus cycle duration, before the next K-bus cycle
is started. In fast FreeRun mode therefore the inputs and outputs are up-to-date, but are not synchronized to
the DP cycle:
Fig.40: K-bus mode fast FreeRun
Synchronous mode
As explained in the table above, there are three different synchronous modes.
Standard synchronous mode
In standard synchronous mode the K-bus cycle is always started immediately following reception of the
Data_Exchange telegram from the DP master. The outputs are therefore generated as quickly as possible,
while the input cycles are always one DP cycle old.
Fig.41: K-bus - standard synchronous mode
It is important here to ensure that the duration of the K-bus cycle plus approx. 20% (to allow for the lower
priority processes on the coupler) is shorter than the DP cycle time (which, under TwinCAT, means the cycle
time of the associated task).
Synchronous mode with optimized input update (one cycle)
In optimized input update, the start of the K-bus cycle can be delayed following reception of the
Data_Exchange telegram, so that the inputs are more up-to-date than they are in standard synchronous
mode, whereas generation of the outputs is more severely delayed. It is important here to ensure that the
duration of the K-bus cycle, plus the delay time, plus approx. 20% (to allow for the lower priority processes
on the coupler) is shorter than the DP cycle time (which, under TwinCAT, means the cycle time of the
associated task).
BK3xx054 Version: 4.3.0
PROFIBUS DP communication
Fig.42: K-bus - synchronous mode with optimized input update (one cycle)
The delay time is set by means of the UserPrmData [}35] (in µs, in Motorola format). The extended GSD file
of the Bus Coupler is, however, necessary for this:
Byte Value: Description
13 Delay time (in µs) high byte
14 Delay time (in µs) low byte
Synchronous mode with optimized input update (two cycles)
In the third mode of synchronous operation, the advantages of the other two operating modes are combined.
Two K-bus cycles are carried out within one DP cycle. The first cycle begins immediately after reception of
the Data_Exchange telegram from the master, which means that the outputs are generated as quickly as
possible. The second cycle is started after a delay time that begins after completion of the first cycle has
elapsed, so that the inputs are as recent as possible. It is important here to ensure that two times the
duration of the K-bus cycle, plus the delay time, plus approx. 20% (to allow for the lower priority processes
on the coupler) is shorter than the DP cycle time (which, under TwinCAT, means the cycle time of the
associated task).
Fig.43: K-bus - synchronous mode with optimized input update (two cycles)
The delay time is set by means of the UserPrmData [}35] (in µs, in Motorola format). The extended GSD file
of the Bus Coupler is, however, necessary for this:
Byte Description
13 Delay time (in µs) high byte
14 Delay time (in µs) low byte
Dummy output byte
The Bus Coupler's PROFIBUS DP ASIC can only generate an interrupt after reception of a Data_Exchange
telegram if output data has been received. This means that at least one output byte must be transferred via
DP in synchronous mode. If only input terminals are plugged in, and no output data is therefore present, a
dummy output byte can be configured. It is activated in the UserPrmData [}35], and must be entered as the
module in the CfgData. The extended GSD file for the Bus Coupler is, however, necessary for this:
BK3xx0 55Version: 4.3.0
PROFIBUS DP communication
Byte Bit Value Description
3 5 1
It is also necessary for the dummy output byte to be configured in the CfgData before the complex terminals:
CfgData DP modules
0x20 Dummy output byte
K-bus cycle counter
In order for the master to be able to check reliably whether precisely one (or two) K-bus cycles are always
being carried out during one DP cycle, a K-bus cycle counter can be transferred in the input data from the
Bus Coupler to the master. This is incremented after each K-bus cycle (0 is omitted, so that 1 follows after
255). The K-bus cycle counter must be activated in the UserPrmData and entered as a module in the
CfgData. The extended GSD file for the Bus Coupler is, however, necessary for this:
Byte Bit Value Description
3 3 1
It is also necessary for the K-bus cycle counter byte to be configured in the CfgData before the complex
terminals:
bin
bin
Dummy output byte
activated
K-bus cycle counter
activated
CfgData DP modules
0x10 K-bus cycle counter
5.2 DPV1 - acyclic data transfer
5.2.1 DPV1 Interface
By default, one MSAC_C1 connection and one MSAC_C2 connection with 52 bytes of data (4 bytes DPV1
header plus 48 bytes of user data) are supported. The MSAC_C1 connection is established along with cyclic
connection, and can be activated via the UserPrmData [}35]:
Byte Bit Value: Description
0 7 1: MSAC_C1 connection is activated
The MSAC_C2 connection can be used either by the C1 master (which communicates with the slave
cyclically) or by a C2 master (which then only communicates with the slave acyclically), and has its own
establishment of connection. The parameters at the establishment of the MSAC_C2 connection
(Feature_Supported, Profile_Feature_Supported, Profile_Ident_Number, etc.) are not examined, and the
parameters of the request are mirrored in the response.
Slot_Number [}57] = 0 addresses PROFIBUS coupler data, Slot_Number [}57] > 0 addresses the data of
the function module(s).
BK3xx056 Version: 4.3.0
PROFIBUS DP communication
PROFIBUS coupler data (Slot_Number = 0)
The data associated with the PROFIBUS coupler is addressed via an index:
Index Access Description
1-2 R/W
5 R
9-19 R/W
90 R
98 R/W
99 W
Function module data (Slot_Number > 0)
Depending on the type of function module, access is made either to the registers (max. 4 channels, each
with 64 registers) or to the parameters (only supported by a few function modules, where the quantity of data
is insufficient for the register model)
Accessing registers
Module assignment in multi-configuration mode [}73]
Firmware information [}59]
Device configuration [}59] (Table 9)
K-bus status [}60] (Table 90)
Internal cycle time [}60]
Commands: local bus reset [}69], starting or stopping the internal cycle time
measurement [}60]
Index Access Length Description
0-63 R(/W) 2 Registers 0-63 of the channel 1 in the function module
64-127 R(/W) 2 Registers 0-63 of the channel 2 in the function module
128-191 R(/W) 2 Registers 0-63 of the channel 3 in the function module
192-254 R(/W) 2 Registers 0-63 of the channel 4 in the function module
Accessing parameters
Index Access Length Description
0 R(/W) 4-32 (must be divisible by 4) Parameters 0x0000-0x0007 of the function
module
1 R(/W) 4-32 (must be divisible by 4) Parameters 0x0008-0x000F of the function
module
... ... ...
127 R(/W) 4-32 (must be divisible by 4) Parameters 0x03F8-0x03FF of the function
module
5.2.2 Assignment of the DPV1 slot number
The Slot_Number = 0 addresses the data of the Bus Coupler, while Slot_Number > 0 addresses the data
(registers or parameters (KL6201)) of the complex terminals:
Device Slot number = 0 Slot number > 0
BK3120,
BK3150,
BK3500, BK3520
BK3x10/LC3100 Data in Bus Coupler Not present, because neither the BK3x10 nor the LC3100
BK3xx0 57Version: 4.3.0
Data in Bus Coupler Slot_Number = 1:
first complex terminal plugged into the Bus Coupler
(KL15xx, KL25xx, KL3xxx, KL4xxx, KL5xxx, KL6xxx,
KL8xxx)
Slot_Number = 2:
second complex terminal plugged into the Bus Coupler
(KL15xx, KL25xx, KL3xxx, KL4xxx, KL5xxx, KL6xxx,
KL8xxx)
etc.
support complex terminals.
PROFIBUS DP communication
5.2.3 DPV1 at the coupler
5.2.3.1 Module Assignment
The multi-configuration mode [}73] is possible with a maximum of 128 modules (terminals, IE modules,
etc.). The specification of which of the modules configured in the CfgData are indeed inserted can be written
with DPV1 Write and read with DPV1 Read.
