BECKHOFF BK3xx0 User Manual

Version: 3.5.1

Date: 2006-02-10

BK3xx0 - Bus Coupler for PROFIBUS DP

Contents

Contents

BK3xx0 - Bus Coupler for PROFIBUS DP

1. Foreword
Notes on the Documentation	3
Safety Instructions	4
Documentation Issue Status	5

2. Product Overview	6
Technical Data	6
Technical Data (Optical Fibres)	9
System Overview	10
PROFIBUS - Introduction	12
PROFIBUS DP	12
PROFIBUS DPV1	14

3. Mounting and Wiring	15
Mechanical Installation	15
Dimensions	15
Assembly	16
Wiring	17
Potential groups, insulation testing and PE	17
Power Supply and Potential Groups	19
PROFIBUS Cabeling	22
PROFIBUS Connection	22
PROFIBUS Cabling	24

4. Parameterisation and Commissioning	26
Start-up behaviour of the Bus Coupler	26
The Bus Coupler's UserPrmData	27
Technical Data - Summary	29
Configuration	30
Configuration - CfgData	30
Configuration of the Coupler Modules	31
Configuration of Complex Modules	32
Configuration of Digital Modules	34
GSD Files	35
Configuration Software KS2000	37
Configuration with TwinCAT	38
Configuration with S7	41
Configuration: Siemens S7 Controller	41
Configuration: Siemens S7 Controller BK3120	42
Fieldbus Components	1

Contents

5. PROFIBUS DP Comunication	47
Cyclic Data Exchange	47
Process Data, Process Image	47
K-Bus Cycle	49
DPV1 - Acyclic Data Transfer	53
DPV1 Interface	53
Assignment of the DPV1 Slot Number	54
DPV1 at the Coupler	55
Module Assignment	55
Firmware Information	56
Terminal Composition	57
K-Bus Status	58
Cycle Time Measuring	59

6. Diagnosis and Error Handling	60
LEDs	60
Overview	60
DP Diagnostic	65
DP Diagnostic Data (DiagData)	65
Errors during DP Start-up	68
Reaction to PROFIBUS Error	70
K-Bus Diagnostic	71
K-Bus Interruption	71
Terminal Diagnostics	72

7. Extended Functions	73
2-byte PLC Interface	73
Word Alignment	74
Deactivating the CfgData Check	75
Multi-Configuration Mode	76
Changing the Size of the Process Data	80
Implementation Levels of the Bus Coupler in
Multi-Configuration Mode	82

8. Appendix	88
General Operating Conditions	88
Approvals	90
Bibliography	91
List of Abbreviations	92
Support and Service	93

2	Fieldbus Components

Notes on the Documentation

1. Foreword

Notes on the Documentation

This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards. It is essential that the following notes and explanations are followed when installing and commissioning these components.

Liability Conditions

The responsible staff must ensure that the application or use of the products described satisfy all the requirements for safety, including all the relevant laws, regulations, guidelines and standards.

The documentation has been prepared with care. The products described are, however, constantly under development. For that reason the documentation is not in every case checked for consistency with performance data, standards or other characteristics. None of the statements of this manual represents a guarantee (Garantie) in the meaning of § 443 BGB of the German Civil Code or a statement about the contractually expected fitness for a particular purpose in the meaning of § 434 par. 1 sentence 1 BGB. In the event that it contains technical or editorial errors, we retain the right to make alterations at any time and without warning. No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in this documentation.

© This documentation is copyrighted. Any reproduction or third party use of this publication, whether in whole or in part, without the written permission of Beckhoff Automation GmbH, is forbidden.

Fieldbus Components

3

Notes on the Documentation

Safety Instructions

Safety Rules

The responsible staff must ensure that the application or use of the products described satisfy all the requirements for safety, including all the relevant laws, regulations, guidelines and standards.

State at Delivery

All the components are supplied in particular hardware and software configurations appropriate for the application. Modifications to hardware or software configurations other than those described in the documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH.

Personnel Qualification

This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards.

Description of safety symbols

The following safety symbols are used in this operating manual. They are intended to alert the reader to the associated safety instructions.

