Helmholz TB20 User manual

Systeme Helmholz GmbH | Hannberger Weg 2 | D-91091 Großenseebach | Germany
Phone [phone] | Fax [phone] | [email protected] | www.helmholz.com
TB20 – EtherNet/IPTM Coupler
Manual
Version 1 / 07.07.2014 for HW 1-1 & FW 1.00 and higher
Manual Order No.: 960-175-1AA11/en

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Notes
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of this 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 Systeme Helmholz GmbH.
All rights reserved in the event of the granting of a patent or the registration of a utility
model.
Copyright © 2014 by
Systeme Helmholz GmbH
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 First version

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Table of contents
1. General information.................................................................... 7
1.1. Target group for this manual ..................................................................................... 7
1.2. Symbols and signal words.......................................................................................... 7
1.3. Safety instructions...................................................................................................... 8
2. Overview ....................................................................................10
2.1. General information................................................................................................. 10
2.2. The components that make up the TB20 I/O system ............................................. 10
2.2.1. Bus coupler .......................................................................................................................10
2.2.2. Peripheral modules ...........................................................................................................10
2.2.3. Power and isolation module.............................................................................................11
2.2.4. Power module ...................................................................................................................12
2.2.5. Final cover ........................................................................................................................12
2.2.6. Components in a module.................................................................................................13
2.2.7. Module coding..................................................................................................................14
3. Installation and removal ............................................................15
3.1. Installation position ................................................................................................. 15
3.2. Minimum clearance ................................................................................................. 15
3.3. Installing and removing peripheral modules .......................................................... 16
3.3.1. Installation........................................................................................................................16
3.3.2. Removal ............................................................................................................................17
3.4. Replacing an electronic module............................................................................... 20
3.5. Installing and removing the coupler ....................................................................... 23
3.5.1. Installation........................................................................................................................23
3.5.2. Removal ............................................................................................................................24
3.6. Installing and removing the final cover .................................................................. 26
3.6.1. Installation........................................................................................................................26
3.6.2. Removal ............................................................................................................................26
4. Wiring.........................................................................................27
4.1. EMC/safety/shielding ............................................................................................... 27
4.2. Front connector........................................................................................................ 27
4.3. Wiring the coupler ................................................................................................... 28
4.4. Using power and isolation modules ........................................................................ 29
4.5. Separate power supply segments for the coupler and the I/O components........... 30
4.6. Using power modules............................................................................................... 31

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4.7. Fusing........................................................................................................................ 32
4.8. Electronic nameplate................................................................................................ 32
5. Characteristics of the EtherNet/IPTM coupler..............................33
6. Setup and use.............................................................................34
6.1. Project planning using TB20 ToolBox ..................................................................... 34
6.1.1. Configuration screen ........................................................................................................35
6.1.2. Network configuration .....................................................................................................36
6.1.3. Syslog ................................................................................................................................37
6.1.4. Setting parameters for the I/O modules ...........................................................................38
6.1.5. Transferring the configuration .........................................................................................39
6.1.6. Other configuration functions .........................................................................................39
6.1.7. Online diagnosis...............................................................................................................40
6.1.8. Simulation mode ..............................................................................................................40
6.1.9. Firmware updating ...........................................................................................................42
6.3. DIP switches.............................................................................................................. 44
6.5. Startup flow .............................................................................................................. 45
6.6. Replacement of modules during operation (hot plugging) .................................... 47
6.7. Resetting to factory settings..................................................................................... 47
6.8. Diagnosis using LED indicators ............................................................................... 48
6.8.1. Diagnostic LED indicators of the EtherNet/IPTM coupler ..................................................48
6.8.2. Diagnostic LED indicators of the modules.......................................................................51
7. EtherNet/IPTM functionality and mapping ..................................52
7.1. Introduction ............................................................................................................. 52
7.1.1. EDS file..............................................................................................................................52
7.1.2. Application options ..........................................................................................................52
7.1.3. Exclusive owner connection.............................................................................................53
7.1.4. Input-only connection .....................................................................................................53
7.1.5. Listen-only connection.....................................................................................................54
7.2. Mapping of I/O data................................................................................................. 55
7.2.1. Attributes of the assembly instances ................................................................................55
7.2.2. Static assembly instances..................................................................................................55
8. Technical specifications..............................................................58
9. Dimensions.................................................................................59
9.1. ModbusTCP coupler ................................................................................................. 59
9.2. 14 mm module ......................................................................................................... 59

