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Error handling and diagnosis

BC8050 und BC8150

Version: 3.0.0

K-Bus error code diagnosis

Error
code

Error

argument

Description

Remedy

EMC problems

• Check power supply for undervoltage or overvoltage peaks

• Implement EMC measures

• If a K-bus error is present, it can be localized by a restart of the

coupler (by switching it off and then on again)

EEPROM checksum error

Enter factory settings with the KS2000 configuration software

Code buffer overflow

Insert fewer Bus Terminals. Too many entries in the table for the pro-
grammed configuration

Unknown data type

Software update required for the Bus Coupler

Reserve

K-bus command error

• No Bus Terminal inserted

• One of the Bus Terminals is defective; halve the number of Bus

Terminals attached and check whether the error is still present
with the remaining Bus Terminals. Repeat until the defective
Bus Terminal is located.

K-bus data error, break be-
hind the Bus Coupler

Check whether the n+1 Bus Terminal is correctly connected; replace if
necessary.

Break behind Bus Terminal n Check whether the KL9010 Bus End Terminal is connected

K-bus error in register com-
munication with Bus Terminal
n

Exchange the nth Bus Terminal

Error at initialization

Exchange Bus Coupler

Internal data error

Perform a hardware reset on the Bus Coupler (switch off and on again)

DIP switch changed after a
software reset

Perform a hardware reset on the Bus Coupler (switch off and on again)

Note: cycle time was ex-
ceeded

Warning: the set cycle time was exceeded. This indication (flashing
LEDs) can only be cleared by booting the Bus Coupler again.
Remedy: increase the cycle time

Checksum error in Flash pro-
gram

Re-transfer the program to the Bus Terminal Controller

Incorrect or faulty library im-
plemented

Remove the faulty library

Bus Terminal n is not consis-
tent with the configuration that
existed when the boot project
was created

Check the nth Bus Terminal. The boot project must be deleted if the in-
sertion of an nth Bus Terminal is intentional.

nth Bus Terminal has the
wrong format

Start the Bus Coupler again, and if the error occurs again then ex-
change the Bus Terminal

Number of Bus Terminals is
no longer correct

Start the Bus Coupler again. If the error occurs again, restore the man-
ufacturers setting using the KS2000 configuration software

Length of the K-bus data is no
longer correct

Start the Bus Coupler again. If the error occurs again, restore the man-
ufacturers setting using the KS2000 configuration software

LED bus - fieldbus diagnostics

LED

Meaning

LED WD

not implemented

LED RX

Flashes when data are being received

LED TX

Flashes when data are being sent

LED PLC - PLC diagnostics

LED

Meaning

PLC LED

LED on: PLC running,
LED off: PLC stopped

Содержание BC8050

Страница 1: ...Documentation BC8050 und BC8150 Bus Terminal Controller with RS485 or RS232 Interface 3 0 0 2017 07 18 Version Date...

Страница 2: ......

Страница 3: ...Programming cable 21 3 2 4 RS232 Connection 22 3 2 5 RS485 connection 23 4 Parameterization and Commissioning 24 4 1 Start up behavior of the Bus Terminal Controller 24 4 2 Setting the Address 25 4 3...

Страница 4: ...62 5 14 2 KS8000 Process Image 62 6 RS232 Interface 64 6 1 Protocol 64 6 1 1 Modbus 64 6 1 2 Protocol Overview 74 6 1 3 KS8000 protocol 74 6 2 Introduction to the system 77 6 2 1 Overview of the phys...

Страница 5: ...of the data diagrams and descriptions in this documentation Trademarks Beckhoff TwinCAT EtherCAT Safety over EtherCAT TwinSAFE XFC and XTS are registered trademarks of and licensed by Beckhoff Automa...

Страница 6: ...re familiar with the applicable national standards Description of symbols In this documentation the following symbols are used with an accompanying safety instruction or note The safety instructions m...

Страница 7: ...e only available in German BC8150 firmware For updating your firmware you need a serial cable the KS2000 configuration software or the firmware update program Document version BC8050 BC8150 Firmware v...

Страница 8: ...essed data can be exchanged between the Bus Terminal Controller and the higher level controller via the fieldbus Fieldbus interface The variants of the BCxx50 series Bus Terminal Controllers differ in...

Страница 9: ...ions of compact terminal boxes Decentralised wiring of each I O level Fieldbus technology allows more compact forms of controller to be used The I O level does not have to be brought to the controller...

Страница 10: ...nything about the function of the K bus or about the internal workings of the terminals and the Bus Coupler Many software tools that can be supplied make project planning configuration and operation e...

