turck BL20 User manual

BL20 –
USER MANUAL
FOR
BL20-PG-EN

All brand and product names are trademarks or registered trade marks of the owner
concerned.
Edition 12/11
© 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 starting 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 (AWA) 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 equal-
ization. The system installer is responsible for implementing this connection.
Connecting cables and signal lines should be installed so that inductive or capacitive interfer-
ence 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.

D301049 1211 BL20-PG-EN i
Table of Contents
1 About this Manual
1.1 Documentation Concept.................................................................................................................................1-2
1.2 Description of Symbols Used..........................................................................................................................1-3
1.3 General Information........................................................................................................................................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
2.1.1 Flexibility ...................................................................................................................................................................................................2-2
2.1.2 Convenient Handling............................................................................................................................................................................2-2
2.2 BL20 Components ...........................................................................................................................................2-3
2.2.1 Gateways ...................................................................................................................................................................................................2-3
2.2.2 Power Distribution Modules ..............................................................................................................................................................2-3
2.2.3 Electronics Modules ..............................................................................................................................................................................2-4
2.2.4 Base Modules ...........................................................................................................................................................................................2-5
2.2.5 BL20 Economy.........................................................................................................................................................................................2-6
2.2.6 End Plate....................................................................................................................................................................................................2-6
2.2.7 End Bracket...............................................................................................................................................................................................2-7
2.2.8 Jumpers......................................................................................................................................................................................................2-7
2.2.9 Marking Material.....................................................................................................................................................................................2-8
2.2.10 Shield Connection, 2-Pole for Analog Modules ..........................................................................................................................2-8
3Ethernet
3.1 System Description .........................................................................................................................................3-2
3.1.1 Ethernet MAC-ID.....................................................................................................................................................................................3-2
3.1.2 IP address ..................................................................................................................................................................................................3-2
3.1.3 Network Classes ......................................................................................................................................................................................3-3
3.1.4 Data transfer.............................................................................................................................................................................................3-3
3.1.5 Checking the communication via "ping-signals"........................................................................................................................3-4
3.1.6 ARP (Address Resolution Protocol) ..................................................................................................................................................3-5
3.1.7 Transmission Media...............................................................................................................................................................................3-5
4 Technical Features
4.1 General .............................................................................................................................................................4-2
4.2 Function ...........................................................................................................................................................4-3
4.3 Function ...........................................................................................................................................................4-4
4.3.1 Programming...........................................................................................................................................................................................4-4
4.4 Technical Data .................................................................................................................................................4-5
4.4.1 Gateway structure..................................................................................................................................................................................4-5
4.5 Connection possibilities..................................................................................................................................4-8
4.5.1 Field bus connection.............................................................................................................................................................................4-8
4.5.2 Power Supply via terminal block with screw connection........................................................................................................4-8

D301049 1211 BL20-PG-ENii
4.5.3 Service Interface Connection (female PS/2 connector) ........................................................................................................... 4-8
4.6 Address Setting............................................................................................................................................. 4-10
4.6.1 LED-behavior.........................................................................................................................................................................................4-10
4.6.2 Default setting of the gateway .......................................................................................................................................................4-11
4.6.3 Address setting via the rotary-mode............................................................................................................................................4-11
4.6.4 Address setting via BootP-mode....................................................................................................................................................4-12
4.6.5 Address setting via DHCP-mode....................................................................................................................................................4-13
4.6.6 Address setting via PGM-mode ......................................................................................................................................................4-14
4.6.7 Addressing via PGM-DHCP...............................................................................................................................................................4-14
4.6.8 Address-setting via I/O-ASSISTANT 3 (FDT/DTM) ....................................................................................................................4-15
4.7 SET Button ..................................................................................................................................................... 4-18
4.8 Status Indicators/Diagnostic Messages Gateway ...................................................................................... 4-19
4.8.1 Diagnostic Messages via LEDs ........................................................................................................................................................4-19
5 Implementation of Modbus TCP
5.1 Modbus Registers ........................................................................................................................................... 5-2
5.2 Structure of the Packed In-/ Output Process Data ....................................................................................... 5-5
5.2.1 Packed input-process data................................................................................................................................................................. 5-5
5.2.2 Packed output process data .............................................................................................................................................................. 5-6
5.3 Data Width of the I/O-Modules in the Modbus-Register Area ....................................................................5-7
5.4 Register 100Ch: "Gateway-Status" ................................................................................................................ 5-9
5.5 Register 1130h: "Modbus-connection-mode" ............................................................................................ 5-10
5.6 Register 1131h: "Modbus-connection time-out" ....................................................................................... 5-10
5.7 Register 0×113C and 0×113D: "Restore Modbus-connection parameter" .............................................. 5-10
5.8 Register 0×113E and 0×113F: "Save Modbus-connection parameters" .................................................. 5-11
5.9 The Service-Object........................................................................................................................................ 5-12
5.9.1 "Indirect reading of registers" .........................................................................................................................................................5-13
5.9.2 "Indirect writing of registers"...........................................................................................................................................................5-14
5.10 Mapping: Input-Discrete- and Coil-Areas ................................................................................................... 5-15
5.11 Mapping the Modbus Registers................................................................................................................... 5-16
5.12 Implemented Modbus Functions ................................................................................................................ 5-17
5.13 Parameters of the Modules .......................................................................................................................... 5-18
5.13.1 Digital input modules ........................................................................................................................................................................5-18
5.13.2 Analog input modules .......................................................................................................................................................................5-18
5.13.3 Analog output modules ....................................................................................................................................................................5-27
5.13.4 Technology modules..........................................................................................................................................................................5-32
5.14 Diagnostic Messages of the Modules .......................................................................................................... 5-45
5.14.1 Power Supply Modules......................................................................................................................................................................5-45
5.14.2 Digital Input Modules.........................................................................................................................................................................5-46
5.14.3 Analog Input Modules .......................................................................................................................................................................5-46
5.14.4 Digital Output Modules.....................................................................................................................................................................5-49
5.14.5 Analog output modules ....................................................................................................................................................................5-51
5.14.6 Technology Modules..........................................................................................................................................................................5-52

