turck BL20 User manual

BL20 –
USER MANUAL
ECO GatEway
fOr EtherCat®
Sense it! Connect it! Bus it! Solve it!

All brand and product names are trademarks or registered trade marks of the owner
concerned.
Edition 09/2012
© Hans Turck GmbH, Muelheim an der Ruhr
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form (printed, photocopy, microfilm or any
other process) or processed, duplicated or distributed by means of electronic systems
without written permission of Hans Turck GmbH & Co. KG, Muelheim an der Ruhr.
Subject to alterations without notice

D301260 0912 - BL20-E-GW-EC i
Table of Contents
1Aboutthismanual
1.1 Documentation concept .................................................................................................................................1-2
1.2 Description of symbols used ..........................................................................................................................1-3
1.3 General ............................................................................................................................................................1-4
1.3.1 Prescribed use .........................................................................................................................................................................................1-4
2 BL20-philosophy
2.1 The basic concept ............................................................................................................................................2-2
2.1.1 Flexibility ...................................................................................................................................................................................................2-2
2.1.2 Compactness ...........................................................................................................................................................................................2-2
2.1.3 Easy to handle .........................................................................................................................................................................................2-2
2.2 BL20 components ............................................................................................................................................2-3
2.2.1 Gateways ...................................................................................................................................................................................................2-3
2.2.2 Power distribution modules...............................................................................................................................................................2-4
2.2.3 Electronics modules (standard product line)...............................................................................................................................2-5
2.2.4 ECO electronics modules.....................................................................................................................................................................2-6
2.2.5 Base modules...........................................................................................................................................................................................2-7
2.2.6 End plate....................................................................................................................................................................................................2-8
2.2.7 End bracket...............................................................................................................................................................................................2-8
2.2.8 Jumpers......................................................................................................................................................................................................2-9
2.2.9 Marking material.....................................................................................................................................................................................2-9
2.2.10 Shield connection (standard product line) ................................................................................................................................ 2-10
3 EtherCAT®-features supported by BL20
3.1 EtherCAT® according to the Modular Device Profile ....................................................................................3-2
3.1.1 EtherCAT®- State Machine...................................................................................................................................................................3-3
3.1.2 SDO-services ............................................................................................................................................................................................3-3
3.1.3 Communication Area............................................................................................................................................................................3-4
3.1.4 Module Object Area (0×6000 - 0×AFFF) ........................................................................................................................................3-7
3.1.5 Device Parameter Area...................................................................................................................................................................... 3-10
3.2 EtherCAT® device description file (ESI-file) ................................................................................................ 3-15
4 Technical features
4.1 Function ...........................................................................................................................................................4-2
4.2 Technical data..................................................................................................................................................4-3
4.2.1 Block diagram ..........................................................................................................................................................................................4-4
4.2.2 General technical data of a station ................................................................................................................................................4-4
4.2.3 Technical data for the push-in tension clamp terminals ........................................................................................................4-7
4.3 Connection options at the gateway...............................................................................................................4-8
4.3.1 Power supply ...........................................................................................................................................................................................4-8
4.3.2 Field bus connection via Ethernet-switch .....................................................................................................................................4-9
4.3.3 Service interface connection (mini USB female connector) ................................................................................................ 4-10
4.4 Address assignment ..................................................................................................................................... 4-11
4.5 ESI-file............................................................................................................................................................ 4-12

D301260 0912 - BL20-E-GW-ECii
4.6 Synchronization of the station configuration ............................................................................................ 4-13
4.7 Status indicators/diagnostic messages gateway ....................................................................................... 4-14
4.7.1 Diagnostic messages via LEDs ........................................................................................................................................................4-14
4.7.2 Device Status Object ..........................................................................................................................................................................4-16
4.7.3 Emergency-telegrams........................................................................................................................................................................4-17
4.7.4 I/O-module diagnosis.........................................................................................................................................................................4-19
4.8 Parameters of the modules. ......................................................................................................................... 4-26
4.8.1 Digital input modules ........................................................................................................................................................................4-26
4.8.2 Analog Input Modules .......................................................................................................................................................................4-26
4.8.3 Analog Output Modules....................................................................................................................................................................4-34
4.8.4 technology modules...........................................................................................................................................................................4-39
5 Connection of the EtherCAT®-gateway to the TwinCAT® Soft-PLC
5.1 Application example ...................................................................................................................................... 5-2
5.1.1 General ...................................................................................................................................................................................................... 5-2
5.1.2 Adding a device specific *.xml-file................................................................................................................................................... 5-3
5.1.3 Hardware configuration in the TwinCAT® System Manager.................................................................................................. 5-3
5.1.4 Parameterization of BL20 I/O-modules.......................................................................................................................................... 5-7
5.1.5 Programming the Soft-PLC ................................................................................................................................................................ 5-8
5.1.6 "Connection" of hardware and program.....................................................................................................................................5-10
5.1.7 Process data exchange ......................................................................................................................................................................5-13
5.1.8 Diagnosis in TwinCAT®.......................................................................................................................................................................5-15
5.1.9 Install EtherCAT®-driver .....................................................................................................................................................................5-17
6 Integration of the technology modules
6.1 Integration of the RS232-module.................................................................................................................. 6-2
6.1.1 Data image ............................................................................................................................................................................................... 6-2
6.2 Integration of the RS485/422-module .......................................................................................................... 6-6
6.2.1 Data image ............................................................................................................................................................................................... 6-6
6.3 Integration of the SSI-module ..................................................................................................................... 6-10
6.3.1 Data image .............................................................................................................................................................................................6-10
6.4 Integration of the SWIRE-module BL20-E-1-SWIRE ................................................................................... 6-16
6.4.1 Data image .............................................................................................................................................................................................6-16
6.5 Integration of the Encoder/PWM-module BL20-E-2CNT/2PWM ............................................................... 6-26
6.6 Integration of RFID-modules BL20-2RFID-S/ -A ......................................................................................... 6-26
7 Guidelines for station planning
7.1 Module arrangement...................................................................................................................................... 7-2
7.1.1 Random module arrangement ......................................................................................................................................................... 7-2
7.1.2 Complete planning ............................................................................................................................................................................... 7-2
7.1.3 Maximum system extension.............................................................................................................................................................. 7-3
7.2 Power supply................................................................................................................................................... 7-5
7.2.1 Power supply to the gateway............................................................................................................................................................ 7-5
7.2.2 Module bus refreshing......................................................................................................................................................................... 7-5
7.2.3 Creating potential groups .................................................................................................................................................................. 7-5
7.2.4 C-rail (cross connection)...................................................................................................................................................................... 7-6

