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Beckhoff
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Fieldbus Box
Installation Manual
296 pgs4.72 Mb0
User Manual
90 pgs1.88 Mb0
Table of contents
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Beckhoff Fieldbus Box User Manual

Documentation | EN
Fieldbus Box for PROFIBUS
2009-10-29 | Version: 1.2.1

Table of contents

Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation issue status ..............................................................................................................7
2 Product Overview ......................................................................................................................................8
2.1 The Fieldbus Box System..................................................................................................................8
2.4.1 Modules - Technical Data ................................................................................................ 13
2.4.2 Controller - Technical Data .............................................................................................. 13
2.4.3 Current Consumption....................................................................................................... 14
3 Profibus ....................................................................................................................................................18
3.4.1 PROFIBUS Cabling ......................................................................................................... 24
3.4.2 PROFIBUS Connection ................................................................................................... 27
3.5.1 Process Data ................................................................................................................... 29
3.5.2 Configuration Data (Cfg Data) ......................................................................................... 30
3.5.3 Activating the DPV1 Functions ........................................................................................ 31
3.6.1 General ............................................................................................................................ 33
3.6.2 Parameter Data ............................................................................................................... 41
4 Parameterization and commissioning...................................................................................................44
4.4.1 Configuration Data (Cfg Data) ......................................................................................... 47
4.4.2 Configuration of the complex Modules ............................................................................ 56
5 Diagnostic LEDs ......................................................................................................................................62
5.5.1 Diagnostic Telegrams Overview ...................................................................................... 71
5.5.2 Diagnostic Telegrams for the Compact Box (IPxxx-B3xx)............................................... 71
5.5.3 Diagnostic Telegrams for the Coupler Box (IL230x-B3xx)............................................... 73
5.5.4 TwinCAT - Example for Diagnostics with the FC310x Fieldbus Card.............................. 76
3Version: 1.2.1
Table of contents
6 Accessories .............................................................................................................................................78
7 Appendix ..................................................................................................................................................84
4 Version: 1.2.1
Foreword

1 Foreword

1.1 Notes on the documentation

Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards. It is essential that the documentation and the following notes and explanations are followed when installing and commissioning these components. It is the duty of the technical personnel to use the documentation published at the respective time of each installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® 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, EP1456722, EP2137893, DE102015105702 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
5Version: 1.2.1
Foreword

1.2 Safety instructions

Safety regulations
Please note the following safety instructions and explanations! Product-specific safety instructions can be found on following pages or in the areas mounting, wiring, commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the application. Modifications to hardware or software configurations other than those described in the documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are familiar with the applicable national standards.
Description of 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.
6 Version: 1.2.1
Foreword

1.3 Documentation issue status

Version Modifications
1.2.1 • System overview updated
1.2 • Check of the IP-Link connection added
1.1 • Expanding of the specification for IP-Link up to 15 meters
1.0 • PROFIBUS-specific contents completed.
• Signal types and the signals' connection assignments have been placed in the fieldbus­neutral documentation covering Signal types (Fieldbus Box I/O Modules). You can find this on
the internet in the Download area at http:// www.beckhoff.com.
0.7 Further Fieldbus Box Modules for special functions added.
0.6 Fieldbus Box Modules for analog signals and special functions added.
0.4 Fieldbus Box Modules added.
0.3 First published version.
7Version: 1.2.1
Product Overview

