BK9103_EK9300_6-30-11

www.infoPLC.net

BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC

Beckhoff Technical Support Department 6/30/2011

www.beckhoffautomation.com

The contents of this information are accurate to the best of our our ability. Hardware and Software are in a constant state of improvement. Screen shots were taken from Siemens Step7 version 5.4 service pack 5.

BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Overview

3-6

DIP Switches

7

Specifications

8

Starting a Step7 Project

9

Setting the PG/PC Interface to MPI

13

Uploading the local S7 rack

20

Setting up the Profinet Network

31

Adding Beckhoff Beckhoff Hardware Hardware (including (including installing installing GSDML GSDML files)

40

Adding the BK9103 and KL Terminals Terminals to Profinet Profinet

48

Adding the EK9300 and EL Terminals Terminals to Profinet Profinet

57

Setting the PG/PC Interface to Ethernet

66

Downloading Completed Beckhoff Hardware Configurati on to S7 PLC

72

Testing KL Terminals on the BK9103 Coupler using the S7 PLC

75

Testing EL Terminals on the EK9300 Coupler using the S7 PLC

82

BK9103 EK9300 on S7 PLC

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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Overview

3-6

DIP Switches

7

Specifications

8

Starting a Step7 Project

9

Setting the PG/PC Interface to MPI

13

Uploading the local S7 rack

20

Setting up the Profinet Network

31

Adding Beckhoff Beckhoff Hardware Hardware (including (including installing installing GSDML GSDML files)

40

Adding the BK9103 and KL Terminals Terminals to Profinet Profinet

48

Adding the EK9300 and EL Terminals Terminals to Profinet Profinet

57

Setting the PG/PC Interface to Ethernet

66

Downloading Completed Beckhoff Hardware Configurati on to S7 PLC

72

Testing KL Terminals on the BK9103 Coupler using the S7 PLC

75

Testing EL Terminals on the EK9300 Coupler using the S7 PLC

82


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The BK9103 series are Fieldbus Couplers (usually abbreviated “bus” coupler) which allow KLxxxx terminals to be used on the Profinet Fieldbus

Profinet Standard

PROFINET is defined by PROFIBUS & PROFINET International (PI) and backed by the INTERBUS Club and, since 2003, is part of the IEC 61158 and IEC 61784 standards. Profinet in General PROFINET is the open industrial Ethernet standard of PROFIBUS & PROFINET International (PI) for automation. PROFINET uses TCP/IP and IT standards, and is, in effect, real-time Ethernet.

The PROFINET concept features a modular structure so that users can select the cascading functions themselves. They differ essentially because of the type of data exchange to fulfill the partly very high requirements of speed. In conjunction with PROFINET, the two perspectives PROFINET CBA and PROFINET IO exist. PROFINET CBA is suitable for the component-based communication via TCP/IP and the real-time communication for real-time requirements in modular systems engineering. Both communication options can be used in parallel.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC PROFINET IO was developed for real time (RT) and isochronous real time (IRT) communication with the decentralized periphery. The designations RT and IRT merely describe the real-time properties for the communication within PROFINET IO. PROFINET CBA and PROFINET IO can communicate at the same time on the same bus system. They can be operated separately or combined so that a PROFINET IO subsystem appears as a PROFINET CBA system from a system perspective Profinet I/O

Interfacing the peripherals is implemented by PROFINET IO. It defines the communication with field connected peripheral devices. Its basis is a cascading realtime concept. PROFINET IO defines the entire data exchange between controllers (devices with "master functionality") and the devices (devices with "slave functionality"), as well as parameter setting and diagnosis. PROFINET IO is designed for the fast data exchange between Ethernet-based field devices and follows the provider-consumer model. Field devices in a subordinate PROFIBUS line can be integrated in the PROFINET IO system without any effort and seamlessly via an IO-Proxy (representative of a subordinate bus system). A device developer can implement PROFINET IO with any commercially available Ethernet controller. It is well-suited for the data exchange with bus cycle times of a few ms. The configuration of an IO-System has been kept nearly identical to the "look and feel" of PROFIBUS. PROFINET IO always contains the real-time concept. A PROFINET IO system consists of the following devices: The IO Controller, which controls the automation task. The IO Device, which is a field device, monitored and controlled by an IO Controller. An IO Device may consist of several modules and sub-modules. The IO Supervisor is software typically based on a PC for setting parameters and diagnosing individual IO Devices.  



