Kollmorgen AKT-PRB-000-000 Installation Manual

I/O Terminal

Installation Manual

Revision 1.1, June 2011

AKT-PRB-000-000 PROFIBUS Coupler

Keep all manuals as a product component during the life span of the product.
Pass all manuals to future users / owners of the product.

Record of Document Revisions

Revision Remarks

1.0 Preliminary edition

1.1 Added dimensions to technical data table and mechanical drawing to
Appendix B. For more information, see “Technical Data” page 8 and
“Appendix B” page 76.

IMPORTANT NOTICE

Copyright© Kollmorgen™2010–2011. All rights reserved. Kollmorgen holds the copyright to this manual. All rights are
reserved and no part of this publication may be reproduced or transmitted in any form or by any means without prior
written consent from Kollmorgen.

Disclaimer

The information in this manual was accurate and reliable at the time of its release. However, Kollmorgen. reserves
the right to change the specifications of the product described in this manual without notice at any time.

This document contains proprietary and confidential information of Kollmorgen. The contents of the document may
not be disclosed to third parties, translated, copied or duplicated in any form, in whole or in part, without the express
written permission of Kollmorgen.

Registered Trademarks

Kollmorgen is a registered trademark of Danaher Corp.
Technical changes which improve the performance of the device may be made without prior notice! Printed in the

Federal Republic of Germany. All rights reserved. No part of this work may be reproduced in any form (by printing,
photocopying, microfilm or any other method) or stored, processed, copied or distributed by electronic means without
the written permission of Kollmorgen. All other proprietary names mentioned in this manual are the trademarks of
their respective owners.

June 2011

Safety Precautions

1

1.1 Safety Rules............................................................................................6

1.2 State at Delivery......................................................................................6

1.3 Personnel Qualification...........................................................................6

1.4 Description of Notes and Warnings ........................................................6

2 Overview

2.1 PROFIBUS Coupler (AKT-PRB-000-000) ..............................................7

2.1.1 Technical Data........................................................................................8

2.2 System Overview....................................................................................9

2.2.1 Bus Terminal System..............................................................................9

2.3 PROFIBUS DP......................................................................................11

2.4 PROFIBUS DPV1 .................................................................................12

3 Mounting and Wiring

3.1 Dimensions ...........................................................................................13

3.2 Installation.............................................................................................14

3.3 Wiring....................................................................................................15

3.3.1 Potential Groups ...................................................................................15

3.3.2 Insulating Testing..................................................................................16

3.3.3 PE Power Contacts...............................................................................16

3.4 Power Supply........................................................................................17

3.4.1 Power Contacts Supply (Up).................................................................18

3.4.2 Power Contacts.....................................................................................18

3.4.3 Configuration and Programming Interface............................................18

3.4.4 Electrical Isolation.................................................................................19

3.5 PROFIBUS Connection ........................................................................19

3.5.1 M12 Circular Connector........................................................................19

3.5.2 Nine Pole D-Sub ...................................................................................20

3.5.3 PROFIBUS Conductor Colors...............................................................20

3.5.4 Connection of Fieldbus Box Modules ...................................................21

3.6 PROFIBUS Cabling...............................................................................21

3.6.1 Cable-Based Transmission...................................................................21

3.6.2 Cabling for Profibus DP and Profibus FMS ..........................................22

3.6.3 Distances ..............................................................................................23

3.6.4 Bus Segments.......................................................................................23

3.6.5 Installation Guidelines...........................................................................23

3.6.6 Checking the Profibus Wiring................................................................24

I/O Terminal / CONTENTS

4 Start-up Behavior of the Bus Coupler

4.1 Self-Test................................................................................................25

5 Automatic Configuration

5.1 Scan Devices........................................................................................26

3

Manual Configuration

6

6.1 The Bus Coupler’s UserPrmData..........................................................28

6.2 Configuration.........................................................................................31

6.2.1 Configuration: CfgData .........................................................................31

6.2.2 Configuration of the Coupler Modules ..................................................31

6.2.3 Configuration of Complex Modules.......................................................32

6.3 Cyclic Data Exchange...........................................................................33

6.3.1 Process Data and Image ......................................................................33

6.3.2 Standard-Bus Cycle..............................................................................35

6.4 DPV1 – Acyclic Data Transfer ..............................................................39

6.4.1 DPV1 Interface......................................................................................39

6.4.2 DPV1 at the Coupler.............................................................................41

7 Extended Functions

7.1 2-byte PLC Interface.............................................................................47