2 Product Overview

2.1 The Fieldbus Box System

Fieldbus box modules are robust fieldbus stations for a large number of different fieldbus systems. They offer a wide range of I/O functionality. All relevant industrial signals are supported. As well as digital and analog inputs and outputs including thermocouple and RTD inputs, there are also incremental encoder interfaces available for displacement and angle measurement as well as serial interfaces to solve a large number of communications tasks.
Three varieties of signal connection
The digital inputs and outputs can be connected with snap-on 8mm diameter plugs, screw-in M8 connectors, or with screw-in M12 pendants. The M12 version is provided for analog signals.
All important signal types
Special input and output channels on the combination I/O modules can be used for either input or output. It is not necessary to configure them, since the fieldbus interface is available for every combination channel as well as for input and output data. The combination modules give the user all of the advantages of fine signal granularity.
The processor logic, the input circuitry and the power supply for the sensor are all fed from the control voltage. The load voltage for the outputs can be supplied separately. In those Fieldbus Boxes in which only inputs are available, the load power supply, UP, can optionally be connected in order to pass it on downstream.
The states of the Fieldbus Box, the fieldbus connection, the power supplies and of the signals are indicated by LEDs.
The label strips can be machine printed elsewhere, and then inserted.
Fieldbus Boxes can be combined for greater flexibility
In addition to the Compact Box, the Fieldbus Box series also includes extendable devices, namely the Coupler Box and the Extension Box, as well as intelligent devices, the PLC Boxes.
Compact Box
The Compact Box makes the I/O data from the connected digital and analog sensors and actuators available to the fieldbus.
Coupler Box
The Coupler Box also collects I/O data from the Extension Boxes via an interference-proof optical fiber connection (IP-Link). Up to 120 Extension Boxes can be connected to a Coupler Box. In this way a distributed IP67 I/O network is formed with only one fieldbus interface.
The Coupler Box is capable of automatically recognizing the extension modules connected to it during start­up, and maps the I/O data automatically into the fieldbus process image – a configuration is not necessary. The Coupler Box appears, from the fieldbus point of view, along with all of the networked Extension Boxes, as a single participating bus device with a corresponding number of I/O signals.
The Coupler Box corresponds to the Bus Coupler in the BECKHOFF Bus Terminal system. BECKHOFF fieldbus devices made to protection class IP 20 (Bus Terminals) and IP 67 (Fieldbus Box) can be combined without difficulty – the data is handled in the same way in either case.
8 Version: 1.2.1
Product Overview
IP-Link
The IP-Link is an optical fiber connection with a transmission rate of 2 MBits/s which is capable of transmitting 1000 items of binary I/O data in approx. 1 ms, rapidly and securely. Smaller configurations are correspondingly faster. Because of the high usable data rate, the coupling via IP-Link does not reduce the performance of the fieldbus at all.
Low-priced plug connectors made according to Protection Class IP67 can be used for the rapid and simple preparation of the IP-Link cable, in situ. The connection does not require special tools, and can be performed quickly and simply. The IP-Link cables can also be obtained with prepared plugs if required.
The separate supply of the output voltage allows output groups to be switched off individually. Differing potentials can also be created within an extension ring without difficulty, since the IP-Link naturally has optimum electrical isolation.
Extension box
Like the Compact Boxes, the Extension Boxes cover the full spectrum of I/O signals, and may be up to 15m apart. They are remarkably small in size, and lead to particularly economical I/O solutions with high levels of protection. Here again, the digital inputs and outputs may optionally be connected via snap-on 8 mm connectors, or via screw-in connectors (M8 and M12). Analog signal types are provided with the M12 version. The snap-on connectors lock in place positively, forming a shake-proof connection, while the screw­in connectors offer the advantage of high resistance to being pulled out.
PLC Box
The PLC Box is an intelligent Fieldbus Box with PLC functionality for distributed pre-processing of the I/O signals. This allows parts of the application to be farmed out from the central controller. This reduces the load on the CPU and the fieldbus. Distributed counting, controlling and switching are typical applications for the PLC Box. The reaction times are independent of the bus communication and of the higher-level controller.
In the event of a bus or controller failure, maintenance of function (e.g. bringing the process to a safe state in an orderly manner) is possible.
Programming is carried out with TwinCAT in accordance with IEC 61131-3. Five different programming languages are available:
• Instruction List (IL)
• Function Block Diagram (FBD)
• Ladder Diagram (LD)
• Sequential Function Chart (SFC)
• Structured Text (ST)
The program download occurs either via the fieldbus or via the programming interface.
Extensive debugging functions (breakpoint, single step, monitoring, etc) are also available. The PLC Box contains a powerful 16 bit controller, 32/96 kByte program memory and 32/64 kByte data memory. A further 512 bytes of non-volatile memory are available for remanent flags.
PLC Box with IP-Link
The programmable PLC Box with IP-Link provides almost unlimited I/O possibilities. Up to 120 extension modules, with more than 2000 I/Os, can be directly addressed from the PLC program. The PLC Box is thus also suitable for use as a small, autonomous controller for the operation of parts of equipment or small machines.
9Version: 1.2.1
Product Overview