Страница 11: ...l data BCxx5x Processor 16 bit micro controller Diagnostics LEDs 2 x power supply 2 x K Bus Configuration and programming software TwinCAT PLC Fieldbus interface BC8050 BC8150 Fieldbus RS485 KS8000 pr...

Страница 12: ...Us 60 mA total K bus current 4 Starting current approx 2 5 x continuous current K bus current 5 V maximum 1000 mA Power contact voltage Up maximum 24 VDC Power contact current load Up maximum 10 A Rec...

Страница 13: ...ss 40 59 ModbusRTU fixed baud rate 1200 2400 4800 9600 19200 38400 DEFAULT 9600 baud 8 bit data optionally even odd no default no parity Number of I O modules 32 99 with repeater Number of I O points...

Страница 14: ...a frame 8 data bits even parity one stop bit Address 40 59 ModbusRTU fixed baud rate 1200 2400 4800 9600 19200 38400 DEFAULT 9600 baud 8 bit data optionally even odd no default no parity Number of I O...

Страница 15: ...rogramming interface or via the fieldbus Program memory 48 kbyte Source code memory 128 kbyte Data memory 32 kbyte Remanent flags 2 kbyte PLC cycle time Approx 3 0 ms for 1000 IL commands without I O...

Страница 16: ...s Coupler and a number of Bus Terminals will be used The mechanical dimensions of the Bus Couplers are independent of the fieldbus system Fig 4 BCxx50 The total width of the fieldbus station is the wi...

Страница 17: ...rectly assembled no significant gap can be seen between the attached housings Fig 6 Power contact on the left Attention Bus Terminals should only be pulled or plugged in switched off state Insertion a...

Страница 18: ...Coupler Bus Terminal Controller and Bus Terminals is realized automatically by latching the components The transfer of the data and the supply voltage for the intelligent electronics in the Bus Termin...

Страница 19: ...from the connected group of other terminals In that case the PE conductors do not have to be disconnected The power contact with the label PE must not be used for other potentials 3 2 2 Power supply...

Страница 20: ...Us must not be connected with unlimited voltage sources Power contacts supply Up The bottom six connections with spring loaded terminals can be used to feed the supply for the peripherals The spring...

Страница 21: ...als guarantees that the power contacts mate securely 3 2 3 Programming cable Use the KS2000 Z2 programming cable for serial programming of the Bus Terminal Controller This cable is included in the sco...

Страница 22: ...t side of the Bus Terminal Controller A three core cable with shield should be used with the shield being connected to the D Sub connector casing Pin assignment of the RS232 D Sub socket Fig 12 RS232...

Страница 23: ...eft side of the Bus Terminal Controller A two core cable with shielding should be used The shielding should be connected to signal ground GND Pin assignment of the RS485 D sub socket Fig 14 RS485 pin...

Страница 24: ...e configures the K bus creates a configuration list based on the connected Bus Terminals and starts its local PLC The I O LEDs flash when the Bus Terminal Controller starts up If the system is in an e...

Страница 25: ...0 baud fixed data frame 8 e 1 Address 40 to 59 ModbusRTU configurable baud rate default 9600 configurable data frame default 8 n 1 Changing the address The switches can be set to the required position...

Страница 26: ...digital Bus Terminals The complex Bus Terminals are mapped as follows Word Alignment complex representation CAUTION The process image depends on the connected terminals The process image changes when...

Страница 27: ...e transferred to the BCxx50 or BXxx00 via fieldbus ADS protocol or serial ADS protocol The TwinCAT configuration can be used to link variables I Os and data The following is possible PLC K BUS PLC fie...

Страница 28: ...iguration Select the corresponding Bus Terminal Controller Fig 19 Selecting the Bus Terminal Controller All Bus Terminal Controller components are now available Fieldbus interface K bus interface 38 P...

Страница 29: ...the master e g fieldbus master card and the Bus Terminal Controller Choose Target System Select the Bus Terminal Controller onto which the configuration is to be loaded Use the function key F8 to open...

Страница 30: ...onding program can now be transferred to the Bus Terminal Controller program download via the fieldbus 4 4 4 Uploading a TwinCAT configuration The TwinCAT configuration is loaded into the Bus Terminal...

Страница 31: ...elect the corresponding Bus Terminal Controller Fig 25 Selecting the Bus Terminal Controller The state of the Bus Terminal Controller is shown at the bottom right of the System Manager Fig 26 State of...

Страница 32: ...he Resources tab of the Bus Terminal Controller Mapping code The mapping code is required for calculating the TwinCAT configuration see Figure Memory for the code mapping The percentages are added her...

