Helmholz TB20 User manual

Helmholz GmbH & Co. KG | Hannberger Weg 2 | D-91091 Großenseebach
Phone [phone] | Fax [phone] | [e-mail] | www.helmholz.com
TB20 – ModbusTCP Coupler
Manual
Version 3 / 18.02.2020
for HW 1-1 & FW 1.20 and higher

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Notes
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manual or of parts thereof.
No part of this manual may be reproduced, processed, duplicated, or distributed in any form
(photocopy, microfilm, or any other methods) - even for training purposes or with the use of
electronic systems - without written approval from Helmholz GmbH & Co. KG.
All rights reserved in the event of the granting of a patent or the registration of a utility model.
Copyright © 2020 by
Helmholz GmbH & Co. KG
Hannberger Weg 2, 91091 Großenseebach, Germany
To download the latest version of this manual, please visit our website at
www.helmholz.de.
We welcome all ideas and suggestions.
Trademarks
Windows is a registered trademark of Microsoft Corporation.
Revision Record
Version Date Change
1 15.05.14 First version
2 - Not released
3 13.02.20
Corrections technical data and pictures
Introductory chapter updated
LED description improved
Layout update
ToolBox V2 update

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Table of Contents
1. General......................................................................................7
1.1. Target audience for this manual ..............................................................................................7
1.2. Safety instructions...................................................................................................................7
1.3. Note symbols and signal words in the manual ........................................................................8
1.4. Intended use............................................................................................................................9
1.5. Improper use ...........................................................................................................................9
1.6. Installation ............................................................................................................................10
1.6.1. Access restriction...............................................................................................................10
1.6.2. Electrical installation ........................................................................................................10
1.6.3. Protection against electrostatic discharges........................................................................10
1.6.4. Overcurrent protection .....................................................................................................10
1.6.5. EMC protection.................................................................................................................10
1.6.6. Operation..........................................................................................................................10
1.6.7. Liability.............................................................................................................................11
1.6.8. Disclaimer of liability........................................................................................................11
1.6.9. Warranty...........................................................................................................................11
1.6.10. Recycling / WEEE ..............................................................................................................11
2. System overview......................................................................12
2.1. General ..................................................................................................................................12
2.2. The components that make up the TB20 I/O system.............................................................12
2.2.1. Bus coupler........................................................................................................................12
2.2.2. Peripheral modules ...........................................................................................................12
2.2.3. Power and isolation module .............................................................................................13
2.2.4. Power module ...................................................................................................................14
2.2.5. Final cover.........................................................................................................................15
2.2.6. Components in a module .................................................................................................15
2.2.7. Module Coding .................................................................................................................16
3. Installation and removal..........................................................17
3.1. Installation position ..............................................................................................................17
3.2. Minimum clearance ..............................................................................................................17
3.3. Installing and removing peripheral modules ........................................................................18
3.3.1. Installation........................................................................................................................18
3.3.2. Removal ............................................................................................................................19
3.4. Replacing an electronic module ............................................................................................22
3.5. Installing and removing the coupler .....................................................................................26

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3.5.1. Installation........................................................................................................................26
3.5.2. Removal ............................................................................................................................27
3.6. Installing and removing the final cover ................................................................................29
3.6.1. Installation........................................................................................................................29
3.6.2. Removal ............................................................................................................................29
4. Setup and wiring .....................................................................30
4.1. EMC/safety/shielding............................................................................................................30
4.2. Front connectors ...................................................................................................................31
4.3. Wiring the coupler ................................................................................................................32
4.4. Using power and isolation modules ......................................................................................33
4.5. Separate power supply segments for the coupler and the I/O components...........................34
4.6. Using power modules ............................................................................................................35
4.7. Electronic nameplate.............................................................................................................36
4.8. Fusing ....................................................................................................................................36
5. ModbusTCP Coupler Characteristics........................................37
6. Setup and Use..........................................................................38
6.1. Configuration with the TB20 ToolBox ..................................................................................38
6.2. Installation of TB20-ToolBox ................................................................................................38
6.3. Start and create a new project ("Home") ................................................................................38
6.4. Configurator..........................................................................................................................39
6.5. Diagnostic .............................................................................................................................40
6.5.1. Load project from the coupler ("Download") ....................................................................41
6.5.2. Simulation ........................................................................................................................41
6.6. Startup Flow...........................................................................................................................42
6.7. Hot Swap ...............................................................................................................................43
6.8. Factory Reset (Restoring the Coupler to Its Factory Settings).................................................43
6.9. LED-Based Diagnosis .............................................................................................................44
6.9.1. ModbusTCP Coupler LEDs................................................................................................44
6.9.2. Module LEDs.....................................................................................................................45
7. ModbusTCP .............................................................................46
7.1. Introduction..........................................................................................................................46
7.2. General Frame Format ...........................................................................................................46
7.3. Communications Management ............................................................................................46
7.4. ModbusTCP function codes ..................................................................................................47
7.5. Sample Frames.......................................................................................................................47