2.2 Fieldbus Box - Naming conventions

The identifications of the Fieldbus Box modules are to be understood as follows: IXxxxy-zyyy
IX describes the design:
"IP" stands for the CompactBox design [}11] "IL" stands for the CouplerBox design (with IP-Link) [}11] "IE" stands for the ExtensionBox design [}11]
xxxy describes the I/O connection:
xxx describes the I/O property: "10x" - 8 x digital inputs "15x" - counter module "20x" - 8 x digital outputs "25x" - PWM module "23x" - 4 x digital inputs and 4 x digital outputs "24x" - 8 x digital inputs and 8 x digital outputs "3xx" - 4 x analog inputs "4xx" - 4 x analog outputs "5xx" - incremental encoder or SSI transducer "6xx" - Gateway module for RS232, RS422, RS485, TTY
y represents the mechanical connection: "0" stands for 8mm snap-on connection, "1" stands for M8 bolted connection "2" stands for M12 bolted connection and "9" stands for M23 bolted connection
zyyy describes the programmability and the fieldbus system
z distinguishes whether the device is a slave or is a programmable slave:
"B" - not programmable "C" - programmable (PLC Box)
"yyy" stands for the fieldbus system and the bus connection: "110" - EtherCAT "200" - Lightbus "310" - PROFIBUS "318" - PROFIBUS with integrated tee-connector "400" - Interbus "510" - CANopen "518" - CANopen with integrated tee-connector "520" - DeviceNet "528" - DeviceNet with integrated tee-connector "730" - Modbus "800" - RS485 "810" - RS232 "900" - Ethernet TCP/IP with RJ45 for the bus connection "901" - Ethernet TCP/IP with M12 for the bus connection "903" - PROFINET "905" - EtherNet/IP
10 Version: 1.2.1
Product Overview
Compact Box
Compact Box
The Compact Box modules offer a wide range of I/O functionality. All relevant industrial signals are supported. The digital inputs and outputs can be connected either with snap-on 8mm diameter plugs, screw­in M8 connectors, or screw-in M12 connectors. The M12 version is made available for analog signals.
Depending on the module, the I/O section and the power supply section can differ.
Coupler Box
Coupler Box
There are three versions of the coupler box named IL230x-Bxxx. It differs from the compact box in that this module offers an interface to what are known as extension boxes. This interface is a subsidiary bus system based on the optical fiber what is known as IPLink. This powerful subsidiary bus system can handle up to 120 extension boxes at one coupler box.
Extension Box
Extension Box
Extension Modules, that are independent of the fieldbus and that can only be operated together with a coupler box via IPLink.
PLC Box
PLC Box
A PLC Box differ from the Coupler Box in that this module can be programmed in IEC 61131-3. This means that this slave is also capable of working autonomously, without a master, for instance for control or regulation tasks.
Also see about this
2 Fieldbus Box - Naming conventions [}11]
11Version: 1.2.1
Product Overview

2.3 Firmware and hardware issue status

The documentation refers to the hardware and software status that was valid at the time it was prepared. The properties are subject to continuous development and improvement. Modules having earlier production statuses cannot have the same properties as modules with the latest status. Existing properties, however, are always retained and are not changed, so that these modules can always be replaced by new ones. The number beginning with a D allows you to recognize the firmware and hardware status of a module.
Syntax:
D.wwyyxyzu
ww - calendar week yy - year x - bus board firmware status y - bus board hardware status z - I/O board firmware status u - I/O board hardware status
Example:
D.22081501
- Calendar week 22
- in the year 2008
- bus board firmware status: 1
- bus board firmware hardware status: 5
- I/O board firmware status: 0 (no firmware is necessary for this board)
- I/O board hardware status: 1
12 Version: 1.2.1
Product Overview