7.2 Word Alignment.....................................................................................47

7.3 Deactivating the CfgData Check...........................................................48

7.4 Multi-Configuration Mode......................................................................49

7.4.1 Creating a DP Configuration for Various Implementation Levels.........49

7.4.2 Reserved Bus Terminals.......................................................................49

7.4.3 Assign Bus Terminals to Freely Choose Process Image Addresses...49

7.4.4 Setting the Multi-configuration Mode ....................................................49

7.4.5 Rules for Multi-configuration Mode.......................................................49

7.4.6 Enabling/disabling Bus Terminals.........................................................50

7.5 Changing the Size of the Process Data................................................53

7.5.1 Exceeding the Input Data Length (InputData) ......................................53

7.5.2 Exceeding the Output Data Length (OutputData).................................53

7.5.3 Exceeding the Configuration Data Length (CfgData) ...........................53

I/O Terminal / CONTENTS

8 Error Handling and Diagnosis

8.1 Fieldbus LEDs.......................................................................................55

8.1.1 DIA-LED Blink Codes............................................................................56

8.1.2 Standard-Bus LEDs (Local Errors) .......................................................57

8.2 DP Diagnostic .......................................................................................58

8.2.1 DP Diagnostic Data (DiagData)............................................................58

8.2.2 Errors During DP Start-up.....................................................................62

8.2.3 Reaction to PROFIBUS Error ...............................................................64

8.3 Standard-Bus Diagnostic......................................................................64

8.3.1 Standard-Bus Interruption.....................................................................64

8.3.2 Terminal Diagnostics.............................................................................65

Appendix A

A.1 GSE File................................................................................................67

4

Appendix B

B.1 AKT-PRB-000-000 Mechanical Drawing...............................................76

Performance Box Controllers / INTRODUCTION

5

1 SAFETY PRECAUTIONS

This chapter provides safety information for the I/O terminal.

1.1 Safety Rules

The appropriate 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 stan dards.

1.2 State at Delivery

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

1.3 Personnel Qualification

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

I/O Terminal / SAFETY PRECAUTIONS

1.4 Description of Notes and Warnings

The following notes and warnings are used in this manual. They are intended to alert the reader
to the associated safety instructions.

Danger — This note is intended to highlight risks for the life or health of personnel.
Warning — This note is intended to highlight risks for equipment, materials or the environment.
Note — Indicates information that contributes to better understanding.

6

2 OVERVIEW

This section provides an overview of the PROFIBUS Coupler.
Note: For information about configuring the PROFIBUS Coupler, see the Kollmorgen Automation

Suite™ IDE software and online help system.

2.1 PROFIBUS Coupler (AKT-PRB-000-000)

The Bus Coupler connects the PROFIBUS system to the electronic terminal blocks, which can be
extended in modular fashion. One unit consists of the Bus Coupler, any number of up to 64
terminals and one end terminal. Up to 64 digital input/output terminals can be connected.

The Bus Coupler recognizes the connected terminals and automatically genera tes the affiliations
of the inputs/outputs to the bytes of the process image. The first input/output signal is inserted in
the first bit of one byte (LSB), beginning from the left. The Bus Coupler inserts further signals in
this byte. Inputs and outputs are clearly separated. The Bus Coupler automatically begins a
further byte if the number of inputs or outputs exceeds 8 bits.

The Bus Coupler supports the operation of all Bus Terminals. As far as the user is concerned,
handling of the analog inputs/outputs is not different to other series. The information is available
in the process image of the controller for processing in the form of a byte array.

I/O Terminal / OVERVIEW

The Bus Terminals can be controlled by the control system. Via function blocks (FBs), the
programmable logic controller (PLC) or the handles configuration of the complete periphery
during the start up phase. If required, the controller can upload the de-centrally created
configuration data in order to centrally manage and store this data. Therefore, new adjustments
are not necessary in the event of replacement of a Bus Terminal. The controller automatically
sets the required setting on power up.

Figure 2.1 PROFIBUS Coupler (Front View)

7

2.1.1 Technical Data

This section provides the technical details for the ETHERCAT Coupler.

