turck BL20 User manual

BL20 –
USER MANUAL
FOR
PROFIBUS-DP

All brand and product names are trademarks or registered trade marks of the owner
concerned.
Edition 12/2011
© 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

Before commencing the installation
Disconnect the power supply of the device.
Ensure that devices cannot be accidentally restarted.
Verify isolation from the supply.
Earth and short circuit.
Cover or enclose neighboring units that are live.
Follow the engineering instructions of the device concerned.
Only suitably qualified personnel in accordance with EN 50 110-1/-2 (VDE 0 105 Part 100) may
work on this device/system.
Before installation and before touching the device ensure that you are free of electrostatic
charge.
The functional earth (FE) must be connected to the protective earth (PE) or to the potential equa-
lization. The system installer is responsible for implementing this connection.
Connecting cables and signal lines should be installed so that inductive or capacitive interfe-
rence do not impair the automation functions.
Install automation devices and related operating elements in such a way that they are well
protected against unintentional operation.
Suitable safety hardware and software measures should be implemented for the I/O interface so
that a line or wire breakage on the signal side does not result in undefined states in the automa-
tion devices.
Ensure a reliable electrical isolation of the low voltage for the 24 volt supply. Only use power
supply units complying with IEC 60 364-4-41 (VDE 0 100 Part 410) or HD 384.4.41 S2.
Deviations of the mains voltage from the rated value must not exceed the tolerance limits given
in the specifications, otherwise this may cause malfunction and dangerous operation.
Emergency stop devices complying with IEC/EN 60 204-1 must be effective in all operating
modes of the automation devices. Unlatching the emergency-stop devices must not cause
restart.
Devices that are designed for mounting in housings or control cabinets must only be operated
and controlled after they have been installed with the housing closed. Desktop or portable units
must only be operated and controlled in enclosed housings.
Measures should be taken to ensure the proper restart of programs interrupted after a voltage
dip or failure. This should not cause dangerous operating states even for a short time. If neces-
sary, emergency-stop devices should be implemented.
Wherever faults in the automation system may cause damage to persons or property, external
measures must be implemented to ensure a safe operating state in the event of a fault or
malfunction (for example, by means of separate limit switches, mechanical interlocks etc.).
The electrical installation must be carried out in accordance with the relevant regulations (e. g.
with regard to cable cross sections, fuses, PE).
All work relating to transport, installation, commissioning and maintenance must only be carried
out by qualified personnel. (IEC 60 364 and HD 384 and national work safety regulations).
All shrouds and doors must be kept closed during operation.

D300458 1211 - BL20 PBDP i
Table of Contents
1 About this Manual
1.1 Documentation concept .................................................................................................................................1-2
1.2 Description of symbols used ..........................................................................................................................1-3
1.3 Overview ..........................................................................................................................................................1-4
1.3.1 Prescribed use .........................................................................................................................................................................................1-4
1.3.2 Notes concerning planning /installation of this product ........................................................................................................1-4
1.4 List of revisions ................................................................................................................................................1-5
2 BL20 Philosophy
2.1 The basic concept ............................................................................................................................................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 ..............................................................................................................................................................................2-5
2.2.4 Base modules...........................................................................................................................................................................................2-6
2.2.5 BL20 Economy.........................................................................................................................................................................................2-7
2.2.6 End plate....................................................................................................................................................................................................2-7
2.2.7 End bracket...............................................................................................................................................................................................2-8
2.2.8 Jumpers......................................................................................................................................................................................................2-8
2.2.9 Shield connection (gateway) .............................................................................................................................................................2-9
2.2.10 Marking material.....................................................................................................................................................................................2-9
2.2.11 Shield connection, 2-pole for analog modules ........................................................................................................................ 2-10
3PROFIBUS-DP
3.1 System overview..............................................................................................................................................3-2
3.1.1 Master/slave system..............................................................................................................................................................................3-2
3.1.2 System configuration and device types.........................................................................................................................................3-2
3.1.3 Topology ...................................................................................................................................................................................................3-3
3.1.4 Maximum system expansion .............................................................................................................................................................3-3
3.1.5 Transmission rate/ cycle times ..........................................................................................................................................................3-4
3.1.6 Transmission cables...............................................................................................................................................................................3-4
3.1.7 Diagnostic functions .............................................................................................................................................................................3-5
3.1.8 Sync and Freeze mode .........................................................................................................................................................................3-6
3.1.9 System performance .............................................................................................................................................................................3-6
3.1.10 GSD files.....................................................................................................................................................................................................3-8
4 Gateways for PROFIBUS-DP
4.1 Introduction .....................................................................................................................................................4-3
4.1.1 Function.....................................................................................................................................................................................................4-3
4.1.2 Versions......................................................................................................................................................................................................4-3
4.1.3 Connections and switches ..................................................................................................................................................................4-5
4.2 Technical data..................................................................................................................................................4-7
4.2.1 General technical data..........................................................................................................................................................................4-7
4.2.2 Structure diagram for the gateways................................................................................................................................................4-9
4.2.3 Technical data for BL20-GWBR-PBDP........................................................................................................................................... 4-10
4.2.4 Technical data for BL20-GW-PBDP-1.5MB/ BL20-GW-PBDP-1.5MB-S/ BL20-GW-PBDP-12MB and