An Application Relation (AR) is established between an IO Controller and an IO Device. These ARs are used to define Communication Relations (CR) with different characteristics for the transfer of parameters, cyclic exchange of data and handling of alarms. The characteristics of an IO Device are described by the device manufacturer in a General Station Description (GSD) file. The language used for this purpose is the GSDML (GSD Markup Language) - an XML based language. The GSD file provides the supervision software with a basis for planning the configuration of a PROFINET IO system.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Profinet and Realtime Operation

Within PROFINET IO, process data and alarms are always transmitted in real time (RT). Real time in PROFINET is based on the definition of IEEE and IEC, which allow for only a limited time for execution of real-time services within a bus cycle. The RT communication represents the basis for the data exchange for PROFINET IO. Real-time data are treated with a higher priority than TCP(UDP)/IP data. RT provides the basis for the real-time communication in the area of distributed periphery and for the PROFINET component model (PROFINET CBA). This type of data exchange allows bus cycle times in the range of a few hundred microseconds. Profinet and Isochronous Operation

The isochronous data exchange with PROFINET is defined in the isochronous real-time (IRT) concept. PROFINET IO field devices with IRT functionality have switch ports integrated in the field device. They can be based e.g. on the Ethernet controllers ERTEC 400/200. The data exchange cycles are usually in the range of a few hundred microseconds up to a few milliseconds. The difference to real-time communication is essentially the high degree of determinism, so that the start of a bus cycle is maintained with high precision. The start of a bus cycle can deviate up to 1 µs (jitter). IRT is required, for example, for motion control applications (positioning control processes). Specifics of the BK9103 Coupler

The BK9103 Bus Coupler connects PROFINET with the modular, extendable electronic terminal blocks. A unit consists of a Bus Coupler, any number (between 1 and 64) of terminals, and a bus end terminal (255 Bus Terminals with Terminal Bus extension). The Bus Couplers recognize the terminals to which they are connected, and perform the assignment of the inputs and outputs to the words of the process image automatically. The BK9103 Bus Coupler supports 10 Mbit/s and 100 Mbit/s Ethernet. Connection is through normal RJ 45 connectors. The IP address is set on a DIP switch (the offset from a freely selectable start address). In networks with DHCP (a service for the allocation of the logical IP address to the physical node address (MAC-ID)) the Bus Coupler obtains its IP address from the DHCP server. The BK9103 has an additional RJ-45 port. Both Ethernet ports operate as 2-channel switches. The I/O stations can thus be configured with a line topology, instead of the classic star topology. In many applications; this significantly reduces the wiring effort and the cabling costs. The maximum distance between two couplers is 100 m. Up to 20 BK9103 Bus Couplers are cascadable, so that a maximum line length of 2 km can be achieved.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Complex signal processing for analog I/O, displacement measurement, etc.

The BK9103 Bus Coupler supports operation of all K-Bus Terminals. As far as the user is concerned, the inputs and outputs are not handled any differently from the way they are by other coupler series. The information is made available for use as a byte array in the process image of the automation device. The KS2000 configuration software allows the analog and multifunctional Bus Terminals to be adapted to the specific application. Depending on the particular type, the registers in the analog Bus Terminals contain temperature ranges, amplification factors and linearization curves. The KS2000 software can be used to set the desired parameterization via the PC. The Bus Terminal stores the setting permanently, even if the voltage supply fails. Having the controller (PLC, IPC) carry out the configuration of the Bus Terminals is a further option. The PLC or IPC uses function blocks (FB) to take care of the configuration of all the peripherals during the start-up phase. The controller can, if required, upload the non-centrally generated configuration data in order to manage and store them centrally. This means that it is not necessary to carry out the setting procedure again if a Bus Terminal is exchanged. The controller carries out the desired setting automatically after switching on.

The EK9300 series are Couplers which allow ELxxxx terminals to be used on the Profinet Fieldbus


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC DIP switch settings

DIP switches can be used to select different addressing options and assign the PROFINET name. The device is PROFINET-compliant if DIP switches 1-8 are off and DIP switches 9 and 10 are on. All other modes are available as options. PROFINET name via DIP switch

The name is formed from bk9103-xxx or ek9300-xxx. The xxx corresponds to DIP switch 1-8. "bk" and “ek” must be lower case. The EK9300 only supports DIP switch 9 and 10 ON and DIP switches 1-8 form both the last octet of the IP address and the ex tension of the device’s name. So if Switches 1, 2, 9, 10 are ON then the device name is EK9300-3 and the station address is 172.16.17.3 IF the Profinet I/O master subnet has been set to 172.16.17.1 for example. DIP 9 DIP 10

0

0

1

1

0

Description

Restart Behavior

Behavior with factory settings

Last byte of the IP address via DIP switches 1-8

- PN name from memory - IP address via DIP switches 1 - 8

- PN name becomes empty string - IP address via DIP switches 172.16.17.xxx (xxx DIP switch) SNM 255.255.0.0

DHCP DIP switches 1-8 set to "0"

- PN name from memory - IP address and SNM via DHCP

- PN name becomes empty string - IP address and SNM via DHCP - DNS name "bk9103-xxyyzz" xxyyzz last 3 bytes of MAC ID

DHCP DIP switches 1-8 not set to "0"

- PN name via DIP switches 1 - 8* - IP address and SNM via DHCP

- PN name via DIP switches 1 - 8 - IP address and SNM via DHCP - DNS name "bk9103-xxyyzz" xxyyzz last 3 bytes of MAC ID

BootP

- PN name from memory - IP address and SNM via BootP

- PN name becomes empty string - IP address via BootP

PROFINET-compliant

- PN name from memory - IP address from memory

- PN name becomes empty string - IP address 0.0.0.0

PROFINET with fixed name

- PN name via DIP switches 1 - 8* - IP address from memory

- PN name via DIP switches 1 - 8 - IP address 0.0.0.0

1

0

1

* The PROFINET name cannot be overwritten by the controller. PN - PROFINET SNM - SubNetMask DHCP - Dynamic Host Configuration Protocol DNS - Domain Name Server