Slot
number
0 1 1-15 Byte 0 (bit 0,1) Assignment of module 1
Index Length Data Description
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 0 (bit 2,3) Assignment of module 2
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 0 (bit 4,5) Assignment of module 3
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 0 (bit 6,7) Assignment of module 4
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 1 (bit 0,1) Assignment of module 5
0: DP DataExchange (default)
2: disabled (configured module missing)
...
Byte 15 (bit 6,7) Assignment of module 64
0: DP DataExchange (default)
2: disabled (configured module missing)
2 1-15 Byte 0 (bit 0,1) Assignment of module 65
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 0 (bit 2,3) Assignment of module 66
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 0 (bit 4,5) Assignment of module 67
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 0 (bit 6,7) Assignment of module 68
0: DP DataExchange (default)
2: disabled (configured module missing)
Byte 1 (bit 0,1) Assignment of module 69
0: DP DataExchange (default)
2: disabled (configured module missing)
...
Byte 15 (bit 6.7) Assignment of module 128
0: DP DataExchange (default)
2: disabled (configured module missing)
BK3xx058 Version: 4.3.0
PROFIBUS DP communication
5.2.3.2 Firmware Information
The following firmware information can be read through DPV1. The data is transferred in Intel format (low
byte first):
Slot number Index Byte Description
0 5 0-1 Bus Coupler number
2-3 Software version
4-5 Manufacturer type (table 0, register 245)
6-7 Coupler type (table 0, register 246)
8-9 Bus Coupler type (table 0, register 247)
10-11 reserved
5.2.3.3 Terminal Composition
The terminal composition can be read by DPV1. A word is transmitted for each terminal containing the
terminal number for complex terminals (KL15xx, KL25xx, KL3xxx, KL4xxx, KL5xxx, KL6xxx, KL8xxx), and
the length and type information for digital terminals:
Bit Value Description
0 1
1 1
bin
bin
2-7 - reserved
8-14 X Length in bits
15 1
bin
Digital terminal has inputs
Digital terminal has outputs
Always 1
(indicates that the terminal is digital)
bin
Reading the terminal composition
The terminal composition is represented in the DPV1 addressing as follows:
Slot number Index Byte Description
0 9 0-1 Number of the Bus Coupler
2-3 Value for terminal 1
... ...
46-47 Value for terminal 23
10 0-1 Value for terminal 24
... ...
46-47 Value for terminal 47
11 0-1 Value for terminal 48
... ... ...
18 46-47 Value for terminal 239
19 0-1 Value for terminal 240
... ...
30-31 Value for terminal 255
Checking the terminal composition
The same data can also be accessed by a DPV1 Write. In this case the Bus Coupler compares the value
that has been written with the true value, returning a negative DPV1 Write response if the data does not
agree. This permits more precise checking of the terminal configuration than is possible by checking the
CfgData. The length must match the actual length of table 9. The calculation should include two bytes for
each terminal with process data. The Bus Coupler ID in register 0 of table 9 is not taken into account.
BK3xx0 59Version: 4.3.0
PROFIBUS DP communication
Error codes in the write response
Error_Code_1 Error_Code_2
0xBE Number of terminals
0xBF First faulty byte in the written data
5.2.3.4 K-bus status
The K-bus status can be read through DPV1. The data is transferred in Intel format (low byte first):
Slot number Index Byte Description
0 90 0-1 Bit 0: Fieldbus errors
Bit 1: K-bus error
Bit 2: Error on the Bus Terminal
Bit 3: Coupler error
2-3 In the presence of a coupler error: Error code
4-5 K-bus error = 0: Bit length of the K-bus
K-bus error = 1: K-bus error code (-> Diagnostic data [}64])
6-7 K-bus error = 0:
Number of terminals
K-bus error = 1:
Bus Terminal number following which the K-bus error is detected (->
Diagnostic data [}64])
5.2.3.5 Cycle Time Measuring
The duration of the process data cycle [}53] can be measured with DPV1.
The cycle time measurement is started or stopped using DPV1 Write:
Slot number Index Length Data Description
0 99 4 Byte 0: 0x04 Start the cycle time measurement
Byte 1: 0x01
Byte 2: 0x01
Byte 3: 0x00
0 99 4 Byte 0: 0x04 Stop the cycle time measurement
Byte 1: 0x01
Byte 2: 0x00
Byte 3: 0x00
The minimum, maximum, mean (of the last 200 cycles) and current cycle time can be read with DPV1 Read
and reset with DPV1 Write:
Slot number Index Length Data Description
0 98 8 Byte 0, 1 Minimum cycle time in µs (INTEL format, low byte first)
Byte 2, 3 Maximum cycle time in µs (INTEL format, low byte first)
Byte 4, 5 Mean cycle time in µs (INTEL format, low byte first)
Byte 6, 7 Current cycle time in µs (INTEL format, low byte first)
BK3xx060 Version: 4.3.0
Diagnostics and error handling
6 Diagnostics and error handling
6.1 LEDs
The Bus Coupler has two groups of LEDs for the display of status. The upper group (BK3xx0) or left hand
group (LC3100) indicates the state of the fieldbus.
On the upper right hand side of the BK3xx0 Bus Coupler are two more green LEDs that indicate the supply
voltage. The left hand LED indicates the presence of the 24V supply for the Bus Coupler. The right hand
LED indicates the presence of the supply to the power contacts. The two K-Bus LEDs (I/O RUN, I/O ERR)
are located under the fieldbus LEDs. These indicate the operational state of the Bus Terminals and the
connection to these Bus Terminals.
Fieldbus LEDs
The upper three LEDs (or the two LEDs on the left) indicate the operating state of the PROFIBUS
communication:
Fig.44: LEDs BK3120 and BK3150
BK3xx0
I/O RUN BF DIA Meaning Remedy
on off off Operating state: RUN, inputs are read
and outputs are set
on on off, blinking 1. Bus activity, but slave is already
parameterized
2. Bus error with reaction to
PROFIBUS error:
a.) K-bus outputs become 0 or b.) Kbus outputs are retained
off off off Data exchange with the master is not
started
off on on No bus activity Start the master, check the bus cable
off on off, blinking Bus error with reaction to PROFIBUS
error: K-bus cycle is stopped
BK3xx0 61Version: 4.3.0
Everything is operating correctly
Start master
Check parameters, configuration
(possible error in DP start-up [}67])
PLC start
Start master, check parameters,
configuration (possible error in DP start-
up [}67])
Diagnostics and error handling
DIA-LED blink codes
If an error occurs in the paramétrisation or configuration during DP start-up [}67], this is indicated both
through the fieldbus LEDs and in the diagnostic data.
