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Bosch IO-BOX32 Manual

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Drive and control technology
B~IO
IO-BOX32
Module Description
Version
101

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Summary of Contents for Bosch IO-BOX32

  • Page 1 Drive and control technology B~IO IO-BOX32 Module Description Version...
  • Page 2 Module Description 1070 072 302-101 (01.06) GB E 2001 by Robert Bosch GmbH, Erbach / Germany All rights reserved, including applications for protective rights. Reproduction or distribution by any means subject to our prior written permission. Discretionary charge 10.00 DM...

  • Page 3: Table Of Contents

    Table of contents Page Safety instructions ......1–1 Use in accordance with intended purpose .
  • Page 4 ......8–9 8.4.5 EMC characteristics of IO-BOX32 ......8–10 8.4.6...

  • Page 5: Safety Instructions

    1–1 Safety Instructions Before you start working with the IO-BOX32, we recommend that you thoroughly familiarize yourself with the contents of this manual. Keep this manual in a place where it is always accessible to all users. Intended use This instruction manual presents a comprehensive set of instructions and information required for the standard operation of the described products.

  • Page 6: Qualified Personnel

    1–2 Qualified personnel This instruction manual is designed for specially trained personnel. The relevant requirements are based on the job specifications as outlined by the ZVEI and VDMA professional associations in Germany. Please refer to the following German-Language publication: Weiterbildung in der Automatisierungstechnik Publishers: ZVEI and VDMA Maschinenbau Verlag Postfach 71 08 64 60498 Frankfurt/Germany...
  • Page 7 1–3 Safety markings on components DANGER! High voltage! CAUTION! Electrostatically sensitive devices (ESD)! Lug for connecting PE conductor only! Functional earthing or low-noise earth only! Screened conductor only! 1070 072 302-101 (01.06) GB...

  • Page 8: Safety Instructions In This Manual

    1–4 Safety instructions in this manual DANGEROUS ELECTRICAL VOLTAGE This symbol warns of the presence of a dangerous electrical voltage. Insufficient of lacking compliance with this warning can result in personal injury. DANGER This symbol is used wherever insufficient or lacking observance of this instruction can result in personal injury.

  • Page 9: Safety Instructions For The Product Described

    If measuring or testing procedures must be carried out on the active system, these must be carried out by trained electricians. CAUTION Only Bosch-approved spare parts may be used! CAUTION Danger to the module! All ESD protection measures must be observed when using the...
  • Page 10 Trademarks All trademarks referring to software that is installed on Bosch products when shipped from the factory represent the property of their respective owners. At the time of shipment from the factory, all installed software is protected by copyright.

  • Page 11: System Introduction

    2–1 System introduction The IO-BOX32 is a decentralised input / output device for the field buses PROFIBUS-DP and CANopen and it provides 32 inputs/outputs per 0.5 A. The device has IP65 protection. In conjunction with a corresponding bus master circuit, the assembly can be used as a decentralised peripheral.

  • Page 12: Designation

    D Simple connection of sensors and actuators with 2-/3-/4-wire connec- tions without intermediate terminals. D The IO-BOX32 provides 24 V for sensors. D The IO-BOX32 processes the input signals, e.g. from switches, light barriers, sensors. D It controls the connected small consumers, e.g. valves, lamps and contactors.

  • Page 13: Structure

    2–3 Structure The IO-BOX32 has a die-cast housing. The housing cover has two windows through which the bus address as well as the status LEDs can be read. All bus and supply cables are led in via metric screw cable fastenings and connected to spring terminals.
  • Page 14 2–4 Notes: 1070 072 302-101 (01.06) GB...

  • Page 15: Installation Of The Io-Box32

    Installation of the IO-BOX32 Installation positions and distances Installation position In general, any desired installation position is possible. The IO-BOX32 is attached directly to the machine using 2 to 4 M6 screws. The earth contact must be a screwed connection to the housing.
  • Page 16 3–2 Minimum spacing The following minimum spacing must be adhered to due to heat: D Horizontal installation minimum cable bending radius plus 20 mm D Vertical installation 1070 072 302-101 (01.06) GB...