D300458 1211 - BL20 PBDPii
BL20-GW-PBDP-12MB-STD ...............................................................................................................................................................................4-11
4.3 Fieldbus connections.................................................................................................................................... 4-13
4.3.1 Fieldbus connection via SUB-D female connectors ................................................................................................................4-13
4.3.2 Fieldbus connection via direct wiring (only for 1.5 MBaud gateway) ..............................................................................4-14
4.4 Service interface connection ....................................................................................................................... 4-15
4.4.1 Connection using a BL20 cable.......................................................................................................................................................4-15
4.4.2 Connection using commercially available cables....................................................................................................................4-16
4.5 Address setting ............................................................................................................................................. 4-18
4.6 Setting parameters ....................................................................................................................................... 4-20
4.6.1 Gateway parameters...........................................................................................................................................................................4-20
4.6.2 Module parameters.............................................................................................................................................................................4-23
4.6.3 Module description in the electronic device data sheets (GSD).........................................................................................4-46
4.6.4 Example of a PROFIBUS-DP configuration..................................................................................................................................4-47
4.7 Status indicators/diagnostic messages gateway ....................................................................................... 4-53
4.7.1 Diagnostic messages via LEDs ........................................................................................................................................................4-53
4.7.2 Diagnostic messages via the software.........................................................................................................................................4-55
4.8 Diagnosis ....................................................................................................................................................... 4-56
4.8.1 Device related diagnosis ...................................................................................................................................................................4-56
4.8.2 Device-/ identifier - and channel specific diagnosis ...............................................................................................................4-57
4.8.3 Description of the gateway diagnostic bits ..............................................................................................................................4-58
5 Connections to automation devices
5.1 Introduction .................................................................................................................................................... 5-2
5.2 Electronic device data sheets (GSD) .............................................................................................................. 5-3
5.2.1 Electronic data sheet file ..................................................................................................................................................................... 5-3
5.2.2 Compressing module process data ................................................................................................................................................ 5-4
5.2.3 Example of compressing module process data.......................................................................................................................... 5-6
5.2.4 General note ............................................................................................................................................................................................ 5-9
5.2.5 Standard module description .........................................................................................................................................................5-10
5.2.6 Module description according to type ........................................................................................................................................5-11
5.3 Connection to a Siemens S7 PLC.................................................................................................................. 5-12
5.3.1 Reading-in the GSD file......................................................................................................................................................................5-12
5.3.2 Selecting the BL20 gateway as a slave.........................................................................................................................................5-13
5.3.3 Example of a mixed usage configuration ...................................................................................................................................5-13
5.3.4 Setting gateway parameters ...........................................................................................................................................................5-14
5.3.5 Configuring the BL20 station ..........................................................................................................................................................5-15
5.3.6 Setting parameters for BL20 modules..........................................................................................................................................5-15
5.3.7 Error diagnostics (station diagnostics) when connected to a Siemens S7 PLC.............................................................5-15
5.4 Diagnostics on PROFIBUS-DP ...................................................................................................................... 5-16
5.4.1 Diagnostic messages in the PLC.....................................................................................................................................................5-16
5.5 Example of diagnostics with a Siemens S7-400 PLC .................................................................................. 5-18
5.5.1 Short-circuit in a digital output module......................................................................................................................................5-20
6 Guidelines for station planning
6.1 Module arrangement on the mounting rail.................................................................................................. 6-2

