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.

About this Manual
D301049 1211 BL20-PG-EN1-4
1.3 General Information
This manual contains all necessary information about the prescibed use of the programmable TURCK
gateway BL20-PG-EN.
It has been specially conceived for personnel with the necessary qualifications.
1.3.1 Prescribed Use
Appropriate transport, storage, deployment and mounting as well as careful operating and thorough
maintenance guarantee the trouble-free and safe operation of these devices.
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.

D301049 1211 BL20-PG-EN 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/ updated
4Address-setting via I/O-ASSISTANT 3 (FDT/DTM)
(page 4-15)
X
5Modbus Registers (page 5-2) X
Data Width of the I/O-Modules in the Modbus-
Register Area (page 5-7), new modules added
X
Parameters of the Modules (page 5-18), new modules
added
X
Diagnostic Messages of the Modules (page 5-45),
new modules added
X
9BL20-Approvals for Zone 2/ Division 2
→separate manual D301255
X
Note
The publication of this manual renders all previous editions invalid.

About this Manual
D301049 1211 BL20-PG-EN1-6

D301049 1211 BL20-PG-EN 2-1
2 BL20 Philosophy
2.1 The Basic Concept ............................................................................................................................. 2
2.1.1 Flexibility .................................................................................................................................................................................................2
2.1.2 Convenient Handling..........................................................................................................................................................................2
2.2 BL20 Components ............................................................................................................................. 3
2.2.1 Gateways.................................................................................................................................................................................................3
2.2.2 Power Distribution Modules ............................................................................................................................................................3
2.2.3 Electronics Modules ............................................................................................................................................................................4
2.2.4 Base Modules.........................................................................................................................................................................................5
2.2.5 BL20 Economy.......................................................................................................................................................................................6
2.2.6 End Plate..................................................................................................................................................................................................6
2.2.7 End Bracket.............................................................................................................................................................................................7
2.2.8 Jumpers ...................................................................................................................................................................................................7
2.2.9 Marking Material...................................................................................................................................................................................8
2.2.10 Shield Connection, 2-Pole for Analog Modules ........................................................................................................................8

BL20 Philosophy
D301049 1211 BL20-PG-EN2-2
2.1 The Basic Concept
BL20 is a modular IP20 I/O-system for use in industrial automation. It connects the sensors and
actuators in the field to the higher-level master.
BL20 offers modules for practically all applications:
Digital input and output modules
Analog input and output modules
Technology modules (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
realized via an internal module bus.
2.1.1 Flexibility
A BL20 station can contain modules in any combination, which means it is possible to adapt the system
to practically all applications in automated industries.
2.1.2 Convenient Handling
All BL20 modules, with the exception of the gateway, consist of a base module and an electronic
module.
The gateway and the base modules are either snapped onto a mounting rail or are directly mounted
onto the machine frame. The electronic modules are plugged onto the appropriate base modules.
After disconnection of the load, the electronic 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.

D301049 1211 BL20-PG-EN 2-3
BL20 Components
2.2 BL20 Components
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/O-ASSISTANT.
The BL20 gateways BL20-PG-EN 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.
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 2-1:
BL20 gateway
Figure 2-2:
Power distribu-
tion module

BL20 Philosophy
D301049 1211 BL20-PG-EN2-4
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

D301049 1211 BL20-PG-EN 2-5
BL20 Components
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 connec-
tion
Figure 2-6:
Base module
with screw con-
nection
Figure 2-7:
Base module in
block design

BL20 Philosophy
D301049 1211 BL20-PG-EN2-6
2.2.5 BL20 Economy
With the BL20 Economy modules the electronics and connection technology is integrated into a single
housing. Thus, the selection of a base module is unnecessary. Within a station the Economy modules
can be combined with the modules with separate electronics/connection technology, provided that
the base modules feature tension spring connections.
2.2.6 End Plate
An end plate on the right-hand side physically completes the BL20 station. An end bracket mounted
into the end plate ensures that the BL20 station remains secure on the mounting rail even when
subjected to vibration.
Figure 2-8:
BL20 Economy
Figure 2-9:
End plate

D301049 1211 BL20-PG-EN 2-7
BL20 Components
2.2.7 End Bracket
A second end bracket to the left of the gateway is necessary, as well as the one mounted into the end
plate to secure the station.
2.2.8 Jumpers
Jumpers (QVRs) are used to bridge a connection level of a 4-wire base module. They can be used to
connect potentials in relay modules (bridging the relay roots); thus considerably reducing the amount
of wiring.
Figure 2-10:
End bracket
Figure 2-11:
Jumpers