Parameters (AKT-PRB-000-000)

Number of Bus Terminals 64
Digital peripheral signals 512 inputs/outputs
Analog peripheral signals 128 inputs/outputs
Configuration possibility IDE software or controller

I/O Terminal / OVERVIEW

Maximum number of bytes

64 bytes (DP and FMS operation)

128 bytes (DP operation only)
Baud rate (automatic detection) Up to max. 12 MBaud
Bus connection 1 x D-sub plug, 9-pin with shielding
Power supply 24 VDC (-15 % /+20 %)
Input current 70 mA + (total Standard-Bus current)/4, max. 500 mA
Starting current 2.5 x continuous current
Standard-Bus current up to 1750 mA (BK3x00)
Power contact voltage (Up) Maximum 24 VDC
Power contact current load (Up) Maximum 10 A
Recommended fuse (Up) Maximum 10 A
Electrical isolation Power contact / supply / fieldbus
Dielectric strength 500 V

(power contact / supply / fieldbus)

rms

Dimensions (H × W ) 100 × 51 mm
Weight ~150 g
Permissible ambient temperature

(operation)

0 °C … +55 °C
Permissible ambient temperature

(storage)

-25 °C … +85 °C
Permissible relative humidity 95 % (no condensation)
Vibration / shock resistance

EMC resistance Burst / ESD

According to EN 60068-2-6 / EN 60068-2-27,
EN 60068-2-29

According to EN 61000-6-2 (EN 50082) /

EN 61000-6-4 (EN 50081)
Protection class IP 20
Installation position Variable

8

2.2 System Overview

This section provides a system overview for the PROFIBUS Coupler.

2.2.1 Bus Terminal System

Up to 64 Bus Terminals each having 2 I/O Channels for each Signal Form

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

Decentralized Wiring of Each I/O Level

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

Programmable Automation Controllers (PAC)

I/O Terminal / OVERVIEW

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

Bus Couplers for all Usual Bus Systems

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

Assembly on Standardized C Mounting Rails

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

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

9

I/O Terminal / OVERVIEW

Modularity

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

Display of the Channel State

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

Standard-Bus

The Standard-Bus is the data path within a terminal strip. The Standard--Bus is led through from
the Bus Coupler through all the terminals via six contacts on the terminals’ side walls. The end
terminal terminates the Standard-Bus. The user does not have to learn anything about the
function of the Standard-Bus or about the internal workings of the terminals and the Bus Coupler.
Many software tools that can be supplied make project planning, configuration and operation
easy.

Potential Feed Terminals for Isolated Groups

The operating voltage is passed on to following terminals via three power contacts. You can
divide the terminal strip into arbitrary isolated groups by means of potential feed terminals. The
potential feed terminals play no part in the control of the terminals, and can be inserted at any
locations within the terminal strip.

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

Bus Couplers for Various Fieldbus Systems

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

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

The Interfaces

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

10

2.3 PROFIBUS DP

In PROFIBUS DP systems, a master (PLC, PC etc.) usually communicates with a large number
of slaves (I/Os, drives etc.). Only the master may here actively access the bus (send telegrams
on its own initiative), while a DP slave only sends telegrams when it is requested to do so by a
master.

DP StartUp

Before the master and slave can cyclically exchange data, the parameter and configuration data
is transmitted from the master to the slaves during the DP StartUp phase. After the parameter
and configuration data has been sent, the master interrogates the slave's diagnostic data until the
slave indicates that it is ready for data exchange. Depending on the extent of the calculations that
the slave must carry out after receiving the parameter and configuration data, it can take up to a
few seconds before it is ready for data exchange. For this reason the slave possesses the
following states:

Parameter Data

The parameter data is sent from the master to the slave in the SetPrmLock request telegram. The
SetPrmLock response telegram does not contain any data, and therefore consists of a singl e
byte, the short acknowledgement. The parameter data consists of DP parameters (e.g. the setting
of the DP watchdog or checking the IdentNumber (unique to each DP device)), of DPV1-/DPV2
parameters and of application-specific parameters that only have to be transmitted once during
the StartUp. If an error is found in the parameter data, this is indicated in the diagnostic data, and
the slave either remains in or enters the WAIT-PRM state.

I/O Terminal / OVERVIEW

Configuration Data

The configuration data is sent from the master to the slave in the ChkCfg request telegram. The
ChkCfg response telegram does not contain any data, and therefore consists of a single byte, the
short acknowledgement. The configuration data describes the assignment of the DP modules to
the cyclic I/O data that is to be exchanged between the master and slave via the Data_Exchange
telegram in the cyclic data exchange phase. The sequence of the DP modules added to a slave
in the DP configuration tool determines the sequence of the associated I/O data in the
Data_Exchange telegram.