This symbol is intended to highlight risks for the life or health of personnel.

Danger

This symbol is intended to highlight risks for equipment, materials or the environment.

Warning

This symbol indicates information that contributes to better understanding.

Note

4	Fieldbus Components

Notes on the Documentation

Documentation Issue Status

Version	Status
3.5.1	Notes about UL certification added
3.5	BK3150 with firmware version B0 added
3.03	Corrections in the context of the translation into the english language
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

Fieldbus Components

5

Notes on the Documentation

2. Product Overview

Technical Data

Technical data BK3000, BK3010, BK3100, BK3110, BK3120, LC3100

	BK3000,		BK3100,
Type	BK3010		BK3110	BK3120	LC3100

Number of Bus	64
Terminals
Digital peripheral	512 inputs/outputs
signals
Analog peripheral	128 inputs/outputs (BK3x00)
signals

	64 (255 with K-Bus	64
	extension)
	max. 1020	256 inputs/outputs
	inputs/outputs
	max. 64 inputs/outputs
		-

Configuration	Via the KS2000 configuration software or the controller
possibility
Maximum number	BK3000: 244	BK3100:	128 bytes	32 bytes
of bytes	bytes	64 bytes (DP and
(inputs and		FMS operation)
outputs)		128 bytes (DP
		operation only)
	BK3010: 32	BK3110: 32 bytes
	bytes
Baud rate	up to max.	up to max. 12 MBaud
(automatic	1.5 MBaud
detection)
Bus connection	1 x D-sub plug, 9-pin with shielding			spring-loaded terminals
Power supply	24 VDC (-15 % /+20 %)
Input current	70 mA + (total K-Bus current)/4,		70 mA + (total K-Bus	70 mA + (total K-Bus
	max. 500 mA (BK3x00)		current)/4, max. 500 mA	current)/4, max. 200 mA
	70 mA + (total K-Bus current)/4,
	max. 200 mA (BK3x10)
Starting current	2.5 x continuous current

6	Fieldbus Components

							Notes on the Documentation
		BK3000,	BK3100,
	Type	BK3010	BK3110		BK3120		LC3100
K-Bus current up to		1750 mA (BK3x00)			1750 mA		500 mA
		500 mA (BK3x10)
	Power contact voltage	maximum 24 VDC
	(Up)
	Power contact current	maximum 10 A
	load (Up)
	Recommended fuse	maximum 10 A
	(Up)
	Electrical isolation	power contact / supply / fieldbus					power supply / fieldbus
	Dielectric strength	500 Vrms (power contact / supply / fieldbus)					500 Vrms (supply /
							fieldbus)
	Weight	approx. 170 g	approx. 150 g			approx. 170 g	approx. 100 g
	Permissible ambient	0 °C … +55 °C
	temperature
	(operation)
	Permissible ambient	-25 °C … +85 °C
	temperature (storage)
	Permissible relative	95 % (no condensation)
	humidity
	Vibration / shock	according to EN 60068-2-6 / EN 60068-2-27, EN 60068-2-29
	resistance
	EMC resistance Burst /	according to EN 61000-6-2 (EN 50082) / EN 61000-6-4 (EN 50081)
	ESD
	Protection class	IP 20
	Installation position	variable

