BECKHOFF FM33xx User Manual

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Technical Documentation for

FM33xx - TC-Plug

Applies to all FM33xx types SW_VERSION 0xB0FA, 2000-25-05

Version: 1.6 Date: 2007-12-21

Table of contents

1. Foreword 1

Notes on the Documentation 1

Liability Conditions 1

Safety Instructions 2

Safety Rules 2 State at Delivery 2 Personnel Qualification 2 Description of safety symbols 2

2. Introduction 3

Overview 3

3. Technical data 3

Mechanical structure 3 Electrical data 4

Fieldbus-specific data 5 Pin assignment for the round connector 6 Pin assignment for the 24-pin connection strip 7 Pin assignment for the 64-pin connection strip 8

4. Functional description 9

The interfaces 9

Round connector 9 PE connection 10 Connecting strip for thermocouples 10 Configuration interface 10 Switches for the station address 10

Thermocouple measurement 11

Input circuits 11 Broken lead detection 11 Cold junction compensation 11

Back voltage protection 12

How the back voltage protection operates 12

Start-up procedure and diagnostics 13

Operating modes 13 Status display LEDs 13 Error codes for the thermocouple inputs 14 PROFIBUS error codes 14

Peripheral data in the process image 15

5. I/O configuration 16

Configuration in the TwinCAT System Manager 16 Configuring the PROFIBUS master 16

Linking of the TC-Plug 18 Linking the TC-Plug modules using the GSD file 20

Linking into the Simatic Manager 21 Configuration of the TC-Plug modules 22

Channel settings for the TC-Plug modules 23 Channel configuration by means of DPV1 services 24

Multiplex mode channel data in the TwinCAT System Manager 25 Protocol for the cyclical data transfer in multiplex mode 26

FM33xx

Table of contents

6. Register description 27

General description of registers 27 TC-Plug - channel-specific register description 30 Register table 33

7. Appendix 34

Support and Service 34

Beckhoff's branch offices and representatives 34

Beckhoff headquaters 34

FM33xx

Foreword

This description is only intended for the use of trained specialists in control

The responsible staff must ensure that the application or use of the

Notes on the Documentation

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

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.

FM33xx 1

Foreword

The responsible staff must ensure that the application or use of the

All the components are supplied in particular hardware and software

This description is only intended for the use of trained specialists in control

The following safety symbols are used in this operating manual. They are

Safety Instructions

Safety Rules

products described satisfy all the requirements for safety, including all the relevant laws, regulations, guidelines and standards.

State at Delivery

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

and automation engineering who are familiar with the applicable national standards.

Description of safety symbols

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

Warning

Note

environment.

This symbol indicates information that contributes to better understanding.

2 FM33xx

Introduction

The various implementation levels of the TC-Plug differ in the number of

Overview

thermocouple input channels (12 channels or 32) and in the type of thermocouple implemented (J or K type).

Technical data

Side view of the TC-Plug

Mechanical structure

Technical data (Version 1F.1 26.05.2000)

Dimensions

Connector Hood

Connector to Thermocouples

Contacts

Coding system

Power supply and PROFIBUS

connection

FM3312 FM3332

120mm x 52mm x 129mm, ,length x wide x height Han24B (Harting) Han24E Han64D Hard gold plated With coding pins in the connector Round-Connector, DIN 45322 (series 423, 723 Binder)

Shield of the Round-Connector is connected to the plug

FM33xx 3

Technical data

Electrical data

The following tables provide a summary of the electrical and fieldbus-

specific data related to the TC-Plug.

Technical data (Version 1F.1 26.05.2000)

General technical data

Power supply

typical operating current

max. operating current

Power supply input protection

Reverse voltage

Over voltage

Potential separation

Thermocouples / PROFIBUS

Thermocouples / Supply Voltage

Supply Voltage / PROFIBUS

Ambient temperature

Operating temperature

Storage temperature

Type of protection

Vibration

Shock

Vibration

EMC immunity / EMC emission

Approvals

Thermocouple technical data

Number of Inputs

Type of Input

Connection

Wiring length

Thermocouple sensor type

Common mode input voltage range

Common mode rejection Common mode rejection

Normal mode rejection

Resolution

Linearization Error

FM3312 FM3332

24 VDC, +- 20% (19,2...28,8 V) 90 mA (24 V) 100 mA (24 V) 120 mA (24 V) 130 mA (24 V)

min. -35V max. 35V

500 V 500 V 100 V

0...+55°C

-25...+85°C

plug: IP65 (PROFIBUS-Connector: IP67)

EN 60068-2-6 10 Hz <= f <= 57 Hz: 0,075mm Amplitude 57 Hz <= f <= 150 Hz: 1,0 g

EN 60068-2-27/29 15 g, 11 ms

conforms to EN 60068-2-6 / EN 60068-2-27, EN 60068-2-29 conforms to EN 61000-6-2 / EN 61000-6-4 CE, cULus* For the compliance of the cULus requirements use 4 Amp. fuse or

class 2 power supply!