Flashing Code
fast blinking Start of the error code
First slow sequence Error code
Second slow sequence Error argument (error location)
Fig.45: LEDs LC3100
LC3100
I/O RUN BF RUN Meaning Remedy
on off on Operating state: RUN, inputs are read
and outputs are set
on on,
blinking
off off on Data exchange with the master is not
off on off No bus activity Start the master, check the bus cable
off on,
blinking
on 1. Bus activity, but slave is already
parameterized
2. Bus error with reaction to
PROFIBUS error:
a.) K-bus outputs become 0 or b.) Kbus outputs are retained
started
on Bus error with reaction to PROFIBUS
error: K-bus cycle is stopped
Everything is operating correctly
Start master
Check parameters, configuration
(possible error in DP start-up [}67])
PLC start
Start master, check parameters,
configuration (possible error in DP start-
up [}67])
BK3xx062 Version: 4.3.0
Diagnostics and error handling
K-bus LEDs (local errors)
Two LEDs, the K-bus LEDs, indicate the operational state of the Bus Terminals and the connection to these
Bus Terminals. The green LED (I/O RUN) lights up in order to indicate fault-free operation. The red LED (I/O
ERR) flashes with two different frequencies in order to indicate an error. The errors are displayed in the blink
code in the following way:
Error type
Error code Error code argu-
ment
Persistent,
continuous
flashing
1 pulse 0 EEPROM checksum error Set manufacturer’s setting with the
2 pulses 0 Programmed configuration
3 pulses 0 K-bus command error No Bus Terminal connected;
4 pulses 0
5 pulses n K-bus error in register
7 pulses n BK3x10 or LC3100:
- general K-bus error Check the Bus Terminal strip
1 Inline code buffer overflow Connect fewer Bus Terminals; too
2 Unknown data type Software update required for the
n>0 Incorrect table entry Bus
n
Description Remedy
KS2000 software
many entries in the table for the
programmed configuration
coupler
Check programmed configuration
incorrect
Coupler / incorrect table
comparison (Bus Terminal n)
K-bus data error, break behind
Bus Coupler n
communication with Bus
Terminal n
unsupported Bus Terminal
detected at location n
for correctness
Correct table entry / Bus Coupler
attach Bus Terminals
One of the Bus Terminals is
defective; halve the number of Bus
Terminals attached and check
whether the error is still present
with the remaining Bus Terminals.
Repeat until the defective Bus
Terminal is located.
Check whether the n+1 Bus
Terminal is correctly connected;
replace if necessary.
Check whether the End Terminal
9010 is connected.
Replace Bus Terminal n
Only use digital (bit oriented) Bus
Terminals, or use a BK3120 Bus
Coupler
BK3xx0 63Version: 4.3.0
Diagnostics and error handling
Error code Error code argu-
ment
9 pulses 0 Checksum error in program
13 pulses 0 Runtime K-bus command error One of the Bus Terminals is
14 pulses n Bus Terminal n has the wrong
15 pulses n Number of Bus Terminals is no
16 pulses n Length of the K-bus data (bit
17 pulses n Number of Bus Terminals is no
18 pulses n Bus Terminal identifier no
Description Remedy
Set manufacturer's setting with the
flash memory
format
longer correct
length) is no longer correct. n =
bit length after booting
longer correct.
n = number of Bus Terminals
after booting
longer correct after reset (n =
Bus Terminal number).
KS2000
defective; halve the number of Bus
Terminals attached and check
whether the error is still present
with the remaining Bus Terminals.
Repeat until the defective Bus
Terminal is located.
Start the coupler again, and if the
error occurs again then exchange
the Bus Terminal
Start the coupler again, and if the
error occurs again after this, use
the KS2000 software to set
manufacturer’s settings
Error location
The number of pulses indicates the position of the last Bus Terminal before the fault. Passive Bus Terminals,
such as a power feed terminal, are not included in the count.
6.2 DP diagnostics
6.2.1 DP Diagnostic Data (DiagData)
The DP diagnostic data consists of six bytes of DP standard diagnosis, along with up to 238 bytes of devicespecific diagnostic data. The device-specific diagnostic data for Beckhoff slaves is represented in the DPV1
status message.
When the DP diagnostic data changes, the slave reports this fact to the master, and the master will
automatically fetch the changed diagnostic data. This means that DP diagnostic data is not included in the
DP process data in real-time, but is always sent to the controller a few cycles later.
In TwinCAT the DP diagnostic data is read from the DP Master interface (FC310x, CX1500-M310) using
ADS (see the section describing Slave Diagnosis in the FC310x documentation).
BK3xx064 Version: 4.3.0
Diagnostics and error handling
DP standard diagnostic data
Offset Meaning
0x00.0 StationNonExistent: slave did not reply to the last telegram
0x00.1 StationNotReady: slave still processing the Set_Prm / Chk_Cfg telegram
0x00.2 CfgFault: slave signaling a configuration error
0x00.3 ExtDiag: extended DiagData available and valid
0x00.4 NotSupported: slave does not support a feature requested via Set_Prm or Global_Control
0x00.5 InvalidSlaveResponse: slave response not DP-compatible
0x00.6 PrmFault: slave reports a paramétrisation error
0x00.7 MasterLock: slave currently exchanging data with another master
0x01.0 PrmReq: re-parameterize and reconfigure slave
0x01.1 StatDiag: slave signaling static diagnosis / DPV1 slave application not yet ready for data
exchange
0x01.2 PROFIBUS DP slave
0x01.3 WdOn: DP watchdog on
0x01.4 FreezeMode: DP slave in freeze mode
0x01.5 SyncMode: DP slave in sync mode
0x01.6 reserved
0x01.7 Deactivated: DP slave has been deactivated
0x02.0 reserved
0x02.1 reserved
0x02.2 reserved
0x02.3 reserved
0x02.4 reserved
0x02.5 reserved
0x02.6 reserved
0x02.7 ExtDiagOverflow: too much extended data present
0x03 MasterAdd: station address of master with which slave is exchanging data
0x04,0x05 IdentNumber
from 0x06 Device-specific diagnostic data (extended DiagData)
Device-specific diagnostic data (DPV1 status message)
The meaning of the first 4 bytes of the DPV1 status message is specified by the DPV1 standard, while the
bytes that follow are manufacturer-specific.
BK3xx0 65Version: 4.3.0
Diagnostics and error handling
Byte Bit Description
6 0-7 The length of the DPV1 status message (including this byte)
7 0-7 StatusType: the StatusType identifies the format of the diagnostic data starting at byte 16
(0x81: max. 64 modules, 0xA1: more than 64 modules)
8 0-7 SlotNumber: always 0
9 0-7 Specifier: always 0
10 0 EEPROM checksum error (can be cleared by setting the manufacturers setting through
KS2000 or DPV1 [}56], followed by a power off/power on cycle)
10 4 Unknown module type
10 5 The length of the CfgData is too great (too many modules are inserted)
10 6 The length of the DP input data is too great (too many modules are inserted)
10 7 The length of the DP output data is too great (too many modules are inserted)
11 0-7
12 0-7 Error code on an internal bus (K-bus, IP-Link, etc.)
13 0-7 Error argument on an internal bus (K-bus, IP-Link, etc.)
14 0-7
15 0-7
Error on an internal bus [}69] (K-bus, IP-Link, etc.)
DP start-up error code [}67]
DP start-up error argument [}67]
Errors in the modules (terminals, IP modules, IE module, etc.)
Diagnosis of the modules [}70] must be activated through the UserPrmData [}35].
Couplers with a maximum of 64 possible modules
Byte Bit Description
16 0-5 Module number (0-63) with an error (bit 6 of the status bytes is set, except for the serial
interface modules (KL6001, KL6011, KL6021, IP6002, IP6012, IP6022, IE6002, IE6012,
IE6022), where bit 3 of the status byte is set)
16 6-7 Associated channel number (0-3)
17 0-7 Status byte of the faulty channel (bits 0-7)
18 0-5 Module number (0-63) with an error (bit 6 of the status bytes is set, except for the serial
interface modules (KL6001, KL6011, KL6021, IP6002, IP6012, IP6022, IE6002, IE6012,
IE6022), where bit 3 of the status byte is set)
18 6-7 Associated channel number (0-3)
19 0-7 Status byte of the faulty channel (bits 0-7)
... ... ...