BK3150

Fieldbus Components

7

Notes on the Documentation

Technical data BK3150

	Type		BK3150
	Number of Bus Terminals		64 (255 with K-Bus extension)
	Digital peripheral signals		max. 1020 inputs/outputs
	Analog peripheral signals		max. 64 inputs/outputs
	Configuration possibility		Via the KS2000 configuration software or the controller
	Maximum number of bytes		128 Byte (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)		24 VDC (-15 % /+20 %) To meet the UL requirements use a 4 A fuse or
			a power supply that has to satisfy NEC class 2!
	Input current (Us)		70 mA + (total K bus current)/4, max. 320 mA
	Starting current (Us)		2,5 x continuous current
	Recommended fuse		maximum 10 A
	K-Bus power supply up to		1000 mA
	Power contact voltage		maximum 24 VDC
	Power contact current load		maximum 10 A
	Electrical isolation		power contact / supply / fieldbus
	Dielectric strength		500 Vrms (power contact / supply / fieldbus)
	Weight		app. 100 g
	Permissible ambient temperature		0 °C … +55 °C
	(operation)
	Permissible ambient temperature		-25 °C … +85 °C
	(storage)
	Permissible relative humidity		95 % (no condensation)
	Vibration / shock resistance		according to EN 60068-2-6 / EN 60068-2-27, EN 60068-2-29
	EMC resistance Burst / ESD		according to EN 61000-6-2 / EN 61000-6-4
	Protection class		IP 20
	Installation position		variable

8	Fieldbus Components

Notes on the Documentation

Technical Data (Optical Fibres)

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
Maximum number of bytes	128 bytes	128 bytes
(inputs and outputs)
Baud rates	up to max. 1.5 Mbaud (manual	up to max. 12 Mbaud (automatic
	setting)	detection)
Bus connection	1 x optical fibre with 2 HP	2 x optical fibres with 2 HP Simplex
	Simplex connectors	connectors each
Power supply	24 VDC (-15 %/+20 %)
Input current	70 mA + (total K-Bus current)/4, 500 mA, 500 mA max.
Starting current	2.5 x continuous current
Recommended fuse	maximum 10 A
K-Bus power supply up to	1750 mA
Power contact voltage	maximum 24 VDC
Power contact current load	maximum 10 A
Electrical isolation	power contact / supply / fieldbus
Dielectric strength	500 Vrms (power contact / supply / fieldbus)
Weight	approx. 170 g	approx. 170 g
Permissible ambient temperature	0 °C … +55 °C
(operation)
Permissible ambient temperature	-25 °C … +85 °C
(storage)
Permissible relative humidity	95 % (no condensation)
Vibration / shock resistance	according to EN 60068-2-6 / EN 60068-2-27, EN 60068-2-29
EMC resistance Burst / ESD	according to EN 61000-6-2 (EN 50082) / EN 61000-6-4 (EN 50081)
Protection class	IP 20
Installation position	variable
Fieldbus Components		9

Notes on the Documentation

The Beckhoff Bus Terminal System

Up to 64 Bus Terminals each having 2 I/O channels for each signal form

The Bus Terminal system is the universal interface between a fieldbus system and the sensor / actuator level. A unit consists of a Bus Coupler as the head station, and up to 64 electronic series terminals, the last one being an end terminal. For each technical signal form, terminals are available each having two I/O channels, and these can be mixed in any order. All the terminal types have the same mechanical construction, so that difficulties of planning and design are minimized. The height and depth match the dimensions of compact terminal boxes.

Decentralized wiring of each I/O level

Fieldbus technology allows more compact forms of controller to be used. The I/O level does not have to be brought to the controller. The sensors and actuators can be wired decentrally, using minimum cable lengths. The controller can be installed at any location within the plant.

Industrial PCs as controllers

The use of an Industrial PC as the controller means that the operating and observing element can be implemented in the controller’s hardware. The controller can therefore be located at an operating panel, in a control room, or at some similar place. The Bus Terminals form the decentralized input/output level of the controller in the control cabinet and the subsidiary terminal boxes. The power sector of the plant is also controlled over the bus system in addition to the sensor/actuator level. The Bus Terminal replaces the conventional series terminal as the wiring level in the control cabinet. The control cabinet can have smaller dimensions.

Bus Couplers for all usual bus systems

The Beckhoff Bus Terminal system unites the advantages of a bus system with the possibilities of the compact series terminal. Bus Terminals can be driven within all the usual bus systems, thus reducing the controller parts count. The Bus Terminals then behave like conventional connections for that bus system. All the performance features of the particular bus system are supported.

Assembly on standardized C mounting rails

The easy, space-saving, assembly on a standardized C-rail, and the direct wiring of actuators and sensors, without cross-connections between the terminals, standardizes the installation. The consistent labelling scheme also contributes.

