Manual

FB Remote I/O for mounting in Zone 1

GHG 210 7003 P0041 (B)

Table of Contents
1 1
1.1 1.2 1.3 1.3.1 1.4 1.5 1.6 1.7 1.7.1

Configuration Software..................................................................................... 5 PC to run FB Remote I/O Configuration Service..................................................... 5 Instructions for the Installation of Software............................................................. 5 FB Remote I/O Configuration Software................................................................... 6 How to Use the FB Remote I/O Configuration Software.......................................... 6 Password Protection............................................................................................... 6 Establishing Connections........................................................................................ 7 Options / Communication Set-up............................................................................ 9 Configuring of Module Data.....................................................................................10 Maintenance............................................................................................................10
Bus Couplers.......................................................................................................... 11 System Speed - Cable Length................................................................................11 Fundamental Principles........................................................................................... 11 PROFIBUS Speed................................................................................................... 12 MODBUS Speed.....................................................................................................12 RS 485 Bus............................................................................................................. 13 Fundamental Principles........................................................................................... 13 Bus Interface Connection in Zone 1........................................................................13 Earthing and Screening...........................................................................................13 System Expansion.................................................................................................. 14 PROFIBUS DA and DPV1....................................................................................... 14 Redundancy............................................................................................................14 Introduction............................................................................................................. 14 Redundancy Concept............................................................................................. 15 Redundancy Function............................................................................................. 15 HART Communication in Case of Redundancy.......................................................15 Redundant Power Supply....................................................................................... 16 Segments................................................................................................................ 16 Cabeling in Case of Redundancy........................................................................... 16 Configure Redundancy........................................................................................... 16 Initial Configuration for Redundant Operation......................................................... 16 Retrofitting of Redundancy......................................................................................17 Bus Change-over....................................................................................................18 Self-Monitoring Features......................................................................................... 18 Collective Alarm.......................................................................................................19 Time Out.................................................................................................................. 19 Safety...................................................................................................................... 19 System Configuration.............................................................................................. 19 ON-LINE.................................................................................................................. 21 OFF-LINE.................................................................................................................21 Self-Documenting.................................................................................................... 22 Station Layout..........................................................................................................23 Printing TAG Numbers............................................................................................. 24 Terminal Plans......................................................................................................... 25 Configuration Data...................................................................................................25 Data Structure.........................................................................................................26 Importing-Exporting of Data.................................................................................... 27 Format of the Import / Export File........................................................................... 27 Example for Importing / Exporting of Data..............................................................28 Power Failure Protection..........................................................................................28 Station Set-up..........................................................................................................29 Field Wiring - Mechanical Coding............................................................................29 Power Consumption................................................................................................ 29 Local Connections...................................................................................................29 Commissioning - Maintenance................................................................................30 Commissioning Information..................................................................................... 31 Introduction............................................................................................................. 33 Module Replacement.............................................................................................. 33 Signal Processing....................................................................................................33 Functional Safety..................................................................................................... 34 FB 1201 Digital Input............................................................................................... 35 How to Configure Digital Inputs............................................................................... 35 FB 1202 Digital Input............................................................................................... 36 How to Configure Digital Inputs............................................................................... 36 FB 1203 Digital Input............................................................................................... 37 How to Configure Digital Inputs............................................................................... 38 39

2
2.1 2.1.1 2.1.1.1 2.1.1.2 2.1.1.3 2.1.2 2.1.2.1 2.1.2.2 2.1.2.3 2.1.3 2.1.4 2.1.5 2.1.5.1 2.1.5.2 2.1.5.3 2.1.5.4 2.1.5.5 2.1.5.6 2.1.5.7 2.1.5.8 2.1.5.9 2.1.5.10 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.6.1 2.3.6.2 2.3.7 2.4 2.4.1 2.4.2 2.5 2.6 2.6.1 3.01 3.02 3.03 3.04 3.1 3.1.1 3.2 3.2.1 3.3 3.3.1

