turck TBPN-L5-4FDI-4FDX User manual

Your Global Automation Partner
Instructions for Use
TBPN-L5-4FDI-4FDX
Safety Block I/O Module

2Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [email protected] | www.turck.com

V01.00 | 2020/07 3
Table of Contents
1 About These Instructions.................................................................................................................. 7
1.1 Target groups................................................................................................................... 7
1.2 Explanation of symbols used ........................................................................................ 7
1.3 Additional documents.................................................................................................... 7
1.4 Feedback about these instructions.............................................................................. 7
2 Notes on the Product......................................................................................................................... 8
2.1 Product identification..................................................................................................... 8
2.2 Scope of delivery ............................................................................................................. 8
2.3 Manufacturer and service.............................................................................................. 8
3 For Your Safety.................................................................................................................................... 9
3.1 Intended use..................................................................................................................... 9
3.1.1 Reasonably foreseeable misuse.................................................................................................. 9
3.2 General safety notes .....................................................................................................10
3.3 Residual risks (EN ISO 12100:2010)............................................................................10
3.4 Warranty and liability ...................................................................................................10
3.5 Directives and standards .............................................................................................11
3.5.1 National and international directives and standards .......................................................11
3.5.2 Cited standards...............................................................................................................................11
4 Product Description .........................................................................................................................12
4.1 Device overview ............................................................................................................12
4.1.1 Type label..........................................................................................................................................12
4.2 Properties and features................................................................................................12
4.2.1 Switches and connectors............................................................................................................13
4.2.2 Block diagram..................................................................................................................................13
4.3 Functions and operating modes ................................................................................14
4.3.1 Safety Function...............................................................................................................................14
4.3.2 Safety inputs (FDI)..........................................................................................................................14
4.3.3 Safety outputs (FDO) ....................................................................................................................15
4.3.4 Configuration memory ................................................................................................................15
5 Mounting............................................................................................................................................16
5.1 Grounding the device...................................................................................................16
5.1.1 Equivalent wiring diagram and shielding concept ...........................................................16
5.1.2 Shielding of the fieldbus and I/O level...................................................................................17
5.1.3 Grounding the device – I/O level and fieldbus level.........................................................17
6 Connecting ........................................................................................................................................19
6.1 Connecting the M12 connectors ................................................................................19
6.2 Connecting the device to Ethernet............................................................................20
6.3 Connecting the power supply ....................................................................................20
6.3.1 24 V Supply (SELV/PELV)..............................................................................................................21
6.4 Connecting safe sensors and actuators ....................................................................22
6.5 Switching examples......................................................................................................24
6.5.1 Inputs..................................................................................................................................................24
6.5.2 Outputs..............................................................................................................................................25
7 Commissioning .................................................................................................................................26
7.1 Initial commissioning ...................................................................................................26