60 0-5 Module number (0-63) with an error (bit 6 of the status bytes is set, except for the serial
interface modules (KL6001, KL6011, KL6021, IP6002, IP6012, IP6022, IE6002, IE6012,
IE6022), where bit 3 of the status byte is set)
60 6-7 Associated channel number (0-3)
61 0-7 Status byte of the faulty channel (bits 0-7)
BK3xx066 Version: 4.3.0
Diagnostics and error handling
Couplers with a maximum of more than 64 possible modules
Byte Bit Description
16 0-7 Module number (1-255) with an error (bit 6 of the status bytes is set, except for the serial
interface modules (KL6001, KL6011, KL6021, IP6002, IP6012, IP6022, IE6002, IE6012,
IE6022), where bit 3 of the status byte is set)
17 6-7 Associated channel number (0-3)
17 0-5 Status byte of the faulty channel (bits 0-5)
18 0-7 Module number (1-255) with an error (bit 6 of the status bytes is set, except for the serial
interface modules (KL6001, KL6011, KL6021, IP6002, IP6012, IP6022, IE6002, IE6012,
IE6022), where bit 3 of the status byte is set)
19 6-7 Associated channel number (0-3)
19 0-5 Status byte of the faulty channel (bits 0-5)
... ... ...
60 0-7 Module number (1-255) with an error (bit 6 of the status bytes is set, except for the serial
interface modules (KL6001, KL6011, KL6021, IP6002, IP6012, IP6022, IE6002, IE6012,
IE6022), where bit 3 of the status byte is set)
61 6-7 Associated channel number (0-3)
61 0-5 Status byte of the faulty channel (bits 0-5)
6.2.2 Errors during DP Start-up
If an error occurs in the paramétrisation (UserPrmData) [}35] or configuration (CfgData) during DP start-up,
this is indicated both through the fieldbus LEDs [}61] and in the diagnostic data (DiagData) [}64].
Possible DP start-up errors are identified by an error code and an error argument.
Errors when checking the UserPrmData
Error code 1
Error code 1 indicates that a reserved bit in the UserPrmData has been set to an incorrect value, or that the
function corresponding to the bit in the UserPrmData is not supported. The error argument describes which
UserPrmData byte has been detected as containing an error (the offset of the faulty byte + 1).
Error code 3
Error code 3 indicates that a combination of functions selected in the UserPrmData is not allowed. The error
argument describes the impermissible combination.
Error code argument
1
2
6
8
10
11 The length of the DP buffer exceeds the size of the DP RAM in the PROFIBUS ASIC
12
Description
The Reaction to DP error [}53] cannot be set to "Outputs unchanged" in synchronous
mode [}69]
The DPV1-MSAC_C1 connection [}56] has been activated by the master, but no DPV1MSAC_C1 connection is defined
The Multi-configuration mode [}73] is not allowed if Checking the CfgData is switched
off [}73]
Synchronous mode [}53] may only be activated when at least one DP output byte is
configured
The optimized input cycle [}53] is only possible in synchronous mode [}53]
Fast-FreeRun mode [}53] may not be activated together with synchronous mode [}53]
BK3xx0 67Version: 4.3.0
Diagnostics and error handling
Errors when checking the CfgData
Error code 2
Error code 2 indicates that a byte in the CfgData is not correct. The error argument describes which CfgData
byte has been detected as containing an error (the offset of the faulty byte +1).
Error code 5
Error code 5 indicates that the length of the digital outputs (in bytes) calculated from the CfgData is not
correct. The error argument contains the expected byte length.
Error code 6
Error code 6 indicates that the length of the digital inputs (in bytes) calculated from the CfgData is not
correct. The error argument contains the expected byte length.
Error code 7
Error code 7 indicates a variety of errors when checking the CfgData. The error argument describes the
error.
Error argument Description
1 The length of the CfgData received is not correct
2 The syntax of the CfgData received is not correct
3 The length of the DP input data that has been calculated from the CfgData is too large
4 The length of the DP output data that has been calculated from the CfgData is too large
5..12 Reserve
13 Maximum input length exceeded
14 Maximum output length exceeded
15 Maximum diagnostic data length exceeded (64bytes) or value below minimum
diagnostic data length (16bytes)
16 Maximum config data length exceeded (240bytes) or value below minimum config data
length (1byte)
17 Maximum parameter data length exceeded (224bytes) or value below minimum
parameter data length (64bytes)
Errors during slave start-up
Error code 8
Error code 8 indicates that the length of the DP buffer is greater than the size of the DP RAM in the
PROFIBUS ASIC. The error argument contains the difference (divided by 8). DP communication is
deactivated.
Error code 9
Error code 9 indicates a variety of errors that may be detected as the device boots. The error argument
describes the error.
Error argument Description
1 The length of the DP input data is too great (too many modules are inserted)
2 The length of the DP output data is too great (too many modules are inserted)
3 The length of the CfgData is too great (too many modules are inserted)
BK3xx068 Version: 4.3.0
Diagnostics and error handling
Error code 10*
Error during the register communication. The settings to be written via the UserPrm data were executed
incorrectly.
Error argument Description
x Problems with terminal x
Error code 11*
Error during the register communication. The settings to be written via the UserPrm data were aborted with a
timeout.
Error argument Description
x Problems with terminal x
* Only for BK3120 or BK3150 with the GSD file and slot-oriented mapping (E312BECE.GS? or
E315BECE.GS?)
6.2.3 Reaction to PROFIBUS Error
A PROFIBUS error (failure of the master, withdrawal of the PROFIBUS plug etc.) is detected after the DP
watchdog has elapsed (usually in the region of 100 ms, unless this has been deactivated in the master) or by
bus timeout (the baud rate supervision time is set to 10 s).
The reaction at the output data of the coupler can be set in the UserPrmData [}35]:
Byte Bit Value Description
10 0-1 00
Reaction to PROFIBUS error: K-bus cycle is abandoned (default, digital outputs
bin
become 0, complex outputs are set to a planned substitute value)
01
10
Reaction to PROFIBUS error: K-bus outputs become 0
bin
Reaction to PROFIBUS error: K-bus outputs remain unchanged
bin
6.3 K-bus diagnosis
6.3.1 K-bus interruption
If the K-bus is interrupted, or suffers from a relatively long malfunction, the coupler enters the K-bus error
state. Depending on the setting made for Reaction to K-Bus error in the UserPrmData [}35], the coupler
abandons DP data exchange and sets the Stat_Diag bit in the diagnostic data [}64] at the next DP start-up
(with the consequence that DP data exchange is not carried out), sets the DP inputs to 0, or leaves the DP
inputs unchanged.
Byte Bit Value Description
10 2-3 00
01
10
Reaction to K-bus error: DP data exchange is abandoned (default)
bin
Reaction to K-bus error: DP inputs set to 0
bin
Reaction to K-bus error: DP inputs remain unchanged
bin
When the interruption or malfunction on the K-bus has been rectified, the setting of Response to K-bus error
in the UserPrmData [}35] determines whether the K-bus error state is left manually (by means of a K-bus
reset), or automatically:
Byte Bit Value Description
7 0 0
1
Response to K-bus error: manual K-bus reset (default)
bin
Response to K-bus error: automatic K-bus reset
bin
BK3xx0 69Version: 4.3.0
Diagnostics and error handling
Signaling the K-bus error
A K-bus error is indicated both on the I/O-ERR LED and in the DPV1 status message in the DP diagnostic
data [}64] (bytes 11-13).