D301049 1211 BL20-PG-EN iii
6 Configuration of the BL20-PG-EN with CoDeSys
6.1 General .............................................................................................................................................................6-2
6.1.1 System requirements............................................................................................................................................................................6-2
6.2 Installation of the BL20 target files................................................................................................................6-3
6.2.1 Installation ................................................................................................................................................................................................6-3
6.3 BL20 Hardware Configuration........................................................................................................................6-6
6.4 Configuration/ Programming of the PG in CoDeSys ....................................................................................6-7
6.4.1 Creating a new project .........................................................................................................................................................................6-7
6.5 Configuration of the BL20 Station .............................................................................................................. 6-12
6.5.1 Parameterization of the I/O modules........................................................................................................................................... 6-13
6.5.2 Addressing the in- and output data ............................................................................................................................................. 6-13
6.5.3 Mapping of the Modbus Registers................................................................................................................................................ 6-14
6.6 PLC-Programming ........................................................................................................................................ 6-16
6.6.1 Online ...................................................................................................................................................................................................... 6-16
6.6.2 Creating a boot project ..................................................................................................................................................................... 6-17
7 Guidelines for Station Planning
7.1 Random Module Arrangement.......................................................................................................................7-2
7.1.1 Complete Planning................................................................................................................................................................................7-2
7.1.2 Maximum System Extension ..............................................................................................................................................................7-2
7.2 Power Supply ...................................................................................................................................................7-4
7.2.1 Module Bus Refreshing ........................................................................................................................................................................7-4
7.2.2 Creating Potential Groups...................................................................................................................................................................7-7
7.2.3 Protecting the Service Interface on the Gateway.......................................................................................................................7-8
7.2.4 C-Rail (Cross Connection) ....................................................................................................................................................................7-9
7.2.5 Direct Wiring of Relay Modules...................................................................................................................................................... 7-10
7.3 Plugging and Pulling Electronics Modules................................................................................................. 7-11
7.4 Extending an Existing Station ..................................................................................................................... 7-12
7.5 Firmware Download..................................................................................................................................... 7-13
8 Guidelines for Electrical Installation
8.1 General Notes ..................................................................................................................................................8-2
8.1.1 General.......................................................................................................................................................................................................8-2
8.1.2 Cable Routing ..........................................................................................................................................................................................8-2
8.1.3 Cable Routing Inside and Outside of Cabinets............................................................................................................................8-2
8.1.4 Lightning Protection .............................................................................................................................................................................8-3
8.1.5 Transmission Media...............................................................................................................................................................................8-3
8.2 Potential Relationships...................................................................................................................................8-4
8.2.1 General.......................................................................................................................................................................................................8-4
8.3 Electromagnetic Compatibility (EMC) ...........................................................................................................8-5
8.3.1 Ensuring Electromagnetic Compatibility.......................................................................................................................................8-5
8.3.2 Grounding of Inactive Metal Components ...................................................................................................................................8-5
8.3.3 PE Connection .........................................................................................................................................................................................8-5

D301049 1211 BL20-PG-ENiv
8.3.4 Earth-Free Operation............................................................................................................................................................................ 8-5
8.3.5 Mounting Rails ........................................................................................................................................................................................ 8-6
8.4 Shielding of cables.......................................................................................................................................... 8-7
8.5 Potential Compensation ................................................................................................................................ 8-8
8.5.1 Switching Inductive Loads ................................................................................................................................................................. 8-8
8.5.2 Protection against Electrostatic Discharge (ESD ........................................................................................................................ 8-8
9 BL20-Approvals for Zone 2/ Division 2
10 Appendix
10.1 Network Configuration ................................................................................................................................ 10-2
10.1.1 Changing the IP address of a PC/ network interface card ....................................................................................................10-2
10.1.2 Deactivating/ adapting the firewall in Windows XP ...............................................................................................................10-5
11 Glossary
12 Index

D301049 1211 BL20-PG-EN 1-1
1 About this Manual
1.1 Documentation Concept ................................................................................................................... 2
1.2 Description of Symbols Used ............................................................................................................ 3
1.3 General Information ......................................................................................................................... 4
1.3.1 Prescribed Use.......................................................................................................................................................................................4
1.3.2 Notes Concerning Planning /Installation of this Product......................................................................................................4
1.4 List of Revisions ................................................................................................................................ 5

About this Manual
D301049 1211 BL20-PG-EN1-2
1.1 Documentation Concept
This manual contains information about the programmable BL20 Modbus TCP gateway BL20-PG-EN.
The following chapters contain a short BL20 system description, a description of the field bus system
Ethernet, exact information about function and structure of the BL20 Ethernet gateways 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.: German D300716/ English D300717)
Furthermore, the manual mentioned above contains a short description of the project planning and
diagnostics software for TURCK I/O-systems, the engineering software I/O-ASSISTANT.

D301049 1211 BL20-PG-EN 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.