Table of Contents
4Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [email protected] | www.turck.com
7.1.1 Mounting and electrical installation.......................................................................................26
7.1.2 Configuring in Turck Safety Configurator.............................................................................26
7.1.3 Commissioning the device at the PLC....................................................................................26
7.2 Safety planning..............................................................................................................27
7.2.1 Prerequisites ....................................................................................................................................27
7.2.2 Reaction time ..................................................................................................................................27
7.2.3 Safety characteristic data............................................................................................................27
7.3 Addressing the device..................................................................................................28
7.3.1 Setting the F address at the device.........................................................................................28
7.3.2 Addressing the device at PROFINET........................................................................................29
8 Configuring........................................................................................................................................30
8.1 Installing Turck Safety Configurator..........................................................................30
8.2 Integrate Turck Safety Configurator in TIA Portal ..................................................30
8.3 Licensing Turck Safety Configurator .........................................................................31
8.4 Creating a configuration with the TSC commissioning wizard ............................32
8.4.1 Creating a new workspace .........................................................................................................32
8.4.2 Selecting a master and creating a basic configuration....................................................33
8.4.3 Adapting the configuration of the safe channels ..............................................................36
8.5 Loading the configuration with the TSC commissioning wizard.........................42
8.6 Application example – configuring a safety function in TSC................................48
8.6.1 Checking and loading the configuration ..............................................................................54
8.7 Configuring single channel safety sensors...............................................................55
8.8 Configuring the device at PROFINET/PROFIsafe in TIA Portal..............................58
8.8.1 Adding the device via GSDML...................................................................................................58
8.8.2 Setting the F_parameters ...........................................................................................................60
9 Operating ...........................................................................................................................................61
9.1 LED displays....................................................................................................................61
9.2 Status- and control word .............................................................................................62
9.3 Process input data.........................................................................................................63
9.4 Process output data......................................................................................................67
9.5 Using the configuration memory...............................................................................69
9.5.1 Storing a configuration................................................................................................................69
9.5.2 Loading a configuration from the memory chip................................................................69
9.5.3 Deleting the memory chip (Erase Memory) .........................................................................69
9.5.4 Configuration transfer and module behavior .....................................................................70
9.6 Reset the device to factory settings (factory reset) ................................................71
10 Restarting after Device Exchange or Modification ....................................................................72
10.1 Changing a device.........................................................................................................72
10.1.1 Prerequisites for device replacement.....................................................................................72
10.1.2 Procedure for device replacement..........................................................................................72
11 Maintenance......................................................................................................................................73
12 Decommissioning.............................................................................................................................74
13 Disposal ..............................................................................................................................................74

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14 Technical Data...................................................................................................................................75
14.1 General technical data..................................................................................................75
14.2 Technical data – safety inputs.....................................................................................76
14.3 Technical data – safety outputs..................................................................................77

Table of Contents
6Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [email protected] | www.turck.com

V01.00 | 2020/07 7
1 About These Instructions
These operating instructions describe the structure, functions and the use of the product and
will help you to operate the product as intended. These instructions contain rules for the use of
the devices in Safety Instrumented Systems (SIS). The assessment of the safety related values is
based on IEC61508, ISO13849-1 and IEC62061.
Read these instructions carefully before using the product. This is to avoid possible damage to
persons, property or the device. Retain the instructions for future use during the service life of
the product. If the product is passed on, pass on these instructions as well.
1.1 Target groups
These instructions are directed to qualified personnel or technically trained personnel (planer,
developer, design engineer, installer, electrical specialist, operator, maintenance personnel etc.)
and must be carefully read by anyone anyone who assembles, commissions, operates, main-
tains, dismantles or disposes of the device.
1.2 Explanation of symbols used
The following symbols are used in these instructions:
DANGER
DANGER indicates a dangerous situation with high risk of death or severe injury if
not avoided.
WARNING
WARNING indicates a dangerous situation with medium risk of death or severe in-
jury if not avoided.
CAUTION
CAUTION indicates a dangerous situation of medium risk which may result in minor
or moderate injury if not avoided.
NOTICE
NOTICE indicates a situation which may lead to property damage if not avoided.
NOTE
NOTE indicates tips, recommendations and useful information on specific actions
and facts. The notes simplify your work and help you to avoid additional work.
uCALL TO ACTION
This symbol denotes actions that the user must carry out.
aRESULTS OF ACTION
This symbol denotes relevant results of actions.
1.3 Additional documents
The following additional documents are available online at www.turck.com:
nData sheet
nEU Declaration of Conformity
1.4 Feedback about these instructions
We make every effort to ensure that these instructions are as informative and as clear as pos-
sible. If you have any suggestions for improving the design or if some information is missing in
the document, please send your suggestions to [email protected].

Notes on the Product
Manufacturer and service
8Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [email protected] | www.turck.com
2 Notes on the Product
2.1 Product identification
These instructions apply for the following full safety module with PROFIsafe:
nTBPN-L5-4FDI-4FDX
2.2 Scope of delivery
The scope of delivery includes:
nTBPN-L5-4FDI-4FDX
nM12 closure caps
n7/8’’ blind caps (not suitable to guarantee IP67/IP69K)
2.3 Manufacturer and service
Hans Turck GmbH & Co. KG
Witzlebenstraße 7
45472 Mülheim an der Ruhr
Germany
Turck supports you with your projects, from initial analysis to the commissioning of your applic-
ation. The Turck product database contains software tools for programming, configuration or
commissioning, data sheets and CAD files in numerous export formats. You can access the
product database at the following address: www.turck.de/products
For further inquiries in Germany contact the Sales and Service Team on:
nSales: [phone]
nTechnology: [phone]
Outside Germany, please contact your local Turck representative.