12 32 Differential Input,

mV measurement, high impedance grounded no electrical separation

two wire, direct connection max. 10 meter

type K:-100...1370°C type J:-100...900°C

-8 V...+8 V typical 90 dB (independent from conversion time) typical 150 dB (at 50 Hz or 60 Hz Rejection) typical 98 dB (at 50 Hz or 60 Hz Rejection)

0.1°C per digit +-0,1°C (voltage to temperature)

rms

4 FM33xx

Technical data

Technical data (Version 1F.1 26.05.2000)

Cold junction compensation Error

Calibration Error

Nonlinearity Error

Temperature Drift

Temperature nonlinearity

Cold junction compensation

Conversation time (per channel)

Data update time

Wiring fail indication

Back voltage indication

Back Voltage Range

Switch off time

Input resistance for current limitation

Input voltage

Input protection mechanism

Range of Input protection

Earth connection The plug must be connected to protective earth with the earth-

FM3312 FM3332

+- 0,1 C (voltage to temperature) +- 0,3°C (Offset and linearization)

+- 0,1°C +- 0,1°C +- 0,2°C +- 0,1°C

Internal (temperature measurement in the plug) Adjustable

50 ms (60 Hz Common Mode Rejection) 60 ms (50 Hz Common Mode Rejection)

200 ms (60 Hz) 230 ms (50 Hz)

Yes (Open Thermocouple)

>10 V, < -10 V 3 ms, max. 2400 R, typical

100 Vac between TC+ and TC- of each channel 240 Vac above Protective Earth 415 Vac to other TC

Current limitation Channel disconnect

240 Vac,dc

connector in the plug!

Fieldbus-specific data

Technical data (Version 1F.1 26.05.2000)

Field bus protocol Transmission rate

Address configuration

Status LED

FM3312 FM3332

PROFIBUS DP, EN50170 Max. 12Mbaud Setting via two rotary switches RUN, BF (Bus Failed), ERR (Error) TC Run, TC Err

FM33xx 5

Technical data

Pin assignment for the round connector

Round connectors

round connector

for input

round connector

for output

Pin assignment (Module) Male Connector

(Input) PROFIBUS PROFIBUS

PROFIBUS Termination PROFIBUS Termination

Power supply Power supply

pin 1 A = RxD / TxD-N A = RxD / TxD-N pin 2 B = RxD / TxD-P B = RxD / TxD-P pin 3 GND pin 4 +5V pin 5 +24V +24V pin 6 0V 0V

Female Connector (Output)

Protect the power supply (24 V) by using a fuse (max. 4 A, medium timelag), to protect the modules in case of short circuit at the hybrid cable

Attention

(PROFIBUS / Power Supply).

6 FM33xx

Technical data

Pin assignment for the 24-pin connection strip

Pin assignment FM3312

pin 1 TC1+ pin 13 TC1pin 2 TC2+ pin 14 TC2pin 3 TC3+ pin 15 TC3pin 4 TC4+ pin 16 TC4pin 5 TC5+ pin 17 TC5pin 6 TC6+ pin 18 TC6pin 7 TC7+ pin 19 TC7pin 8 TC8+ pin 20 TC8pin 9 TC9+ pin 21 TC9pin 10 TC10+ pin 22 TC10pin 11 TC11+ pin 23 TC11pin 12 TC12+ pin 24 TC12-

FM33xx 7

Technical data

Pin assignment for the 64-pin connection strip

Pin assignment FM3332

A.. B.. C.. D.. pin 1 TC1+ TC1- TC17+ TC17pin 2 TC2+ TC2- TC18+ TC18pin 3 TC3+ TC3- TC19+ TC19pin 4 TC4+ TC4- TC20+ TC20pin 5 TC5+ TC5- TC21+ TC21pin 6 TC6+ TC6- TC22+ TC22pin 7 TC7+ TC7- TC23+ TC23pin 8 TC8+ TC8- TC24+ TC24pin 9 TC9+ TC9- TC25+ TC25pin 10 TC10+ TC10- TC26+ TC26pin 11 TC11+ TC11- TC27+ TC27pin 12 TC12+ TC12- TC28+ TC28pin 13 TC13+ TC13- TC29+ TC29pin 14 TC14+ TC14- TC30+ TC30pin 15 TC15+ TC15- TC31+ TC31Pin 16 TC16+ TC16- TC32+ TC32-

8 FM33xx

Functional description

Status LEDs for the PROFIBUScommunication

Status LEDs for the thermocouple input channels

Serial configuration interface and switches for station addresses

6-pin plug and socket for fieldbus connection

The interfaces

The module has manual and electrical interfaces. The electrical interfaces connect the PROFIBUS cable to the termination resistor and the power supply for the fieldbus connection. For the temperature measurement, the thermocouples are wired via the 24 or 64 pin connection strips and the PE connection. The module also has a serial interface for configuration. The module's station address can be set via the manual interface. The LEDs of the visual display supply information about the current status of the TCPlug module.

PE connection

Round connector

The round 6-pin connectors are used to connect the PROFIBUS cables and the module's operating voltage. The operating voltage is fed via the module's 6-pin male connector. The operating voltage is brought out on the 6-pin female connector side to supply the next module. The supply voltage for the PROFIBUS cables is also fed in at the plug side and brought out again on the socket side. The internal 5V bus voltage is brought out on the socket side in order to supply the termination resistor. This voltage must not be used for other purposes, and must not be connected elsewhere through the cables. The screw threads on the round connector are in metallic contact with the module housing, and provide a low-resistance connection for the PE line. Grounding the screening braid on the PROFIBUS cable is therefore effective.

