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.