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3 For Your Safety
The product is designed according to state-of-the-art technology. However, residual risks still
exist. Observe the following warnings and safety notices to prevent damage to persons and
property. Turck accepts no liability for damage caused by failure to observe these warning and
safety notices.
3.1 Intended use
These devices are designed solely for use in industrial areas.
TBPN-L5-4FDI-4FDX is a decentralized safety module for PROFIsafe. The module collects field
signals and forwards them safely to a PROFIsafe master. Thanks to an extended temperature
range from -40…+70 °C and IP67/IP69K protection, the module can be used directly on the ma-
chine.
The module serves for controlling signal devices as for example emergency stop buttons, posi-
tion switches or OSSDs which are used to ensure human, material or machine protection.
TBPN-L5-4FDI-4FDX can be used in the following applications:
napplications up to SIL 3 (according to IEC 61508)
napplications up to SIL CL3 (according to EN 62 061)
napplications up to Category 4 and Performance Level e (according to EN ISO 13 849-1)
The devices may only be used as described in these instructions. Any other use is not in accord-
ance with the intended use. Turck accepts no liability for any resulting damage.
3.1.1 Reasonably foreseeable misuse
The device is not suitable for:
nThe use in explosive areas
nOutdoor use
nThe permanent use in liquids
Modifications to the device
It is not permitted to modify the technical function or the construction of the device.

For Your Safety
Warranty and liability
10 Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [email protected] | www.turck.com
3.2 General safety notes
nThe device may only be assembled, installed, operated, parameterized and maintained by
professionally-trained personnel.
nThe device may only be used in accordance with applicable national and international regu-
lations, standards and laws.
nThe device only meets the EMC requirements for industrial areas and is not suitable for use
in residential areas.
nThe Performance Level as well as the safety category according to EN ISO 13849-1 depend
on the external wiring, the application, the choice of the control devices as well as their ar-
rangement on the machine.
nThe user has to execute a risk assessment according to EN ISO 12100:2010.
nBased on the risk assessment a validation of the complete plant/machine has to be done in
accordance with the relevant standards.
nOperating the device beyond the specification can lead to malfunctions or to the destruction
of the device. The installation instructions must be observed.
nFor trouble-free operation, the device must be properly transported, stored, installed and
mounted.
nFor the release of safety circuits in accordance with EN IEC 60204-1, EN ISO 13850 only use
the output circuits of connectors C4…C7.
nChange the default password of the integrated web server after the first login. Turck recom-
mends using a secure password.
3.3 Residual risks (EN ISO 12100:2010)
The wiring proposals described in the following have been tested under operational conditions
with the greatest care. Together with the connected periphery of safety related equipment and
switching devices they fulfill relevant standards.
Residual risks remain, if
nthe proposed wiring concept is is changed and connected safety related devices or protect-
ive devices are possibly not or insufficiently included in the safety circuit.
nthe operator does not observe the relevant safety regulations specified for the operation, ad-
justment and maintenance of the machine. Here, the inspection and maintenance intervals
for the machine should be strictly observed.
Failure to follow these instructions can result in serious injury or equipment damage.
3.4 Warranty and liability
Any warranty and liability is excluded for:
nimproper application or not intended use of the product
nnon-observance of the user manual
nmounting, installation, configuration or commissioning by unqualified persons