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9.3. 25 mm module ......................................................................................................... 60
10. Spare parts .................................................................................61
10.1. Base modules ............................................................................................................ 61
10.1.1. 14 mm width standard base module................................................................................61
10.1.2. 25 mm width base module...............................................................................................61
10.1.3. Power and isolation base module.....................................................................................61
10.1.4. Power base module ...........................................................................................................62
10.2. Front connectors ...................................................................................................... 62
10.2.1. 10-terminal front connector.............................................................................................62
10.2.2. 20-terminal front connector.............................................................................................62
10.3. Electronic modules................................................................................................... 63
10.4. Final cover ................................................................................................................ 63

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1. General information
This document serves as the basis for the implementation, testing, and documentation of
the EtherNet/IPTM coupler (order no. 600-175-1AA11) for the Systeme Helmholz IO system
TB20.
1.1. Target group for this manual
This manual is intended for all project engineers, design engineers, technicians (skilled
workers with electrical training), and users who work with the TB20 I/O system.
1.2. Symbols and signal words
The following symbols and signal words are used in this documentation. The combination
of a pictogram and signal word classifies each safety warning. The symbol may vary
according to the type of hazard.
Symbol Signal word Explanation
Death
Hazard This signal word must be used when death or irreversible health damage
can result if the hazard statement is ignored.
Injury and property damage
Warning This signal word indicates personal injury and property damage, including
injury, accident, and health risks.
Caution This signal word indicates a risk of property damage. In addition, there is a
slight risk of injury.
Property damage only
Attention This signal word may be used only if no health damage can occur. It
warns of damage to property.
No damage
Note This signal word indicates hints for making operation easier and cross
references. It excludes all risks of damage or injury.

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Warnings used
Symbol
Explanation
Symbol
Explanation
General warning sign Electrical voltage warning
1.3. Safety instructions
For your own safety, and for the safety of others in the vicinity of the equipment, please
follow the safety instructions below.
Note
All applicable accident prevention and safety regulations must be complied with when planning
the use of, installing, and operating this equipment. The company operating the equipment is
responsible for ensuring compliance with these regulations.
Hazard
Risk of death by electric shock
There is residual electrical energy in pipes, equipment, and devices.
Allow work on the electrical supply to be carried out only by qualified electricians.
Hazard
Risk of death, injury, and damage to property
There are hazards if the operating instructions and all safety warnings in the device are not
obeyed.
Read the operating instructions carefully before initial use. Fulfill the required security conditions
before the initial start-up.
Observe the general safety instructions and the specific safety information included in the other
sections.

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Hazard
Risk of death and injury in case of defective safety switches
Hazards exist if the safety switches do not work.
Any processes in the equipment that have the potential of resulting in property damage or
bodily injury must be safeguarded with the use of additional external devices.
These devices must ensure that the equipment will remain in a safe operating state even in the
event of a fault or malfunction. These devices include, but are not limited to, electromechanical
safety switches, mechanical interlocks, etc. (refer to EN 954-1, Risk Assessment).
Hazard
Risk of death and injury in case of improper use
Define the responsibilities of the staff.
The TB20 modules should only be used for the functions characteristic of a communications and
signaling system. Safety-relevant functions should not be controlled solely with the coupler or
with an operating terminal.
Emergency stop devices as per EN 60204/IEC 204 must remain fully functional and effective in
all of the equipment’s operating modes.
The equipment must not be able to restart in an uncontrolled or undefined manner.
Uncontrolled restarts must be rendered impossible by means of appropriate programming.

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2. Overview
2.1. General information
The TB20 I/O system is an open-ended, modular, and distributed peripheral system
designed to be mounted on 35 mm DIN rails.
It is made up of the following components:
1. A bus coupler
2. One or more peripheral modules
3. Optionally, one or more power and isolation modules
4. Optionally, one or more power modules
By using these components, you can build a custom automation system that is tailored to
your specific needs and that can have up to 64 modules connected in series to a bus
coupler.
All components have a protection rating of IP 20.
2.2. The components that make up the TB20 I/O system
2.2.1. Bus coupler
The system’s bus coupler includes a bus interface and a power module. The bus interface is
responsible for establishing a connection to the higher-level bus system and is used to
exchange I/O signals with the automation system’s CPU.
The power module is responsible for powering the coupler’s electronics and all connected
peripheral modules.
2.2.2. Peripheral modules
The system’s peripheral modules are electronic components to which peripheral devices
such as sensors and actuators can be connected. A variety of peripheral modules with
different tasks and functions are available.
Example: Peripheral module with 10-terminal front connector

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Example: Peripheral module with 20-terminal front connector
2.2.3. Power and isolation module
The system’s bus coupler provides the supply voltage for the communications bus (5 V,
top) and for external signals (24 V, bottom). These voltages are passed from module to
module through the base modules.
Power and isolation modules make it possible to segment the power supply for external
signals into individual power supply sections that are powered separately. Meanwhile, the
communications bus’ signals and supply voltage simply continue to be passed through, in
contrast to the way they are handled by power modules (see below).
Note
Power and isolation modules can be recognized by the bright color of their case.