FM33xx 9

Functional description

Serial interface under the screwed cover

PE connection

The screening braids on the PROFIBUS cables are to be earthed at the modules, in accordance with the PROFIBUS specification. This requirement is satisfied by a low-resistance connection between the PE connection to the ground of the local environment (the machine). The PE connection is also responsible for the potential equalization of grounded and non-grounded thermocouples, and for thermocouples grounded at different potentials (see thermocouple measurement). The back voltage protection diverts mains voltages via the PE connection. This means that it is essential for proper earthing of the module to be guaranteed. When the module is being fitted, the PE connection should be established first. Connection of the module to the thermocouples via the connecting strip should be performed subsequently. In this way the risk of back voltage being present at the thermocouple inputs during assembly is avoided. If the earthing is inadequate the user is exposed to hazardous voltages on the housing. When the module is being dismantled, the module should, for this reason, first be disconnected from the thermocouples before the PE connection is removed.

Connecting strip for thermocouples

The thermocouples are connected to the 24-pin or 64-pin connection strips. The signal assignment and polarity must be correctly observed. Cold junction compensation is implemented on the circuit board within the module. The connection between the module electronics and the connector pins is made with the corresponding thermal material. The use of thermocouples other than those listed in the documentation is not permitted. Good thermal conduction between the module's plug and socket means that no significant thermal voltage is created by the plugged connections. Thermal insulation on the socket side of the connection should be ensured in order to avoid a large temperature error. Draughts and unevenly heated areas in particular are to be avoided.

Configuration interface

The module has an RS232 interface at the top of the front panel under the PG threaded fitting. The miniature connector can be linked through a special cable to the serial interface of a PC. The module can be configured with the KS2000 configuration software. The interface allows the analog channels to be configured.

Switches for the station address

Two rotary switches are used to set the station address. The rotary switches are located under the screwed cover next to the serial configuration interface. The address is set as decimal number. The righthand rotary switch is for the units, and the left-hand switch sets the tens. (Example: station address 18: left hand switch = 1, right hand switch = 8). In order for a new station address that has been set to be permanently stored in the module it must be reset (either by a brief interruption of the power supply or by means of a software reset).

10 FM33xx

Functional description

The thermocouples consist of two different metal alloys. Voltages

The module can contain up to 32 thermocouple inputs. Electrical isolation

Broken leads are detected as a diagnosis of the state of the thermocouple.

When a thermocouple is used for temperature measurement, a voltage is

Thermocouple measurement

proportional to the temperature arise where the alloys are in contact. In the case of a type K thermocouple these voltages are typically in the range of 50 µV/°C. This means that the inputs for the thermocouples must be capable of measuring voltages in the µV and mV range. In addition to the signal measurement itself, the module performs functions related to error detection, interference suppression and protection from external voltages.

Input circuits

between the channels could not be implemented, for reasons of both cost and space. In order to exclude the possibility of mutual interference, every input has a high-impedance differential amplifier. This rejects interfering voltages that can be coupled into the thermocouple circuit. Voltage differences between individual thermocouples are also suppressed without them having any effect on one another. The conditioned measurement signals are digitized with a sigma-delta converter, and are then transmitted over the PROFIBUS.

Broken lead detection

The break is recognized through the infinite resistance of the broken thermocouple. Broken leads are detected in both grounded and ungrounded thermocouples.

Cold junction compensation

thermally generated at the other end of the connection as well as at the location of the measuring junction. On both the 12-pin and the 64-pin contact strips the socket contact at the module is connected to the thermal wire. Other requirements mean that it is not possible to measure directly at the socket contacts (plugging in without contact losses, and ability to withstand mains voltage). There is another cold junction on the plug side, opposite the cold junction on the socket side. Good temperature equalization between the socket and plug contacts, and thermal insulation of the socket and plug contacts, ensure that the thermal voltages on the two sides are equalized. The voltages thus cancel each other out. To achieve this structure, the connection in the module between the plug contact and the circuit board is made with the necessary thermal material in each case (J or K type). The resulting cold junction is then on the circuit board for the module electronics. At this point it is possible to perform a simple yet effective measurement of temperature in order to implement the cold junction compensation.

FM33xx 11

Functional description

Back voltage protection

The back voltage protection guards against external voltages applied

through the thermocouple inputs. Voltages of up to 230 V

are tolerated,

or are withstood without damage to the module. Those thermocouple inputs that are not affected remain functionally operative, or are only affected for a short time. The module switches measurements from the affected channel off and disconnects the voltage, so that the unwanted voltage can remain connected to the thermocouple input for a long period. If it is possible to manage without that particular thermocouple channel, it is not necessary to rectify the fault immediately.

How the back voltage protection operates

The thermocouple inputs are protected within the module against voltages

that are outside the permitted signal range. The permitted range is about –10V...+10V. If voltages outside this range appear, the current is limited by an internal resistance and is diverted to a protective circuit. The currentlimiting function of the input circuit protects the thermocouple wires from excessive short-circuit currents, so that they are not destroyed. A protective circuit is responsible for a group of at most eight thermocouple inputs. The central protective circuit detects the excess voltage and switches off all the thermocouple inputs in the group. This process affects the current measurements being taken by the channels in this group, and those measurements will have to be made again. Monitoring and switching groups off means that the channel that is directly affected cannot be identified. The faulty thermocouple input is identified by switching on the channels that have been switched off again one by one. As soon as it is seen that the protective circuit for these thermocouple inputs is triggered again after a channel is switched on, this channel is recognized as faulty, and remains switched off. When all the channels in the group have been tested, and are either operating again or have been switched off because they are faulty channels, it is possible to continue with the normal measuring process. The fault in the channels that have been switched off is checked by switching on again after a configurable time, so that the faulty channels can be automatically brought back into operation.