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Addressing is assigned via the S7 controller except for the last octet which is controlled via DIP switches 1-8. Please note these DIP switches are only read on power up so if a change is made to the DIP switches the change doesn’t take ef fect until power is cycled to the coupler. Technical Data System Data

BK9103 and EK9300

Number of I/O modules

only limited by the IP address space

Number of I/O points

depending on controller

Data transfer medium

4 x 2 twisted pair copper cable; category 5 (100 Mbaud)

Distance between modules Transmission rate

100 m (between switch and Bus Coupler) 10/100 Mbaud

Topology

line or star wiring

Cascading

20 couplers over max. line length of 2 km (100m between couplers max)

Technical Data

BK9103

EK9300

Number of Bus Terminals

64 (255 with K-bus extension)

depends on the process data size

Digital peripheral signals

256 inputs/outputs


Analog peripheral signals

128 inputs/outputs


Protocol

PROFINET RT (TCP-ADS for access via Ethernet with KS2000 configuration software)

PROFINET RT

Configuration possibility

Via the KS2000 configuration software or the controller

Not required

Maximum number of bytes

512 bytes of input data and 512 bytes of output data


Bus connection

2 x RJ 45

Power supply

24 VDC (-15%/+20%)

Input current

70 mA + (total K-Bus current)/4

120 mA + (total E-Bus current)/4

Starting current Bus power supply up to

approx. 2.5 x continuous current 1750 mA

?? 2000 mA

Power contact voltage

maximum 24 VDC

Power contact current load

max. 10 A

Dielectric strength Recommended fuse

500 Vrms (power contact / supply voltage / fieldbus) <= 10 A

Dimensions (W x H x D)

49 mm x 100 mm x 75 mm

65 mm x 100 mm x 80 mm

Weight approx.

170 g

??

Operating temperature

32°F to +131°F (0°C... +55°C)

Storage temperature Relative humidity

-13°F to +185°F (-25°C... +85°C) 95 % no condensation

Vibration / shock resistance

conforms to EN 60068-2-6 / EN 60068-2-27, EN 60068-2-29

EMC resistance burst / ESD

conforms to EN 61000-6-2 / EN 61000-6-4

Installation pos.

variable

Protection class

IP20


Vertical (upright – not on side)

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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC From here on out the Step7 (Siemens software) screens will be used to demonstrate the setup and use of these two Beckhoff Profinet couplers: To start the Step7 software double click on the step7 ICON on your desktop

Or select it from Program Files

A Blank SIMATIC Manager opens (or whatever was last in the SIMATIC Manger the last time before it was closed)


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Make sure the version of Step7 software is version 5.4 or newer. If exactly version 5.4 then be sure service pack 5 is installed.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC From the MENU select File and New.

Enter a project name. In this example a long but descriptive descri ptive name was was used to indicate the hardware to be used used with this exercise. Press the OK button after after the project name has been entered.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The SIMATIC Manager screen should now look as shown below. There is a project but no PLC station.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Next – Next – must must set the programming Interface between the PC and the PLC (Set PG/PC Interface..) Go to the MENU and from the OPTIONS menu drop down select Set PG/PC Interface.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC All possible interfaces are scanned for and loaded


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Scroll through the listed interfaces and find the PC Adapter (MPI). Either double-click this item off the list or select the item on the list and press the Properties button. Either action gives the same result.

This is what the serial to MPI cable looks like


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC MPI Adapter close up view

Plug the long end of the cable to the programming computer’s serial port


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The MPI Side can be either 19.2KB, 187.5KB or 1.5MB between the MPI adapter to the PLCDP/MPI port

The default is 187.5 KB if the PLC is reset to factory defaults


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Station numbers to scan can also be set but the higher the number the longer you have to wait for the scan to complete. Stay with the lowest number of 15 stations unless you know the MPI of the PLC port you are trying to reach is higher than this.

There is the possibility there are several masters in a Siemens network. At the Beckhoff BUSA lab there is just the one PLC station so check the box this is the only master on the system. Leave the PG/PC address at 0 and leave the communication timeout at the default 30 seconds.

Choose the correct COM port for your computer and the baud rate to match the MPI RS232 port. The MPI adapter only supports 19.2 or 38.4 KB. There is a selector switch on the side of the MPI adapter. Make sure it matches the settings you select in software. At the BUSA lab the switch is normally set to 19.2 KB. You can check the checkbox for “Apply settings for all modules” but this is not necessary for communbcations to work. Press the OK button to accept this setup.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC A message “like” the one shown will appear. This message could be for changing from the ethernet port to the serial port or other selections being changed. In this case all that changed was the “path”.

The change from one interface to another is confirmed by the status box at the bottom of the Step7 screen showing what interface is being used to communicate with the Siemens CPU.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The local I/O rack can be uploaded saving the time to append in any of this nonBeckhoff hardware.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The MPI adapter is fixed at address 2. The Siemens PLC power supply takes up slot 0 and 1. The processor, at least in the Beckhoff lab, always sits at slot 2. This are why the numbers shown below are used.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC As soon as the 2 is ENTERED (must hit the ENTER key) for the MPI address the CPU name should appear in that row for the target. If the CPU name does not appear then a connection or setup of the interface is not right. Assuming everything is showing up properly, press the OK button to start the upload.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC If there are differences between what is being uploaded and the offline configuration, a message like the one below may show up. Just press the OK button and allow the upload to continue.

The SIMATIC Manager screen should now have the components shown in the picture below. You may have to open the tree view in the left as you do in the Beckhoff System Manager to see all the elements. Double-Click the icon to go to the hardware configuration screen.


Page 23

BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The hardware configuration screen shows only the local rack hardware in the top left window. In the bottom left window are the items found along with details about the address assignment to those devices. The right most window may or may not be on your screen right now. If it is not then need to goto the main menu and select view. From the view drop down select “Catalog” (or press Ctrl+K to toggle the catalog view active or not).


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Let’s explore the local rack for a moment. Double Click on the CPU in slot 2 to bring up the window shown below. These are all the properties of the PLC processor that can be viewed and/or changed. Do not make any changes. This is just a brief tour of what is possible.

Notice at the bottom of the screen how the SIMATIC Manager and the HW Config windows are both present. Each one is a separate module that can be viewed and worked with at the same time. At some point along the way in this presentation we will be jumping between these two windows to make certain changes to the programming envirement.


Page 25

BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Double Click on the MPI/DP in slot 2 ’s X1 connection port to bring up the window shown below. These are all the properties for the MPI/DP port that can be viewed and/or changed. Do not make any changes. This is just a brief tour of what is possible and to show the settings of a properly working system in case a comparison is needed. Each of the TABs will be opened again to show the settings of a working system for comparison to your system if it is not working properly. The General TAB:


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Subscreens burried under the General TAB for the MPI interface can be seen by pressing the Properties button on this popup screen:

There’s nothing that should need adjusting to any of these settings. We are just looking at all the possible windows that can be viewed from this location in the Step7 software. The Parameters TAB of the MPI interface is shown below.

Pressing the Properties button of MPI(1) goes to another sub window with more tabs. Shown below is the General TAB.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The network setting TAB. These are all settings we had matched to the MPI interface to do the initial upload of the local S7 PLC hardware.

Press cancel and then press cancel again to get back to this screen.

The MPI/DP Properties, General TAB, should now be the active window. Select the Addresses TAB.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The MPI/DP Addresses TAB:

The MPI/DP Operating Mode TAB:


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The MPI/DP Configuration TAB:

The MPI/DP Clock TAB:


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC There were a lot of sub screens in the MPI/DP properties and they were all reflecting the settings of the offline cofiguration for the MPI/DP port of the S7 CPU module. Lets move on to the port we are really interested in and does need setup – the Profinet port. Double Click on the PN-IO in slot 2’s X2 connection port to bring up the window shown below. These are all the properties for the Profinet port that can be viewed and/or changed. Each of the TABs will be opened and changes made to get a properly working Profinet system with the Beckhoff BK9103 and EK9300 couplers. In the below screen the interface is now ethernet as device 0 on the network with an IP address as shown of 192.168.0.2 and at this time ethernet is NOT networked. This is where the ethernet address of the CPU is set or changed. Press the Properties button for the ethernet interface to change the setup.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Now the IP address and subnet mask can be changed as needed for your situation. The BK9103 address switches are set to be station 3 and the EK9300 address switches are set to be station 4 so making the master start as station 2 in this case makes sense. Each new station added is incremented by one from the master’s starting address!

After setting the IP address and subnet mask press the NEW button in the subnet window area to create a Profinet network we can connect Beckhoff devices to.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The below popup window now appears with a generic name like “Ethernet(1)”. There is nothing magical about this name.

Just for fun let’s change the name to “BeckhoffOnProfinet”. Then press the OK button.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Now the subnet has a network name to attach itself to.

Pressing the New button again and the default name “Ethernet(1)” comes up as it did before. This time leave the name Ethernet(1) and press the OK button.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Now there are two named networks to choose from. Pick “BeckhoffOnProfinet” and press the OK button.

Ethernet is now networked in the general TAB.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC None of the other PN-IO screens need any changing but for the sake of completeness here are the other screens just to know what is on them: Addresses TAB -

PROFINET TAB -


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Sychronization TAB -

Time-of-Day Synchronization TAB -


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Double Click on Port 1 in slot 2 ’s X2 P1 as shown in the below window. These are all the properties for Port 1 that can be viewed and/or changed. Each of the TABs will be shown for completeness but none of these require any changes from the default values to get the Beckhoff couplers on the Profinet network. General TAB -

Addresses TAB -


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Topology TAB -

Options TAB -


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC There’s nothing of interest about the local Siemens I/O cards. It’s time to get moving on the Beckhoff hardware! Right-Click on the PN-IO row in the top left window and from the popup menu that appears select “Insert PROFINET IO System”.


Page 40

BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The screen should now show a profinet network as seen below.