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8. Registers ..................................................................................48
8.1. Inputs / Outputs ....................................................................................................................49
8.1.1. Section: Diagnostic Status Bits ..........................................................................................51
8.1.2. Section: Module Status Bits ...............................................................................................51
8.1.3. Section: Coupler Control Bits ...........................................................................................51
8.1.4. Section: Module Parameters..............................................................................................52
8.1.5. Section: Diagnostic Status .................................................................................................52
8.1.6. Section: Coupler Parameters .............................................................................................53
8.1.7. Section: Coupler Status .....................................................................................................54
8.1.8. Section: Module List..........................................................................................................54
8.1.9. Section: Mapping Information .........................................................................................55
9. Technical Specifications ..........................................................56
10. Dimensions..............................................................................57
11. Spare Parts...............................................................................58
11.1. Base Modules .........................................................................................................................58
11.1.1. 14 mm-Width Standard Base Module ...............................................................................58
11.1.2. 25 mm-Width Base Module ..............................................................................................58
11.1.3. Power and Isolation Base Module .....................................................................................58
11.1.4. Power Base Module ...........................................................................................................59
11.2. Front Connectors ..................................................................................................................59
11.2.1. 10-Terminal Front Connector...........................................................................................59
11.2.2. 20-Terminal Front Connector...........................................................................................59
11.3. Electronic Modules................................................................................................................60
11.4. Final Cover ............................................................................................................................60

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1. General
This operating manual applies only to devices, assemblies, software, and services of Helmholz GmbH
& Co. KG.
1.1. Target audience for this manual
This description is only intended for trained personnel qualified in control and automation
engineering who are familiar with the applicable national standards. For installation, commissioning,
and operation of the components, compliance with the instructions and explanations in this
operating manual is essential.
Configuration, execution, and operating errors can interfere with the proper operation of the TB20
devices and result in personal injury as well as material or environmental damage. Only suitably
qualified personnel may operate the TB20 devices!
Qualified personnel must ensure that the application and use of the products described meet all the
safety requirements, including all relevant laws, regulations, provisions, and standards.
1.2. Safety instructions
The safety instructions must be observed in order to prevent harm to persons and living creatures,
material goods, and the environment. The safety instructions indicate possible hazards and provide
information on how hazardous situations can be prevented.

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1.3. Note symbols and signal words in the manual
If the hazard warning is ignored, there is an imminent danger to life and health of people from electrical
voltage.
If the hazard warning is ignored, there is a probable danger to life and health of people from electrical
voltage.
If the hazard warning is ignored, people can be injured or harmed.
Draws attention to sources of error that can damage equipment or the environment.
Gives an indication for better understanding or preventing errors.

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1.4. Intended use
The TB20 I/O system is an open, modular, and distributed peripheral system designed to be mounted
on a 35 mm DIN rail.
Communication with a higher-level control system takes place via a bus system / network through a
TB20 bus coupler. Up to 64 modules from the TB20 range can be set up on a bus coupler. The bus
couplers support hot plug for replacing modules during ongoing operation.
All components are supplied with a factory hardware and software configuration. The user must carry
out the hardware and software configuration for the conditions of use. Modifications to hardware or
software configurations which are beyond the documented options are not permitted and nullify the
liability of Helmholz GmbH & Co. KG.
The TB20 devices should not be used as the only means for preventing hazardous situations on
machinery and equipment.
Successful and safe operation of the TB20 devices requires proper transport, storage, installation,
assembly, installation, commissioning, operation, and maintenance.
The ambient conditions provided in the technical specifications must be adhered to.
The TB20 systems have a protection rating of IP20 and must have a control box/cabinet fitted to
protect against environmental influences in an electrical operating room. To prevent unauthorized
access, the doors of control boxes/cabinets must be closed and possibly locked during operation.
TB20 devices can be equipped with modules that can carry dangerously high voltages. The voltages
connected to the TB20 devices can result in hazards during work on the TB20 devices.
1.5. Improper use
The consequences of improper use may include injury of the user or third parties, as well as property
damage to the control system, the product, or environment. Use TB20 devices only as intended!

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1.6. Installation
1.6.1. Access restriction
The modules are open operating equipment and must only be installed in electrical equipment rooms,
cabinets, or housings.
Access to the electrical equipment rooms, cabinets, or housings must only be possible using a tool or
key, and access should only be granted to trained or authorized personnel.
1.6.2. Electrical installation
Observe the regional safety regulations.
TB20 devices can be equipped with modules that can carry dangerously high voltages. The voltages
connected to the TB20 devices can result in hazards during work on the TB20 devices.
1.6.3. Protection against electrostatic discharges
To prevent damage through electrostatic discharges, the following safety measures are to be followed
during assembly and service work:
•Never place components and modules directly on plastic items (such as polystyrene, PE film) or
in their vicinity.
•Before starting work, touch the grounded housing to discharge static electricity.
•Only work with discharged tools.
•Do not touch components and assemblies on contacts.
1.6.4. Overcurrent protection
To protect the TB20 and the supply line, a slow-blowing 8 A line protection fuse is required.
1.6.5. EMC protection
To ensure electromagnetic compatibility (EMC) in your control cabinets in electrically harsh
environments, the known rules of EMC-compliant configuration are to be observed in the design and
construction.
1.6.6. Operation
Operate the TB20 only in flawless condition. The permissible operating conditions and performance
limits must be adhered to.
Retrofits, changes, or modifications to the device are strictly forbidden.
The TB20 is an operating means intended for use in industrial plants. During operation, the TB20 can
carry dangerous voltages. During operation, all covers on the unit and the installation must be closed
in order to ensure protection against contact.