12 FM33xx

Functional description

Start-up procedure and diagnostics

Installation guidelines

The PROFIBUS Nutzerorganisation e.V. technical guidelines must be followed when installing and laying the PROFIBUS lead. PROFIBUS-DP/FMS assembly guidelines

www.profibus.com

Operating modes

After being switched on, the TC-Plug carries out a self-test, and checks all

the functions of its components. If there is a fault, the TC-Plug enters the "STOP" mode, but otherwise goes into the "fieldbus start" state.

Status display LEDs

The module has two groups of LEDs for the display of status. The upper group contains three LEDs and indicates the state of the PROFIBUS, while the lower group indicates the states of the thermocouple inputs.

RUN LED The “RUN” LED is illuminated cyclically by process data exchange over the

fieldbus.

BF LED The “BF" LED indicates any fieldbus errors.

ERR LED The “ERR" LED indicates the error code of any fieldbus error.

TC RUN The “TC RUN” LED is illuminated cyclically by process data exchange.

TC ERR The “TC ERR” LED indicates the error code for the thermocouple inputs.

Local errors The bottom two LEDs are used to indicate the operating status of the

thermocouple inputs. The green LED lights up in order to indicate fault-free operation. The red LED blinks with two different frequencies in order to indicate an error. The error is encoded in the blinks as follows:

Blink code

Fast blinking First slow sequence Second slow sequence

Start of the error code Error code Error code argument

Start of the error code Error type Error location

FM33xx 13

Functional description

Error codes for the thermocouple inputs

Error code Error code argument Description Remedy

1 pulse 1 pulse 1 pulse 2 pulses 3 pulses

4 pulses

0 EEPROM checksum error 1 Inline code buffer overflow 2 Unknown data type

Programmed configuration

Faulty channel number. The first faulty channel is indicated.

Back voltage

Open circuit

Fieldbus error The upper three LEDs indicate the operating status of the PROFIBUS. The

red ERR LED flashes with two different frequencies in order to indicate an error. The sequence of flashes has the same structure as that for the "TC ERR" LED. The first slow sequence follows the fast flashing, and the second slow sequence follows this. The error is encoded in the blinks as follows:

PROFIBUS error codes

I/O-RUN BF DIA Meaning Remedy

off

off off Operating state: RUN

Inputs are read and outputs are set.

on off,

blinking

off off Terminal bus cycles synchronized

on on No bus activity

on off,

blinking

1. Bus activity, but slave is not yet parameterized

2. Bus error in which the outputs a.) become 0 b.) remain unchanged

DP-watchdog switched off, no exchange of data

Bus error, reaction Terminal bus cycles are stopped

Everything is operating correctly

- Start master

- Check parameters (-> Diagnostics data, DIA-LED)

- Check configuration (-> Diagnostics data, DIA-LED)

PLC is in STOP mode, start PLC

- Start master

- Check bus cable

- Start master

- Check parameters (-> Diagnostics data, DIA-LED)

- Check configuration (-> Diagnostics data, DIA-LED)

ERR

1 pulse

2 pulses

0 n (n>0)

Meaning Remedy Not enough DP-Cfg data received.

Faulty DP-Cfg data byte. Not enough User-Prm data received.

Faulty User-Prm data byte.

Check DP configuration.

Check DP user parameters.

14 FM33xx

Functional description

Peripheral data in the process image

One 16 bit value is supplied for each configured channel in the minimal

configuration. In addition to this value there is a 32 bit value for open circuit, a 32 bit value for back voltage, and a 16 bit status word.

32 channels can be configured in the maximal configuration.

D0..D31 Temperature in 1/10 degree Celsius (16 bit signed integer per channel)

Open circuit One bit is reserved for each channel. If the channel is deactivated this bit

will always have the value zero. If a channel is activated, this bit will be set to 1 when an open circuit is detected, and this fact is indicated through the channel data by the limit value of the implemented thermocouple:

Limit values of the thermocouples for an open

Type J: 900°C Type K: 1370°C

circuit channel

Back voltage One bit is reserved for each channel, in a procedure similar to that for open

circuit. If excess voltage is detected at a channel, the corresponding bit is set and the limit value of the implemented thermocouple is displayed.

Status word Each channel has a status word. The error bits in the status word are set

when an error is detected, and have the following meaning:

Error message Bit

OVERRANGE 0

UNDERRANGE 1

CHERROR 6

Underrange, Overrange and Error are all set if there is an open circuit.

Depending on whether the thermocouple is grounded or not, the ADC value will go to 0x8000 or 0xFFFF.

FM33xx 15

I/O configuration

The TC-Plug modules can be configured with a configuration software that

supports the integration of the modules via a GSD file. TC-Plug modules are slave modules conforming to PROFIBUS.