Hardware..............................................................................................................11

How to Configure I/O Modules.........................................................................33

3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.6 3.6.1 3.6.2 3.7 3.7.1 3.7.2 3.8 3.8.1 3.8.2 3.8.3 3.9 3.9.1 3.9.2 3.9.3 3.10 3.10.1 3.10.2 3.11 3.11.1 3.11.2 3.12 3.12.1 3.12.2

Calculation of a Valve Circuit................................................................................... 39 How to Configure Digital Outputs............................................................................ 40 Dosing System using Valves................................................................................... 41 Interconnection with an LED signal lamp.................................................................41 FB 3201 Analogue Input, Transmitter Power Supply, Input Isolator........................ 42 How to Configure Analogue Inputs.......................................................................... 42 FB 3202 Analogue Input, HART Transmitter Power Supply, Input Isolator..............43 HART Communication for FB 3202..........................................................................43 How to Configure Analogue Inputs.......................................................................... 44 FB 3203 Analogue Input, HART Transmitter Power Supply, Input Isolator..............45 HART Communication for FB 3203..........................................................................45 How to Configure Analogue Inputs.......................................................................... 46 FB 4201 Analogue Output....................................................................................... 47 Local Connections for FB 4201............................................................................... 47 Strain Gauge Measurement.................................................................................... 47 How to Configure Analogue Outputs....................................................................... 48 FB 4202 Analogue Output, HART Output Isolator....................................................49 HART Communication for FB 4202..........................................................................49 Local Connections for FB 4202............................................................................... 49 How to Configure Analogue Outputs....................................................................... 50 FB 4203 Analogue Output....................................................................................... 51 Local Connections for FB 4203............................................................................... 51 How to Configure Analogue Outputs....................................................................... 51 FB 5201 Temperature Converter.............................................................................52 Line Resistance....................................................................................................... 52 How to Configure Temperature Inputs.................................................................... 53 FB 5202 Temperature Converter.............................................................................54 How to Configure Temperature Inputs.................................................................... 54 Cold Junction Compensation.................................................................................. 55

4 5

4 5
5.1 5.2 5.3 5.3.1 5.3.2 5.3.3

HART communication......................................................................................... 56 Software - Marshalling................................................................................... 57 Automatic Marshalling............................................................................................. 57 Manual Marshalling.................................................................................................58 Software Marshalling by means of Table Imports...................................................59 Description of Format..............................................................................................59 Conversion of Tables.............................................................................................. 60 Explanation for Importing/Exporting of Data........................................................... 61
PROFIBUS DP......................................................................................................... 62 GSD File...................................................................................................................62 PROFIBUS DP Configuration.................................................................................. 63 Bus coupler Configuration.......................................................................................63 Control System Configuration.................................................................................. 63 PROFIBUS Configuration String.............................................................................. 64 Data Parcel..............................................................................................................65 Modul Status and Commando Register..................................................................66 Error Codes............................................................................................................ 67 Module Related Error Codes FB 520X................................................................... 68 Command Register.................................................................................................. 68 Commands.............................................................................................................. 68 Data Format.............................................................................................................68 Analogue Data......................................................................................................... 68 Binary Input.............................................................................................................69 Binary Outputs........................................................................................................ 69 PROFIBUS FMS...................................................................................................... 70 FB 8202 MODBUS Interface...................................................................................71 Status Register........................................................................................................ 71 MODBUS System Addresses................................................................................ 72 Elsag Bailey (H+B).................................................................................................. 72 Fisher Rosemount RS3........................................................................................... 72 HIMA....................................................................................................................... 72

6.1 6.1.1 6.1.2 6.1.2.1 6.1.2.2 6.1.2.3 6.1.2.4 6.1.3 6.1.3.1 6.1.3.2 6.1.3.3 6.1.3.4 6.1.4 6.1.4.1 6.1.4.2 6.1.4.3 6.2 6.3 6.3.1 6.3.2 6.3.2.1 6.3.2.2 6.3.2.3