Страница 33: ...Fig Code and data memory 3 Used PLC source in Fig 30 Code and data memory Other memory Fig Other Memory 1 Used Near Heap is required for the COM interface and SSB values Fig Other Memory 2 Used Huge...

Страница 34: ...2 16 21 20 1 1 If the IP address of the BX9000 is changed the AMS Net ID of the BX9000 also changes There is a menu option for displaying the cur rent AMS Net ID Example If you change the IP address t...

Страница 35: ...t called see above Enter the name AMS Net ID and transport type and close the dialog With the second call you can enter your COM port The communication starts when TwinCAT is in Config mode TwinCAT ic...

Страница 36: ...Select BC8150 Fig 34 Selection of Bus Controller Open the device BC8150 and click on BC8150 On the right in the System Manager there are two tabs i e General and Communication Properties Select Commu...

Страница 37: ...150 and right click on Inputs for setting up inputs or Outputs for setting up outputs to be received or sent via the RS232 interface Fig 36 Creating variables inputs outputs Please not that an even st...

Страница 38: ...selected the Bus Terminal Controller does not enter into data exchange The PLC project will not be started Auto K Bus Reset Once a K bus error has been rectified the Bus Terminal Controller automatic...

Страница 39: ...Bus Re Trigger 3 4 x 85 ms 340 ms Reaction on K Bus Error In the event of a K Bus error the K Bus inputs are set to 0 or retain their last state Response on PLC Stop The user can set the behavior of t...

Страница 40: ...ud 8 data bits even 1 stop bit Note COM1 automatic baud rate detection The COM 1 interface of the BXxx00 features automatic baud rate detection between 9 6 kbaud and 56 4 kbaud Note Required KS2000 ve...

Страница 41: ...e 2nd generation Bus Terminal Controllers are configured with the TwinCAT System Manager and programmed with TwinCAT PLC Control TwinCAT PLC must be installed for these couplers Windows NT4 Windows 20...

Страница 42: ...rror Out of global data memory Error POUs For each function block one POU process object unit is created 256 function blocks are available by default Fig 40 Maximum number of POUs exceeded If librarie...

Страница 43: ...will deactivate online changes Global memory error Fig 43 Global memory insufficient 2 x 16 kbyte of data are available by default If large data quantities are to be used this range should be increas...

Страница 44: ...Programming BC8050 und BC8150 44 Version 3 0 0 Fig 45 Build...

Страница 45: ...AIN should not be used in function blocks All FB data are copied into the retain memory This leads to an unnecessary increase in cycle time and the retain memory is filled with unnecessary data Note D...

Страница 46: ...D Flag_M WORD END_VAR fbADRSREAD NETID 172 16 3 0 2 3 AMSNetId BX PORT 800 800 PLC IDXGRP 16 4020 0x4020hex falgs IDXOFFS 0 byte offset LEN 2 Lenght byte DESTADDR ADR Merker READ TRUE TMOUT t 1s IF NO...

Страница 47: ...ble for read access If the serial ADS is used it is recommended to access the flag area that can be reached via port 800 and IndexGroup 0x4020 Addressing of the connected Bus Terminals The default set...

Страница 48: ...em Manager under Project Import Now you will have the entry TwinCAT import under the global variables and you will find here all the variables that you have assigned to the local PLC BX BCxx50 5 7 Map...

Страница 49: ...ble links Fig 47 Linking a variable with an input In the default configuration all Bus Terminals are assigned fixed addresses If a Bus Terminal is inserted the whole address range may be shifted The T...

Страница 50: ...nge when the boot project is deleted Note Using the current project as boot project After an online change the old project is still shown as boot project To use the current project after the online ch...

Страница 51: ...iValue_1 INT iValue_2 INT iValue_3 INT END_STRUCT END_TYPE Creating a variable structure VAR_Global strData_Out AT QB1000 PB_Data PLC Variables bInput_01 AT IX0 0 BOOL Input from a terminal END_VAR Sm...

Страница 52: ...icient the source code may be stored without task configuration and libraries This takes up significant less memory space General settings The timing of the source code download to the target system c...

Страница 53: ...s transferred Login is only possible when the PLC stops Which option you can use depends on the size of your projects Downloading a program The source code can be transferred to the target system on r...

Страница 54: ...Fig 52 Uploading a program Select the data transfer route BCxx50 or BX via AMS if you are connected to the Bus Terminal Controller via the fieldbus or BCxx50 or BX via serial if you are connected to t...