Multiplex mode and simple mode

The TC-Plug modules can be operated in two modes. Different GSD files are required, depending on whether the TC-Plug is to be configured in multiplex or simple mode. Multiplex mode enables the quantity of data transferred via the fieldbus to be minimized. In this mode, communication with the TC-Plug occurs via the status/control word, and at the same time the channel data from a maximum of 4 channels are transferred via the fieldbus (see chapter: Protocol for the cyclic transfer in multiplex mode). For most applications, the TC-Plug can be operated in simple mode. In this mode, the channel data from a maximum of 32 channels can be transferred at the same time via the fieldbus. The simple mode is easier to configure and is recommended for most applications.

Configuration in the TwinCAT System Manager

This section describes the configuration of the TC-Plug modules with the

TwinCAT System Manager. A PROFIBUS master card such as the CP5412A2 from Siemens can be used as the master. The configuration of a TC-Plug module with the CP5412A2 is described below.

If the right mouse button is clicked on the I/O Devices branch in the

Add a PROFIBUS master

Configuring the PROFIBUS master

TwinCAT System Manager, the following context menu appears.

Using the menu command Append Device… a PROFIBUS master can be

inserted into the configuration. The PROFIBUS master card can be selected in the dialog box which then opens.

16 FM33xx

I/O configuration

Available PROFIBUS master cards

After you have confirmed with OK the master card appears in the branch

that shows the configured I/O devices. A mouse click on the CP5412 will open a dialog box on the right with the master's configuration settings

Configuring the master card

The port number, address range and baud rate must be set on the

CP 5412 tab. Baud rates up to 12 Mbaud are supported by the TC-Plug, and the port number can be found automatically with the Search.. menu command. The address range should be selected in such a way that no conflict with other hardware is caused.

FM33xx 17

I/O configuration

Linking of the TC-Plug

Clicking with the right mouse button on the CP5412A2 master card causes

the following context menu to appear in the TwinCAT System Manager:

Adding of the PROFIBUS slaves

The menu command Append Box… opens a dialogue with all the available

PROFIBUS slaves.

FM33xx or FM33xx (multiplex mode) is selected from the list, depending on

whether the TC-Plug is to be operated in simple or multiplex mode. Select FM33xx (simple mode) from the list and confirm with OK. A new box (slave) will be added to the configuration tree.

In the next step, the individual modules are appended. Click with the right

mouse button on the FM3xx box and select Append module... from the context menu.

add TC-Plug modules

18 FM33xx

I/O configuration

A dialogue with the available modules will appear.

The modules are added in the following order:

• Add Channel compact. Repeat n times for n channels;

• Add Channel State Open Circuit;

• Add Channel State Back Voltage;

• Add Measure Control;

• Add Measure State;

TC-Plug example configuration in simple mode with 2 channels

TC-Plug example configuration in multiplex mode

FM33xx 19

I/O configuration

Linking the TC-Plug modules using the GSD file

The TC-Plug modules can be linked into the TwinCAT System Manager

through a GSD file. A GSD file can configure any PROFIBUS slave in the TwinCAT System Manager. Clicking with the right mouse button on the CP5412A2 master card causes the following context menu to appear in the TwinCAT System Manager:

Adding a TC-Plug module to the I/O configuration

The menu command Append Box… opens a dialogue with all the available

PROFIBUS modules.

Linking a slave using the GSD file

If the Generic Profibus Box is selected, a File Open dialog box appears.

The corresponding TC-Plug GSD file can be selected in this dialog window. Once you have confirmed with OK, the TwinCAT System Manager reads the device-specific parameters from the GSD file and inserts the TC-Plug into the existing configuration.

20 FM33xx

I/O configuration

Linking into the Simatic Manager

The following steps are required for linking the TC-Plug into the Simatic

Manager in simple mode and for configuring it.

• Install the GSD file in the Simatic Manager, add the module in the hardware configuration and set the PROFIBUS address;

• Data format: MOTOROLA; Connection Channel 0: Channel connected; set;

• n times for n channels: Add Channel compact, set the required I- addresses for the data;

• Append Channel State Open Circuit;

• Append Channel State Back Voltage;

• Append Measure Control;

• Append Measure State;

• Download the configuration into the station;

• Start master;

• Reset TC-Plug by switching it on and off (power is removed);

FM33xx 21

I/O configuration

Configuration of the TC-Plug modules

Clicking with the mouse on a TC-Plug module in the I/O configuration tree

permits the necessary configuration settings to be made on the tabs:

The station number of the TC-Plug module must correspond to the station

number physically set with the rotary switches.

The "User Parameter Data" can easily be configured in a dialog box on the

PrmData(Text) tab.

The dialog box displays the most important TC-Plug PROFIBUS parameter

data in textual form, and this can be configured by the user. A double mouse-click on one of the parameters will open a selection menu showing the available parameters.

Data format

The analog thermocouple inputs can be evaluated either in Intel or in

Motorola format. s The reaction to a fieldbus or I/O error can be configured through

associated parameters.

Reaction on PROFIBUSfault

22 FM33xx

I/O configuration

Reaction on I/O-fault

Channel settings for the TC-Plug modules

The number of active analog channels can be configured by means of the

channel settings. Only the data of the channels that are associated are transmitted over the fieldbus and can be evaluated. At least one channel must be associated in the minimal configuration. A maximum of 32 channels can be associated through the configuration. If a channel is to be associated, the user can choose between complex or compact mapping of the channel data. Only compact mapping is presently supported. This means that 16 data bits are transmitted over the fieldbus for each channel.