Byte Bit Description
11 0 too many K-bus command errors
11 1 too many K-bus timeouts
11 2 too many K-bus receive errors
11 3 too many K-bus transmit errors
11 4 K-bus reset error
11 5 general K-bus error
12 0-7 K-bus error code
13 0-7 K-bus error argument
K-bus reset
A K-bus reset can be carried out manually by means of a DPV1 Write:
Slot number Index Byte Value
0 99 0 2
1 1
2 0
3 0
6.3.2 Terminal Diagnostics
If terminal diagnosis has been activated, then each channel of a complex terminals is examined to see
whether bit 6 in the status has changed (exceptions are the KL6001, KL6011 and KL6021, where the
relevant bit is bit 3), and whether the diagnostic bit of each channel of a digital terminal with diagnostics
(KL12x2 or KL22x2) has changed. If that is the case, the existence of new diagnostic data is reported to the
master, and two bytes of diagnostic information starting at byte 16 of each channel for which a diagnosis is
pending are inserted (see Diagnostic data [}64]).
Terminal diagnosis can be activated in the UserPrmData [}35]:
Byte Bit Value Description
7 1 1
bin
Digital terminal diagnosis
By default, the diagnostic bits for the digital terminals that have diagnosis (KL12x2 and KL22x2) are
transmitted cyclically in the process image. These terminals occupy 4 bits each in both the input and output
data. If terminal diagnosis is active, then UserPrmData can be used to specify that only the I/O data for the
digital terminals with diagnosis (KL12x2: 2 bit inputs, KL22x2: 4 bit outputs) is to be included in the cyclic
process image transfer:
Byte Bit Value Description
7 4 1
bin
Terminal diagnosis is active
Diagnostic data of digital terminals not in the cyclic process image
Real-time capacity of the diagnostic data
When making use of terminal diagnosis, it should always be borne in mind that the diagnostic data always
reaches the controller at least one cycle later, and that as a rule access also takes place through different
mechanisms from those used for cyclic process data. This means that process data can already be faulty,
BK3xx070 Version: 4.3.0
Diagnostics and error handling
but the controller program is only informed of this in the following cycle or the one after that. If the diagnostic
bits of digital terminals with diagnostics or the status of complex terminals are mapped to the process image,
the control program always has a consistent state between process and diagnostic data. The appropriate
setting therefore depends on the way that the diagnosis is to be used. If it is only intended for diagnostic
display, transmission within the cyclic process data is unnecessary, but if on the other hand consistency
between the process data and the diagnostic data is desired, then the diagnostic data should be transmitted
along with the cyclic process data.
Maximum diagnosis data length
If more diagnostic terminal data are active than specified in the maximum diagnostic data length, the
ExtDiagOverflow bit of the standard diagnostic data [}64] is set. Since older controllers have trouble
handling the maximum diagnostic data length of 64bytes (default setting), the maximum diagnostic data
length can be limited in UserPrmData [}35]:
Byte Bit Description
11 3-6 Maximum length of the diagnostic data. Allowed values: 16, 24, 32, 40, 48, 56, 64
It is only possible to set the maximum diagnostic data length in text form in the extended GSD file.
BK3xx0 71Version: 4.3.0
Extended functions
7 Extended functions
7.1 2-byte PLC Interface
Checking the CfgData can be deactivated if a DP master is not capable of operating with the modules listed
in the GSD file. In that case the master can send any CfgData, and as many inputs and outputs are
transferred as are described by the CfgData.
Deactivation of the CfgData checking can also be useful if a specific address range is to be reserved in the
PLC for future extensions. In that case, more input and output data is to be transferred than is in fact
necessary.
Deactivation of the CfgData check can be set in the UserPrmData [}35]:
Byte Bit Value Description
1 0 1
In general, the I/O data from the modules (terminals or IE modules) is written by the coupler in the standard
sequence (first the complex, then the digital modules), as is also the case for other fieldbus couplers; this
has already been described in connection with the structure of the process image in the coupler. The
decision on a module-to-module basis as to whether the module is mapped in compact or complex form,
which would otherwise be possible under DP, is omitted when CfgData checking is deactivated. In that case,
the setting made in the UserPrmData applies to all modules:
bin
CfgData checking is deactivated
The compact or complex mapping can be set in the UserPrmData [}35]:
Byte Bit Value Description
9 2 0
The extended GSD file must be used to deactivate CfgData checking and to specify compact/complex
mapping textually in the master's configuration tool.
bin
1
bin
Analog modules are mapped in compact form (only with the input or
output user data)
Analog modules are mapped in complex form (including control/status
for register access and the same data length in the inputs and outputs)
7.2 Word Alignment
In order to obtain the I/O data in the controller's process image in a clear form in controllers with wordoriented process images, it is possible to specify that word alignment is used when the coupler generates its
process image. This involves a dummy byte being inserted for every variable that is larger than one byte and
which would start on an uneven address.
Word alignment can be set in the UserPrmData [}35]:
Byte Bit Value Description
9 5 1
When using the DP modules it is necessary to ensure that only those complex modules that are identified
with word alignment are used.
bin
Word alignment is active
The extended GSD file must be used in order to set word alignment in text form in the master's configuration
tool and to be able to select the word alignment module.
BK3xx072 Version: 4.3.0
Extended functions
7.3 Deactivating the CfgData Check
Checking the CfgData can be deactivated if a DP master is not capable of operating with the modules listed
in the GSD file. In that case the master can send any CfgData, and as many inputs and outputs are
transferred as are described by the CfgData.
Deactivation of the CfgData checking can also be useful if a specific address range is to be reserved in the
PLC for future extensions. In that case, more input and output data is to be transferred than is in fact
necessary.
Deactivation of the CfgData check can be set in the UserPrmData [}35]:
Byte Bit Value Description
1 0 1
bin
In general, the I/O data from the modules (terminals or IE modules) is written by the coupler in the standard
sequence (first the complex, then the digital modules), as is also the case for other fieldbus couplers; this
has already been described in connection with the structure of the process image in the coupler. The
decision on a module-to-module basis as to whether the module is mapped in compact or complex form,
which would otherwise be possible under DP, is omitted when CfgData checking is deactivated. In that case,
the setting made in the UserPrmData applies to all modules:
The compact or complex mapping can be set in the UserPrmData [}35]:
CfgData checking is deactivated
Byte Bit Value Description
9 2 0
bin
Analog modules are mapped in compact form (only with the input
or output user data)
1
bin
Analog modules are mapped in complex form (including control/
status for register access and the same data length in the inputs
and outputs)
The extended GSD file must be used to deactivate CfgData checking and to specify compact/complex
mapping textually in the master's configuration tool.
7.4 Multi-Configuration Mode
Applications of the multi-configuration mode
Multi-configuration mode can be used for the following types of application. A more extensive consideration,
considering, in particular, the various implementation levels of the Bus Coupler, is given in the Requirements
of a production machine [}77].
Creating a DP configuration for various implementation levels of the Bus Coupler
If a PLC program is to be used for controlling different configurations of a process, it may make sense to use
the same DP configuration even if the terminal configuration is different. In this case the address offsets in
the process image do not change, and the DP configuration of the PROFIBUS DP master does not have to
be re-saved for each version. With the multi-configuration mode it is now possible to define a maximum
configuration for the Bus Coupler, and in this case it will only be necessary to disable those terminals that
are not present in accordance with the current implementation level.
Reserved Bus Terminals
Because all the analog terminals are configured first in the DP configuration, before the digital terminals, the
consequence of inserting analog terminals at a later stage is that the address offsets of the digital terminals
are shifted. The insertion of a digital terminal within the existing terminal structure (which can, for instance,
be useful if digital terminals with different input voltages are used) also has the consequence that the offsets
of the digital terminals that follow it are shifted. If a digital terminal is inserted before the end terminal
however, the offset of the existing terminals are not shifted. With multi-configuration mode it is now possible
to configure additional terminals as reserves at any location within the terminal structure.