  • Page 17: Connection

    4–1 Connection Overview of connections All connections of the IO-BOX32 can be plugged in socket terminal strips (grid 3.5 mm). The cover must be opened to enable connection. Inputs/outputs Metric EMC screw cable fastening Supply voltage Field bus connections 1070 072 302-101 (01.06) GB...
  • Page 18 Spring terminal (4-pin) for field bus (outgoing) Screw cable fastening All cables are fed through a removeable inlet plate on the underside of the housing. This makes it relatively simple to replace the IO-BOX32. Tight sealing is ensured by metric screw cable fastenings. Power supply...

  • Page 19: Voltage Supply

    4–3 Voltage supply The IO-BOX32 requires a 24 V power supply. A 3-phase power connection with simple full-bridge rectification is adequate. The superimposed AC voltage proportion must not exceed 5 %. All voltages in the device are electrically coupled, reverse-connect protected and can be drawn from a power connection.

  • Page 20: Inputs/Outputs

    4–4 Inputs/Outputs 4.3.1 Arrangement of inputs/outputs Power jumpers determine the arrangement in inputs/outputs per terminal block: 0 inputs, 32 outputs 8 inputs, 24 outputs D 16 inputs, 16 outputs D 24 inputs, 8 outputs D 32 inputs, 0 outputs CAUTION It is not permitted to mix inputs and outputs within one byte.

  • Page 21: Connection

    4–5 4.3.2 Connection X1 to X8 Allocation 1 to 4 Digital input/output of a terminal block Sensor supply, byte-wise (n = 1 to 4), short–circuit monitored 0 V for return current or sensors and/or load Protective earth Connection techniques The following connection techniques are possible: D 2-wire technology sensors with 24 V and signal;...
  • Page 22 4–6 LED display per output byte LED collective fault message LED sensor supply 4 x LED red Collective fault message The LED lights up in the event of overload or short circuit in the corresponding output byte. 4 x LED green Sensor supply The LED lights up when the supply for sensors in the corresponding terminal block is active.

  • Page 23: Field Bus

    On assembly, ensure that the connectors are relieved of strain from the weight of the cables. Bus termination If the IO-BOX32 is the last device on the bus, the integrated bus termination must be added to the circuit by means of a sliding switch. Sliding switch If the bus termination is active, X72 is switched off.

  • Page 24: Connection

    4–8 4.4.1 Connection X71, X72 Incoming Outgoing 1 2 3 4 field bus field bus The pin assignment is different for the PROFIBUS-DP and CANopen. PROFIBUS-DP Allocation Meaning B–H A cable Bus cable 1 B–L B cable Bus cable 2 ISO ground Insulated GND of interface Shield...
  • Page 25 4–9 4.4.2 Interface to the field bus The IO-BOX32 occupies the following addresses on the field bus: D I/O data, no diagnosis Input field Output field Terminal block X1, X2 X3, X4 X5, X6 X7, X8 D I/O data, with device diagnosis embedded in the input field...
  • Page 26 4–10 Notes: 1070 072 302-101 (01.06) GB...

  • Page 27: Operation With Profibus-Dp

    The rotary switches for setting the bus address are located beneath the housing cover. Each IO-BOX32-DP must be assigned its own bus participant address. This may only be assigned once in the entire PROFIBUS-DP. The bus participant address is set using rotary switches. Addresses 0 and 1 are reserved and therefore not permitted.

  • Page 28: Baud Rate

    5–2 5.1.1 Baud rate The baud rate is detected automatically at “power on”. Supported baud rates: MBaud MBaud MBaud MBaud kBaud 187.5 kBaud 93.75 kBaud 19.2 kBaud kBaud 1070 072 302-101 (01.06) GB...

  • Page 29: Displays

    No 24 V power supply present Overload at an output or sensor supply No diagnosis IO-BOX32 is searching for the baud rate IO-BOX32 has detected and adopted the baud rate Invalid parameter data Explanations: Display does not light up Display lights up Display flashes (0.8 s on / 0.2 s off)

  • Page 30: Configuring And Setting Parameters

    In the case of a system halt, D the outputs of the IO-BOX32 are place in the safe state (“0”) D the bus traffic to the bus master is discontinued A system halt can only be cancelled by means of “power off”. In this case, contact Bosch Service.
  • Page 31 Setting parameters The parameter setting telegram of the bus master provides the IO-BOX32-DP with the data for control of the diagnosis characteristics. The following settings can be made by the user in the DP configuration program. The states printed in bold indicate default settings.
  • Page 32 D SYNC mode The IO-BOX32-DP works in the SYNC mode when it receives a SYNC command from the DP master. This freezes the outputs in the current state. In the subsequent useful data transmission, the output data is stored, but the output states remain unchanged.