The small physical size and the great flexibility of the Bus Terminal system allows it to be used wherever a series terminal is also used. Every type of connection, such as analog, digital, serial or the direct connection of sensors can be implemented.

Modularity

The modular assembly of the terminal strip with Bus Terminals of various functions limits the number of unused channels to a maximum of one per function. The presence of two channels in one terminal is the optimum compromise of unused channels and the cost of each channel. The possibility of electrical isolation through potential feed terminals also helps to keep the number of unused channels low.

Display of the channel state

The integrated LEDs show the state of the channel at a location close to the sensors and actuators.

10	Fieldbus Components

Notes on the Documentation

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 64 terminals can be used within one terminal strip. This count does include potential feed terminals, but not the end terminal.

Bus Couplers for various fieldbus systems

Various Bus Couplers can be used to couple the electronic terminal strip quickly and easily to different fieldbus systems. It is also possible to convert to another fieldbus system at a later time. The bus coupler performs all the monitoring and control tasks that are necessary for operation of the connected Bus Terminals. The operation and configuration of the Bus Terminals is carried out exclusively by the Bus Coupler. Nevertheless, the parameters that have been set are stored in each Bus Terminal, and are retained in the event of voltage drop-out. Fieldbus, K-Bus and I/O level are electrically isolated.

If the exchange of data over the fieldbus is prone to errors or fails for a period of time, register contents (such as counter states) are retained, digital outputs are cleared, and analog outputs take a value that can be configured for each output when commissioning. The default setting for analog outputs is 0 V or 0 mA. Digital outputs return in the inactive state. The timeout periods for the Bus Couplers correspond to the usual settings for the fieldbus system. When converting to a different bus system it is necessary to bear in mind the need to change the timeout periods if the bus cycle time is longer.

The interfaces

A Bus Coupler has six different methods of connection. These interfaces are designed as plug connectors and as spring-loaded terminals.

Fieldbus Components

11

Notes on the Documentation

PROFIBUS - Introduction

PROFIBUS DP

In PROFIBUS DP systems, a master (PLC, PC etc.) usually communicates with a large number of slaves (I/Os, drives etc.). Only the master may here actively access the bus (send telegrams on its own initiative), while a DP slave only sends telegrams when it is requested to do so by a 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 extent of the calculations that the slave must carry out after receiving the parameter and configuration data, it can take up to a few 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 checking the IdentNumber (unique to each DP device)), of DPV1-/DPV2 parameters and of application-specific 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 WAIT-PRM 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

The heart of the PROFIBUS DP protocol is cyclic data exchange, during which the master carries out an exchange of I/O data with every slave during 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 recognises that there is new diagnostic data in the slave. It then fetches that data in the SlaveDiag telegram. This means that diagnostic data is not transmitted to the controller with the cyclic I/O data in real-time, but is always at least one DP cycle later.

12	Fieldbus Components

Notes on the Documentation

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.

Fieldbus Components

13

Notes on the Documentation

PROFIBUS DPV1

PROFIBUS DPV1 refers primarily to the acyclic read and write telegrams, with which data sets in the slave are acyclically accessed. A distinction between a Class 1 and a Class 2 master is also made for DPV1. The difference between acyclic Class 1 (C1) and Class 2 (C2) connections is that the acyclic C1 connection is established during the DP StartUp phase of cyclic DP operation. Once the slave has reached the WAIT-CFG state it is possible for acyclic DPV1-C1 read and write telegrams to be sent from the master to the slave, whereas the C2 connection is established separately, independently of the cyclic DP connection. This is usually carried out by a second (C2) master so that, for instance, a manufacturer-specific project configuration and diagnostic tool can access the slave's data.

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 favourable than in the case of a single master system.

14	Fieldbus Components

Notes on the Documentation

3. Mounting and Wiring

Mechanical Installation

Dimensions

The system of the Beckhoff Bus Terminals is characterized by low physical volume and high modularity. When planning a project it must be assumed that at least one Bus Coupler and a number of Bus Terminals will be used. The mechanical dimensions of the Bus Couplers are independent of the fieldbus system.