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7.2.5 Direct wiring of relay modules ..........................................................................................................................................................7-8
7.3 Protecting the service interface on the gateway ..........................................................................................7-9
7.4 Plugging and pulling electronics modules....................................................................................................7-9
7.5 Extending an existing station.........................................................................................................................7-9
7.6 Firmware download ..................................................................................................................................... 7-10
8 Guidelines for Electrical Installation
8.1 General notes...................................................................................................................................................8-2
8.1.1 General.......................................................................................................................................................................................................8-2
8.1.2 Cable routing ...........................................................................................................................................................................................8-2
8.1.3 Lightning protection.............................................................................................................................................................................8-3
8.1.4 Transmission media...............................................................................................................................................................................8-3
8.2 Potential relationships....................................................................................................................................8-4
8.2.1 General.......................................................................................................................................................................................................8-4
8.3 Electromagnetic compatibility (EMC) ............................................................................................................8-5
8.3.1 Ensuring electromagnetic compatibility .......................................................................................................................................8-5
8.3.2 Grounding of inactive metal components....................................................................................................................................8-5
8.3.3 PE connection..........................................................................................................................................................................................8-5
8.3.4 Earth-free operation..............................................................................................................................................................................8-5
8.3.5 Mounting rails..........................................................................................................................................................................................8-6
8.4 Shielding of cables ..........................................................................................................................................8-7
8.5 Potential compensation..................................................................................................................................8-8
8.5.1 Switching inductive loads...................................................................................................................................................................8-8
8.5.2 Protection against Electrostatic Discharge (ESD) .......................................................................................................................8-8
9 BL20-Approvals for Zone 2/Division 2
10 Glossary
11 Index

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D301260 0912 - BL20-E-GW-EC 1-1
1 About this manual
1.1 Documentation concept ............................................................................................................................... 2
1.2 Description of symbols used ....................................................................................................................... 3
1.3 General .......................................................................................................................................................... 4
1.3.1 Prescribed use .......................................................................................................................................................................................4

About this manual
D301260 0912 - BL20-E-GW-EC1-2
1.1 Documentation concept
This manual contains all information about the EtherCAT®-Gateway of the product line BL20-ECO
(BL20-E-GW-EC).
The following chapter contain a short BL20-description, a description of the field bus system EtherCAT®,
exact information about function and structure of the field bus specific BL20-gateway for EtherCAT® as
well as all bus specific information concerning the connection to automation devices, the maximum
system extension etc.
The bus-independent I/O-modules of the BL20-system as well as all bus independent information as
mounting, labeling etc. are described in a separate manual.
BL20 I/O-modules (TURCK-documentation no.: German D300716; English D300717)
In addition to that, the manual contains a short description of the I/O-ASSISTANT, the project planning
and configuration software tool for TURCK I/O-systems-

D301260 0912 - BL20-E-GW-EC 1-3
Description of symbols used
1.2 Description of symbols used
Warning
This sign can be found next to all notes that indicate a source of hazards. This can refer to
danger to personnel or damage to the system (hardware and software) and to the facility.
This sign means for the operator: work with extreme caution.
Attention
This sign can be found next to all notes that indicate a potential hazard.
This can refer to possible danger to personnel and damages to the system (hardware and
software) and to the facility.
Note
This sign can be found next to all general notes that supply important information about one
or more operating steps.
These specific notes are intended to make operation easier and avoid unnecessary work due
to incorrect operation.

About this manual
D301260 0912 - BL20-E-GW-EC1-4
1.3 General
This manual includes all information necessary for the prescribed use of the BL20-E-GW-EN. It has been
specially conceived for personnel with the necessary qualifications.
1.3.1 Prescribed use
Appropriate transport, storage, deployment and mounting as well as careful operating and thorough
maintenance guarantee the trouble-free and safe operation of these devices.
Attention
Please read this section carefully. Safety aspects cannot be left to chance when dealing with
electrical equipment.
Warning
The devices described in this manual must be used only in applications prescribed in this
manual or in the respective technical descriptions, and only with certified components and
devices from third party manufacturers.