Double-Click on the Profinet network line. The gneral TAB is shown. Pressing the Properties button on this screen brings up a screen we have already worked with and don’t need to be concerned with further.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC No changes need to be made to the update time TAB to get Beckhoff couplers added to the Profinet network. The Update Time TAB -

The catalog should be shown on the far right side of the hardware configuration screen As shown below. Beckhoff hardware will also be chosen form this tree of devices.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC If the hardware catalog is not being shown go to the menu item “View” and select the catalog (or press Ctrl+k).

Expand the tree view under Profinet IO


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC If there are no Beckhoff couplers in the “Additional Field Devices” folder then the GSDML for these devices must be installed and added to the Siemens hardware catalog. Go to the menu item “Options” and select Install GSD File from the drop down menu items.

The GSDML files need to be copied to the C:\Program Files\Siemens\Step7\S7TMP folder.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Get GSDML files for the couplers from the Beckhoff website: http://www.beckhoff.com/english/download/bkconfg.htm?id=71003277100522 The BK9103 coupler being tested in this case was a new BK9103 with B7 firmware in it so the correct GSDML file need to be downloaded and put in the Step7 folder.

The EK9300 GSDML file is still under development. There is a copy of this file that provides limited functionality for simple digital and some analog terminals. Here are the needed files embedded in this word document.

GSDML-V2.2-beckhoff-EK9300-20110526.xml


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Select the Beckhoff GSDML files to install and then press the install button. A popup message appears to ask for conformation. Press the YES button.

The installation progress bar should proceed with no incident until each GSDML is installed.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC If the GSDML file name is found in the existing installed GSDML files progress of the current installation will stop and this message will popup. The older GSDML is not lost. It is copied to a backup location shown in the popup window when you press the YES button to proceed.

This should be the last message you get during the installation – Installation completed successfully.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC It’s a very good idea to update the hardware catalog before looking for the newly installed Beckhoff I/O couplers and I/O. To do this, go to the menu item “Options” and from the drop down menu select “Update Catalog”. If the catalog tree view is open the tree will colapse and then re-open as this update takes place.

Now expand the Profinet IO tree to see the items below it. Expand Additional Field Devices. Expand I/O. Now the BK9103 and EK9300 folders should appear as see below.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Expand the BK Device folder and there are two versions of the BK9103 coupler. They both work fine. The version 2.1 just has a couple of extra diagnostic registers for the coupler’s Port 1 and Port 2 being passed to Profinet. For this example pick the BK9103 PROFINET I/O V2.0 by holding down the left mouse button and dragging this item to the BeckhoffOnProfinet network line. When you drag it over on the line the “+” symbol appears on the screen indicating the object may be “Dropped” at this location. Release the left mouse button to drop the BK9103 rack on the Profinet network line when you see that “+” symbol being shown.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The Profinet network should now have the BK9103 icon hanging from the network line.

Click on the BK9103 icon just created on the Profinet network. The bottom left window shows the details of the BK9103 I/O rail. As of now there is just the coupler. The next task is to make sure the coupler is setup correctly and then add the I/O terminals that are physically associated with this coupler.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The coupler in this example has been set for ethernet station number of 3 and switches 9 and 10 are also both ON. So the coupler name must also include the station address: “bk9103-3”.

Double-Click the BK9103 I/O rack and the below window appears. The Device Name must be changed to “bk9103-3” as shown. Make the Device number 3 to match. The IP address must be 192.168.0.3 for this example. Since the master was at 192.168.0.2 this node automatically added itself correctly as 192.168.0.3 in the general TAB.

In the I/O Cycle TAB the update time may be adjusted. Just leave it at the default settings for this example and press the OK button to close this window (OK button is not shown in the picture below to save space). BK9103 EK9300 on S7 PLC

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Now that the coupler is setup its time to add the I/O terminals. For the example I/O terminal rail there is only a KL2012 and a KL1104. The KL9010 does not generate any process image so it doesn’t have to be added in the Step7 hardware configuration.

There are no I/O terminals added below the BK9103 yet but the setup of the BK9103 now shows it has the correct settings for the coupler.


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Open the Digital Outputs (KL2xxx) folder

The digital outputs (KL2xxx) folder does not contain every possible Beckhoff part number specifically – but all possibilities are being represented. Some are represented BK9103 EK9300 on S7 PLC

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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC by generic types like the KL2012 we need to match for this example. Select the Kx2xx2. This is a digitial output with two bits in the process image so this will work with ANY Beckhoff output terminal that has two outputs (not just the KL2012 specifically)

Once the Kx2xx2 is selected the area under the “bk9103 -3” in the lower left window turns green and specifically dark green where the next device can be placed. You can drag the Kx2xx2 device to that location in dark green OR just double click it and the Kx2xx2 will be put in the location of the darker green row. The darker green row then moves down by one row automatically.

