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Helmholz TB20 Manual

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TB20 – Energy Meter
Manual
Version 0.8 / 2/5/2016 for HW1-1 & FW 1.00.004 and higher
Manual order no.: 960-255-7AA21/en
Systeme Helmholz GmbH | Hannberger Weg 2 | D-91091 Großenseebach
Phone +49 9135 7380-0 | Fax +49 9135 7380-110 | info@helmholz.de | www.helmholz.com

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  • Page 1 TB20 – Energy Meter Manual Version 0.8 / 2/5/2016 for HW1-1 & FW 1.00.004 and higher Manual order no.: 960-255-7AA21/en Systeme Helmholz GmbH | Hannberger Weg 2 | D-91091 Großenseebach Phone +49 9135 7380-0 | Fax +49 9135 7380-110 | info@helmholz.de | www.helmholz.com...
  • Page 3 (photocopy, microfilm, or any other methods), even for training purposes or with the use of electronic systems, without written approval from Systeme Helmholz GmbH. All rights reserved in the event of the granting of a patent or the registration of a utility model.

  • Page 4: Table Of Contents

    1.6.8 Exclusion of liability ....................9 1.6.9 Warranty ........................9 System overview ................10 General ........................10 The components of the TB20 I/O system ..............10 2.2.1 The bus coupler ........................ 10 2.2.2 Peripheral module ......................10 2.2.3 Power and isolation module ..................... 12 2.2.4...
  • Page 5 Using the Energy Meter with STEP7 ................ 54 Measuring connections ..............55 Specific safety instructions ..................55 Measuring procedures ....................56 7.2.1 Measuring values ......................57 7.2.2 Diagnoses .......................... 57 7.2.3 Power measurement at a consumer 3-phase ..............58 TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 6 Power base module ......................78 11.2 Front connector ......................79 11.2.1 Front connector, 10-pin ....................79 11.2.2 Front connector, 20-pin ....................79 11.3 Electronic modules ....................79 11.4 Final bus cover ......................79 TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 7: General

    Configuration, execution, and operating errors can interfere with the proper operation of the TB20 devices and result in personal injury as well as material or environmental damage. Only suitably qualified personnel may operate the TB20 devices!

  • Page 8: Note Symbols And Signal Words In The Manual

    If the hazard warning is ignored, people can be injured or harmed. Draws attention to sources of error that can damage equipment or the environment. Gives an indication for better understanding or preventing errors. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 9: Intended Use

    Communication with a higher-level control system is via a bus system / network and a TB20 bus coupler. Up to 64 modules from the TB20 range can be set up on a bus coupler. The bus couplers support hot-plugging for replacing modules during ongoing operation.

  • Page 10: Installation

    Observe the regional safety regulations. TB20 devices can be equipped with modules that can carry dangerously high voltages. The voltages connected to the TB20 devices can result in hazards during work on the TB20 devices. 1.6.3 Protection against electrostatic discharges...

  • Page 11: Operation

    Retrofits, changes, or modifications to the device are strictly forbidden. The TB20 is an operating means intended for use in industrial plants. During operation, the TB20 can carry dangerous voltages. During operation, all covers on the unit and the installation must be closed in order to ensure protection against contact.

  • Page 12: System Overview

    System overview General information The TB20 I/O system is an open, modular, and distributed peripheral system designed to be mounted on 35 mm DIN rails. It is made up of the following components: • Bus couplers • Peripheral modules •...

  • Page 13: Power And Isolation Module

    (see section 2.2.4). Power and insulation modules have a lighter body color. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 14: Power Module

    The “TB20 ToolBox” configuration program can be used to determine whether power modules are needed, as well as how many of them will be needed.

  • Page 15: Final Bus Cover

    The final bus cover protects the contacts on the last base module from accidental contact by covering the outer right-hand side of the base module. 2.2.6 Components in a module Each module consists of three parts: • Base module • Electronic module • Front connectors TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 16: Module Coding

    (Digital In, Digital Out, Analog In, Analog Out, and Power) from the TB20 system. It will only be possible to plug an electronic module into a base module if the position of the coding plug and the position of the coding socket match.

  • Page 17: Installation And Removal

    Insulation must be carried out according to VDE 0100/IEC 364 and performed in accordance with applicable national standards. The TB20 IO system has protection rating IP20. If a higher protection rating is required, the system must be installed in a housing or control cabinet. In order to ensure safe operation, the ambient temperature must not exceed 60 °C.