Diagnostic data

The diagnostic data is requested by the master using a SlaveDiag request telegram without any
data. The slave replies with the diagnostic data in a SlaveDiag response telegram. The diagnostic
data consists of the standard DP diagnostics (e.g. the state of the slave, the IdentNumber) and of
application-specific diagnostic data.

Cyclic Data Exchange

The heart of the PROFIBUS DP protocol is cyclic data exchange, during which the master carries
out an exchange of I/O data with every slave during a PROFIBUS DP cycle. This involves the
master sending the outputs to each slave with a DataExchange request telegram, while the slave
replies with the inputs in a DataExchange response telegram. This means that all the output
and/or input data is transmitted in one telegram, in which the DP configuration (the sequence of
DP modules) specifies the assignment of the output and/or input data to the slave's actual
process data.

11

I/O Terminal / OVERVIEW

Diagnosis During Cyclic Data Exchange

A slave can send a diagnostics signal to the master during cyclic data exchange. In this case, the
slave sets a flag in the DataExchange response telegram, whereby the master recognizes that
there is new diagnostic data in the slave. It then fetches that data in the SlaveDiag telegram. This
means that diagnostic data is not transmitted to the controller with the cyclic I/O data in real-time,
but is always at least one DP cycle later.

Synchronization with Sync and Freeze

The Sync and Freeze commands in the GlobalControl request telegram (b roadcast telegram)
allow the master to synchronize the activation of the outputs (Sync) or the reading of the inputs
(Freeze) in a number of slaves. When the Sync command is used, the slaves are first switched
into Sync mode (a process that is acknowledged in the diagnostic data). The I/O data is then
exchanged sequentially with the slaves in the DataExchange telegram. Transmitting the Sync
command in the GlobalControl telegram then has the effect of causing the slaves to generate the
most recently received outputs. In Freeze operation a Freeze command is first sent in the
GlobalControl telegram, in response to which all the slaves latch their inputs. These are then
fetched sequentially by the master in the DataExchange telegram.

States in the Master

The master distinguishes between the CLEAR state (all outputs are set to the Fail_Safe value)
and the OPERATE state (all outputs have the process value). The Master is usually switched into
the CLEAR mode when, for instance, the PLC enters STOP.

Class 1 and Class 2 DP Masters

The Class 1 master refers to the controller that carries out cyclic I/O data exchange with the
slaves, while a Class 2 master is a B&B device that generally only has read access to the slaves'
I/O data.

2.4 PROFIBUS DPV1

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

When two masters are used, however, is must always be borne in mind that these share bus
access (a token is exchanged), so that time relationships are less favorable than in the case of a
single master system.

12

3 MOUNTING AND WIRING

This section provides mounting and wiring information for the PROFIBUS Coupler.
Note: For information about configuring the PROFIBUS Coupler, see the Kollmorgen Automation

Suite™ IDE software and online help system.

3.1 Dimensions

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

I/O Terminal / MOUNTING AND WIRING

The total width in practical cases is composed of the width of the Bus Coupler with the Bus End
Terminal and the width of the Bus Terminals in use. Depending on function, the Bus Terminals
are 12 or 24 mm wide. The front wiring increases the total height of 68 mm by about 5 to 10 mm,
depending on the wire thickness.

13

3.2 Installation

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

I/O Terminal / MOUNTING AND WIRING

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

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

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

14

I/O Terminal / MOUNTING AND WIRING

The right hand part of the Bus Coupler can be compared to a Bus Terminal. Eight connections at

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

3.3 Wiring

The section provides potential groups, insulation testing, and PE information for the
PROFIBUS Coupler.

3.3.1 Potential Groups

The Bus Terminals stations usually have three different potential groups:
 The fieldbus interface is electrically isolated (except for individual Low Cost cou plers) and

forms the first potential group

 Bus Coupler / Bus Terminal Controller logic, Standard-Bus a nd terminal logic form a

second galvanically separated potential group

 The inputs and outputs are supplied via the power contacts and form further potential

groups.