Configuring the channels

At least one channel must be configured in the minimal configuration. This

means that a compact association must be configured for at least one channel.

FM33xx 23

I/O configuration

Channel configuration by means of DPV1 services

Channel configuration over the fieldbus

The channels of the TC-Plug module can be activated or deactivated over

the fieldbus by means of the DPV1 Services. Once the configuration was

changed, the vendor settings can only be set back with the configuration

software KS2000. The module holds the new configuration settings after

TwinCAT restart and after the Power-Off of the TC-Plug module. You can

call the DPV1-Services from the PLC by means of the ADSWRITE function

block. The ADSWRITE function block can be found in the PLC library

PlcSystem.Lib. The Ads parameters have following values:

If you use CP5412A2 as master:

NETID = NetId of the TwinCAT System;

PORT = Port number from the TC-Plug -> Ads tab in the TwinCAT System

Manager;

IDXGRP = 0x0;

IDXOFFS = 0x1;

LEN = 1 until max. 16 Byte configuration data;

SRCADDR =Pointer to the data buffer with the configuration data;

If you use FC310x as Master:

NETID = NetId of the FC310x card in the TwinCAT System Manager;

PORT = 0x1000 + Station number of the TC-Plug module;

IDXGRP = 0x0;

IDXOFFS = 0x1;

LEN = 1 until max. 16 Byte configuration data;

SRCADDR =Address of the data buffer with the configuration data;

Maximal 4 channels can be switched on or off by the means of one byte in

the configuration data. Every channel uses 2 bits of configuration data

which tells if its activated or not. The channel is deactivated if one of the

two bits is 1 and activated if both bits are zero. The thermo outputs are set

to zero during the change of the TC-Plug configuration.

Example:

We want to change the configuration for the first 4 channels of the TC-Plug

module. From the PLC we write one byte of configuration data ( 10000001

binary ) to the TC-Plug module. After that the channels 1 and 4 are

deactivated and channels 2 and 3 are activated. The configuration of all

other channels stays unchanged.

Remark: channel no. 1 is the very first TC channel connected to Pin 1 .

24 FM33xx

I/O configuration

Multiplex mode channel data in the TwinCAT System Manager

The channel data of a TC-Plug module is mapped and displayed as follows

in the TwinCAT System Manager, independently of the number of channels that are configured (associated):

Process data for the TCPlug modules in the TwinCAT System Manager

Control/status byte

Channel

Control/status byte and channel data for the 4 thermocouple inputs

In order to reduce the quantity of data that has to be transferred over the fieldbus, the thermocouple input data for a maximum of 4 channels only (e.g. for channels 0 to 3) is transferred over the fieldbus in any one fieldbus cycle. The control/status byte can be used to request the analog values of another 4 channels (e.g. for channels 4 to 7, 8 to 11 etc.).

FM33xx 25

I/O configuration

Protocol for the cyclical data transfer in

multiplex mode

The following protocol has been specified for communication with the TC-

Plug module in order to reduce the quantity of data transferred over the

fieldbus.

Appropriate channel selection request bits are set by the PLC in the control

byte. The channel selection request bits select the 4 channels that are to

be transferred. The TC-Plug copies the corresponding data in the input

bytes [1-8] and confirms it in the channel confirmation bits of the status

byte. If the control byte == status byte, then the data is valid.

Control byte Value Description

Channel Selection Request Bits 0-3

1 2 3 4 5 6 7 8 9

Bit 4-6 Bit 7 1/0

Status byte Value Description

Channel Selection Confirmation Bits 0-3

1 2 3 4 5 6 7 8 9

Bit 4-6 Bit 7 1/0

The AD conversion of the thermocouple input data in the TC-Plug module

During a conversion procedure the TC-Plug converts all its active

no channel selected

Channel 0-3 in Input Data [1..8] Channel 4-7 in Input Data [1..8] Channel 8-11 in Input Data [1..8] Channel 12-15 in Input Data [1..8] Channel 16-19 in Input Data [1..8] Channel 20-23 in Input Data [1..8] Channel 24-27 in Input Data [1..8] Channel 28-31 in Input Data [1..8] Status (Open circuit Channel 0-31 in Input Data [1..4] and Back Voltage in

Input Data [5..8]) Reserved for future use Toggle-Bit Measure Control

no channel selected

Input Data [5..8]) Reserved for future use Toggle-Bit Measure Status

can be initiated by the PLC by toggling bit 7 in the control byte. After the bit

has been toggled, the status and control bytes have different values in

bit 7. When the measuring cycle in the TC-Plug module has been

completed the TC-Plug will also toggle bit 7 in the status byte. The toggled

bits in the status and control bytes then have the same value.

By setting the appropriate channel selection request bits the PLC can then

request the current thermocouple input data. Every request in the control

byte is appropriately acknowledged in the status byte by the TC-Plug.

configured channels. Once completed, the PLC can request the channel

data over a number of cycles.