How to Address from the PLC or DCS............................................................62

7.1 7.2 7.3 7.4 7.5 7.6

Communication........................................................................................................ 73 Faulty Power Supply Units...................................................................................... 73 Faulty Modules........................................................................................................73 Red LEDs................................................................................................................73 Searching for Errors................................................................................................74 Check List at Failure of Signals............................................................................... 75

Troubleshooting.................................................................................................73

8 9

8 9

Literary References........................................................................................... 76 Index of Keywords..............................................................................................76

Manual FB Remote I/O

1 Configuration Software
Introduction
The FB Remote I/O product line is designed for the galvanic isolation and the conditioning of signals between the measured values of a production process and the process control (DCS) or programmable logic systems (PLC). The new concept offers the following advantages: Cost reductions. Simplified planning. PLC and DCS only use serial data links. Input / Output cards are no longer required. Various standard bus systems are available. HART communication possible via the service bus. Multistage redundancy concept. Selfmonitoring feature for all the modules and field wiring. Reduced power dissipation and, therefore, less heat rise. Easy installation using plug-in modules. Modern backplane technology. Screw / plug-in connectors for all field cables. This manual explains the function of each module and tells you how to install and use the configuration software. It also provides important tips on the assembly and commissioning of field stations. For all exrelevant data as well as for the assembly and for commissioning see the operation instruction FB 9224 - FB 9249.

1.1 PC to run FB Remote I/O Configuration Service

Your personal computer or LAPTOP must fulfil the following minimum specifications to run the configuration software: Processor 80486 DX, 33 MHz or higher; 8 MB RAM minimum; 3 floppy-disk drive (CD-Rom); ca. 2 MB hard disk space required; uses Windows 3.1, Windows 3.11, or Windows 95, NT version; You will obtain information about your hardware using the DOS command MSD. Leave WINDOWS* completely. Do not use the MSDOS prompt in WINDOWS but restart your computer under DOS. Then enter MSD. * WINDOWS is a registered trade mark of Microsoft Corp.

1.2 Instructions for the Installation of Software

You can now install the disk supplied. The configuration software is suited for our LB Remote I/O product, as well as for the FB Remote I/O. Change to the disk index using the file manager. Carry out SETUP. The files are unzipped automatically. Space requirement on the hard disk: 2MB + programme size LOCBUS.EXE + manual file. See the README file for important information on the latest software version. CD-ROM Version: hard disk installation is not necessary. Dictionary: SOFT\16-BIT\Englisch\DEMO\ Setup 16.exe:16 bit version for (Installation) WINDOWS 3.1, WINDOWS 3.11 and WINDOWS 95. Setup 32.exe:32 bit version for (Installation) WINDOWS NT 4.0 and WINDOWS 95. NOTE: Only the 32 Bit version is kept up to date. 16 Bit versions are frozen in the V2.24 status.

Fig. 1

1.3 FB Remote I/O Configuration Software

Fig. 2

The FB Remote I/O configuration software has been designed according to the rules of VDI/VDE 2187 (general design rules for PCrelated software regarding display properties and menu support for digital field devices). The software helps you to configure FB Remote I/O devices and shows measured values and device status information during commissioning.