  • Page 33: Operation With Canopen

    Rotary switches for node ID Each IO-BOX32-DP must be assigned its own bus participant address (node ID). This may only be assigned once in the entire CANopen. The node ID is set using rotary switches. Node ID 0 is not permitted; this leads to a sys- tem halt.

  • Page 34: Rotary Switch For Baud Rate

    6–2 6.1.1 Rotary switch for baud rate Baud rate Baud Select the baud rate prior to ’power on’. To do so, use a small screwdriver to turn the arrow-shaped recess into the right position. The rotary switch must click into place. Switch position S3 baud rate (kBaud) 500 (factory setting)

  • Page 35: Displays

    In the case of a system halt, D the outputs of the IO-BOX32 are place in the safe state (’0’) D the bus traffic to the bus master is discontinued A system halt can only be cancelled by means of ’power off’. In this case, contact Bosch Service.

  • Page 36: Operating Characteristics Canopen

    CAN node 2 channels for transmission and 2 channels for reception of PDOs (Process Data Objects). The IO-BOX32-CAN occupies a maximum of 5 bytes inputs and/or outputs, so that 1 transmission and 1 reception PDO are sufficient. SDO channel: There is one SDO channel (Service Data Object) available per CAN node in transmit and receive direction.
  • Page 37 6–5 Diagnosis Diagnosis is supported and can be enabled/disabled by means of parameter bytes (2040). Shipped state: No diagnosis The diagnosis case is reported to the master by means of an Emergency (EMCY) telegram. The diagnostic data is stored in an SDO and can be picked up by the master.

  • Page 38: Setting Parameters Via Dip Switches

    6–6 6.1.4 Setting parameters via DIP switches The DIP switches S5.1 to S5.3 are used to: D enable diagnosis D set the method of transfer for the diagnostic information The DIP switches S5.4 to S5.8 are used to set: D the CAN operating modes MODE MODE Shipped state: S5.8 to S5.1 = 00000000...
  • Page 39 D RTR (Remote Transmission Request), only asynchronous D asynchronous manufacturer-specific D Transmit characteristics ’all PDOs’: If one or more inputs are changed, the IO-BOX32-CAN transmits the PDOs of all inputs D Transmit characteristics ’1 PDO’: If one or more inputs are changed, the IO-BOX32-CAN only transmits the PDO(s) of the inputs that have changed The set transmission type applies to all PDOs.

  • Page 40: Setting Parameters Via The Can Master

    6–8 6.1.5 Setting parameters via the CAN master The Object Dictionary (OD) is used to, among other things, specify which communication objects are provided and in what way. General OD objects For general OD objects, the CiA DS-301 specifies the following types of entries: Entry Constants...
  • Page 41 6–9 Manufacturer-specific OD objects Over and above the OD objects specified by the CiA, there is an area reserved for manufacturers in which device-specific objects are entered and thus made accessible to the user: Index Subindex Object description (HEX) (HEX) page 1002 Manufacturer Status Register (MSR)
  • Page 42 2000 Module Control Register (MCR) Subindex The MCR can be used to change the characteristics of the IO-Box32: D Bit 0 to bit 3 specify the characteristics in the event of an error or after receipt of an NMT service D Bit 8 (high byte) controls the input transmit characteristics.
  • Page 43 6–11 Characteristics in the event of an error: Error Module Outputs EMCY status reaction BUS OFF according to according to according to MCR bit 0 MCR bit 2,1 MCR bit 3 The ’transmit error counter’ of the CAN controller has exceeded the limit of 256.
  • Page 44 01 hex: diagnosis message present Index 2020 Diagnostic Data Subindex Diagnosis byte of the IO-Box32-CAN. Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 no message Overload sensor supply US1 no message Overload sensor supply US2...
  • Page 45 : 4 bytes I/O without embedded diagnosis : 5 bytes I/O with embedded diagnosis Index 2040 Parameter Information This index is used to set parameters for the IO-Box32-CAN. Index 2040 Number of parameter data Subindex Number of data = 1...