Close the Digital Outputs (KL2xxx) folder. BK9103 EK9300 on S7 PLC

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Expand the Digital Inputs (KL1xxx) folder. As with the digital inputs (KL1xxx) folder does not contain every possible Beckhoff part number specifically – but all possibilities are being represented. Some are represented by generic types like the KL1104 we need to match for this example. Select the Kx1xx4. This is a digitial input with four bits in the process image so this will work with ANY Beckhoff output terminal that has four inputs (not just the KL1104 specifically) Once the Kx1xx4 is selected the area under the “bk9103 -3” in the lower left window turns green and specifically dark green where the next device can be placed. You can drag the Kx1xx4 device to that location in dark green OR just double click it and the Kx1xx4 will be put in the location of the darker green row. The darker green row then moves down by one row automatically as before.

The BK9103 I/O is now complete and should look as seen below.

If you wish BK9103 EK9300 on S7 PLC

to change the Page 55

BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC I/O address of say the KL2012 output in Siemens Double-click the row with the Kx2xx2 in slot one of the bk9103-3. The properties window pops up and usually goes to the general TAB.

Select the addresses TAB instead.

The output currently is addressed at Q2.0 and Q2.1 in the Siemens PLC. The starting byte may be changed. For this example we will be leaving at all the I/O at the locations the software simple auto selected when the I/O was added. Just cancel out of this window.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Colapse the BK Devices folder. Expand the EK Device folder and there are two versions of the EK9300 coupler. They both work fine. The version 2.2 just has a couple of extra diagnostic registers for the coupler’s Port 1 and Port 2 being passed to Profinet.

For this example pick the EK9300 V2.0 by holding down the left mouse button and dragging this item to the BeckhoffOnProfinet network line. When you drag it over on the line the “+” symbol appears on the screen indicating the object may be “Dropped” at this location. Release the left mouse button to drop the EK9300 rack on the Profinet network line when you see that “+” symbol being shown. Your screen should now appear as shown below.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The EK9300 coupler in this example has been set for ethernet station number of 4 and switches 9 and 10 are also both ON. So the coupler name must also include the station address: “ek9300-4”. The address switches 1-8 determine the station address as a binary number. If Sw1 were ON for example this is 2 0 power or the value 1. Since we want station 4 Sw3 is ON so 2 2 power or value of 4.

Double-Click the EK9300 I/O rack and the below window appears. The Device Name must be changed to “ek9300-4” as shown. Make the Device number 4 to match. The IP address must be 192.168.0.4 for this example.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC In the I/O Cycle TAB the update time may be adjusted. Also, the number of cycles missing I/O data may be selected to determine the watchdog timeout period. Just leave everything at the default settings for this example and press the OK button to close this window (OK button is not shown in the picture below to save space).

Now that the coupler is setup its time to add the I/O terminals. For the example I/O terminal rail there will be the terminals shown in the picture below.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC There are no I/O terminals added below the EK9300 but the setup of the EK9300 now shows it has the correct settings for the coupler.

Open the Digital Outputs (EL2xxx) folder. There a lot a lot fewer device folders as the EK9300 is still in development. Only simple digital and analog terminals will function correctly at this time (as of June 2011).


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Expand the digital output terminals (ELxxxx) folder. Select slot 1 under the ek9300-4. Select the EL2002. The area under the “ek9300-4” in the lower left window turns green and specifically dark green where the next device can be placed. You can drag the EL2002 device to that location in dark green OR just double click it and the EL2002 will be put in the location of the darker green row. The darker green row then moves down by one automatically.

The dark green is now at slot 2 and the EL2002 appears in the listing of devices so far As shown below.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Continue this procedure for the next terminal by closing the digital outputs folder and opening the digital inputs folder and then double-clicking the EL1014 terminal. The configuration should now appear as shown below.

The next device is the bus extender terminal – EK1110. This device is found in the system terminals folder.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC After double-clicking the EK1110 the hardware configuration should now appear as shown below.

Next comes the EK1100 EtherCAT coupler. Collapse the system terminals folder and open the system couplers folder.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC After double-clicking the EK1100 coupler the hardware configuration should now appear as shown below.

Next comes the following remaining terminal. Colapse the system couplers folder and open whichever folder applies to the type of terminal to be added next. Add the following terminals to the hardware configuration: EL2022 (Digital outputs folder EL2xxx) EL1004 (Digital inputs folder EL1xxx) EL1114 EL4008 (Analog outputs folder EL4xxx) EL3102 (Analog inputs folder EL3xxx) EL3102


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The hardware configuration should now appear as shown below when all the terminals have been added. Unlike the KL terminals where process image size is all that matters, for the EL terminals each has an identity via the ASIC inside the terminal so each terminal is specifically called out.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Download the hardware configuration to the actual CPU via ethernet. The last time we did the upload is was via the serial MPI cable. To change the interface to the PLC we need to return to the SIMATIC Manager screen which is still open. From the menu on this screen select “Options” and from the drop down select “Set PG/PC Interface”

All the interfaces load before the list of choices is presented.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Pick the item on the list that represents the ethernet port for the computer programming station.

Either double-click or press the Properties button after selecting the TCP/IP network card. Now press the Network Properties button on this popup screen.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC This screen now pops up and should look very familiar. It’s the same network connections window you get to from windows. In the case of the computer being used for this example the built in local area connection is the port being used.

Right-click on the Local Area Connection to the the pop up menu shown below and select the Properties menu item.

