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.

D300458 1211 - BL20 PBDP 1-3
Description of symbols used
1.2 Description of symbols used
Danger
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
D300458 1211 - BL20 PBDP1-4
1.3 Overview
This manual includes all information necessary for the prescribed use of BL20 products. 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.
1.3.2 Notes concerning planning /installation of this product
Attention
Please read this section carefully. Safety aspects cannot be left to chance when dealing with
electrical equipment.
Danger
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.
Danger
All respective safety measures and accident protection guidelines must be considered
carefully and without exception.

D300458 1211 - BL20 PBDP 1-5
List of revisions
1.4 List of revisions
In comparison to the previous manual edition, the following changes/ revisions have been made:
Table 1-1:
List of revisions
Chapter Subject/Description new changed deleted
8 BL20-Approvals for Zone 2/ Division 2
→separate manual D301255
X
Note
The publication of this manual renders all previous editions invalid.

About this Manual
D300458 1211 - BL20 PBDP1-6

D300458 1211 - BL20 PBDP 2-1
2 BL20 Philosophy
2.1 The basic concept.............................................................................................................................. 2
2.2 BL20 components.............................................................................................................................. 3
2.2.1 Gateways..............................................................................................................................................3
– Gateways with integrated power supply...........................................................................................3
– Gateways without power supply ......................................................................................................3
2.2.2 Power distribution modules..................................................................................................................4
2.2.3 Electronics modules .............................................................................................................................5
2.2.4 Base modules.......................................................................................................................................6
2.2.5 BL20 Economy.....................................................................................................................................7
2.2.6 End plate...............................................................................................................................................7
2.2.7 End bracket ..........................................................................................................................................8
2.2.8 Jumpers................................................................................................................................................8
2.2.9 Shield connection (gateway).................................................................................................................9
2.2.10 Marking material...................................................................................................................................9
2.2.11 Shield connection, 2-pole for analog modules...................................................................................10

BL20 Philosophy
D300458 1211 - BL20 PBDP2-2
2.1 The basic concept
BL20 is a modular I/O system for use in industrial automation. It connects the sensors and actuators in
the field with the higher-level master.
BL20 offers modules for practically all applications:
Digital input and output modules
Analog input and output modules
Technology modules (counters, RS232 interface...)
A complete BL20 station counts as one station on the bus and therefore occupies one fieldbus address
in any given fieldbus structure. A BL20 station consists of a gateway, power distribution modules and I/
O modules.
The connection to the relevant fieldbus is made via the bus-specific gateway, which is responsible for
the communication between the BL20 station and the other fieldbus stations.
The communication within the BL20 station between the gateway and the individual BL20 modules is
regulated via an internal module bus.
Flexibility
All BL20 stations can be planned to accommodate the exact number of channels to suit your needs,
because the modules are available in block and slice design.
A BL20 station can contain modules in any combination, which means it is possible to adapt the system
to practically all applications in automated industry.
Compactness
The slim design of the BL20 modules (gateway 50.4 mm / 1.98 inch, slice 12.6 mm / 0.49 inch and block
100.8 mm / 3.97 inch) and their low overall height favor the installation of this system in confined
spaces.
Easy to handle
All BL20 modules, with the exception of the gateway, consist of a base module and an electronics
module.
The gateway and the base modules are snapped onto a mounting rail. The electronics modules are
plugged onto the appropriate base modules.
The base modules are designed as terminal blocks. The wiring is secured by tension clamp or screw
connection. The electronics modules can be plugged or pulled when the station is being commissioned
or for maintenance purposes, without having to disconnect the field wiring from the base modules.
Note
The gateway is the only fieldbus-dependent module on a BL20 station. All other BL20
modules are not dependent on the fieldbus used.

D300458 1211 - BL20 PBDP 2-3
BL20 components
2.2 BL20 components
For a detailed explanation of the individual BL20 components, please refer to chapter 2 and chapter 4.
The “Appendix“ to this manual contains (amongst others) a list of all BL20 components and the
assignment of electronics modules to base modules.
2.2.1 Gateways
The gateway connects the fieldbus to the I/O modules. It is responsible for handling the entire process
data and generates diagnostic information for the higher-level master and the software tool
I/Oassistant.
Gateways with integrated power supply
The BL20 gateways BL20-GWBR-PBDP offer an integrated power supply unit for feeding the gateway
and the connected I/O modules.
It is not necessary to supply each individual module with a separate voltage.
Gateways without power supply
Figure 2-1:
Gateway
BL20-GWBR-PBDP
Note
The gateways without integrated power supply unit need an additional power supply
module (bus refreshing module) which feeds the gateway an the connected I/O modules.

BL20 Philosophy
D300458 1211 - BL20 PBDP2-4
2.2.2 Power distribution modules
The power supply for gateways and I/O modules is fed to the power distribution modules; therefore, it
is not necessary to supply each individual module with a separate voltage.
Figure 2-2:
Power
distribution
module

D300458 1211 - BL20 PBDP 2-5
BL20 components
2.2.3 Electronics modules
Electronics modules contain the functions of the BL20 modules (power distribution modules, digital
and analog input/output modules, and technology modules).
Electronics modules are plugged onto the base modules and are not directly connected to the wiring.
The assignment table in the Section “Ordering Information“ of the “Appendix“ shows the possible
combinations of electronics and base modules. They can be plugged or pulled when the station is
being commissioned or for maintenance purposes, without having to disconnect the field wiring from
the base modules.
Figure 2-3:
Electronics
module in slice
design
Figure 2-4:
Electronics
module in block
design

BL20 Philosophy
D300458 1211 - BL20 PBDP2-6
2.2.4 Base modules
The field wiring is connected to the base modules. These are constructed as terminals in block and slice
designs and are available in the following variations with either tension clamp or screw connections: 2-
/3-wire (2-channel), 4-wire (2-channel) and 4x 2-/3-wire (4-channel).
The assignment table in the Section “Ordering Information“ of the “Appendix“ shows the possible
combinations of electronics and base modules.
Figure 2-5:
Base module with
tension clamp
connection
Figure 2-6:
Base module with
screw connection
Figure 2-7:
Base module in
block design