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3.5 Directives and standards
Manufacturers and operators of machines and plants in which the device is used are respons-
ible for observing all relevant directives and standards.
3.5.1 National and international directives and standards
The following guidelines and regulations must be observed:
n2006/42/EG (machine directive )
n2014/30/EU (electromagnetic compatibility)
n2011/65/EU (RoHS Directive)
n89/655/EWG (work equipment directive)
nAccident prevention regulation
nSafety rules and safety regulations according to the actual state of the art
3.5.2 Cited standards
Standard Title
DIN EN ISO 13849-1:2016-06 Safety-related parts of control systems
EN 62061:2005 + Cor.:2010 + A1:2013 + A2:2015
IEC 62061:2005 + A1:2012 + A2:2015
Safety of machinery - Functional safety of
safety-related electrical, electronic and pro-
grammable electronic control systems
DIN EN 61508:2011
IEC 61508:2010
Functional safety of electrical/electronic/
programmable electronic safety-related sys-
tems
DIN EN 61131-2:2008
IEC 61131-2:2007
Programmable controllers
EN ISO 12100:2010
DIN EN ISO 12100:211-03
Safety of machinery - General principles for
design - Risk assessment and risk reduction

Product Description
Properties and features
12 Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [email protected] | www.turck.com
4 Product Description
TBPN-L5-4FDI-4FDX is a safety block I/O module for PROFIsafe via PROFINET. The device has
four 2-channel digital safety inputs (FDI) for the connection of different safety sensors as for ex-
ample light barriers or emergency stop buttons. Four further safety channels (FDX) can be
freely used as inputs (FDI) or outputs (FDO).
The configuration of the safe I/Os and their function is realized by means of a software tool the
Turck Safety Configurator.
4.1 Device overview
218 [8.58]
230.5 [9.08]
C4C5C6C7
6.3 [0.25]
38.8 [1.53]
60.4 [2.38]
C0C1C2C3
24 [0.95]
30.2 [1.19]
X2
X1
P2
P1
yellow
Fig.1: TBPN-L5-4FDI-4FDX
4.1.1 Type label
TBPN-L5-4FDI-4FDX
Ident-No.: 100001826
HW:
Charge code:
YoC:
Hans Turck GmbH & Co. KG
D-45466 Mülheim a. d. Ruhr
www.turck.com
Made in Germany
Fig.2: Type label TBPN-L5-4FDI-4FDX
4.2 Properties and features
nFour safety-related SIL3 inputs FDI
nFour safety-related SIL3 in-/outputs FDX
nSafe PP/PM-switching of the actuator power supply
nUsable in SIL CL3 according to EN 62061 or PLe according to DIN EN ISO 13849-1
n7/8’’ power supply connectors
nTwo 4-pole M12-connectors for Ethernet
nMultiple LEDs for status indication
nIntegrated Ethernet switch, allows line topology
nIntegrated web server
nTransmission rate 10 Mbps and 100 Mbps
nFiberglass reinforced housing
nShock and vibration tested
nFully potted module electronics
nProtection class IP65/IP67/IP69K

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4.2.1 Switches and connectors
TBPN-L5-4FDI-4FDX
Meaning
C4
C5
C6
C7
C0
C1
C2
C3
X2X1
P2
P1
FE
F-Address
X1 Power IN
X2 Power OUT
C0 FDI0/1, safety-related input
C1 FDI2/3, safety-related input
C2 FDI4/5, safety-related input
C3 FDI6/7, safety-related input
C4 FDX8/9, safety-related in-/output
C5 FDX10/11, safety-related in-/output
C6 FDX12/13, safety-related in-/output
C7 FDX14/15, safety-related in-/output
F-Address Rotary coding switch for address setting for
PROFIsafe (F-address setting)
P1 Ethernet 1
P2 Ethernet 2
FE Functional earth
4.2.2 Block diagram
4
2
C0
V1
4
2
C1
4
2
1
5
1
5
1
5
1
5
C2
4
2
4
2
4
2
4
2
1
5
1
5
1
5
1
5
4
2
C3
C4
C5
C6
C7
4
3
4
3
4
3
4
3
V2
Safety
FDI
0/1
Safety
FDX
8/9
Safety
FDI
2/3
Safety
FDX
10/11
Safety
FDI
4/5
Safety
FDX
12/13
Safety
FDX
14/15
Safety
FDI
6/7
Fig.3: Block diagram TBPN-L5-4FDI-4FDX