BK3xx0 73Version: 4.3.0
Extended functions
Assigning the Bus Terminals to freely chosen process image addresses
Because digital terminals are always grouped into bytes, which therefore means that the smallest DP
configuration module is an 8-bit module, a difficulty arises when the associated terminals are to be
distributed over a number of bytes in the PLC process image. This is because in the PLC it is usually only
possible to assign addresses for each DP configuration module. With multi-configuration mode it is now
possible to configure additional digital terminals as "dummy" terminals at any desired locations, enabling the
address offsets of the other terminals to be shifted in the PLC process image.
Setting the multi-configuration mode
Multi-configuration mode is activated via the UserPrmData [}35]:
Byte Bit Description
3 4 1: Multi-configuration mode is active
Rules for multi-configuration mode
Multi-configuration mode requires a few additional rules to be observed, in addition to those for standard
configuration:
• Only one DP module may be configured for each analog terminal
• The digital terminals are to be declared as KLxxxx Multi-Cfg mode modules at their true position
• The digital terminals are to be declared after the analog modules moreover as input/output sum
modules, corresponding to their bit width, as is also the case for standard configuration in the process
image.
• All modules for the maximum configuration, including the reserve modules, are to be declared
• Modules that are not inserted must be disabled
Enabling/disabling Bus Terminals
Those Bus Terminals that are present in the DP configuration, but that are not in fact plugged in, must be
disabled. This can be done in the UserPrmData [}35], via DPV1, KS2000 or through the 2-byte PLC
interface.
Making the setting through DPV1 or through the 2-byte PLC interface has the advantage that the terminal
assignment for the multi-configuration mode can usually be made directly from the PLC program, without
having to change the DP configuration of the master.
As long as the inserted Bus Terminals do not agree with the non-disabled Bus Terminals to be expected
from the DP configuration, the Bus Terminal will normally set the Stat_Diag bit in the diagnostic data, with
the consequence that it is not yet ready for cyclic data exchange.
If, however, the enabling and disabling is to be carried out via the 2-byte PLC interface, it is a precondition
for function of the 2-byte PLC interface that the coupler is in cyclic data exchange mode. For that reason it is
also possible to deactivate remaining in the Stat_Diag state:
Byte Bit Description
3 6 1: In multi-configuration mode the coupler also enters the data exchange even when
the configuration is not consistent, although K-bus cycles are not yet executed
Enabling/disabling via UserPrmData
The assignment of the terminals (a maximum of 128 terminals is possible) is entered from byte 15 to byte 30
and from byte 41 to byte 56 of the UserPrmData [}35]. Two bits are reserved here for each terminal,
indicating whether the relevant terminal is enabled (value 0) or disabled (value 2). If the UserPrmData is to
be displayed as text in the DP configuration tool, then the parameters Assignment of module x are to be set
to DP DataExchange (enabled) or Multi-Config. mode (disabled).
BK3xx074 Version: 4.3.0
Byte Bit Description
15 0,1 Assignment for terminal 1
0: DP DataExchange (default)
2: disabled (Multi-Config mode)
2,3 Assignment for terminal 2
0: DP DataExchange (default)
2: disabled (Multi-Config mode)
4,5 Assignment for terminal 3
0: DP DataExchange (default)
2: disabled (Multi-Config mode)
6,7 Assignment for terminal 4
0: DP DataExchange (default)
2: disabled (Multi-Config mode)
... ... ...
30 6,7 Assignment for terminal 64
0: DP DataExchange (default)
2: disabled (Multi-Config mode)
41 0,1 Assignment for terminal 65
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
... ... ...
56 6,7 Assignment for terminal 128
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
Extended functions
Enabling/disabling via DPV1 Write
The terminals are enabled/disabled through Slot_Number 0 and Index 1 or 2:
Index Byte Bit Description
1 0 0,1 Assignment for terminal 1
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
2,3 Assignment for terminal 2
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
4,5 Assignment for terminal 3
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
6,7 Assignment for terminal 4
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
... ... ...
15 6,7 Assignment for terminal 64
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
2 0 0,1 Assignment for terminal 65
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
... ... ...
15 6,7 Assignment for terminal 128
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
BK3xx0 75Version: 4.3.0
Extended functions
Enabling/disabling via the 2-byte PLC interface or through KS2000
The terminals are enabled or disabled through table 1, registers 0-31:
Register Bit Description
0 0,1 Assignment for terminal 1
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
2,3 Assignment for terminal 2
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
4,5 Assignment for terminal 3
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
6,7 Assignment for terminal 4
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
8,9 Assignment for terminal 5
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
10,11 Assignment for terminal 6
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
12,13 Assignment for terminal 7
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
14,15 Assignment for terminal 8
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
... ... ...
31 14,15 Assignment for terminal 128
0: DP-DataExchange (Default)
2: disabled (Multi-Config-Mode)
Note the size of the Cfg data
It can happen under multi-configuration mode that the CfgData exceeds 64 bytes.
In such a case, the CfgData [}76] must be enlarged.
7.5 Changing the Size of the Process Data
Exceeding the input data length (InputData)
By default, a maximum of 128 bytes of input data is set on the Bus Coupler.
The maximum lengths of the DP buffers can be changed, although the amount by which a length is
increased has to be subtracted from another, and the sizes must only be modified in 8-byte steps:
Exceeding the output data length (OutputData)
By default, a maximum of 128 bytes of output data is set on the Bus Coupler.
The maximum length of the DP buffer can be changed. The amount, however, by which one length is
increased must be taken away from another, and it must be noted that the sizes can only be changed in 8byte steps:
BK3xx076 Version: 4.3.0
Extended functions
Exceeding the configuration data length (CfgData)
By default, a maximum of 64 bytes of configuration data is set on the Bus Coupler. Normally, this is only a
problem in very rare cases. In multi-configuration mode, however, this limit is reached with no more than a
30 digital terminals, because each KLxxxx MultiCfgMode module occupies two bytes in the configuration
data, on top of which there is at least one sum byte for digital inputs or for digital outputs.
The maximum lengths of the DP buffers can be changed, although the amount by which a length is
increased has to be subtracted from another, and the sizes must only be modified in 8-byte steps:
Maximum DP buffer sizes
DP buffer Maximum sizes under default settings
Inputs 128 bytes
Outputs 128 bytes
Diagnostic data 64 bytes
Configuration data 64 bytes
Setting via the 2-BYTE PLC interface or KS2000
The maximum DP buffer sizes can be modified in Table 100, although it is necessary for the Bus Coupler to
be reset (power off/power on, or a software reset) before the new value is adopted:
Register Description
2 maximum length of input data
3 maximum length of output data
4 maximum length of diagnosis data
5 maximum length of configuration data
Setting via UserPrmData
The Bus Coupler's reset is carried out automatically if the DP buffers are set using UserPrmData [}35]:
Byte Bit Description
12 4-7 15 dec or 0xF hex: the maximum DP buffer lengths are changed using the values
from UserPrmData 37-40
37 0-7 maximum length of input data
38 0-7 maximum length of output data
39 0-7 maximum length of diagnosis data
40 0-7 maximum length of configuration data
Example1:Notenoughconfigurationdata
128bytesinput
128bytesoutput
80bytesCfgData
48bytesdiagnosisdata
Example2:Notenoughinputdata
160bytesinput
96bytesoutput
64bytesCfgData
64bytesdiagnosisdata
7.6 Bus Coupler versions in multi-configuration mode
Structure of a production machine
Production machines often consist of a machine part that is always present in the machine and of machine
extensions that may be added as options. This division also usually applies as well both to the software (the
control program) and to the hardware (the necessary process signals via Beckhoff Bus Terminals)
BK3xx0 77Version: 4.3.0
Extended functions
associated with the machine. A machine, with machine extensions A, B and C, whose process signals are to
be read or output over the PROFIBUS DP through Beckhoff Bus Couplers BK3110, BK3120 or BK3520,
could be structured as follows.