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 12 or 24 mm wide. The front wiring increases the total height of 68mm by about 5 to 10 mm, depending on the wire thickness.

	BK30x0, BK35x0, KL3110,
Mechanical data	BK3120	BK3150	LC3100
Material	polycarbonate, polyamide (PA 6.6)
Dimensions (W x H x D)	50 mm x 100 mm x 68 mm	44 mm x 100 mm x	21 mm x 100 mm x
		68 mm	68 mm
Mounting	on 35 mm C-rail conforming to EN50022 with lock
Side by side mount. by	double slot and key connection
means of
Marking	standard terminal block marking and plain language side (8 mm x 47 mm, not
	BK3150)

Fieldbus Components

15

Notes on the Documentation

Installation

The Bus Coupler and all the Bus Terminals can be clipped, with a light press, onto a 35 mm mounting rail. A locking mechanism prevents the individual housings from being pulled off again. For removal from the mounting rail the orange colored tension strap releases the latching mechanism, allowing the housing to be pulled off the rail without any force.

Up to 64 Bus Terminals can be attached to the Bus Coupler on the right hand side. When plugging the components together, be sure to assemble the housings with groove and tongue against each other. A properly working connection can not be made by pushing the housings together on the mounting rail. When correctly assembled, no significant gap can be seen between the attached housings.

Insertion and removal of Bus Terminals is only permitted when switched off. The electronics

in the Bus Terminals and in the Bus Coupler are protected to a large measure against Warning damage, but incorrect function and damage cannot be ruled out if they are plugged in under

power.

The right hand part of the Bus Coupler can be compared to a Bus Terminal. Eight connections at the top enable the connection with solid or fine wires from 0.08 mm² to 2.5 mm². The connection is implemented with the aid of a spring device. The spring-loaded terminal is opened with a screwdriver or rod, by exerting gentle pressure in the opening above the terminal. The wire can be inserted into the terminal without any force. The terminal closes automatically when the pressure is released, holding the wire securely and permanently.

16	Fieldbus Components

Notes on the Documentation

Wiring

Potential Groups, Insulation Testing and PE

Potential groups

The Beckhoff Bus Terminals stations usually have three different potential groups:

∙The fieldbus interface is electrically isolated (except for individual Low Cost couplers) and forms the first potential group

∙Bus Coupler / Bus Terminal Controller logic, K-Bus and terminal logic form a second galvanically separated potential group

∙The inputs and outputs are supplied via the power contacts and form further potential groups.

Groups of I/O terminals can be consolidated to further potential groups via potential supply terminals or separation terminals.

Insulation testing

The connection between the Bus Coupler / Bus Terminal Controller and the Bus Terminals is automatically realized by pushing the components together. The transfer of the data and the supply voltage for the intelligent electronics in the Bus Terminals is performed by the K-Bus. The supply of the field electronics is performed through the power contacts. Plugging together the power contacts creates a supply rail. Since some Bus Terminals (e.g. analog Bus Terminals or 4-channel digital Bus Terminals) are not looped through these power contacts (or not completely) the Bus Terminal contact assignments must be considered.

The potential feed terminals interrupt the power contacts, and represent the start of a new supply rail. The Bus Coupler / Bus Terminal Controller can also be made use of to feed the power contacts.

Fieldbus Components

17

Notes on the Documentation

PE power contacts

The power contact labelled PE can be used as a protective earth. For safety reasons this contact mates first when plugging together, and can ground short-circuit currents of up to 125 A.

It should be noted that, for reasons of electromagnetic compatibility, the PE contacts are capacitively coupled to the mounting rail. This can both lead to misleading results and to damaging the terminal during insulation testing (e.g. breakdown of the insulation from a 230 V power consuming device to the PE conductor). The PE conductor to the Bus Coupler / Bus Terminal Controller must be disconnected for the insulation testing. In order to uncouple further feed locations for the purposes of testing, the feed terminals can be pulled at least 10 mm out from the connected group of other terminals. In that case, the PE conductors do not have to be disconnected.

The PE power contact must not be used for other potentials.