Product Description
Functions and operating modes
14 Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [email protected] | www.turck.com
4.3 Functions and operating modes
4.3.1 Safety Function
The TBPN-L5-4FDI-4FDX provides four safe digital SIL3 inputs (FDI) and four SIL3-connectors
(FDX), configurable as inputs or outputs.
The following devices can be connected to the safety inputs:
n1- and 2-channel safety switches and sensors
nContact based switches, e.g. emergency switches, protective door switches
nSensors with OSSD switching outputs
nAntivalently switching OSSD sensors
The four safe SIL3 outputs can be used PP- or PM-switching.
Safe status
In the safe state the device outputs are in LOW-state (0). The inputs report a LOW-state (0) to
the logic.
Fatal error
nIncorrect wiring at the output (i.e. capacitive load, energetic recovery)
nShort-circuit at the line control output T2
nIncorrect power supply
nStrong EMC disturbances
nInternal device error
4.3.2 Safety inputs (FDI)
The safe inputs are suitable for the connection of safety-related sensors:
nMax. eight 2-channel safety switches and sensors
nContact based switches, e.g. emergency switches, protective door switches
nSensors with OSSD switch outputs with test pulses
nSensors with OSSD switch outputs without test pulses
Error detection and diagnostics
Internal:
nDevice self test: Diagnosis of internal device errors
External:
nCross connection diagnosis: The device detects a cross connection between the sensor sup-
plies at the inputs or between one sensor supply to another potential (if the test pulses are
activated)
nDiscrepancy diagnosis: for 2-channel inputs
nShort-circuit diagnosis
Parameters
For each input the following types can be selected:
nSafe input for potential free contacts (NC/NC)
nSafe antivalent input for potential free contacts (NC/NO)
nSafe electronic input at OSSD-output with test pulses

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4.3.3 Safety outputs (FDO)
The safe SIL3 outputs can be used PP- or PM-switching.
nMax. four 2-channel safety output (outputs are supplied via V1)
Error detection and diagnostics
Internal:
nDevice self test: Diagnosis if an output can not change to the safe state due to an internal er-
ror.
External:
nOverload diagnosis
nCross connection diagnosis
nShort-circuit diagnosis
Parameters
nSafe output PP-switching:
Safe output, the load is connected between P-terminal and Ground-terminal.
nSafe output PM-switching:
Safe output, the load is connected between P-terminal and M-terminal (mass), necessary for
special loads which need a separation from Ground.
4.3.4 Configuration memory
A pluggable memory stick is included in the scope of delivery of TBPN-L5-4FDI-4FDX. It serves
for storing the safety function configured via Turck Safety Configurator. It allows to transfer the
configuration of one device to another device, e. g. for device exchange.

Mounting
Grounding the device
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5 Mounting
NOTICE
Mounting on uneven surfaces
Device damage due to stresses in the housing
Fix the device on a flat mounting surface.
Use two M6 screws to mount the device.
The device can be screwed onto a flat mounting plate.
Attach the module to the mounting surface with two M6 screws. The maximum tighten-
ing torque for the screws is 1.5 Nm.
Avoid mechanical stresses.
Optional: Ground the device.
218 [5.58]
M6 (2x)
max. 1.5 Nm
Fig.4: Mounting the device onto a mounting plate
5.1 Grounding the device
5.1.1 Equivalent wiring diagram and shielding concept
1 nF
2,2 MΩ
X1
C0
C1
C2
C3
P1
X2
C4
C5
C6
C7
P2
4 x 15 nF
Fig.5: Equivalent wiring diagram and shielding
concept