  • Page 46: Can Identifiers

    An application master, DBT master or NMT master can use the node ID of the slave to calculate its identifier. D no communication between slaves. Via SDO, a DBT master can change the identifiers of the IO-BOX32-CAN in any way so that direct communication of process data is possible among slaves.
  • Page 47 Transmit NMT Node Guarding 1796 Transmit/Receive 1412 Transmit 1540 Receive PDO1 Transmit PDO2 Transmit PDO1 Receive PDO2 Receive The factory setting for the IO-BOX32-CAN is that only the PDO1 is assigned for transmission and reception. 1070 072 302-101 (01.06) GB...

  • Page 48: Range Of Functions

    6–16 6.1.7 Range of functions Performance/Function Features Comments independent of protocol Baud rates in kBaud 10, 20, 50, 125, CANopen 250, 500, 1000 125, 250, 500, CANrho 1000 Max. input data 32 bytes max. 5 bytes used Max. output data 32 bytes max.

  • Page 49: Technical Data

    7–1 Technical data IO-BOX32 Technical data IO-BOX32 corresponds to the standards D EN 61 131-2 corresponds to IEC 1131-2 D EN 61 131-2/A11 D EN 50 178 corresponds to VDE 0160 D EN 60 204-1 corresponds to VDE 0113, Part 1...
  • Page 50 7–2 Technical data IO-BOX32 Temperature D Operation complying with 0 to 50 °C EN 61 131-2 with a maximum average temperature of 45 °C over 25 hours 25 to 70 °C D Storage/Transport corresponds to 2K3 complying with EN 61 131-2...
  • Page 51 7–3 Technical data IO-BOX32 Radio interference suppression Requirement from EN 50 081-2, Measurement complying with EN 55 011, class A D Housing (radiated variables), test conditions D Frequency 30 to 230 MHz Limit value 40 dB (µV/m) in 10 m D Frequency 230 to 1000 MHz Limit value 47 dB (µV/m) in 10 m...
  • Page 52 ESD complying with EN 50 082–2, 4 kV D Coupling plate ESD complying with EN 61 131–2, 15 kV Transport resilience Inspection based on BOSCH standard N42 AP450. Original packaging complying with EN 61 131-2 Transport shock test D Duration of load...

  • Page 53: Profibus-Dp

    7–5 PROFIBUS-DP Technical data PROFIBUS-DP corresponds to standard EN 50 170, Part 2 Potential isolation yes, dielectric strength 500 V DC Bus address 2 to 99 (setting via rotary switch) shipped state: 2 Baud rate kBaud MBaud (automatically detection) 19.2 kBaud MBaud 93,75...

  • Page 54: Inputs

    7–6 Inputs Technical data Inputs Inputs complying with EN 61 131-2 maximum 32 digital inputs, type I Reverse polarity protection Input voltage D Rated voltage 24 V DC Sensor supply US1 to US4 D Current consumption maximum 0.5 A Status indicator via LEDs Short circuit/overload display via LEDs...

  • Page 55: Installation Guidelines

    EN 60 204-1: 1997, section 14.1.3. All peripheral devices such as digital sensors / actuators or other bus connections connected to the interfaces of the IO-BOX32 must also meet the criteria of safe isolation from power circuits.

  • Page 56: Circuit Diagrams

    8–2 Circuit diagrams Structure of IO-BOX32 Short-circuit protection Housing 1070 072 302-101 (01.06) GB...

  • Page 57: Reference Lead Connected To The Protective Earth

    This type of connection is to be used where possible. The supply circuit is thus a PELV circuit, see also section 8.1. if required other IO-BOX32 24 V separable connec- tion 1070 072 302-101 (01.06) GB...

  • Page 58: Reference Lead Not Connected To The Protective Earth

    8.2.3 Capacitive load of the power supply Capacitances are installed in the IO-BOX32 between the power supply leads and protective earth for interference suppression. This is to be taken into account if an earth fault monitoring device is deployed.

  • Page 59: Master Switch

    The IO-BOX32 logic supply can bridge voltage drops of up to 10 milliseconds to ensure the continuity of its operation. 8.2.5 Master switch A master switch complying with VDE 0100 must be fitted for the IO-BOX32, sensors and actuators. 1070 072 302-101 (01.06) GB...

  • Page 60: Fuses

    Fuses Fuses and cable circuit breakers are used to protect the supply leads in a network. The cables of the power supply for the IO-BOX32 must be secured with fuses/circuit breakers. Here, the supply of sensors and actuators should be secured separately with fuses/circuit breakers. If the supply leads are shorter than 3 m, and installed so that they are secured against earth faults and short circuits, these fuses/circuit breakers can be omitted.