26 FM33xx

The open circuit and back voltage status information is also requested in a

similar manner by means of the channel selection control bits. When these have been confirmed in the status byte the status information can be read from the data for the 4 channels. For each channel that is registering open circuit, one bit is set in bytes 1 to 4, while bits are set in bytes 5 to 8 for channels registering back voltage.

The registers for a channel can be written to if the code word 0x1235 is

The TC-Plug can be configured via the serial interface using the KS2000 configuration software. The individual thermocouple input channels are represented in the configuration software as complex terminals.

Each logical thermocouple input channel has its own set of registers. Various operating modes and functionalities can be set for each channel by means of the registers.

The "General Description of Registers" explains those register contents that are the same for all complex terminals.

The terminal-specific registers are explained in the following section.

entered in R31 (register 31). The data is only permanently stored when the code word is cleared and the module is reset.

General description of registers

Complex terminals that possess a processor are able to exchange data bidirectionally with the higher-level controller. These terminals are referred to below as intelligent Bus Terminals. These include the analog inputs (0-10 V, -10-10 V, 0-20 mA, 4-20 mA), the analog outputs (0-10 V, -10-10 V, 020 mA, 4-20 mA), the serial interface terminals (RS485, RS232, TTY, data exchange terminals), counter terminals, encoder interface and SSI interface terminals, PWM terminals and all the terminals that can be parameterized.

The main features of the internal data structure are the same for all the intelligent terminals. This data area is organized as words and includes 64 memory locations. The important data and parameters of the terminal can be read and set through this structure. It is also possible for functions to be called by means of corresponding parameters. Each logical channel in an intelligent terminal has such a structure (so a 4-channel analog terminal has 4 sets of registers).

FM33xx 27

The structure of a register set is divided into the following areas:

Range Address

Process variables

Type register

Manufacturer parameters

User parameters

Extended user region

0-7 8-15 16-30 31-47 48-63

Process variables

R0-R7 Registers in the terminal's internal RAM:

The process variables can be used in addition to the actual process image.

Their function is specific to the terminal.

R0-R5:

The function of these registers depends on the type of terminal.

R6: Diagnostic register

The diagnostic register can contain additional diagnostic information. Parity

errors, for instance, that occur in a serial interface during data transmission

are indicated here.

R7: Command register

High-Byte_Write = function parameter

Low-Byte_Write = function number

High-Byte_Read = function result

Low-Byte_Read = function number

Type register

R8-R15 Registers in the terminal's internal ROM:

The type and system parameters are hard programmed by the

manufacturer, and the user can read them but cannot change them.

R8: Terminal type:

The terminal type in register R8 is needed to identify the terminal.

R9: Software version X.y

The software version can be read as a string of ASCII characters.

R10: Data length

R10 contains the number of multiplexed shift registers and their length in

bits.

The Bus Coupler sees this structure.

R11: Signal channels

Related to R10, this contains the number of channels that are logically

present. Thus for example a shift register that is physically present can

perfectly well consist of several signal channels.

R12: Minimum data length

The particular byte contains the minimum data length for a channel that is

to be transferred. If the MSB is set, the control/status byte is not absolutely

necessary for the terminal's function, and if the coupler is appropriately

configured it is not transferred to the controller.

28 FM33xx

R13: Data type register

Data type register

0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x11 0x12 Structure 1 byte n bytes with variable logical channel

0x13 0x14 Structure 1 byte n words with variable logical channel

0x15 0x16 Structure 1 byte n double words with variable logical

Terminal with no valid data type Byte array Structure 1 byte n bytes Word array Structure 1 byte n words Double word array Structure 1 byte n double words Structure 1 byte 1 double word Structure 1 byte 1 double word Byte array with variable logical channel length

length (e.g. 60xx) Word array with variable logical channel length

length Double word array with variable logical channel length

channel length

R14: reserved

R15: Alignment bits (RAM)

The analog terminal is placed on a byte boundary in the terminal bus with the alignment bits.

Manufacturer parameters

R16-R30 is the region for the "manufacturer parameters" (SEEROM)

The manufacturer parameters are specific for each type of terminal. They are programmed by the manufacturer, but can also be modified by the controller. The manufacturer parameters are stored in a serial EEPROM in the terminal, and are retained in the event of voltage drop-out. These registers can only be altered after the code word has been set in R31.

User parameters

R31-R47 is the "application parameters" region (SEEROM)

The application parameters are specific for each type of terminal. They can be modified by the programmer. The application parameters are stored in a serial EEPROM in the terminal, and are retained in the event of voltage drop-out. The application region is write-protected by a code word.

R31: Code word register in RAM The code word 0x1235 must be entered here so that parameters in the

Note

user area can be modified. If any other value is entered into this register, the write-protection is active. When write protection is not active, the code word is returned when the register is read. If the write protection is active, the register contains a zero value.

R32: Feature register

This register specifies the terminal's operating modes. Thus, for instance, a user-specific scaling can be activated for the analog I/Os.

R33 - R47

Registers that depend on the terminal type

Extended application region

R47 - R63

Extended registers with additional functions.

FM33xx 29

TC-Plug - channel-specific register

description

Process variables

R0: Unprocessed ADC value X_R

This register contains the unprocessed ADC value.