2.4 Technical Data

2.4.1 Modules - Technical Data

Technical data IPxxxx-B31x IL230x-B310, IL230x-C310
Extension modules - Max. 120 with altogether 128 bytes
input and 128 bytes output Digital peripheral signals according to I/O type max. 960 inputs and outputs Analog peripheral signals according to I/O type max. 60 inputs and outputs Configuration facilities Using KS2000, via the controller
(register communication, DPV1, or
parameter data) Baud Rate automatic detection up to max. 12 Mbaud Power supply connection Control voltage: 24V DC (-15%/+20%); load voltage: according to I/O
type Control voltage current
consumption Load voltage current consumption according to I/O type Power supply connection Feed: 1 x M8 connector, 4-pin
Fieldbus connection 1 x M12 socket, 5-pin, (inverse coding) Electrical isolation Channels/control voltage: no
Permissible ambient temperature during operation
Permissible ambient temperature during storage
Vibration / shock resistance conforms to EN60068-2-6/ EN60068-2-27, EN60068-2-29 EMC resistance burst / ESD conforms to EN61000-6-2 / EN61000-6-4 Protection class IP 65/66/67 (according to EN 60529) Installation position variable Approval CE, UL E172151
according to I/O type + current consumption of sensors, max. 0.5 A
downstream connection: 1 x M8 socket, 4-pin (except IP/IE204x)
between the channels: no
control voltage/fieldbus: yes
0°C ... +55°C
-25 °C ... +85°C
Using KS2000, via the controller (register communication or DPV1)

2.4.2 Controller - Technical Data

Requirements
PLC data IL230x-C31x
Programmability Via the programming interface (TwinCAT) or via
PROFIBUS (TwinCAT with FC310x) Program memory 32/96 kbyte Data memory 32/64 kbyte Remanent flags 512 bytes PLC cycle time approx. 3 ms for 1000 IL commands (without I/O
cycle) Programming languages IEC 6-3 (IL, LD, FBD, ST, SFC)
13Version: 1.2.1
Product Overview

2.4.3 Current Consumption

It is important to know the current consumption of the individual modules in order to know how much current is available, and for fusing the modules as well as considering the voltage drop in the power lead supply. The following table contains the current consumption at 24 VDC. Current for supplying the sensors and that eventually required for the outputs must be added on to these figures.
14 Version: 1.2.1
Table1: I/O type Compact Box
Product Overview
15Version: 1.2.1
Product Overview
Modules −B310 −B510, −B520 −B730, −B800, −B810
IP1000−Bxxx, IP1001−Bxxx, IP1002−Bxxx, IP1010−Bxxx, IP1011−Bxxx, IP1012−Bxxx
IP1502-Bxxx Is = 85mA
IP2000−Bxxx, IP2001−Bxxx, IP2002−Bxxx
IP2020−Bxxx, IP2021−Bxxx, IP2022−Bxxx
IP2040−Bxxx, IP2041−Bxxx, IP2042−Bxxx
IP2300−Bxxx, IP2301−Bxxx, IP2302−Bxxx, IP2310−Bxxx, IP2311−Bxxx, IP2312−Bxxx
IP2320−Bxxx, IP2321−Bxxx, IP2322−Bxxx, IP2330−Bxxx, IP2331−Bxxx, IP2332−Bxxx
IP2400−Bxxx, IP2401−Bxxx
IP2512−Bxxx Is = 85mA
IP3102−Bxxx Is = 140mA
IP3112−Bxxx Is = 140mA
IP3202−Bxxx Is = 110mA
IP3312−Bxxx Is = 110mA
IP4112−Bxxx Is = 115mA
IP4132−Bxxx Is = 140mA
IP5009−Bxxx Is = 140mA
IP5109−Bxxx Is = 140mA
IP5209−Bxxx Is = 110mA
IP6002−Bxxx Is = 115mA
IP6012−Bxxx Is = 115mA
Is = 85mA Ip = 5mA
Ip = 5mA Is = 90mA
Ip = 5mA
Is = 90mA Ip = 5mA
Is = 90mA Ip = 5mA
Is = 90mA Ip = 5mA
Is = 90mA Ip = 5mA
Is = 90mA Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 35mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 35mA
Ip = 35mA
Is = 45mA
Ip = 5mA
Is = 45mA
Ip = 5mA
Is = 45mA
Ip = 5mA
Is = 45mA
Ip = 5mA
Is = 45mA
Ip = 5mA
Is = 50mA
Ip = 5mA
Is = 50mA
Ip = 5mA
Is = 50mA
Ip = 5mA
Is = 45mA
Ip = 5mA
Is = 105mA
Ip = 5mA
Is = 105mA
Ip = 5mA
Is = 70mA
Ip = 5mA
Is = 70mA
Ip = 5mA
Is = 85mA
Ip = 35mA
Is = 105mA
Ip = 5mA
Is = 105mA
Ip = 5mA
Is = 105mA
Ip = 5mA
Is = 70mA
Ip = 5mA
Is = 85mA
Ip = 35mA
Is = 85mA
Ip = 35mA
Is = 45mA Ip = 5mA
Is = 45mA Ip = 5mA
Is = 45mA Ip = 5mA
Is = 45mA Ip = 5mA
Is = 45mA Ip = 5mA
Is = 50mA Ip = 5mA
Is = 50mA Ip = 5mA
Is = 50mA Ip = 5mA
Is = 45mA Ip = 5mA
Is = 105mA Ip = 5mA
Is = 105mA Ip = 5mA
Is = 70mA Ip = 5mA
Is = 70mA Ip = 5mA
Is = 85mA Ip = 35mA
Is = 105mA Ip = 5mA
Is = 105mA Ip = 5mA
Is = 105mA Ip = 5mA
Is = 70mA Ip = 5mA
Is = 85mA Ip = 35mA
Is = 85mA Ip = 35mA
16 Version: 1.2.1
Product Overview
Modules −B310 −B510, −B520 −B730, −B800, −B810
IP6022−Bxxx Is = 115mA
Ip = 35mA
Table2: I/O type Coupler Box
Modules −B310 −B510, −B520 −B730, −B800, −B810
IL2300−Bxxx, IL2301−Bxxx, IL2302−Bxxx
IL2300−Cxxx, IL2301−Cxxx, IL2302−Cxxx
Table3: I/O type Extension Box
Modules
IE1000, IE1001, IE1002, IE1010, IE1011, IE1012 Is = 25mA
IE1502 Is = 25mA
IE2000, IE2001, IE2002 Is = 25mA
IE2020, IE2021, IE2022 Is = 25mA
IE23xx, IE240x Is = 25mA
IE2512 Is = 25mA
IE2808 Is = 40mA
IE3102 Is = 55mA
IE3112 Is = 55mA
IE3202 Is = 40mA
IE3312 Is = 40mA
IE4112 Is = 40mA
IE4132 Is = 40mA
IE5009 Is = 55mA
IE5109 Is = 55mA
IE6002 Is = 40mA
IE6012 Is = 40mA
IE6022 Is = 40mA
Is = 100mA Ip = 5mA
Is = 100mA Ip = 5mA
Is = 85mA
Ip = 35mA
Is = 60mA
Ip = 5mA
− −
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Ip = 5mA
Is = 85mA Ip = 35mA
Is = 60mA Ip = 5mA
17Version: 1.2.1
Profibus

