Helmholz TB20 User manual

Systeme Helmholz GmbH | Hannberger Weg 2 | D-91091 Großenseebach | Germany
Phone [phone] | Fax [phone] | [email protected] | www.helmholz.com
TB20 – Serial interface 1SI
Manual
Version 1 / 10/29/2015 for HW 1 & FW V1.04.000 and higher
Manual order no.: 960-400-7BA31/en

TB20 – Serial interface 1SI | Version 1| 13.03.2019 2
Notes
All rights reserved, including those related to the translation, reprinting, and reproduction
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 © 2015 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
STEP and SIMATIC are registered trademarks of SIEMENS AG.
Windows is a registered trademark of Microsoft Corporation.
Revision Record
Version Date Change
1 10/16/2015 First version 1SI RS232/RS422/485 Renner 10-5-15

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Table of contents
1General Information.................................................................... 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..........................................................................................................................11
1.6.7 Liability.............................................................................................................................11
1.6.8 Disclaimer of liability .......................................................................................................11
1.6.9 Warranty...........................................................................................................................11
2System overview ........................................................................12
2.1 General Information ................................................................................................ 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 bus cover..................................................................................................................15
2.2.6 Components in a module.................................................................................................15
2.2.7 Module Coding.................................................................................................................16
3Installation 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
3.5.1 Installation........................................................................................................................26
3.5.2 Removal ............................................................................................................................27

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3.6 Installing and removing the final bus cover ........................................................... 29
3.6.1 Installation........................................................................................................................29
3.6.2 Removal ............................................................................................................................29
4Configuration/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 Function of the OK-LED........................................................................................... 36
4.8 Electronic nameplate................................................................................................ 36
4.9 Fusing........................................................................................................................ 36
4.10 Dimensions............................................................................................................... 37
5TB20 – Serial interface 1SI..........................................................38
5.1 Properties RS232 ....................................................................................................... 38
5.2 Properties RS422/RS485............................................................................................ 39
5.2.1 Functions in the RS232 operating mode ..........................................................................40
5.2.2 Functions in the RS422 operating mode ..........................................................................40
5.2.3 Functions in the RS485 operating mode ..........................................................................41
5.2.4 Pin assignment RS232.......................................................................................................42
5.2.5 Cable assignment of point-to-point connection RS232...................................................43
5.2.6 Pin assignment RS422.......................................................................................................44
5.2.7 Cable assignment of point-to-point connection RS422...................................................45
5.2.8 Pin assignment RS485.......................................................................................................46
5.2.9 Cable assignment of point-to-point connection RS485...................................................47
5.2.10 USB interface.....................................................................................................................48
5.2.11 LEDs of the serial interface ...............................................................................................49
6Commissioning...........................................................................50
6.1 TB20-ToolBox ........................................................................................................... 50
6.2 Firmware update....................................................................................................... 50
6.3 Integrating the 1SI serial interface with the GSD file.............................................. 50
6.4 Using the serial 1SI serial interface with other PLCs............................................... 50
7Parameterization........................................................................51
7.1 ASCII protocol .......................................................................................................... 51

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7.1.1 Features .............................................................................................................................51
7.1.2 Transmitting data .............................................................................................................51
7.1.3 Receiving data...................................................................................................................51
7.1.4 Minimum character delay time........................................................................................52
7.1.5 Receive buffer....................................................................................................................52
7.1.6 Reception error .................................................................................................................52
7.1.7 RS232 escort lines .............................................................................................................53
7.1.8 Control of the RS232 escort lines .....................................................................................53
7.1.9 Automatic control of the RS232 escort lines ....................................................................53
7.1.10 Data flow control via RS232 escort lines (RTS/CTS).........................................................54
7.1.11 Data flow control via XON and XOFF / software handshake ..........................................55
7.1.12 Data flow control via manual reading and control of RS-232 escort lines ......................55
7.2 ASCII configuration.................................................................................................. 56
7.3 3964R protocol ......................................................................................................... 59
7.3.1 Control characters ............................................................................................................59
7.3.2 Conduct upon occurrence of the character DLE in the payload data .............................59
7.3.3 Block checksum ................................................................................................................59
7.3.4 Transmitting data .............................................................................................................60
7.3.5 Establishing a connection ................................................................................................60
7.3.6 Payload data transmission................................................................................................60
7.3.7 Clearing a connection ......................................................................................................60
7.3.8 Initialization conflict........................................................................................................61
7.3.9 Receiving data...................................................................................................................62
7.3.10 Establishing a connection ................................................................................................62
7.3.11 Payload data transmission................................................................................................62
7.3.12 Clearing a connection ......................................................................................................63
7.3.13 Configuration of 3964R protocol .....................................................................................64
8Reference data for communication with bus masters ...............67
8.1 Data exchange between the master and the serial interface................................... 67
8.2 Coordination byte .................................................................................................... 69
8.3 Definitions of the job codes..................................................................................... 70
8.3.1 Sequence for sending data from the bus master to the 1SI serial interface .....................72
8.3.2 Sequence for receiving data in the bus master from the RS232 serial interface ..............75
8.3.3 Sequence for reading the V.24 signal status.....................................................................76
8.3.4 Sequence for writing V.24 signals ....................................................................................77
8.3.5 Example sequence for XON/XOFF ...................................................................................78
9Error handling ............................................................................80
10 General technical specifications.................................................82

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11 Spare parts .................................................................................83
11.1 Base modules ............................................................................................................ 83
11.1.1 14 mm width standard base module................................................................................83
11.1.2 25 mm width base module...............................................................................................83
11.1.3 Power and isolation base module.....................................................................................84
11.1.4 Power base module ...........................................................................................................84
11.2 Front connectors ...................................................................................................... 85
11.2.1 Front connector, 10-pin ...................................................................................................85
11.2.2 Front connector, 20-pin ...................................................................................................85
11.3 Electronic modules................................................................................................... 85
11.4 Final bus cover.......................................................................................................... 85

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1General Information
This operating manual applies only to devices, assemblies, software, and services of Systeme
Helmholz GmbH.
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 notes must be observed in order to prevent harm to living creatures, material
goods, and the environment. The safety notes indicate possible hazards and provide
information about 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-ended, modular, and distributed peripheral system
designed to be mounted on 35 mm DIN rails.
Communication with a higher-level control system is via a bus system / network and 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-swapping 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 Systeme Helmholz GmbH.
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 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 personal injuries 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.