R1: Unprocessed ADC value for the cold junction compensation

R2: Temperature of the cold junction compensation

Unit: 1/10 degree Celsius, 16-bit signed int

R6: Diagnostic register

High byte: reserved

Low byte: status byte

R7: Command register

Commands:

0x0101

Offset adjustment with short-circuited input. An automatic offset

adjustment is carried out. At the same time the unprocessed ADC value

with which the cold junction compensation was carried out is kept in R23.

The corresponding inputs are to be short-circuited.

0x0102

Gain adjustment at 30 mV. An automatic gain adjustment is carried out on

the assumption that 30 mV is present at the corresponding input.

0x0103

Adjustment for temperature drift with short-circuited input. An offset

adjustment should be carried out at room temperature. This function is

called in order to take account of temperature drift. The comparison

temperature is entered into R24, and the corresponding coefficient into

R22.

R17: Calibration offset

In order to carry out a calibration, a zero is entered into R32 and R17, and

a comparison with 0 V is made. The process data value (in microvolts) is

multiplied by -1.9074, and entered into R17.

R18: Calibration gain

Value: [4096]

R19: Manufacturer scaling offset

Value: [0x0000]

R20: Manufacturer scaling gain

Fixed point number /256, so that 1 corresponds to a value of 256

30 FM33xx

R21: Cold junction compensation adjustment

Unit: 1/10 degree Celsius, 16-bit signed int

There are 8 cold junction compensations, and these are distributed as follows. The cold junction compensation is purely an offset adjustment.

Comp[0] Channel0 R21 Comp[1] Channel4 R21 Comp[2] Channel8 R21 Comp[3] Channel12 R21 Comp[4] Channel16 R21 Comp[5] Channel20 R21 Comp[6] Channel24 R21 Comp[7] Channel28 R21

The cold junction compensation for a channel is calculated as follows:

Cold junction compensation =

(((~channel) & 0x7) * U_compensation [(channel>>3)<<1]+(channel & 0x7) *U_compensation[((channel>>3)<<1)+1])/7;

e.g., for channel 20: 4/7*U_compensation[5]+3/7*U_compensation[4]

R26: Number of hardware channels valid

12 with the number of channels 0 - 12

the hardware is different => the two outer boards are inserted all values != 12 result in a standard version

R32: Feature register

R32.0 1 User scaling active 0 User scaling inactive

R32.1 1 Manufacturer scaling active 0 Manufacturer scaling inactive

R32.2 1 Cold junction compensation is active 0 Cold junction compensation is inactive

R32.7...R32.4 0x0000 Output in 2 microvolts / digit R32.7...R32.4 0x0001 Type K active R32.7...R32.4 0x0010 Type J active R32.7...R32.4 0x1110 Output the unprocessed ADC value in the process

data. Default output in 2 microvolts / digit.

R33: User scaling offset

R34: User scaling gain

Fixed point number /256, so that 1 corresponds to a value of 256.

FM33xx 31

R37: Filter register

with the following possible entries:

The changes can only be made by way of the first channel, and are

adopted after a reset.

Entry – Conversion time – Suppression

0x0C 191 ms with 4.9 MHz 50 Hz filter

0x0D 160 ms with 4.9 MHz 60 Hz filter

0x0E 46 ms with 4.9 MHz 250 Hz filter

0x0F 30 ms with 4.9 MHz 500 Hz filter

R38: Back voltage reset time

Unit is seconds. Minimum value is 10 seconds. If an error occurs, another

attempt is made to activate the channel after the specified interval.

Measurement is then not carried out for one cycle.

32 FM33xx

Address Description

Unprocessed ADC value Variable R RAM

R1 Unprocessed ADC value for the cold junction

compensation

Temperature of the cold junction compensation Unit: 1/10 degree Celsius, 16-bit signed int

reserved 0x0000 R

Diagnostic register Variable R RAM

Command register Variable R

reserved 0x0000 R ROM

R10 R11 R12 R13 R14 R15 R16 R17

R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 R34 R35 R36 R37 R38

reserved 0x0000 R ROM reserved 0x0000 R ROM reserved 0x0000 R ROM reserved 0x0000 R ROM reserved 0x0000 R reserved 0x0000 R/W RAM reserved 0x0000 R/W SEEROM Calibration offset 0x0000 R/W SEEROM

Calibration gain app. 0x1ED8 R/W SEEROM Manufacturer scaling offset [0x0000] R/W SEEROM Manufacturer scaling gain [0x0100] R/W SEEROM Cold junction compensation adjustment Specific R/W SEEROM reserved 0x0000 R/W SEEROM reserved 0x0000 R/W SEEROM reserved 0x0000 R/W SEEROM reserved 0x0000 R/W SEEROM Number of hardware channels valid Specific R/W SEEROM reserved 0x0000 R/W SEEROM reserved 0x0000 R/W SEEROM reserved 0x0000 R/W SEEROM reserved 0x0000 R/W SEEROM Code word Variable R/W RAM Feature register Variable R/W SEEROM User scaling offset [0x0000] R/W SEEROM User scaling gain [0x0100] R/W SEEROM reserved 0x0000 R/W SEEROM reserved 0x0000 R/W SEEROM Filter register 0x000D R/W SEEROM Back voltage reset time 0x000A R/W SEEROM

Default value

Variable R

0x0000 R

R/W Memory medium

FM33xx 33

Appendix

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34 FM33xx

BECKHOFF FM33xx User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual