Helmholz TB20 User manual

Systeme Helmholz GmbH | Hannberger Weg 2 | D-91091 Großenseebach
Phone [phone] | Fax [phone] | [email protected] | www.helmholz.com
TB20 – Energy Meter
Manual
Version 0.8 / 2/5/2016 for HW1-1 & FW 1.00.004 and higher
Manual order no.: 960-255-7AA21/en

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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 © 2016 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
0.1 6/5/2015 First version
0.2 7/13/2015 First revision
0.3 11/11/2015 Revision O. Brünen
0.4 12/15/2015 Revision S. Renner
0.5 1/20/2016 Revision S. Renner
0.6 2/2/2016 Corrections S. Schrödl
0.7 2/3/2016 Corrections O. Brünen
0.8 2/5/2015 Supplement S.Schrödl
File: Handbuch_TB20_Energy_ Meter 01-5-16 EN.doc 20.01.2016 22:21:00

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Table of contents
1 General........................................................................................ 5
1.1 Target group of manual.............................................................................................. 5
1.2 Safety instructions...................................................................................................... 5
1.3 Note symbols and signal words in the manual......................................................... 6
1.4 Intended use ............................................................................................................... 7
1.5 Improper use............................................................................................................... 7
1.6 Installation.................................................................................................................. 8
1.6.1 Access restriction ........................................................................................................ 8
1.6.2 Electrical installation.................................................................................................. 8
1.6.3 Protection against electrostatic discharges ................................................................ 8
1.6.4 Overcurrent protection .............................................................................................. 8
1.6.5 EMC protection .......................................................................................................... 8
1.6.6 Operation.................................................................................................................... 9
1.6.7 Liability....................................................................................................................... 9
1.6.8 Exclusion of liability................................................................................................... 9
1.6.9 Warranty..................................................................................................................... 9
2 System overview ........................................................................10
2.1 General...................................................................................................................... 10
2.2 The components of the TB20 I/O system................................................................ 10
2.2.1 The bus coupler ................................................................................................................10
2.2.2 Peripheral module ............................................................................................................10
2.2.3 Power and isolation module.............................................................................................12
2.2.4 Power module ...................................................................................................................13
2.2.5 Final bus cover..................................................................................................................14
2.2.6 Components in a module.................................................................................................14
2.2.7 Module coding..................................................................................................................15
3 Installation and removal ............................................................16
3.1 Installation position ................................................................................................. 16
3.2 Minimum distance ................................................................................................... 16
3.3 Installing and removing peripheral modules .......................................................... 17
3.3.1 Installation........................................................................................................................17
3.3.2 Removal ............................................................................................................................18
3.4 Replacing an electronic module............................................................................... 21
3.5 Installing and removing the coupler ....................................................................... 25
3.5.1 Installation........................................................................................................................25

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3.5.2 Removal ............................................................................................................................26
3.6 Installing and removing the bus cover.................................................................... 28
3.6.1 Installation........................................................................................................................28
3.6.2 Removal ............................................................................................................................28
4 Configuration/wiring .................................................................29
4.1 EMC / safety / shielding ........................................................................................... 29
4.2 Front connector........................................................................................................ 30
4.3 Wiring the coupler ................................................................................................... 31
4.4 Using power and isolation modules ........................................................................ 32
4.5 Separate power supply segments for the coupler and the I/O components........... 33
4.6 Using power modules............................................................................................... 34
4.7 Function of the OK-LED........................................................................................... 35
4.8 Electronic nameplate................................................................................................ 35
4.9 Fusing........................................................................................................................ 35
4.10 Dimensions............................................................................................................... 36
5 TB20 – Energy Meter..................................................................37
5.1 Purpose ..................................................................................................................... 37
5.2 Measuring values ...................................................................................................... 37
5.2.1 Functions of the Energy Meter .........................................................................................39
5.2.2 Pin assignment .................................................................................................................40
5.2.3 LEDs of the Energy Meter .................................................................................................41
6 Commissioning...........................................................................42
6.1 TB20 ToolBox ........................................................................................................... 42
6.1.1 Installing TB20 Toolbox ...................................................................................................43
6.1.2 Configuration of the Energy Meter in a project...............................................................44
6.1.3 Diagnosis of the Energy Meter .........................................................................................48
6.1.4 Reading the measurement values without a connection with the bus master................52
6.1 Using the Energy Meter with PLCs .......................................................................... 54
6.2 Using the Energy Meter with STEP7 ........................................................................ 54
7 Measuring connections ..............................................................55
7.1 Specific safety instructions....................................................................................... 55
7.2 Measuring procedures .............................................................................................. 56
7.2.1 Measuring values ..............................................................................................................57
7.2.2 Diagnoses..........................................................................................................................57
7.2.3 Power measurement at a consumer 3-phase ....................................................................58

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7.2.4 Power measurement at a consumer without accompanying neutral conductor.............59
7.2.5 Power measurement at a consumer 1-phase ....................................................................60
7.2.6 Power measurement of 3 consumers with an Energy Meter ............................................61
7.2.7 Current measurement at a consumer...............................................................................62
8 Configuration .............................................................................63
8.1 Modes........................................................................................................................ 63
8.1.1 Mode 1x3 phase................................................................................................................63
8.1.2 Mode 3x1 phase................................................................................................................64
8.1.3 Parameters.........................................................................................................................65
8.1.4 Process values index .........................................................................................................67
9 Reference data for communication with bus masters ...............68
9.1 Data exchange between the master and the Energy Meter..................................... 68
9.1.1 Read out process values with the ToolBox .......................................................................72
9.1.2 Read out process values with the master control.............................................................73
9.2 General technical specifications .............................................................................. 74
9.3 Certifications ............................................................................................................ 74
9.4 Standards and guidelines ......................................................................................... 74
10 Instructions for usage.................................................................75
10.1 Current transformer ................................................................................................. 75
10.2 Voltage transformer.................................................................................................. 76
11 Spare parts .................................................................................77
11.1 Base modules............................................................................................................. 77
11.1.1 14 mm width standard base module................................................................................77
11.1.2 25 mm width base module..............................................................................................77
11.1.3 Power and isolation base module.....................................................................................78
11.1.4 Power base module ...........................................................................................................78
11.2 Front connector........................................................................................................ 79
11.2.1 Front connector, 10-pin ...................................................................................................79
11.2.2 Front connector, 20-pin ...................................................................................................79
11.3 Electronic modules................................................................................................... 79
11.4 Final bus cover.......................................................................................................... 79

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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 instructions 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, 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-plugging 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.

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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.
1.6.7 Liability
The contents of this manual are subject to technical changes resulting from the continuous
development of products of Systeme Helmholz GmbH. In the event that this manual
contains technical or clerical errors, we reserve the right to make changes at any time
without notice. No claims for modification of delivered products can be asserted based on
the information, illustrations, and descriptions in this documentation. Beyond the
instructions contained in the operating manual, the applicable national and international
standards and regulations also must be observed in any case.
1.6.8 Disclaimer of liability
Systeme Helmholz GmbH is not liable for damages if these were caused by use or
application of products that was improper or not as intended.
Systeme Helmholz GmbH assumes no responsibility for any printing errors or other
inaccuracies that may appear in the operating manual, unless there are serious errors about
which Systeme Helmholz GmbH was already demonstrably aware.
Beyond the instructions contained in the operating manual, the applicable national and
international standards and regulations also must be observed in any case.
Systeme Helmholz GmbH is not liable for damage caused by software that is running on
the user’s equipment which compromises, damages, or infects additional equipment or
processes through the remote maintenance connection and which triggers or permits
unwanted data transfer.
1.6.9 Warranty
Report any defects to the manufacturer immediately after discovery of the defect.
The warranty is not valid in case of:
•Failure to observe these operating instructions
•Use of the device that is not as intended
•Improper work on and with the device
•Operating errors
•Unauthorized modifications to the device
The agreements met upon contract conclusion under “General Terms and Conditions of
Systeme Helmholz GmbH” apply.

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2System overview
2.1 General information
The TB20 I/O system is an open, modular, and distributed peripheral system designed to be
mounted on 35 mm DIN rails.
It is made up of the following components:
•Bus couplers
•Peripheral modules
•Power and isolation modules
•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 IP20.
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-pin front connector

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Example: Peripheral module with 20-pin 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 section 2.2.4).
Power and insulation modules have a lighter body color.

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2.2.4 Power 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 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.
Power modules deliver all 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. A
power module is required whenever the power supplied by the coupler alone is not
sufficient, e.g., when there are a large number of modules with high power requirements.
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.
Power modules have a lighter body color.

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2.2.5 Final bus cover
The final bus cover protects the contacts on the last base module from accidental contact
by covering the outer right-hand side of the base module.
2.2.6 Components in a module
Each module consists of three parts:
•Base module
•Electronic module
•Front connectors

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2.2.7 Module Coding
Electronic modules 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 following figure).
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, and Power) from the TB20 system. It will only be possible to plug
an electronic module into a base module if the position of the coding plug and the position
of the coding socket match. If the positions differ, the electronic module is mechanically
blocked.

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3Installation and removal
TB20 modules can carry lethal voltage.
Before starting any work on TB20 system components, make sure to deenergize all
components, as well as the cables supplying them with power! During work when the system
is live, there is the risk of fatal electrocution!
Insulation must be carried out according to VDE 0100/IEC 364 and performed in accordance
with applicable national standards. The TB20 IO system has protection rating IP20. If a higher
protection rating is required, the system must be installed in a housing or control cabinet. In
order to ensure safe operation, the ambient temperature must not exceed 60 °C.
3.1 Installation position
The TB20 I/O system can be installed in any position.
In order to achieve optimum ventilation and be able to use the system at the specified
maximum ambient temperature, it will, however, be necessary to use a horizontal
installation layout.
3.2 Minimum clearance
It is recommended to adhere to the minimum clearances specified 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 is 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 mounting TB20 components are: 30 mm on the top and on
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 fastens
into place on the inside snaps 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 16) on the base module in a straight line from above 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 remove the front connector, 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 remove the electronic module, 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).