Fig. 3 appears. After entering this key, you should change the password for the supervisor to limit free access via this main key to yourself only. After this you can set up further user rights for your colleagues. Users without a password can break off the password entering stage; however, then they can only read data and call up measured values. Without a password they cannot carry out any changes to the station setting. With the main key you can: Change the user: enter all user rights, Settings: Read password (Fig. 4): Read own and all others of a lesser level (user rights). Change password (Fig.5): Change own and all others of a lesser level (user rights). Set up users: Open for users with lesser user rights. User Rights: Main key: Set-up supervisor => Supervisor Level 3 has all rights Setting-up of specialist => Specialist Level 2 Setting-up of maintenance man => Maintenance Level 1 Specialist: Clearance by supervisor => Specialist Level 2 With the exception of access to the passwords of other specialists, has all rights. Can install passwords for maintenance staff. Maintenance: Clearance by specialist/supervisor => Maintenance staff Level 1 Compared to specialists, the following restrictions exist regarding user rights: Maintenance person cannot set up new users and can only read his own password; He cannot switch the bus coupler to the packed mode He cannot look into the RamView memory; He cannot jump data. Observer: Clearance by specialist/supervisor => Observer Level 0 Has extremely restricted user rights. Without a password he can only load data and display measured values.

1.3.1 How to Use the FB Remote I/O Configuration Software

Fig. 3

Execute LOCBUS.EXE under one of above mentioned Windows versions. You will receive the opening menu fig.1, page before. A menu will appear showing you the current software identification number. Click on the OK button to gain access to the main window of the application. Select whether you wish to configure LB Remote I/O or FB Remote I/O stations. You will now see a blank BUS station with 48 I/O slots. You now have the option of: - entering a password, - establishing a connection to the field station, - changing to the device window of a station to configure it, - displaying the status or the measured values of preconfigured modules, - setting the serial interface, - setting the printer options, - documenting the configured stations, - switching on or off of the simulation mode, - changing the station configuration, - combining parameter strings to perform optimum adaptation to the PLC or DCS (marshalling of zipped data) or - call upon HELP functions.

Fig. 4

Fig. 5

1.4 Password Protection

To protect station settings from unauthorized users, the setting parameters can be safeguarded by passwords. Here it is possible to set up various user levels. When the configuration software is called up with the command LOCBUS.EXE and the main menu has been acknowledged by pressing the OK key, the password inquiry appears (Fig. 2). Enter the users name and the password here. When putting into service for the first time, you can issue a list of user names and passwords to allow your colleagues access to the various levels. Therefore, do not enter this information on the original disk supplied, but on your hard copy. Your original disk acts as a key if the main password should ever get lost. The main key reads as follows: Users name: CGD Password: Safety

1.5 Establishing Connections

Bus stations can be configured ONLINE via a permanently installed service bus. Bus couplers can be set in the office with the aid of a configuration kit FB 9250 and then plugged into the slot provided during operation. Configuration of a station in Zone 1 is only permitted via the Service bus or with a hot work permit or appropriate certified aids. When the menu item Establish Connection is selected, the program searches for any stations that are connected. Please note that this menu item is only available when the demo mode is turned off (Fig. 6). Using the connector cable RS 232/485, connect the bus terminals of the configuration kit to a free COM port of the PC. The cable is a component part of the configuration kit. In the case of a permanently installed service bus, the cable must be connected to a free RS 232 interface of the PC using a commercially available RS 232RS 485 converter (Fig. 7). The connections are described in operating instruction FB 92XX. During the permanent installation of the service bus, the bus terminals, that are available in duplicate, are used as a T-connection in accordance with the RS 485 standard. All stations of a bus are of equal standing and are independent of each other. However, it is necessary to ensure that the bus terminating resistors are mounted at the last station. In addition to this, it is also necessary to ensure that the settings to the port connections of the bus coupler FB 8201/2 match those of the PC. The bus couplers are supplied with the following factory setting of the PC ports: BAUDRATE = 9600, PARITY=NONE (see also Options/Communication Set-up). Address is 1. Address 0 is blocked. Setting of the address range to be searched is shown in Fig. 8. The setting from 0 to 0 records all address areas.