Fig.46: Representation of a production machine
The machine illustrated consists of a controller (e.g. TwinCAT, S7-400, etc.), a PROFIBUS DP master
interface (e.g. FC3101, CP???, etc.) that sends or receives the process signals over the PROFIBUS DP, and
of Bus Couplers with Bus Terminals that form the interface to the machine process. The areas shown in grey
relate to machine parts that are always present. The machine extensions A, B and C are shown in red, green
and blue. It can be seen that each machine extension is associated both with software modules within the
control program and process signals that are connected to the controller via Bus Terminals.
Because the machine builder will not want to maintain eight different control programs for all possible
combinations of the machine extensions, it is helpful if the control program is designed in such a way that the
necessary software modules are activated according to whichever machine extensions are in fact being
used. In order to create a control program suited to all implementation levels of the machine it is however
necessary for the same process signals always to appear at the same addresses in the controller's process
image, independently of which process signals are in fact present in the relevant implementation level. For
conventional DP slaves, a different configuration of the PROFIBUS DP master interface is necessary in such
cases. The following sections explain how this problem can be solved with Beckhoff Bus Couplers, using a
single configuration of the PROFIBUS DP master interface.
The advantage of this solution is that two machine configurations only differ in terms of the hardware used
(machine components and Bus Terminals), but not in terms of the software. If the machine is upgraded, it is
only necessary for the additional Bus Terminals to be inserted and wired-up, and for the relevant extension
to be activated (e.g. via the man-machine interface to the machine). Software changes are no longer
required.
Process image interfaces
The interfaces between controller, PROFIBUS DP master interface, Bus Coupler and Bus Terminals form
process images, in which the process signals are stored according to certain algorithms.
BK3xx078 Version: 4.3.0
Extended functions
Fig.47: Process image of the production machine
The process signals of a DP slave (Bus Coupler BK3110, BK3120 or BK3520) are always transferred in a
Data_Exchange telegram, in which the outputs are sent by the DP master and the inputs are received in the
associated telegram response. In the PROFIBUS DP master interface, the process images exchanged with
the Bus Couplers are mapped to the process images of the control according to a mapping rule.
Process images of the machine configurations
As shown in the two examples in the figure below, the mapping rule in the PROFIBUS DP master interface
changes, depending on which machine extensions are used (there are two examples here).
BK3xx0 79Version: 4.3.0
Extended functions
Fig.48: Process images of the two different machine configurations
In order to solve the problem of the changed mapping rule, a facility is provided in the BK3110, BK3120 and
BK3520 Bus Couplers through which the mapping can be carried out in the Bus Coupler (multi-configuration
mode), so that they always exchange the same process image with the PROFIBUS DP master,
independently of the Bus Terminals present:
Setting the Bus Terminal extension in the Bus Coupler
So that the same process image can always be transferred between the PROFIBUS DP master and the Bus
Coupler, independently of the implementation level of the machine or of the Bus Terminals, the maximum
Bus Terminal implementation for the Bus Coupler is always configured in the PROFIBUS DP master under
multi-configuration mode. This PROFIBUS DP configuration is sent from the PROFIBUS DP master to the
Bus Coupler when the PROFIBUS DP bus is starting up. This then compares the received PROFIBUS DP
configuration with the bus terminals that are actually present.
BK3xx080 Version: 4.3.0
Extended functions
If the Bus Coupler is not already being operated with the maximum Bus Terminal implementation level, the
PROFIBUS DP configuration will not agree with the Bus Terminal structure that it finds. So that the Bus
Coupler can nevertheless represent the process signals from the connected Bus Terminals in the process
image that is to be exchanged with the PROFIBUS DP master, the mapping rule is now required.
Because the Bus Coupler maps the process signals from the Bus Terminals into the DP process image
according to a fixed algorithm (first complex, then digital terminals, each in the sequence in which they are
plugged in), the only information that is missing is that of which of the Bus Terminals that are included in the
PROFIBUS DP configuration are indeed truly present. This information can be transmitted via the acyclic
DPV1 Write, or through the 2-byte PLC interface for those PROFIBUS DP master interfaces that do not
support PROFIBUS DPV1. The acyclic DPV1 Write is usually available through function blocks (TwinCAT:
ADS-Write, S7 400: SFB 52 (read) and SFB53 (write)) from the controller program. The 2-byte PLC interface
of the Bus Coupler is mapped directly into the controller's process image. As soon as a machine extension is
activated or deactivated, the controller program can therefore activate or deactivate the associated Bus
Terminals.
Example as above, where deactivated terminals are marked in yellow:
Fig.49: Process images of the two different machine configurations with deactivated terminals
BK3xx0 81Version: 4.3.0
Extended functions
State transitions in the Bus Coupler
If the PROFIBUS DP configuration received does match the Bus Terminal configuration in multi-configuration
mode, the Bus Coupler sets the "static diagnostics" bit in the PROFIBUS DP diagnostic data and delays the
execution of a terminal bus cycle (I/O RUN LED remains off). As soon as the terminal assignment (activated/
not activated) has been written by the PROFIBUS DP master, the Bus Coupler again carries out an
examination of the PROFIBUS DP configuration, and automatically enters cyclic data exchange (the "static
diagnosis" bit in PROFIBUS DP diagnostic data is cleared, and the terminal bus cycle is executed cyclically
(the I/O-RUN LED goes on during the terminal cycle)). Furthermore, the terminal assignment is stored in the
non-volatile memory of the Bus Coupler, so that during a restart of the PROFIBUS DP, the PROFIBUS DP
master does not have to write the terminal configuration again.
BK3xx082 Version: 4.3.0
Extended functions
Fig.50: State transitions in the Bus Coupler
BK3xx0 83Version: 4.3.0
Appendix
8 Appendix
8.1 General operating conditions
The following conditions must be met in order to ensure flawless operation of the fieldbus components.
Environmental conditions
Operation
The components may not be used without additional protection in the following locations:
• in difficult environments, such as where there are corrosive vapors or gases, or high dust levels
• in the presence of high levels of ionizing radiation
Condition Permissible range
Permissible ambient temperature during operation see technical data
Installation position variable
Vibration resistance According to EN60068-2-6
Shock resistance According to EN60068-2-27
EMC resistance According to EN61000-6-2
Emission According to EN61000-6-4
Transport and storage
Condition Permissible range
Permissible ambient temperature during storage -25°C... +85°C
Relative humidity 95 %, no condensation
Free fall up to 1 m in the original packaging
Protection classes and types
Condition Permissible range
Protection class in accordance with IEC 536 (VDE
0106, Part 1)
Protection class conforms to IEC 529 IP20 (protection against contact with a standard test
Protection against foreign objects Less than 12mm in diameter
Protection against water no protection
Component identification
Every supplied component includes an adhesive label providing information about the product's approvals.
For example, on the BK2000:
A protective conductor connection to the mounting rail is
necessary!
finger)
BK3xx084 Version: 4.3.0
Fig.51: Sticker with information about the BK2000 Bus Coupler certification
The following information is printed on the label:
Appendix
Printed item Meaning for this label
Precise product
identification
Supply voltage 24 V
Data transfer rate 2.5 Mbit/s
Manufacturer Beckhoff Automation GmbH
CE mark Conformity mark
UL mark Mark for UL approval. UL stands for the Underwriters Laboratories Inc., the
Production identification From left to right, this sequence of characters indicates the week of production
Lightbus Coupler BK2000
DC
leading certification Organisation for North America, based in the USA.