Scroll down to the Internet Protocol (TCP/IP), pick that item by left clicking on it, and then press the Properties button on this screen.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The IP address must be a fixed address. In this example we need to be on the same subnet of 192.168.0.x and the same subnet mask of 255.255.255.0 Please enter the numbers as shown in the example below and press the OK button.

This screen appears again. Press the “Close” button to accept the changes to the IP address.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC It takes the computer a variable amount of time to make this change. It usually feels like quite a long time! Wait for it to get done – the network connection screen should be the top window again after the change is complete. Just close this window.

Now this screen is on top again. Press the OK button.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Finally we are back to the screen we started on to pick the TCP/IP network card as the programming interface. Press the OK button.

A warning pops up after pressing the OK button to let you know the interface is going to change to the ethernet network card. Just press OK.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC At the very bottom of the screen and a little to the right is the indication of the the interface being used. Your screen should look as shown below.

Now switch back to the harware config screen which should still be open. If the window got closed just double-click the icon to go to the hardware configuration screen. From the HW Config menu under the PLC drop down select “download”


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC This popup window appears after selecting the download. Since this is not a network with many stations on it the only choice is the correct one. Just press the OK button.

The following popup message will occur if the PLC “was” running prior to this download. This is a last chance to let you know the PLC is going to STOP if you continue. If this were a real running machine this would be a good time to be sure the coast is clear from the operators before continuing. If it is OK to stop the PLC then press the OK button.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC When the download is complete another popup message appears to ask if it is OK to go back to the start or complete restart mode (basically go back to running the PLC program). Press the YES button. If the coast is clear around a real machine – then press the YES button.

It’s time to test some real I/O and prove the Beckhoff couplers and I/O on Profinet is working.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC In the upper window with the two Beckhoff Profinet nodes shown just click on the bk9103-3 node. The lower window changes to the I/O terminals on that coupler. Right click on the Kx2xx2 terminal and you should get the popup window shown below. Choose Monitor/Modify.

On the monitor modify window are the physical addresses of the KL2012 terminal. BK9103 EK9300 on S7 PLC

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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC In the “run conditionally” area of the window check the checkbox for Monitor. The status area of the table will now display the state of the outputs. Put a 1 or 0 or a true or false in the modify value box and press enter. These values are only written out when the “Modify Value” button is pressed.

Using the Monitor Modify window to test digital ouputs: BK9103 EK9300 on S7 PLC

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1. 2. 3. 4. 5.

Check the Modify box The RUNNING scroll bar shows data exchange by continuously scrolling Put 1 or true in the boxes to turn ON outputs The outputs do not change state until the Modify Value button is pressed The status of the outputs is displayed and matches matches the real world outputs


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Turn the second output OFF OFF and press the Modify button. The status shows the actual output is in fact OFF.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Turn off both outputs and press the Modify button. Uncheck the Monitor Monitor button. Press the Close button to leave this screen. If we left the outputs ON and leave this screen the outputs simply remain in the last state and stay ON.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Moving on to digital inputs, right-click the Kx1xx4 input and select Monitor/Modify from the popup menu.

For inputs, just check the monitor checkbox and flag inputs to see the state changes in the PLC. The RUNNING bar scrolls continuously when monitoring is turned on.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Flagging inputs 1 and 2 ON gives the results shown below.

This completes the I/O on the BK9103 Profinet coupler. There is considerably more I/O on the EK9300 coupler to examine. Uncheck the modify checkbox and close the Monitor/Modify window.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC In the top left section of the screen select the ek9300-4 icon and notice how the lower left window changes to show the I/O for the EK9300 coupler.

Right-click the EL2002 terminal and select Monitor/Modify.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The first thing to notice with the EK9300 coupler is this is not a released firmware yet so there are many definitions that either don’t exist or are not fully developed. The EL2002 for instance only has two bits to define the two outputs yet the monitor modify screen shows an entire byte. Only the Q3.0 and Q3.1 outputs will turn on physical outputs on the real world terminal.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Even if those “other” ouputs are ON, they don’t map to the physical device and nothing changes on the physical EL2002 terminal.

Please turn OFF all the outputs. Press the modify button to actually turn the outputs OFF. Uncheck the monitor checkbox. Then, press the close button to leave this window.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Right-click and select Monitor/Modify for the EL1014 terminal.

As for the outputs, an entire byte of data is shown but the real world input are only I1.0 to I1.3


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Channels 3 and 4 on the EL1014 have been flagged ON as the LEDs of that terminals clearly show.

Other mapping issue now show up. Only I1.2 and I1.3 should be on but the bits I1.6 and I1.7 are also on even though they have no meaning to the real world input terminal and should be ignored. Once the EK9300 coupler’s firmware is completed tested issues like this would not be expected.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC If the flagged inputs are changed to only channel 1 and 2 then we see the results in the below picture.

Everything appears normal in this case with only the expected inputs turned ON.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC One last test with all 4 inputs flagged and as you see below from the LEDs this is the case on the actual terminal.