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2.2.4. Power module
The system’s bus coupler provides the supply voltage for external signals (24 V, bottom)
and for the communications bus (5 V, top). These voltages are passed from module to
module through the base modules.
Power modules make it possible to segment the power supply for both external signals and
the communication bus into individual power supply sections that are powered separately.
In other words, power modules deliver all the necessary power to the peripheral modules
connected after them and, if applicable, all the way to the next power module or power
and isolation module. This is required whenever the power supplied by the coupler alone is
not sufficient, e.g., when there are a large number of modules on the bus. The “TB20
ToolBox” configuration program can be used to determine whether power modules are
needed as well as how many of them will be needed.
Note
Power modules can be recognized by the bright color of their case.
2.2.5. Final cover
The final cover protects the contacts on the last base module from accidental contact by
covering its outer right-hand side.

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2.2.6. Components in a module
Each module consists of three parts:
•A base module
•The electronics module and
•The front connector

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2.2.7. Module coding
Electronic and base modules feature coding elements meant to prevent the wrong spare
electronic modules from being plugged in during maintenance and repairs.
These coding elements consist of a coding plug on the electronic module and a coding
socket on the base module (see figure below).
The coding plug and coding socket can each be in one of eight different positions. Each of
these eight positions is factory-assigned to a specific type of module (digital in, digital out,
analog in, analog out, power, etc.) from the TB20 I/O system. It is only possible to plug an
electronic module into a base module if the positions of the coding plug and the positions
of the coding socket match. Otherwise, the electronic module will be mechanically
prevented from being plugged in.

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3. Installation and removal
Hazard
Risk of death and injury through electrical energy
Risk of death by electric shock!
Before starting any work on the TB20 system, make sure to de-energize all components as well
as the cables supplying them with power.
Attention
Installation must be carried out as per VDE 0100/IEC 364. Since the coupler and segments are
modules with a protection rating of IP 20, they must be installed inside an enclosure. In order to
ensure safe operation, the ambient temperature must not exceed 60 °C. Also note that the
maximum ambient temperature for UL applications is 50 °C.
3.1. Installation position
The TB20 I/O system can be installed in any position.
However, in order to achieve optimum ventilation and be able to use the system at the
specified maximum ambient temperature, it is necessary to use a horizontal installation
layout.
3.2. Minimum clearance
It is recommended to adhere to the minimum clearances specified below when installing
the coupler and modules. Adhering to these minimum clearances will ensure that:
•The modules can be installed and removed without having to remove any other
system components
•There will be enough space to make connections to all existing terminals and contacts
using standard accessories
•There will be enough space for cable management systems (if needed)
The minimum clearances for TB20 components are: 30 mm on the top and on the bottom
and 10 mm on each side.

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3.3. Installing and removing peripheral modules
3.3.1. Installation
Installing an assembled peripheral module
Place the assembled module on the DIN rail by moving it straight towards the rail. Make
sure that the module engages the upper and lower guide elements of the previous module.
Then push the upper part of the module towards the DIN rail until the rail fastener on the
inside snaps into place with a soft click.
Installing the individual parts of a peripheral module one after the other:
Place the base module on the DIN rail from below in an inclined position. Then push the
upper part of the base module towards the rail until the module is parallel to the rail and
the rail fastener on the inside snaps into place with a soft click.
Place an electronic module with matching coding (see the “Module coding” section on
page 7) on the base module in a straight line from the front and then gently push it into
the base module until both modules are fully resting against each other and the module
fastener snaps into place with a soft click.
Finally, place the front connector on the electronic module from below in an inclined
position and then gently push it onto the electronic module until the front connector
fastener snaps into place with a soft click.

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3.3.2. Removal
To remove a peripheral module, follow the four steps below:
Step 1: Remove the front connector
To do so, push the tab above the front connector upwards (see the picture below). This will
push out the front connector, after which you can pull it out.

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Step 2: Remove the electronic module
To do so, use your middle finger to push on the lever from above and then use your thumb
and index finger to pull out the electronic module while holding the lever down (see the
picture below).

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Step 3: Release the base module
Use a screwdriver to release the base module by turning the locking mechanism 90°
counterclockwise.
Step 4: Remove the base module
Remove the base module by pulling it towards you.

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3.4. Replacing an electronic module
The procedure for replacing the electronic module on a peripheral module consists of four
steps.
If you need to replace the electronic module while the system is running, make sure to take
into account the general technical specifications for the bus coupler being used.
Step 1: Remove the front connector
To do so, push the tab above the front connector upwards. The front connector will come
loose, after which you can pull it out.