18	Fieldbus Components

Notes on the Documentation

Power Supply

Bus Coupler / Bus Terminal Controller and Bus Terminal Supply (Us)

BKxx00, BKxx10, BKxx20 and LCxxxx

The Bus Coupler / Bus Terminal Controller require a 24 VDC supply for their operation.

The connection is made by means of the upper spring-loaded terminals labeled 24 V and 0 V. This supply voltage feeds the Bus Coupler / Bus Terminal Controller electronics and, over the K-Bus, the electronics of the Bus Terminals. It is electrically separated from the potential of the field level.

Fieldbus Components

19

Notes on the Documentation

BKxx50 and BKxx51

The Bus Coupler / Bus Terminal Controller require a 24 VDC supply for their operation. To meet the UL requirements use 4 A fuse or class 2 power supply!

The connection is made by means of the upper spring-loaded terminals labeled Us and GNDs. This supply voltage feeds the Bus Coupler / Bus Terminal Controller electronics and, over the K-Bus, the electronics of the Bus Terminals. It is electrically separated from the potential of the field level.

UL requirements

Danger

Danger

For the compliance of the UL requirements Us should only be supplied

∙by a 24 VDC supply voltage, supplied by an isolating source and protected by means of a fuse (in accordance with UL248), rated maximum 4 Amp.

∙by a 24 VDC power source, that has to satisfy NEC class 2.

A NEC class 2 power supply shall not be connected in series or parallel with another (class 2) power source!

To meet the UL requirements, Us must not be connected to unlimited power sources!

Power contacts supply (Up)

The bottom six connections with spring-loaded terminals can be used to feed the supply for the peripherals. The spring-loaded terminals are joined in pairs to a power contact. The feed for the power contacts has no connection to the voltage supply for the Bus Coupler / Bus Terminal Controller.

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 drawn from the power contact must not exceed 10 A for long periods. The current carrying capacity between two spring-loaded terminals is identical to that of the connecting wires.

Power contacts

On the right hand face of the Bus Coupler / Bus Terminal Controller there are three spring contacts for the power contact connections. The spring contacts are hidden in slots so that they can not be accidentally touched. By attaching a Bus Terminal the blade contacts on the left hand side of the Bus Terminal are connected to the spring contacts. The tongue and groove guides on the top and bottom of the Bus Coupler / Bus Terminal Controller and of the Bus Terminals enables that the power contacts mate securely.

20	Fieldbus Components

Notes on the Documentation

Configuration and Programming Interface

The Bus Coupler / Bus Terminal Controller have an RS232 interface at the bottom of the front face. The miniature connector can be joined to a PC and the KS2000 configuration software with the aid of a connecting cable. 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.

Electrical isolation

The Bus Coupler / Bus Terminal Controller operate by means of 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.

Remark: All the Bus Terminals are electrically isolated from the K-Bus. The K-Bus is thus electrically isolated from everything else.

Fieldbus Components

21

Notes on the Documentation

PROFIBUS Cabeling

PROFIBUS Connection

M12 circular connector

The M12 socket is inverse coded, and has five pins. Pin 1 is 5 VDC and 3 is GND for the active termination resistor. These must never be misused for other functions, as this can lead to destruction of the device. Pin 2 and pin 4 are the Profibus signals. These must never be swapped over, as this will prevent communication. Pin 5 is the shield, and this is capacitatively coupled to the Fieldbus Box chassis.

M12 socket pin assignment

Nine pole D-Sub

Pin 6 is 5 VDC und Pin 5 is GND for the active termination resistor. These must never be misused for other functions, as this can lead to destruction of the device. Pin 3 and pin 8 are the Profibus signals. These must never be swapped over, as this will prevent communication. Shield is connected to the D-Sub housing that is coupled with lowresistance to the mounting rail.

D-Sub socket pin assignment

22	Fieldbus Components

			Notes on the Documentation
	Profibus conductor colors
	Profibus conductors	M12		D-Sub
	B red	Pin 4		Pin 3
	A green	Pin 2		Pin 8

Connection of FieldbusBox modules

The connection of the Fieldbus Box modules is done direct or via a T-piece (or Y-piece).