As expected I1.0 through I1.3 are ON and as before the I1.6 and I1.7 inputs are ON but don’t relate to the physical terminal in any meaningfull way. Just disregaurd these bits. Uncheck the monitoring checkbox and close this monitor/modify window.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC There is no I/O data in the EK1110 bus extension or the EK1100 bus coupler so they will not allow the Monitor/Modify menu item to be selected.

The terminals on the EK1100 coupler:


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Beyond the bus extension, right-click on the EL2022 and choose monitor modify.

Check the monitor checkbox. Set the first output to TRUE or enter a 1. Press the modify button.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC As seen in the below picture the first output channel of the EL2022 is ON.

Turning ON all the outputs is still only going to affect the first two channels.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Turn OFF all the EL2022 outputs. Press the modify button. Close the monitor modify window. Right-click the EL1004 and select Monitor/Modify for that terminal.

Check the Monitor checkbox. The RUNNING bar scrolls continuously when monitoring is turned on.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Channel 2 of the EL1004 is flagged and this is exactly as it appears in the PLC.

Flag all 4 channels.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC As before with the EL1014 terminal. When all 4 channels are flagged not only does the 3rd and 4 th input turn ON I2.2 and I2.3 - but also I2.6 and I2.7 even though they are not physically related to the terminal. Just ignore these bits.

Close the EL1004 monitor/modify window.

Right-click the EL1114 and select Monitor/Modify for that terminal. Check the monitor checkbox after the window opens.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Flag all the inputs of the EL1114.

All the 4 channel digital input terminals have done exactly the same thing in the PLC. Channel 3 and 4 also turn ON bit 6 and 7 even though these bits have no meaning to the physical terminal.

Close the EL1114 monitor/modify window. BK9103 EK9300 on S7 PLC

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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Right-click on the EL4008 0-10VDC analog output terminal and select monitor/modify.

For the analog outputs things are pretty much the same as the digital points. Check the monitor checkbox. Enter an analog output value in HEX with the high/low bytes in reverse order. So where 3FFF hex is 16383 in decimal which is the halfway point so 5VDC output, it must be entered in the PLC modify value box as 16#FF3F. Then press the modify button. The PLC adds the W, for word, after the value is entered.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Since the EL4008 uses all 8 connection points for the 8 analog outputs the DC common must be referenced from a terminal that has a 0VDC connection point – in this case pin 7 of the EL2022 terminal.

Now modify the output for the full 10VDC output – so 32767 counts in decimal and 7FFF in hex. In reverse order for the byte swap this means entering 16#FF7F. The PLC adds the W, for word, when you press the enter key. Press the modify button.


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Finally, modify the output for the 0VDC output – so 0 counts or 0 hex (decimal and hex are the same from 0 – 9). No reverse order is required in this case. Just type a 0 in the Modify value box and press enter. The PLC adds the W#16#0000 when you press the enter key but this is still the value 0 in decimal. Press the modify button.


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Set the remaining channels as shown and then press the Modify button.


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For the remaining channel settings we get the following readings from the voltmeter: CH2: Ouput 3FFFh is 16383d so 50% of 10VDC or 5.0VDC: meter reads 4.98VDC CH3: Ouput 1FFFh is 8191d so 25% of 10VDC or 2.5VDC: meter reads 2.49VDC CH4: Ouput 2FFFh is 12287d so 37.5% of 10VDC or 3.75VDC: meter reads 3.74VDC CH5: Ouput 3FFFh is 16383d so 50% of 10VDC or 5.0VDC: meter reads 4.98VDC CH6: Ouput 4FFFh is 20479d so 62.4% of 10VDC or 6.25VDC: meter reads 6.22VDC CH7: Ouput 5FFFh is 24575d so 75% of 10VDC or 7.5VDC: meter reads 7.47VDC CH8: Ouput 6FFFh is 28671d so 87.5% of 10VDC or 8.75VDC: meter reads 8.72VDC

For the analog inputs, right-click on the EL3102 terminal and select monitor/modify. Make sure and check the monitor checkbox.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC Using a process calibrator to input 5VDC.

The value is bouncing coming back in the PLC so 3 random screen shots were taken of the input value which in an ideal world is expected to be 3FFF at 5VDC.

1. 3FDD is 16349: 16349 / 32767 = 0.4989 of 10V = 4.989 VDC 2. 3FD5 is 16341: 16341 / 32767 = 0.4987 of 10V = 4.987 VDC 3. 3FD1 is 16337: 16337 / 32767 = 0.4986 of 10V = 4.986 VDC The average is 4.9873 VDC which is within 99.75% of the desired value of 5 VDC.


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BK9103 and EK9300 Profinet Fieldbus Couplers on S7 PLC The calibrator is now set to 10VDC into the analog input.

The value is bouncing so 3 random screen shots were taken of the input value which in an ideal world is expected to be 7FFF at 10VDC.

1. 7FCD is 32717: 32717 / 32767 = 0.9985 of 10V = 9.985 VDC 2. 7FCE is 32718: 32718 / 32767 = 0.9985 of 10V = 9.985 VDC 3. 7FCB is 32715: 32715 / 32767 = 0.9984 of 10V = 9.984 VDC The average is 9.9847 VDC which is within 99.85% of the desired value of 10 VDC.


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BK9103_EK9300_6-30-11

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