  • Page 61: I/O Connections

    8.3.1 Outputs Inductive loads In general, the outputs of the IO-BOX32 limit inductive deactivation peaks to a level that causes no problems by means of built-in terminal diodes. However, the occurrence of a cable break, pulling put a connector for inductive load, e.

  • Page 62: Electromagnetic Compatibility

    8–8 Electromagnetic compatibility The electromagnetic compatibility (EMC) is the capability of an electrical unit to operate satisfactorily in its electromagnetic environment without influencing this environment, to which other units belong, to more than a permitted degree (EN 61 000-4-1). 8.4.1 General An important aim in automation technology is to achieve the greatest possible level of system availability.
  • Page 63 8–9 8.4.4 EMC legislation and CE identification As a whole, the system must meet certain minimum requirements as regards interference immunity. The system manufacturer or seller of the overall machine is responsible for complying with these specifications. This is specified by the EMC legislation based on the EMC Directive of the Council of Europe.

  • Page 64: Emc Characteristics Of Io-Box32

    Under the following conditions, the requirements of a system the IO-BOX32 can be met: D All voltage supplies must be fitted either with external varistor modules, e.
  • Page 65 Protection against electrostatic discharges All assemblies of the I/O system IO-BOX32 contain components that can be destroyed by electrostatic discharges (ESD = Electro-Static Discharge). A defective assembly will not necessarily be recognizable immediately, but can become apparent in the form of occasional or delayed failures.

  • Page 66: Installation Measures To Ensure Interference Immunity

    Interference suppression of inductive loads In general, most control outputs reduce inductive deactivation peaks to a level that causes no problems by means of built-in terminal diodes. This also applies to the outputs of the IO-BOX32. 1070 072 302-101 (01.06) GB...
  • Page 67 Filter Normally, the interference immunity of the IO-BOX32 is sufficient that a function is assured even in an environment with relatively strong interference. To improve the EMC properties even further, it might be necessary to implement additional filtering measures.
  • Page 68 8–14 Notes: 1070 072 302-101 (01.06) GB...

  • Page 69: Ordering Data And Accessories

    9–1 Ordering data and accessories IO-BOX32 Designation Order no. IO-BOX-DP with PROFIBUS-DP 1070 083 818 IO-BOX-DP with CAN-Bus 1070 083 819 Accessories Designation Order no. Screw cable fastening M16 (resistant to EM interference) on request Screw cable fastening M16 on request...
  • Page 70 9–2 Notes: 1070 072 302-101 (01.06) GB...

  • Page 71: A Appendix

    A–1 Appendix Abbreviations alternating current bus participant (address) Controller Area Network CANopen (open) transfer protocol on the bus of the Controller Area Network CANrho CANrho conforming communication char- acteristics on the bus of the Controller Area Network direct current Digital inputs Dual Inline Package Digital outputs Field bus PROFIBUS-DP...

  • Page 72: Index

    A–2 Index Numbers 7–segment displays Fail_Safe mode, 5–6 CANopen, 6–3 Field bus, Connection, 4–8 PROFIBUS–DP, 5–4 Freeze mode, 5–6 Fuses, 8–6 Accessories, 9–1 Assembly of the screw cable fastening, 4–7 Inductive loads, 8–7 Input characteristic curve, 4–6 Input voltage, 7–6 Baud rate Inputs, 4–4, 4–6 CANopen, 6–2...
  • Page 73 A–3 Reference lead, 8–3, 8–4 Registered trade marks, 1–6 Rotary switch, PROFIBUS–DP, 5–1 Rotary switches, CANopen, 6–1 Safety instructions, 1–4 Screw cable fastening, 4–2 Setting parameters, 6–13 PROFIBUS–DP, 5–5 via DIP switches, CANopen, 6–6 via the CAN master, 6–8 Shielding, 8–12 Signal–to–interference ratio, 8–8 Spare parts, 1–5 Standards, 7–5...
  • Page 74 A–4 Notes: 1070 072 302-101 (01.06) GB...
  • Page 76 A–1 Bosch Automation Technology Australia Great Britain Robert Bosch (Australia) Pty. Ltd. Robert Bosch Limited Robert Bosch Corporation Head Office Automation Technology Division Automation Technology Division Cnr. Centre - McNaughton Roads Meridian South Meridian Business Park Fluid Power Products P.O. Box 66...

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