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

15

3.3.2 Insulating Testing

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

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

3.3.3 PE Power Contacts

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

I/O Terminal / MOUNTING AND WIRING

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

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

16

3.4 Power Supply

The Bus Coupler / Bus Terminal Controller require a 24 VDC supply for their operation.
The connection is made by means of the upper spring-loaded terminals labeled 24 V and 0 V.

This supply voltage feeds the Bus Coupler / Bus Terminal Controller electronics and, over the
Standard-Bus, the electronics of the Bus Terminals. It is electrically separated from the
potential of the field level.

I/O Terminal / MOUNTING AND WIRING

DANGER!! For the compliance of the UL requirements Us should only be supplied:
 By a 24 VDC supply voltage, supplied by an isolating source and protected by means of

a fuse (in accordance with UL248), rated maximum 4 Amp.

 By a 24 VDC power source, that has to satisfy NEC class 2.

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

17

3.4.1 Power Contacts Supply (Up)

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

The spring-loaded terminals are designed for wires with cross-sections between 0.08 mm² and

2.5 mm².
The assignment in pairs and the electrical connection between feed terminal contacts allows the

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

3.4.2 Power Contacts

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

I/O Terminal / MOUNTING AND WIRING

3.4.3 Configuration and Programming Interface

The Bus Coupler / Bus Terminal Controller have an RS232 interface at the bottom of the front
face. The miniature connector can be joined to a PC IDE software with the aid of a connecting
cable. The interface permits the Bus Terminals to be configured, for example adjusting the
amplification factors of the analog channels. The interface can also be used to change the
assignments of the bus terminal data to the process image in the Bus Coupler. The functionality
of the configuration interface can also be reached via the fieldbus using string communication
facility.

18

3.4.4 Electrical Isolation

The Bus Coupler / Bus Terminal Controller operate by means of three independent potential
groups. The supply voltage feeds the Standard-Bus electronics and the Standard-Bus itself. The
supply voltage is also used to generate the operating voltage for the fieldbus interface.

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

I/O Terminal / MOUNTING AND WIRING

3.5 PROFIBUS Connection

This section provides information about the PROFIBUS connection for the PROFIBUS
Coupler.

3.5.1 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

19

3.5.2 Nine Pole D-Sub

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

D-Sub Socket Assignment

3.5.3 PROFIBUS Conductor Colors

I/O Terminal / MOUNTING AND WIRING

PROFIBUS
Conductors

B Red Pin 4 Pin 3
A Green Pin 2 Pin 8

M12 D-Sub

20

3.5.4 Connection of Fieldbus Box Modules

The connection of the Fieldbus Box modules is done direct or via a T-piece (or Y-piece).
The B318 series does have a male and female connector, that means no external T-piece is

required. The supply voltage (+5VDC) for the termination resistor is only supplied via the
female M12 connector. The termination resistor is only available with male connector,
therefore the incoming PROFIBUS line should end in a female connector.

I/O Terminal / MOUNTING AND WIRING

Two T-pieces are available:

 +5VDC on male and female connector for the termination resistor
 +5VDC only on the female connector

3.6 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.

3.6.1 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.

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Two types of conductor are available, with differing maximum conductor lengths (see the RS­485 table).

RS485 - Fundamental Properties

RS-485 Transmission According to the Profibus Standard

Network topology

Medium

Number of stations
Maximum bus length

without repeater
Maximum bus length with

repeater
Transmission speed

(adjustable in steps)
Plug connector

Linear bus, active bus terminator at both ends, stubs are
possible.

Screened twisted cable, screening may be omitted,
depending upon the environmental conditions (EMC).

32 stations in each segment with no repeater. Can be
extended to 127 stations with repeater

100 m at 12 MBit/s
200 m at 1500 KBit/s, up to 1.2 km at 93.75 KBit/s

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.

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

9-pin D-Sub connector for IP20
M12 round connector for IP65/67

3.6.2 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 surprisi ng
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 disco nnected. 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.

Note: Installation is made a great deal more straightforward if pre-assembled cables are
used! Wiring errors are avoided, and commissioning is more rapidly completed. The 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.

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Note: 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.

3.6.3 Distances

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

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Baud Rate in kbits/sec 9.6 19.2 93.75 187.5 500 1500 12000

Cable length in m 1200 1200 1200 1000 400 200 100

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

3.6.4 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 to which up to 120 extension modules 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.

3.6.5 Installation Guidelines

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

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3.6.6 Checking the Profibus Wiring

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

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

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

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

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

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

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

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).

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