The B318 series does have a male and female connector, that means no external T-piece is required. The supply voltage (+5VDC) for the termination resistor is only supplied via the female M12 connector. The termination resistor ZS1000-1610 is only available with male connector, therefore the incoming PROFIBUS line should end in a female connector.

Two T-pieces are available:

∙ZS1031-2600 with +5VDC on male and female connector for the termination resistor

∙ZS1031-2610 with +5VDC only on the female connector

Fieldbus Components

23

Notes on the Documentation

PROFIBUS Cabling

Physical aspects of the data transmission are defined in the Profibus standard (see Profibus layer 1: Physical Layer).

The types of area where a fieldbus system can be used is largely determined by the choice of the transmission medium and the physical bus interface. In addition to the requirements for transmission security, the expense and work involved in acquiring and installing the bus cable is of crucial significance. The Profibus standard therefore allows for a variety of implementations of the transmission technology while retaining a uniform bus protocol.

Cable-based transmission

This version, which accords with the American EIA RS-485 standard, was specified as a basic version for applications in production engineering, building management and drive technology. A twisted copper cable with one pair of conductors is used. Depending on the intended application area (EMC aspects should be considered) the screening may be omitted.

Two types of conductor are available, with differing maximum conductor lengths (see the RS-485 table).

RS485 - Fundamental properties

RS-485 transmission according to the Profibus standard

Network topology	Linear bus, active bus terminator at both ends, stubs are possible.
Medium	Screened twisted cable, screening may be omitted, depending upon the
	environmental conditions (EMC).
Number of stations	32 stations in each segment with no repeater. Can be extended to 127 stations
	with repeater
Max. bus length without	100 m at 12 MBit/s
repeater	200 m at 1500 KBit/s, up to 1.2 km at 93.75 KBit/s
Max. bus length with	Line amplifiers, or repeaters, can increase the bus length up to 10 km. The number
repeater	of repeaters possible is at least 3, and, depending on the manufacturer, may be up
	to 10.
Transmission speed	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
(adjustable in steps)
Plug connector	9-pin D-Sub connector for IP20
	M12 round connector for IP65/67

Cabling for Profibus DP and Profibus FMS

Note the special requirements on the data cable for baud rates greater than 1.5 MBaud. The correct cable is a basic requirement for correct operation of the bus system. If a simple 1.5 Mbaud cable is used, reflections and excessive attenuation can lead to some surprising phenomena. It is possible, for instance, for a connected Profibus station not to achieve a connection, but for it to be included again when the neighboring station is disconnected. Or there may be transmission errors when a specific bit pattern is transmitted. The result of this can be that when the equipment is not operating, Profibus works without faults, but that there are apparently random bus errors after start-up. Reducing the baud rate (< 93,75 kBaud) corrects this faulty behavior.

If reducing the baud rate does not correct the error, then in many cases this can indicate a wiring fault. The two data lines maybe crossed over at one or more connectors, or the termination resistors may not be active, or they may be active at the wrong locations.

Installation is made a great deal more straightforward if pre-assembled cables from BECKHOFF are used! Wiring errors are avoided, and commissioning is more rapidly

Note completed. The BECKHOFF range includes fieldbus cables, power supply cables, sensor cables and accessories such as terminating resistors and T-pieces. Connectors and cables for field assembly are nevertheless also available.

24	Fieldbus Components

Notes on the Documentation

		In systems with more than two stations all devices are wired in parallel. It is essential that
	Note	the bus cables are terminated with resistors at the conductor ends in order to avoid
		reflections and associated transmission problems.

Distances

The bus cable is specified in EN 50170. This yields the following lengths for a bus segment.

Baud rate in kbits/sec	9.6	19.2	93.75	187.5	500	1500	12000
Cable length in m	1200	1200	1200	1000	400	200	100

Stubs up to 1500 kbaud <6.6 m; at 12 Mbaud stub segments should not be used.

Bus segments

A bus segment consists of at most 32 devices. 126 devices are permitted in a Profibus network. Repeaters are required to refresh the signal in order to achieve this number. Each repeater is counted as one device.

