The Fieldbus Box System

Fieldbus box modules are robust fieldbus stations for a large number of different fieldbus systems. They offer a wide range of I/O functionality. All relevant industrial signals are supported. As well as digital and analog inputs and outputs including thermocouple and RTD inputs, there are also incremental encoder interfaces available for displacement and angle measurement as well as serial interfaces to solve a large number of communications tasks.

Three varieties of signal connection

The digital inputs and outputs can be connected with snap-on 8 mm diameter plugs, screw-in M8 connectors, or with screw-in M12 pendants. The M12 version is provided for analog signals.

All important signal types

Special input and output channels on the combination I/O modules can be used for either input or output. It is not necessary to configure them, since the fieldbus interface is available for every combination channel as well as for input and output data. The combination modules give the user all of the advantages of fine signal granularity.

The processor logic, the input circuitry and the power supply for the sensor are all fed from the control voltage. The load voltage for the outputs can be supplied separately. In those Fieldbus Boxes in which only inputs are available, the load power supply, UP, can optionally be connected in order to pass it on downstream.

The states of the Fieldbus Box, the fieldbus connection, the power supplies and of the signals are indicated by LEDs.

The label strips can be machine printed elsewhere, and then inserted.

Fieldbus Boxes can be combined for greater flexibility

In addition to the Compact Box, the Fieldbus Box series also includes extendable devices, namely the Coupler Box and the Extension Box, as well as intelligent devices, the PLC Boxes.

Compact Box

The Compact Box makes the I/O data from the connected digital and analog sensors and actuators available to the fieldbus.

Coupler Box

The Coupler Box also collects I/O data from the Extension Boxes via an interference-proof optical fiber connection (IP-Link). Up to 120 Extension Boxes can be connected to a Coupler Box. In this way a distributed IP67 I/O network is formed with only one fieldbus interface.

The Coupler Box is capable of automatically recognizing the extension modules connected to it during start-up, and maps the I/O data automatically into the fieldbus process image – a configuration is not necessary. The Coupler Box appears, from the fieldbus point of view, along with all of the networked Extension Boxes, as a single participating bus device with a corresponding number of I/O signals.

The Coupler Box corresponds to the Bus Coupler in the BECKHOFF Bus Terminal system. BECKHOFF fieldbus devices made to protection class IP 20 (Bus Terminals) and IP 67 (Fieldbus Box) can be combined without difficulty – the data is handled in the same way in either case.

IP-Link

The IP-Link is an optical fiber connection with a transmission rate of 2 MBits/s which is capable of transmitting 1000 items of binary I/O data in approx. 1 ms, rapidly and securely. Smaller configurations are correspondingly faster. Because of the high usable data rate, the coupling via IP-Link does not reduce the performance of the fieldbus at all.

Low-priced plug connectors made according to Protection Class IP 67 can be used for the rapid and simple preparation of the IP-Link cable, in situ. The connection does not require special tools, and can be performed quickly and simply. The IP-Link cables can also be obtained with prepared plugs if required.

The separate supply of the output voltage allows output groups to be switched off individually. Differing potentials can also be created within an extension ring without difficulty, since the IP-Link naturally has optimum electrical isolation.

Extension box

Like the Compact Boxes, the Extension Boxes cover the full spectrum of I/O signals, and may be up to 15 m apart. They are remarkably small in size, and lead to particularly economical I/O solutions with high levels of protection. Here again, the digital inputs and outputs may optionally be connected via snap-on 8 mm connectors, or via screw-in connectors (M8 and M12). Analog signal types are provided with the M12 version. The snap-on connectors lock in place positively, forming a shake-proof connection, while the screw-in connectors offer the advantage of high resistance to being pulled out.

PLC Box

The PLC Box is an intelligent Fieldbus Box with PLC functionality for distributed pre-processing of the I/O signals. This allows parts of the application to be farmed out from the central controller. This reduces the load on the CPU and the fieldbus. Distributed counting, controlling and switching are typical applications for the PLC Box. The reaction times are independent of the bus communication and of the higher-level controller.

In the event of a bus or controller failure, maintenance of function (e.g. bringing the process to a safe state in an orderly manner) is possible.

Programming is carried out with TwinCAT in accordance with IEC 61131-3. Five different programming languages are available:

  • Instruction List (IL)
  • Function Block Diagram (FBD)
  • Ladder Diagram (LD)
  • Sequential Function Chart (SFC)
  • Structured Text (ST)

The program download occurs either via the fieldbus or via the programming interface.

Extensive debugging functions (breakpoint, single step, monitoring, etc) are also available. The PLC Box contains a powerful 16 bit controller, 32/96 kByte program memory and 32/64 kByte data memory. A further 512 bytes of non-volatile memory are available for remanent flags.

PLC Box with IP-Link

The programmable PLC Box with IP-Link provides almost unlimited I/O possibilities. Up to 120 extension modules, with more than 2000 I/Os, can be directly addressed from the PLC program. The PLC Box is thus also suitable for use as a small, autonomous controller for the operation of parts of equipment or small machines.