3 Profibus

3.1 Fieldbus Overview

PROFIBUS is a manufacturer - independent, open fieldbus standard with a wide range of applications in manufacturing and process automation. Manufacturer-independence and openness are guaranteed by the International standards EN 50170 and EN 50254. PROFIBUS allows devices from different manufacturers to communicate without the need for specially adapted interfaces. PROFIBUS is suitable both for fast, time­critical applications and for complex communication tasks.
PROFIBUS offers communication protocols of different functional levels: DP and FMS. According to the application, RS-485, IEC 1158-2 or optical fiber are available as transmission techniques.
PROFIBUS specifies the technical features of a serial fieldbus system with which distributed digital automation devices can be networked together, from the field level up to the cell level. PROFIBUS is a multi­master system, and therefore permits common operation of a number of automation, engineering or visualization systems with their distributed peripheral devices on one bus.
PROFIBUS device types
PROFIBUS distinguishes the following device types:
Master devices determine the data traffic on the bus. A master may transmit messages without having received an external request when it is in possession of the bus access authorization (token). Masters are also referred to as active devices.
Slave devices are peripheral devices such as input/output devices, valves, drives, measuring transducers and the Beckhoff PROFIBUS slaves from the BK3xx0, BC3xx0, IPxxxx-B310, IL230x-B310 and IL230x-C310 series. They do not receive any bus access authorization, so that they are only allowed to acknowledge messages that have been received, or to send messages in response to a request from master. Slaves are referred to as passive devices. They only require a small proportion of the bus protocol, which means that they can be implemented with little effort.
PROFIBUS DP
PROFIBUS DP is designed for efficient data exchange at the field level. The central automation devices such as PLC/PCs or process control systems communicate here over a fast serial link with distributed field devices such as I/O, drives, valves etc.. Data is primarily exchanged with these distributed devices cyclically. The communication functions required for this are specified by the basic DP functions in accordance with EN
50170.
In addition to these basic functions, PROFIBUS DP also offers extended acyclic communication services for such purposes as parameterization and other operations. These are also supported by the Beckhoff PROFIBUS slaves of the IPxxxx-B310, IL230x-B310 and IL230x-C310 series. A central controller (master) cyclically reads the input information from the slaves, and writes the output information cyclically to the slaves. The bus cycle time here should be shorter than the central automation system's program cycle time, which lies around 10 ms in many applications.
A high data throughput is not in itself sufficient for successful use of a bus system. Ease of handling, good diagnostic facilities and secure transmission technology are also of the utmost importance if the user’s demands are to be satisfied. These properties are ideally combined in PROFIBUS DP.
System configuration and device types
PROFIBUS DP allows single master or multi-master systems to be implemented. This permits a high level of flexibility in system configuration. A maximum of 126 devices (master or slaves) can be connected to one bus. A station address between 0 and 99 can be chosen for the Beckhoff PROFIBUS slaves from the IPxxxx-B310, IL230x- B310 and IL230x-C310 series. The specifications for the system configuration contain the number of stations, the assignment of the station addresses to the I/O addresses, data consistency of the I/O data and the format of the diagnostics messages and the bus parameters being used. Every PROFIBUS DP system consists of different device types. Three types of device are distinguished:
18 Version: 1.2.1
Profibus
Type Description
DP master class 1 (DPM1)
e.g. Beckhoff PC master card FC310x
DP master class 2 (DPM2) Devices of this type are engineering, project design
DP slave
e.g. Beckhoff Bus Coupler IPxxxx-B310
In single master systems only one master is active on the bus in the operating phase of the bus system. The PLC controller is the central control element. The distributed slaves are coupled to the PLC controller via the transmission medium. The shortest bus cycle time is achieved with this system configuration.
This involves a central controller that exchanges
information cyclically with the distributed stations
(slaves) in a specified message cycle. Typical
devices include, for instance, programmable logic
controllers (PLCs) or PCs.
or operating devices. They are used for
commissioning, for servicing and diagnosis in order
to configure the connected devices, to evaluate
measured values and parameters and to interrogate
the status of devices.
A PROFIBUS DP slave is a peripheral device (I/O,
drive, measuring transducer etc.) that reads input
information and passes output information on to the
peripherals. It is also possible to have devices that
only handle either input or output information. The
quantity of input and output information is device-
dependent, and may not exceed 246 bytes of input
data and 246 bytes of output data.
