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
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