D300458 1211 - BL20 PBDP iii
6.1.1 Random module arrangement..........................................................................................................................................................6-2
6.1.2 Complete planning................................................................................................................................................................................6-2
6.1.3 Maximum system extension ..............................................................................................................................................................6-2
6.1.4 Overview of the process data, diagnostic, parameter and configuration bytes based on an example .................6-9
6.2 Power supply ................................................................................................................................................ 6-12
6.2.1 Power supply to the gateway ......................................................................................................................................................... 6-12
6.2.2 Module bus refreshing ...................................................................................................................................................................... 6-12
6.2.3 Creating potential groups................................................................................................................................................................ 6-16
6.2.4 Protecting the service interface on the gateway..................................................................................................................... 6-18
6.2.5 C-rail (cross connection) ................................................................................................................................................................... 6-18
6.2.6 Direct wiring of relay modules ....................................................................................................................................................... 6-20
6.3 Plugging and pulling electronics modules................................................................................................. 6-21
6.4 Extending an existing station...................................................................................................................... 6-22
6.5 Firmware download ..................................................................................................................................... 6-23
7 Guidelines for electrical installation
7.1 General notes...................................................................................................................................................7-2
7.1.1 Cable routing ...........................................................................................................................................................................................7-2
7.1.2 Lightning protection.............................................................................................................................................................................7-3
7.1.3 Transmission cables...............................................................................................................................................................................7-3
7.1.4 Cable types ...............................................................................................................................................................................................7-4
7.2 Potential relationships....................................................................................................................................7-5
7.2.1 General.......................................................................................................................................................................................................7-5
7.2.2 Potential-free installation....................................................................................................................................................................7-5
7.2.3 Non-isolated installation .....................................................................................................................................................................7-6
7.3 Electromagnetic compatibility (EMC) ............................................................................................................7-7
7.3.1 Ensuring electromagnetic compatibility .......................................................................................................................................7-7
7.3.2 Grounding of inactive metal components....................................................................................................................................7-7
7.3.3 Protection against high frequency interference signals..........................................................................................................7-7
7.3.4 EMC compliant cabinet installation.................................................................................................................................................7-9
7.3.5 Shielding of cables.............................................................................................................................................................................. 7-10
7.3.6 Potential compensation.................................................................................................................................................................... 7-10
7.3.7 Switching inductive loads ................................................................................................................................................................ 7-12
7.3.8 Protection against electrostatic discharge (ESD)..................................................................................................................... 7-12
7.4 Bus connection ............................................................................................................................................. 7-13
7.5 Two-pole shield connection ........................................................................................................................ 7-15
8 Integration of Technology Modules in PROFIBUS-DP
8.1 Integration of the counter module BL20-1CNT-24VDC................................................................................8-2
8.1.1 Count mode: data image.....................................................................................................................................................................8-2
8.1.2 Measurement mode: data image .................................................................................................................................................. 8-15
8.1.3 Guide to setting the high and low words................................................................................................................................... 8-27
8.1.4 Setting the lower and upper measuring limits......................................................................................................................... 8-31
8.2 Integration of the RS232 module BL20-1RS232 ........................................................................................ 8-36
8.2.1 Data Image............................................................................................................................................................................................. 8-36
8.3 Integration of the RS485/422 module BL20-1RS485/422 ......................................................................... 8-40

D300458 1211 - BL20 PBDPiv
8.3.1 Data Image .............................................................................................................................................................................................8-40
8.4 Integration of the SSI module BL20-1SSI.................................................................................................... 8-44
8.4.1 Data image .............................................................................................................................................................................................8-44
8.5 Integration of the SWIRE Module BL20-E-1SWIRE ..................................................................................... 8-50
8.5.1 Data mapping under PROFIBUS-DP..............................................................................................................................................8-50
9 BL20-Approvals for Zone 2/ Division 2
10 Apendix
10.1 Function blocks for S7 .................................................................................................................................. 10-2
10.1.1 Function blocks for BL20-1RSxxx ...................................................................................................................................................10-2
10.1.2 Function block for BL20-1SSI........................................................................................................................................................ 10-10
10.2 Parameter gateway – assignment in hexadecimal format ...................................................................... 10-14
10.2.1 Parameter 4......................................................................................................................................................................................... 10-15
10.2.2 Parameter 5......................................................................................................................................................................................... 10-18
10.3 Conversion table decimal to hexadecimal................................................................................................ 10-23
10.4 BL20 accessories ......................................................................................................................................... 10-24
11 Glossary
12 Index

D300458 1211 - BL20 PBDP 1-1
1 About this Manual
1.1 Documentation concept.................................................................................................................... 2
1.2 Description of symbols used ............................................................................................................. 3
1.3 Overview ........................................................................................................................................... 4
1.3.1 Prescribed use......................................................................................................................................4
1.3.2 Notes concerning planning /installation of this product.......................................................................4
1.4 Description of symbols used ............................................................................................................. 5
1.5 List of revisions ................................................................................................................................. 6

About this Manual
D300458 1211 - BL20 PBDP1-2
1.1 Documentation concept
This manual contains all information about the PROFIBUS-DP-gateway of the BL20-system.
The following chapters contain a short BL20 system description, a description of the field bus system
PROFIBUS-DP, exact information about function and structure of the BL20 PROFIBUS-DP gateway as
well as all bus specific information concerning the connection to automation devices, the maximum
system extension etc.
The bus-independent I/O-modules for BL20 as well as all further fieldbus-independent chapters like
mounting, labelling etc. are described in a separate manual.
BL20 I/O-modules (TURCK-Documentation-No.: English D300717)
Furthermore, the manual contains a short description of the project planning and diagnostics software
for TURCK I/O-systems, the engineering software I/O-ASSISTANT.