In a multi-master mode there is more than one master on the bus. They either form sub-systems that are independent of one another, each consisting of one DPM1 and the associated slaves, or additional project design and diagnostic devices. All the DP masters can read the input and output images of the slaves. Writing the outputs is only possible for one DP master (the one assigned as DPM1 during the project design). Multi-master systems achieve a medium bus cycle time. In time-critical applications, the increase in bus cycle time should be observed by adding a diagnostic tool.
Basic device files (GSD) In PROFIBUS DP, the performance characteristics of devices are documented by the manufacturers and made available to users in the form of a device data sheet and of a basic device file. The structure, content and coding of these basic device files (GSD) is standardized. They make it easy to plan a project with any PROFIBUS DP slaves using project planning devices from a various manufacturers. The PROFIBUS User Organization (PROFIBUS Nutzer Organization - PNO) archives this information for all manufacturers, and will provide information about the GSD from any manufacturer on request. The GSD files are read by a PROFIBUS master configuration software, and appropriate adjustments are transferred to the PROFIBUS master. Please see the appropriate software manual from the master manufacturer for a description.
The Beckhoff GSD files may be obtained from the internet under www.beckhoff.com.
Diagnostic functions
The extensive diagnostic functions of PROFIBUS DP allow rapid fault localization. Diagnosis of the Beckhoff Bus Coupler is not activated in the default setting of the type file or the GSD file. The diagnostic messages are transmitted over the bus and collated by the master.
They are divided into three levels:
Diagnosis type Description Related to the station Messages relating to the general readiness of a
device for operation such as over-temperature or
under-voltage Related to the module These messages indicate that diagnostic signals are
pending within a specific I/O sub range of the device
(e.g. an 8 bit output module) Related to the channel Here the cause of an error is related to a single input/
output bit (channel), such as a short circuit on output
2
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The Beckhoff PROFIBUS slaves from the IPxxxx-B310, IL230x-B310 and IL230x-C310 series support the PROFIBUS DP diagnostic functions. Assessment of the diagnostic data by means of the controller depends on the support for the PROFIBUS master. Please refer to the device manuals for the master interfaces for details of how to handle the diagnosis.
Sync and Freeze Mode
In addition to the user data traffic related to the device, which is automatically dealt with by DPM1, a DP master has the option of sending control commands to one DP slave, to a group of them or to all of them at the same time. These control commands are transmitted as multicasts. These control commands can be used to specify the sync and freeze operating modes, in order to synchronize the DP slave. They permit event-controlled synchronization of the DP slaves.
The DP slaves start sync mode when they receive a sync control command from the assigned DP master. In this operating mode, the outputs of all the addressed DP slaves are frozen at their current values. In the following user data transmissions, the DP slaves store the output data, but the output states themselves nevertheless remain unchanged. Only when the next sync control command is received from the master the stored output data is switched through to the outputs. Sync operation is ended with an unsync control command.
A freeze control command similarly causes the addressed DP slaves to enter freeze mode. In this operating mode the states of the inputs are frozen at their current value. The input data is only updated again when the DP master has sent the next freeze control command to the devices concerned. Freeze operation is ended with an unfreeze command.
System behavior
The system behavior is also standardized in PROFIBUS DP, so that devices can to a large extent be interchanged. It is largely determined by the operating condition of the DPM1. This can either be controlled locally, or over the bus by the project design device.
The following three principal conditions are distinguished:
Operation mode Description Stop There is no data traffic between the DPM1 and the
DP slaves. The Bus Coupler only addresses the Bus
Terminals once after the power has been switched on
(none of the I/O LEDs are lit). Clear The DPM1 reads the input information from the DP
slaves, and maintains the outputs of the DP slaves in
a safe state (depending on the reaction to fieldbus
errors, the green I/O LED is lit and the outputs are
set). Operate The DPM1 is in a data transfer phase. In the course
of cyclic data traffic the inputs of the DP slaves are
read and the output information is transmitted to the
DP slaves (the green I/O LED is lit).
The DPM1 sends its local status at a configurable time interval using a multicast command cyclically to all the DP slaves that have been assigned to it. The reaction that the system has to the occurrence of an error during the DPM1's data transfer phase, such as the failure of a DP slave, is specified in the Auto-Clear operating parameter. If this parameter is set to True, then the DPM1 switches the outputs of all the associated DP slaves into a safe state as soon as one DP slave is no longer ready for the transfer of user data. The DPM1 then switches into the Clear state. If the parameter is False then the DPM1 remains in the operating state even after a fault, and the user can himself specify the system's reaction.
Data traffic between the DPM1 and the DP slaves