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5.1.2 Shielding of the fieldbus and I/O level
The fieldbus and the I/O level of the modules can be grounded separately.
1
2
3
Fig.6: Grounding clip (1), grounding ring (2) and metal screw (3)
The grounding ring (2) is the module grounding. The shielding of the I/O level is permanently
connected to the module grounding. The module grounding is only connected to the refer-
ence potential of the installation when the module is mounted.
Shielding concept of the I/O modules (I/O level)
In the case of direct mounting on a mounting plate, the module grounding is connected to the
reference potential of the system via the metal screw in the lower mounting hole (3). If module
grounding is not desired, the electrical connection to the reference potential must be interrup-
ted, e.g. by using a plastic screw.
Shielding concept of the fieldbus level
On delivery, a grounding clip is provided on the connectors for the fieldbus connection.
When mounted directly on a mounting plate, the shielding of the fieldbus cables is routed dir-
ectly to the module ground via the grounding clip and the metal screw in the lower mounting
hole.
If direct grounding of the fieldbus shield is not desired, the grounding clip must be removed. In
this case, the fieldbus shield is connected to the module ground via an RC element.
5.1.3 Grounding the device – I/O level and fieldbus level
The grounding of the fieldbus level can either be connected directly via the grounding clip (1)
or connected and routed indirectly via an RC element to the grounding of the I/O level. If the
grounding is to be routed via an RC element, the grounding clip must be removed.
1
2
3
Fig.7: Grounding clamp (1)

Mounting
Grounding the device
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Removing the grounding clip: Disconnect the direct grounding of the fieldbus level
Use a flat screwdriver to slide the grounding clamp forward and remove it.
Mounting the grounding clip: grounding the fieldbus level directly
Place the grounding clamp between the fieldbus connectors by using a screwdriver in
such way that the clamp contacts the metal housing of the connectors.
The shielding of the fieldbus cables is connected to the grounding clip.
Fig.8: Mounting the grounding clip
Grounding the device – mounting on a mounting plate
For mounting onto a mounting plate: Fix the Device with an M6 metal screw through the
lower mounting hole.
aThe shielding of the M12 flanges for the I/O level is connected to the reference potential
of the installation via the M6 metal screw.
aWith mounted grounding clip: The shielding of the fieldbus is connected to the reference
potential of the installation via the module grounding of the I/O level.

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6 Connecting
WARNING
Intrusion of liquids or foreign bodies through leaking connections
Danger to life due to failure of the safety function
Tighten M12 connectors with a tightening torque of 0.8 Nm.
Always seal unused connectors with suitable screw caps or blind caps.
Use appropriate 7/8" sealing caps, e.g. type RKMV-CCC. The caps not part of the
scope of delivery.
6.1 Connecting the M12 connectors
When connecting the cables to the M12-connectors, use the torque screwdriver men-
tioned below.
Fig.9: Torque screwdriver
Description Type Ident no.
Torque screwdriver,
torque range 0.4…1.0 Nm
nM8 (SW9)
nM12 for bus cables (SW13)
nM12 for sensor cables (SW14)
Torque-Wrench-Set
Turck Line + BUS
6936171

Connecting
Connecting the power supply
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6.2 Connecting the device to Ethernet
For the connection to Ethernet the device has an integrated auto-crossing switch with two 4-
pole, D-coded M12 x 1-Ethernet-connectors. The maximum tightening torque is 0.6 Nm.
Fig.10: M12 Ethernet connector
Connect the device to Ethernet according to the pin assignment below.
v
4
13
2
P1, P2
1 = TX +
2 = RX +
3 = TX –
4 = RX –
flange = FE
Fig.11: Pin assignment Ethernet connectors
6.3 Connecting the power supply
NOTE
We recommend the use of pre-assembled 5-pole power supply cables,Turck type 52
(e.g. RKM52-1-RSM52). Suitable cables can be found on www.turck.com.
For the connection to the power supply, the device has two 5-pin 5-pole 7/8" connectors. V1
and V2 are galvanically isolated. The maximum tightening torque is 0.8 Nm.
Fig.12: 7/8’’ connector for connecting the supply voltage
Connect the device to the power supply according to the pin assignment shown below.
1 BK = GND V2
2 BU = GND V1
3 GNYE = FE
4 BN = 24 VDC V1
5 WH = 24 VDC V2
3
4
5
2
1
w v
3
4
5
2
1
X1 X2
Fig.13: Pin assignment voltage supply connectors
Connector Function
X1 Power feed
X2 Continuation of the power to the next node
V1 System voltage: Supply voltage 1 (incl. supply of electronics)
V2 Load voltage: Power supply 2