Страница 55: ...nt 1033 bc8x50 Resources zip 3730728971 zip TcSystemBCxx50 requires the TcBaseBCxx50 library TcBaseBCxx50 https infosys beckhoff com content 1033 bc8x50 Resources zip 3730731147 zip ChrAscBX lbx https...

Страница 56: ...ntrol System Time TBus Version Firmware BC3150 BC5150 BC5250 BC8150 DRAND B0 B0 B1 B0 SYSTEMTIME_TO_DT B0 B0 B1 B0 DT_TO_SYSTEMTIME B0 B0 B1 B0 GetSysTick B0 B0 B1 B0 PresetSysTick B0 B0 B1 B0 Reboot...

Страница 57: ...L bReadSet BOOL strBC8150_Set Seriell_Set Key bWriteSet Rising edge starts the block and reads writes the parameters If these have changed the new parameters are written and the flag bReboot_Necessary...

Страница 58: ...ol address 40 59 iWatchdog Watchdog for KS8000 and Modbus protocol Modbus_Baudrate Baud rate for the ModbusRTU protocol address 40 59 iErrorId Return parameter iErrorId Meaning 0 no Error 1 Wrong BC T...

Страница 59: ...system library For accessing the variable the system library has to be integrated in the project Development environment Target platform PLC libraries to be linked TwinCAT v2 9 0 BCxx50 BC9x20 Contro...

Страница 60: ...PLC is stopped AdsServerDeviceState Data type read only Meaning INT 0 Start the local PLC is running 1 Start the local PLC is stopped AdsServerType Data type read only Meaning String BX PLC Server Re...

Страница 61: ...d rate etc are found under Online Communication parameters in PLC Control The Bus Terminal Controller requires the following setting Baud Rate 9600 19200 38400 57600 baud automatic baud rate detection...

Страница 62: ...tored in the controller input section from address IB1000 Modbus address 42049 depending on master The maximum data length is 512 bytes input and 512 bytes output Recommendation We recommend limiting...

Страница 63: ...3 Version 3 0 0 The output data from the master perspective are stored in the controller input section from address IB1000 address offset 0 from the master perspective The maximum data length is 512 b...

Страница 64: ...n Data CRC END t1 t2 t3 t4 1 byte 1 byte n Bytes 2 bytes t1 t2 t3 t4 ASCII In ASCII mode the telegram starts with a colon character 0x3A and ends with a carriage return line feed CRLF characters 0x0D...

Страница 65: ...the watchdog timer is initiated and is triggered each time a telegram is received from this device A second approach which represents a more sensitive condition for the watchdog is for the watchdog o...

Страница 66: ...function and the error code 0x80 is added to the value returned by the function Code Name Meaning 1 ILLEGAL FUNCTION Modbus function not implemented 2 ILLEGAL DATA ADDRESS Invalid address or length 3...

Страница 67: ...ith byte count 4 i e 4 bytes of data are returned The query was for 2 analog channels and these are now distributed over 2 words In the analog output process image the first channel has the value 0x3F...

Страница 68: ...0 Count high 0 0x00 00 0x30 0x30 Count low 2 0x02 02 0x30 0x32 Error check LRC CRC 0x71 0x61 EF 0x45 0x46 End frame t1 t2 t3 CRLF 0x0D 0x0A The Fieldbus Box Coupler Box responds with byte count 4 i e...

Страница 69: ...Function code 6 0x06 06 0x30 0x36 Start address high 8 0x08 08 0x30 0x36 Start address low 0 0x00 00 0x30 0x30 Data high 63 0x3F 3F 0x33 0x46 Data low 255 0xFF FF 0x46 0x46 Error check LRC CRC 0xDA 0x...

Страница 70: ...3 0x03 03 0x30 0x33 Error check LRC CRC 0xA1 0xC0 E8 0x45 0x38 End frame t1 t2 t3 CRLF 0x0D 0x0A Response Byte Name Modbus RTU Modbus ASCII Start frame 0x3A Address 11 0x0B 0B 0x30 0x42 Function code...

Страница 71: ...tes the number of error response telegrams which the Bus Coupler Fieldbus Box has sent Subfunction Data field query Data field response 00 0D 00 00 Counter value The following functions contain the co...

Страница 72: ...3FFF Query Byte Name Modbus RTU Modbus ASCII Start frame 0x3A Address 11 0x0B 0B 0x30 0x42 Function code 16 0x10 10 0x31 0x30 Start address high 8 0x08 08 0x30 0x38 Start address low 0 0x00 00 0x30 0x...