IP-Link is the subsidiary bus system for Fieldbus Boxes, whose topology is a ring structure. There is an IP master in the coupler modules (IP230x-Bxxx or IP230x-Cxxx) to which up to 120 extension modules (IExxxx) may be connected. The distance between two modules may not exceed 5 m. When planning and installing the modules, remember that because of the ring structure the IP-Link master must be connected again to the last module.

Installation guidelines

When assembling the modules and laying the cables, observe the technical guidelines provided by the Profibus User Organization (Profibus Nutzerorganisation e.V.) for Profibus DP/FMS (see www.profibus.com).

Checking the Profibus wiring

A Profibus cable (or a cable segment when using repeaters) can be checked with a few simple resistance measurements. The cable should meanwhile be removed from all stations:

1.Resistance between A and B at the start of the lead: approx. 110 Ohm

2.Resistance between A and B at the end of the lead: approx. 110 Ohm

3.Resistance between A at the start and A at the end of the lead: approx. 0 Ohm

4.Resistance between B at the start and B at the end of the lead: approx. 0 Ohm

5.Resistance between screen at the start and screen at the end of the lead: approx. 0 Ohm

If these measurements are successful, the cable is okay. If, in spite of this, bus malfunctions still occur, this is usually a result of EMC interference. Observe the installation notes from the Profibus User Organization (www.profibus.com).

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25

Notes on the Documentation

4. Parameterisation and Commissioning

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. 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.

The Bus Coupler can be made to enter the normal operating state by switching it on again once the fault has been rectified.

26	Fieldbus Components

Notes on the Documentation

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 is obtained in 90% of applications, some of the settings are only contained in text form in the extended GSD file, and these are indicated in the last column by Extended. The standard settings are contained both in the standard and the extended GSD file.

Byte	Bit	Value	Description	GSD file
0	7	0bin	MSAC_C1 connection is not active (default)	Standard
		1bin	MSAC_C1 connection is active (see DPV1)
1	0	0bin	CfgData checking is active (default)	Extended
		1bin	CfgData checking deactivated (see Deactivating the CfgData checking)
2	3	0bin	Diagnostic data is transferred in a form compatible with the BK3100	Extended
		1bin	Diagnostic data is transferred in a form compatible with DPV1 (default)
3	3	0bin	Multi-configuration mode is not active (default)	Extended
		1bin	Multi-configuration mode is active (see Multi-configuration mode)
3	4	0bin	K-Bus cycle counter is not active (default)	Extended
		1bin	K-Bus cycle counter is active (see K-Bus cycle)
3	5	0bin	Dummy output byte not active (default)	Extended
		1bin	Dummy output byte is active (see K-Bus cycle)
3	6	0bin	In multi-configuration mode, the coupler sets the Stat_Diag bit in the	Extended
			diagnostic data if the configuration is not consistent, and does not yet enter
			data exchange (default).
		1bin	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)
5	0	0bin	2-byte PLC interface not activated (default)	Extended
		1bin	2-byte PLC interface is active (see 2-byte PLC interface)
7	0	0bin	Response to K-Bus error: manual K-Bus reset (default) (see K-Bus	Standard
			interruption)
		1bin	Response to K-Bus error: automatic K-Bus reset
7	1	0bin	Terminal diagnosis is not active (default) (see Terminal diagnosis)	Standard
		1bin	Terminal diagnosis is active
7	4	0bin	Diagnostic data for digital terminals included in process image (default) (see	Standard
			Terminal diagnosis)
		1bin	Diagnostic data of digital terminals not in the process image (default)
9	2	0bin	Analog modules are mapped in compact form (only showing the input and/or	Extended
			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)
		1bin	Analog modules are mapped in complex form (with control/status for 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	0bin	Representation in INTEL format	Standard
		1bin	Representation in Motorola format (default)
9	4	0bin	K-Bus mode slow FreeRun (default) (see K-Bus cycle)	Standard
		1bin	K-Bus mode fast FreeRun

Fieldbus Components

27