  • Page 18: Installing And Removing Peripheral Modules

    Finally, place the front connector on the electronic module from below in an inclined position and then gently push it onto the electronic module until the front connector fastener snaps into place with a soft click. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 19: Removal

    To remove the front connector, push the tab above the front connector upwards (see the picture below). This will push out the front connector, after which you can pull it out. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 20 To remove the electronic module, use your middle finger to push on the lever from above and then use your thumb and index finger to pull out the electronic module while holding the lever down (see the picture below). TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 21 Step 3: Release the base module Use a screwdriver to release the base module by turning the locking mechanism 90° counterclockwise. Step 4: Remove the base module Remove the base module by pulling it towards you. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 22: Replacing An Electronic Module

    TB20 modules can carry lethal voltage. Before starting any work on TB20 system components, make sure to deenergize all components, as well as the cables supplying them with power! During work when the system...
  • Page 23 To remove the electronic module, use your middle finger to push on the lever from above and then use your thumb and index finger to pull out the electronic module while holding the lever down (see the picture below). TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 24 The electronic module must be snapped into place on the base module with a single continuous movement. If the electronic module is not snapped into place firmly and straight on the base module, bus malfunctions may occur. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 25 For more information on coding elements, please consult section 2.2.7. Step 4: Plug in the front connector TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 26: Installing And Removing The Coupler

    Step 2: Secure the coupler on the DIN rail Use the locking lever on the left side of the coupler to lock the coupler into position on the DIN rail. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 27: Removal

    Step 2: Remove the coupler Use your middle finger to push on the lever from above and use your thumb and index finger to pull out the coupler while holding the lever down. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 28 Step 3: Release the base module Use a screwdriver to release the base module. Step 4: Remove the base module Remove the base module by pulling it towards you. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 29: Installing And Removing The Bus Cover

    3.6.2 Removal Pull the final bus cover along the module’s case and away from the DIN rail in order to remove it from the module. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 30: Configuration/Wiring

    Configuration/wiring EMC/safety/shielding The TB20 IO system complies with EU Directive 2004/108/EC (“Electromagnetic Compatibility”). One effective way to protect against disturbances caused by electromagnetic interference is to shield electric cables, wires, and components. When putting together the system and routing the required cables, make sure to fully comply with all standards, regulations, and rules regarding shielding (please also consult the relevant guidelines and documents published by the PROFIBUS User Organization).

  • Page 31: Front Connector

    1.5 mm² per terminal is not exceeded. The cables can be attached to the underside of the front connector with a cable tie. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 32: Wiring The Coupler

    The coupler and the modules are grounded via the shield contact to the DIN rail. The DIN rail must be grounded. The surface of the DIN rail must be clean and conduct electricity well. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 33: Using Power And Isolation Modules

    Its electronic module and base module have the same light gray color as the front connector, ensuring that all power and isolation modules will stand out visually in the system and make it easy to clearly distinguish each individual power supply segment. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 34: Separate Power Supply Segments For The Coupler And The I/O Components

    If the power supply for the coupler needs to be separate from the power supply for the I/O modules, a power and isolation module can be used right after the coupler. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 35: Using Power Modules

    The “TB20 ToolBox” parameter configuration and diagnosis program can be used to calculate a system’s total current draw.

  • Page 36: Function Of The Ok-Led

    This information can be read in a number of ways, one of which is using the “TB20 ToolBox” configuration and diagnosis program. The modules’ electronic nameplates not only make it possible to prevent configuration errors (setup), but also make maintenance (servicing) easier.

  • Page 37: Dimensions

    4.10 Dimensions TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 38: Tb20 - Energy Meter

    1 or 3-phase network up to 400 V AC. The energy measuring values are forwarded to the internal bus of the TB20 system and can be read out over the available TB20 bus couplers by the master control. The TB20 Energy Meter can be operated as an individual module or in combination with additional Energy Meter and I/O modules on the TB20 bus coupler.

  • Page 39: Functions Of The Energy Meter

    Output current of the current transformer Current/voltage gain (PGA) Configurable Zero transition timeout Configurable Overvoltage / undervoltage limit values Configurable Diagnostics Zero transition timeout (missing phase) Incorrect phase sequence Invalid parameter, false parameter length TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 40: Pin Assignment

    5.2.2 Pin assignment Terminal Assignment Terminal Assignmen TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 41: Leds Of The Energy Meter

    IDLE mode (quickly flashing blue LED) indicates modules that have not been added to ongoing system operation by the coupler. One of the reasons that can cause this is an incorrect configuration (wrong module model in the slot). TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 42: Commissioning

    The Energy Meter is configured using the user program of the bus master, see chapter 8, when using the following couplers: • PROFIBUS • PROFINET The Energy Meter is configured using the TB20 ToolBox when using the following couplers: • ® CANopen • EtherNet/IP •...

  • Page 43: Installing Tb20 Toolbox

    Tools. TB20 ToolBox runs on Windows* 7, 8, 8.1, 10. A cable with USB 2.0 A plug to USB Mini B plug is required for communication with a TB20 bus coupler. The Helmholz USB driver must be installed once on the computer under Windows* 7, 8, 8.1.

  • Page 44: Configuration Of The Energy Meter In A Project

    The Energy Meter is found under Analog input modules. Select the Energy Meter appropriate for the current transformer and the mode and insert it with a double-click or drag and drop. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 45 Name of the module according to the catalog • Order number according to Helmholz catalog • Comment Free comment text of the user A print template can be created for the module label. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 46 The diagnostics are also initiated when no voltage is present. • Primary current Primary current of the current transformer used • Secondary current Secondary current of the current transformer used TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 47 - The phase shift L1- L2 - L3 is tested and configured diagnostics are initiated in the event of errors. • Phase angle measurement Phase angle between the voltages or between voltage and current or between the currents TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 48 The diagnostics of zero crossing can be activated. • Diagnostics of overvoltage The diagnostics of overvoltage can be activated. • Diagnosis of undervoltage • Diagnostics of overcurrent The diagnostics of overcurrent can be activated. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 49: Diagnosis Of The Energy Meter

    Display of errors detected by the Energy Meter The messages of the measuring channels are displayed: Channel 0 = Phase L1 Channel 1 = Phase L2 Channel 2 = Phase L3 TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 50 Phase angle error correction Phase x configured value • Diagnostics for zero crossing active/inactive • Diagnostics for overvoltage active/inactive • Diagnostics for undervoltage active/inactive • Diagnostics for overcurrent active/inactive • Energy meter gate active/inactive TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 51 Load value of current value QB4 - QB7 • Display of process value 1 … 7 current values IB4 - IB7 • Display of process value index 1 … 7 current values QB8 - QB14 TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 52: Reading The Measurement Values Without A Connection With The Bus Master

    Reading the measurement values without a connection with the bus master With the simulation via the TB20 ToolBox it is possible to configure and test a TB20 installation without a connection with a bus master and thus also without a user program.
  • Page 53 The operating mode must be set in the Energy Meter configurator and cannot be changed in the simulation. Display of process values: Possible to read out measuring values without CPU TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 54: Using The Energy Meter With Plcs

    Using the Energy Meter with PLCs Depending upon the coupler type, the Energy Meter can be parameterized with the TB20 ToolBox or with coupler-specific methods. The data exchange with the Energy Meter is described in chapter 9. For configuration see chapter 8.

  • Page 55: Measuring Connections

    Risk of injury by electric shock and damage to the device possible! The Energy Meter carries potentially fatal voyage. Set the TB20 system to a safe, deenergized state before starting with the installation, disassembly or wiring of the connection terminals! Note the applicable occupational safety regulations for carrying out work on live components.

  • Page 56: Measuring Procedures

    Reactive energy Capacitive (-) Active energy Active energy Active energy Active energy Reference (+) Delivery (-) Delivery (-) Reference (+) Assignment of the active and reactive energy in the 4 quadrants TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 57: Measuring Values

    Value can be configured • Overcurrent Diag-ID: 22 Value can be configured The diagnostics on the Energy Meter can be switched on or off for each measurement channel when configuring the operating mode. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 58 The voltage measurement takes place via the connections UL1, UL2, and UL3. The current measurement takes place with the three current transformers via the connections IL1, IL2, and IL3. All values can be measured or calculated, see Process values index, page 67. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 59 In the case of a grounded neutral conductor and a negligible load on the grounding path, the neutral conductor connection of the Energy Meter can be grounded (functional ground FG). All values can be measured or calculated, see Process values index, page 67. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 60 The voltage measurement takes place via connection UL1. The current measurement takes place with a current transformer via the connections IL1 + IL-. All values for phase L1 can be measured or calculated, see Process values index, page 67. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 61 Apparent/active/reactive energy can be determined for each phase individually, and thus also for three isolated consumers. The consumers can be connected to any phases. All phases must have the same frequency. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 62 The current measurement takes place with three isolated current transformers via the connections IL , IL , and IL for three isolated loads. The loads can be connected to any phase. All phases must have the same frequency. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 63 Par 19 Par 20 Process value 3 Index Par 21 Process value 4 Index Par 22 Process value 5 Index Par 23 Process value 6 Index Par 24 Process value 7 Index TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 64 Par 43 Par 44 Process value 3 Index Par 45 Process value 4 Index Par 46 Process value 5 Index Par 47 Process value 6 Index Par 48 Process value 7 Index TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 65: Parameters

    Default: 2800 [0.1V] (1-4000) value this voltage is exceeded. 1A: Default: 100 [0.01A] (1-65535) Overcurrent threshold Diagnostics are initiated when value this current level is exceeded. 5A: Default: 500 [0.01A] (1-65535) TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 66 "0" with "Load energy value" and "Save energy values". In the case of reconfiguration, the energy values return to the most recently saved status. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 67: Process Values Index

    ** The power factor PF serves to represent the type of load. Only the amount of active power (P) is incorporated into the calculation. The energy flow direction remains unconsidered. The sign of the power factor is positive for inductive load and negative for capacitive load. TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 68 Data exchange between the master and the Energy Meter The user must program function modules in the master control program for operation of the Energy Meter behind a TB20 bus coupler. The master writes data into the outputs and reads data from the inputs of the bus coupler.
  • Page 69 Phase L1 Load Accept Save energy Meter gate Meter gate Meter gate apparent QB 1 process values L3 On/Off L2 On/Off L1 On/Off energy values Phase L3 QB 2 QB 3 TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 70 '1'. The bit can now be deleted again. Accept process values: The process value indexes from the output interface are activated with this bit and displayed in the input reproduction. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 71: Read Out Process Values With The Toolbox

    Read out process values with the ToolBox All energy values can also be displayed without a connected master control with the help of the TB20 ToolBox. The Energy Meter must be configured and the coupler must run in simulation mode; see chapter 6.1.4.

  • Page 72: Read Out Process Values With The Master Control

    • additional cycles with other index values Thanks to the cyclical query, 7 permanently configured process values can be periodically read out or any 7 process values cyclically, see chapter 8.1.4. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 73: General Technical Specifications

    UL pending Standards and guidelines Interference immunity: DIN EN 61000-6-2 “EMC Immunity” Interference emission: DIN EN 61000-6-4 “EMC Emission” Vibration and shock resistance DIN EN 60068-2-8:2008 "Vibration" DIN EN 60068-27:2010 "Shock" TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 74: Current Transformer

    [VA] [VA] 0.02 0.04 0.09 0.18 0.35 0.01 0.03 0.06 0.12 0.23 Table: Standard values for the cable apparent power (VA) as a function of the cable length and the cross-section TB20 – Energy Meter | Version 1 | 04.03.2016...
  • Page 75 Deenergize the current paths in which the connected current transformers are operated before working on the Energy Meter! Note the regulations for use of the current transformer manufacturer! Exception: Current transformer with internal load impedance and overvoltage protection (electronic current transformer). TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 76: Spare Parts

    The 14 mm standard base module is available in sets of five with order no. 600-900-9AA01. 11.1.2 25 mm width base module The 25 mm standard base module is available in sets of five with order no. 600-900-9AA21. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 77: 11.1.3 Power And Isolation Base Module

    11.1.4 Power base module The power base module is available in sets of five with order no.600-900-9CA01. It can be used with the power module (600-700-0AA01) and with all bus couplers. TB20 – Energy Meter | Version 1 | 04.03.2016...

  • Page 78: Front Connector

    Electronic modules are always sent as a complete assembly, including the corresponding base module and front connector. 11.4 Final bus cover The final bus cover is available in sets of five with order no. 600-920-9AA01. TB20 – Energy Meter | Version 1 | 04.03.2016...

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