Страница 73: ...2 Function code 23 0x17 17 0x31 0x17 Read start address high 0 0x00 00 0x30 0x30 Read start address low 0 0x00 00 0x30 0x30 Read length high 0 0x00 00 0x30 0x30 Read length low 2 0x02 02 0x30 0x32 Wri...

Страница 74: ...aud rate 38400 8 e 1 TwinCAT PLC BCxx50 or BX serial TwinCAT PLC programming software for the program download Address 1 up to 39 baud rate 38400 8 e 1 Modbus ASCII Open protocol for data exchange Mod...

Страница 75: ...Start ID The start ID consists of one byte It identifies the start of a data packet Number of process data output words The number of process data output words specifies the size of the output process...

Страница 76: ...be read Message Ident The message Ident is a freely selectable value returned by the receiver in the response string so that the sender can correlate received and sent strings Multipoint address The...

Страница 77: ...ns consist of what are known as front panels which serve as the man machine interface and of a block diagram which embodies the actual control program KS8000 provides LabVIEW users with a greatly simp...

Страница 78: ...BC8050 und BC8150 78 Version 3 0 0 6 2 2 Topology of the physical RS232 structure RS232 is a peer to peer connection The means that only two devices can be connected at any time The maximum cable leng...

Страница 79: ...tion block in preparation To this end link the K Bus state variable with your PLC program Fig 61 State of the K bus Error bit Description Error type 0 No error No ERROR Bit 0 K bus error ERROR Bit 2 K...

Страница 80: ...indicates the supply voltage and the K Bus state Fig 62 LEDs LEDs for power supply diagnostics LED Power LEDs Meaning LED Us LED off No power supply 24 VDC for electronics and K Bus supply connected L...

Страница 81: ...a hardware reset on the Bus Coupler switch off and on again 2 DIP switch changed after a software reset Perform a hardware reset on the Bus Coupler switch off and on again 7 0 Note cycle time was ex c...

Страница 82: ...information is available in TcSystemBCxx50 lbx as a function for the BCxx50 BCxx20 The allocated flags do not act as retain variables Retain data The retain data have to be declared as VAR_RETAIN Up t...

Страница 83: ...Default Config the PLC variables start from IB1000 and QB1000 Large model Not applicable for BXxx00 Max memory 256 kB Task time The task time is specified in the PLC Control It should be set to a rea...

Страница 84: ...le https infosys beckhoff com content 1033 bc8x50 Resources zip 4059887115 zip Example program for BC8150 communication with VB6 with KS8000 OCX Source code and EXE file https infosys beckhoff com con...

Страница 85: ...and stop when F2 is pressed on the Cimrex 12 sample program in ST for BC8150 any terminal configuration https infosys beckhoff com content 1033 bc8x50 Resources prx 4059893643 prx Example Cimrex 12 p...

Страница 86: ...com content 1033 bc8x50 Resources zip 3238791819 zip 71 kbytes for Windows NT4 0 SP6 2000 XP The program FirmwareUpdate exe and the file TcRouterHelper dll have to be in the same directory Open the p...

Страница 87: ...via the green traffic light The download begins after about a minute and is then also shown on the BX s display After successful download approx 2 to 3 minutes the Bus Terminal Controller reboots aut...

Страница 88: ...000 6 4 Transport and storage Condition Permissible range Permissible ambient temperature during storage 25 C 85 C Relative humidity 95 no condensation Free fall up to 1 m in the original packaging Pr...

Страница 89: ...the Underwriters Laboratories Inc the leading certification organization for North America based in the USA C Canada US USA UL file number E172151 Production identification From left to right this seq...

Страница 90: ...dards for device testing EMC EMC immunity EN 61000 6 2 Electromagnetic emission EN 61000 6 4 Vibration shock resistance Vibration resistance EN 60068 2 6 Shock resistance EN 60068 2 27 8 7 Bibliograph...

Страница 91: ...components there Beckhoff Headquarters Beckhoff Automation GmbH Co KG Huelshorstweg 20 33415 Verl Germany Phone 49 0 5246 963 0 Fax 49 0 5246 963 198 e mail info beckhoff com Beckhoff Support Support...

Страница 92: ...Controller 28 Fig 20 Downloading a TwinCAT configuration 29 Fig 21 Selecting the Bus Terminal Controller 29 Fig 22 State of the Bus Terminal Controller 29 Fig 23 Activating the TwinCAT configuration...

Страница 93: ...tion block BC8150_SETTINGS 57 Fig 56 Selecting the data transfer route serial interface 61 Fig 57 Parameterization of the serial interface 61 Fig 58 Selecting the data transfer route AMS 62 Fig 59 Sel...

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