C = Canada, US = USA, LISTED 22ZA (the test results can be inspected
under this entry)
(2 characters), the year of production (2 characters), the software version (2
characters) and hardware version (2 characters), along with any special
indications (4 characters).
This case therefore is a BK2000
- produced in the 9th calendar week
- in the year 2001
- containing the BF firmware version
- and using the 6th hardware version
- with no special indications
8.2 Approvals
Underwriter laboratories
UL E172151
Conformity mark
CE
BK3xx0 85Version: 4.3.0
Appendix
Protection class
IP20 conforms to EN60529
8.3 Bibliography
German books
PROFIBUS
• PROFIBUS-DP/DPV1
Basic principles, tips and tricks for users
by Manfred Popp
ISBN: 3778527819
General fieldbus technology
• Gerhard Gruhler (Pub.): Fieldbuses and device communication systems
Practical knowledge with comparison options
Franzis Verlag 2001
244 pages
ISBN 3-7723-5745-8
English books
(in preparation)
Standards PROFIBUS-DP
• IEC 61158 and IEC 61784
• DIN 19245, Part 3
• Euronorm EN 50170
Web sites
• http://www.profibus.de
8.4 List of Abbreviations
DP
Decentralised periphery. PROFIBUS protocol for fast cyclic data exchange
FMS
PROFIBUS transfer protocol (Fieldbus Message Specification).
Freeze mode
This command makes the slave freeze its inputs
GSD file
German device master file
GSE file
English device master file
BK3xx086 Version: 4.3.0
IP20, IP65, IP66, IP67
Protection class (contact, water, dust)
K-bus
Terminal Bus: Internal bus for communication between Bus Coupler and Bus Terminals
PNO
PROFIBUS User Organisation (seewww.profibus.de)
Repeater
Provides signal conditioning, connecting individual bus segments
PLC
Programmable logic controller
Sync mode
Appendix
This command makes the slave hold its outputs unchanged until it receives the Sync telegram.
BK3xx0 87Version: 4.3.0
Appendix
8.5 Support and Service
Beckhoff and their partners around the world offer comprehensive support and service, making available fast
and competent assistance with all questions related to Beckhoff products and system solutions.
Beckhoff's branch offices and representatives
Please contact your Beckhoff branch office or representative for local support and service on Beckhoff
products!
The addresses of Beckhoff's branch offices and representatives round the world can be found on her internet
pages:
http://www.beckhoff.com
You will also find further documentation for Beckhoff components there.
Beckhoff Headquarters
Beckhoff Automation GmbH & Co. KG
Huelshorstweg 20
33415 Verl
Germany
Phone: +49(0)5246/963-0
Fax: +49(0)5246/963-198
e-mail: info@beckhoff.com
Beckhoff Support
Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:
• support
• design, programming and commissioning of complex automation systems
• and extensive training program for Beckhoff system components
Hotline: +49(0)5246/963-157
Fax: +49(0)5246/963-9157
e-mail: support@beckhoff.com
Beckhoff Service
The Beckhoff Service Center supports you in all matters of after-sales service:
• on-site service
• repair service
• spare parts service
• hotline service
Hotline: +49(0)5246/963-460
Fax: +49(0)5246/963-479
e-mail: service@beckhoff.com
BK3xx088 Version: 4.3.0
List of illustrations
List of illustrations
Fig. 1 BK3120 and LC3100 - Bus Couplers for PROFIBUS DP ............................................................ 9
Fig. 2 BK3150 - Bus Coupler for PROFIBUS DP ................................................................................. 11
Fig. 3 BK3500 and BK3520 - Bus Couplers with optical fiber connection for PROFIBUS DP............... 13
Fig. 4 Spring contacts of the Beckhoff I/O components......................................................................... 18
Fig. 5 Dimensions, using BK3120 and LC3100 as examples................................................................ 19
Fig. 6 Release the locking mechanism by pulling the orange tab.......................................................... 20
Fig. 7 Groove and tongue of the housings............................................................................................. 20
Fig. 8 Standard wiring............................................................................................................................ 21
Fig. 9 Pluggable wiring .......................................................................................................................... 21
Fig. 10 High Density Terminals................................................................................................................ 22
Fig. 11 Connecting a cable on a terminal point ....................................................................................... 23
Fig. 12 Potential groups of a Bus Terminal block .................................................................................... 24
Fig. 13 Power contact on the left ............................................................................................................. 25
Fig. 14 Power supply connections for BKxx00, BKxx10, BKxx20 and LCxxxx ........................................ 26
Fig. 15 Power supply connections for BKxx50 and BKxx51 .................................................................... 27
Fig. 16 UL identification ........................................................................................................................... 27
Fig. 17 Potential connection diagram of an EKxxxx ................................................................................ 28
Fig. 18 Pin assignment M12 socket (-B310) ............................................................................................ 29
Fig. 19 Pin assignment M12 socket/plug connector (-B318) ................................................................... 29
Fig. 20 Pin assignment of the PROFIBUS D-sub socket ......................................................................... 29
Fig. 21 Pin assignment socket/plug connector Fieldbus Box modules .................................................... 30
Fig. 22 PROFIBUS cable assignment ..................................................................................................... 31
Fig. 23 Start-up behaviour of the Bus Coupler ........................................................................................ 35
Fig. 24 KS2000 configuration software .................................................................................................... 42
Fig. 25 TwinCAT System Manager .......................................................................................................... 44
Fig. 26 Configuration of the PROFIBUS DP I/O modules - selection of the PROFIBUS DP master PC
card.............................................................................................................................................. 45
Fig. 27 Configuration of the PROFIBUS DP I/O modules - inserting the bus nodes ............................... 45
Fig. 28 Configuration of the PROFIBUS DP I/O modules - appending the Bus Terminals...................... 46
Fig. 29 Busklemn.bmp ............................................................................................................................. 46
Fig. 30 Busklems.bmp ............................................................................................................................. 46
Fig. 31 Parameter data for the BK3120 ................................................................................................... 47
Fig. 32 Example for entering individual bytes. ......................................................................................... 48
Fig. 33 Example for entering associated bytes. ....................................................................................... 49
Fig. 34 Example for compact representation of the Bus Terminal KL3312 ............................................. 50
Fig. 35 Example for compact representation of the Bus Terminal KL3312 ............................................. 50
Fig. 36 Output data in the Bus Coupler ................................................................................................... 52
Fig. 37 Input data in the Bus Coupler ..................................................................................................... 52
Fig. 38 Configuration of the K-bus cycle for the DP couplers .................................................................. 53
Fig. 39 K-bus - Slow FreeRun mode (default setting).............................................................................. 53
Fig. 40 K-bus mode fast FreeRun............................................................................................................ 54
Fig. 41 K-bus - standard synchronous mode ........................................................................................... 54
Fig. 42 K-bus - synchronous mode with optimized input update (one cycle)........................................... 55
Fig. 43 K-bus - synchronous mode with optimized input update (two cycles) ......................................... 55
BK3xx0 89Version: 4.3.0
List of illustrations
Fig. 44 LEDs BK3120 and BK3150 ......................................................................................................... 61
Fig. 45 LEDs LC3100 .............................................................................................................................. 62
Fig. 46 Representation of a production machine ..................................................................................... 78
Fig. 47 Process image of the production machine................................................................................... 79
Fig. 48 Process images of the two different machine configurations....................................................... 80
Fig. 49 Process images of the two different machine configurations with deactivated terminals ............ 81
Fig. 50 State transitions in the Bus Coupler ............................................................................................ 83
Fig. 51 Sticker with information about the BK2000 Bus Coupler certification .......................................... 85
BK3xx090 Version: 4.3.0
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