The data traffic between the DPM1 and the DP slaves that have been assigned to it is automatically executed by the DPM1 in a specified, continuously repeated sequence. The user specifies the assignment of a DP slave to the DPM1 when the bus system's project is being planned. Those DP slaves that are included in or excluded from the cyclic user data traffic are also defined.
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The data traffic between the DPM1 and the DP slaves is divided into the parameterization, configuration and data transfer phases.
Before a DP slave is included in the data transfer phase, the DPM1 checks, in the parameterization and configuration phase, whether the theoretical configuration that has been planned agrees with the actual configuration of devices. The check requires the device type, the format and length information, as well as the number of inputs and outputs, to be in agreement. The user is thus provided with reliable protection against errors in parameterization. In addition to the transfer of user data, which is automatically carried out by the DPM1, it is possible to send new parameterization data to the DP slaves at the user's request.
Protection mechanisms
In the context of distributed peripherals it is necessary, for reasons of safety and reliability, for the system to be given extremely effective functions to protect against incorrect parameterization or the failure of the transmission mechanisms. PROFIBUS DP uses monitoring mechanisms in the DP Master and in the DP Slaves. They are implemented in the form of time monitors. The monitoring interval is specified in when the DP system project is planned.
Protection mechanisms Description At the DP Master The DPM1 monitors the slave's transfer of user data
with the Data_Control_Timer. An individual
monitoring timer is used for each assigned slave. The
time monitor triggers if a proper transfer of user data
does not take place within the monitoring interval. In
this case the user is informed. If automatic error
reaction is enabled (Auto_Clear = True) then the
DPM1 leaves the Operate state, switches the outputs
of the assigned slaves into a safe state, and then
goes into the Clear operating mode. At the DP Slave The slave uses communication monitoring in order to
detect errors of the master or in the transmission
segment. If data is not transferred with the assigned
master within the communication monitoring interval
the slave switches the outputs into the safe state
itself. The slave inputs and outputs further require
access protection in multi-master systems, to ensure
that direct access is only made from the authorized
master. The slaves will make an image of the inputs
and outputs available to other masters, and this can
be read by any other master even if it does not have
access authorization.
Ident number
Every DP slave and every DPM1 must have an individual identification number. This is required so that a DP master can identify the types of the connected devices without any significant protocol overhead. The master compares the identification numbers of the connected DP devices with the identification numbers in the project planning data specified by DPM2. The transfer of user data only starts if the correct device types are connected to the bus at the correct station addresses. This provides protection from project planning errors. Manufacturer-specific identification numbers are issued by the PROFIBUS User Organization (PNO). The PNO administers the identification numbers along with the basic device data (GSD).
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3.2 Topology

• A bus segment may consist of a maximum of 32 devices (including the repeaters).
• The maximum conductor length of a segment depends on the transmission speed in use and on the quality of the bus cables being used.
• No more than 9 repeaters may be installed between two devices.
• Stubs are to be avoided, and are not permitted above 1.5 Mbaud.
• The maximum number of devices is 127
• Interrupting the supply voltage from cable ends by switching off the repeater/slave, or by pulling out the plug, is not permitted.
Fig. 1: RS485 topology with 3 segments and 2 repeaters.
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3.3 Application

Example of an PROFIBUS Application
Profibus
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3.4 PROFIBUS Cabling

3.4.1 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).
Table4: 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) 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
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.
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Pre-assembled cables from Beckhoff
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 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.
Termination resistors
In systems with more than two stations all devices are wired in parallel. It is essential that 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
Cable length in m
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
9.6 19.2 93.75 187.5 500 1500 12000
1200 1200 1200 1000 400 200 100
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
(seewww.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:
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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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3.4.2 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 (-B310)
M12 socket/plug pin assignment (-B318)
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.
D-Sub socket pin assignment
PROFIBUS conductor colors
PROFIBUS conductors M12 D-Sub
B red Pin 4 Pin 3 A green Pin 2 Pin 8
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