Fig. 6

Adapter

Configuration cable

Configuration kit

GHG139 0008C0000

FB 9250

HE

to PC COM 1 or COM 2

Commercial

RS232 - RS485
Converter

FB Station 1

FB Station n

to PC COM 1 or COM 2
Fig. 7 Service bus for the connection of several FB stations to the PC

FB Station 31

Fig. 8

The Service bus is wired from station to station in each case from the redundancyjeweils von unit with the help of the existing unit to the basis der Redundanzeinheit zur double terminals. The termination resistors are assembled on the Basiseinheit mit Hilfe der vorhandenen final terminal block.

Der Servicebus wird von Station zu Station

Doppelklemmen verdrahtet. Am letzten Klemmenblock wird der Abschlusswiderstand montiert.

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N(-) X1.1 PE x1.3

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N(-) X1.1 PE x1.3

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N(-) X1.1 PE x1.3

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N(-) X1.1 PE x1.3

Redundanzeinheit Redundancy unit

Fig. 9 Service bus in redundancy

Basiseinheit Base unit

Redundanzeinheit Redundancy unit

Basiseinheit Base unit

The System Bus is wired from station zu station in each case from the redundancy unit to the redundancy unit and from the basis unit to the basis unit with the help of the existing double terminals. The termination resistors are assembled on the final terminal block.

Der Systembus wird von Station zu Station jeweils von der Redundanzeinheit zur Redundanzeinheit und von Basiseinheit zu Basiseinheit mit Hilfe der vorhandenen Doppelklemmen verdrahtet. Am letzten Klemmenblock wird der Abschlusswiderstand montiert.

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N (-) X1.1 PE x1.3

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N (-) X1.1 PE x1.3

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N (-) X1.1 PE x1.3

x2.6 x2.5 x2.4 x2.3 x2.2 x2.1 L(+) x1.2 N (-) X1.1 PE x1.3

Redundancy unit

Base unit

Redundancy unit

Base unit

Redundanzeinheit

Basiseinheit

Redundanzeinheit

Basiseinheit

Fig. 10 System bus in redundancy mode

Fig. 11 Status window during station search

While the PC is searching for any connected bus couplers, a bar graph display shows the progress of the search in per cent (Fig. 11). It searches for bus couplers from address 1 to 10 (max. 255). After completion of the search, a list of stations found is displayed. Use the MOUSE to select the station with which you wish to communicate. If you happen to know that the bus coupler you are looking for has an address within the range 1 to 25, you can limit the search to this range. If connection to the station cannot be established, the picture Fig. 12 appears. Make sure that no other applications on your PC that could have access to the set

sition of your setup drawing. Then load the complete station configuration. The order of the modules hereby is arbitrary. The system recognizes the correct position in relation to existing configurations, just as it is also able to recognize new configurations. The modules themselves do not require any presetting of addresses and, for this reason, they do not feature switches or potentiometers. If, when loading, you do not wish to carry out any immediate new setting of modules, press the Y key to take over the existing standard setting during the loading process for all modules. The setup drawing shows the modules used for the station selected. The part number of each module is entered at the top of each slot, the slot number is entered at the bottom and the TAG-No. is entered vertically between them (see illustration Fig. 13). You can now select the module data menu to configure stations or to transfer configuration data to or from the station.

Fig. 12

1.6 Options / Communication Set-up

The service bus is generally a MODBUS, even if the main bus works with other bus standards.

When a commercially available RS 232 RS 485 converter is used, the RS 232 interface of your PC or LAPTOP is converted into a true bus connection and can operate up to 31 stations via a single bus line. You can connect the service bus cable to any free serial interface of your LAPTOP or PC (COM 1 to COM 4). Enter the port number in the window (Fig. 14). Fig. 13 interface are active. This could, for example, be the case if you use the HART software of other manufacturers and have not yet closed the application when you call up the FB Remote I/O configuration. Check that the connection cable is connected correctly to the PC and the bus station. Check that the settings according to Section 1.2 have been carried out. Close the other programmes that also use the interface. During the communication yellow luminious diodes flash in the window of the bus coupler. After selecting a station and pressing the OK button, you return to the main menu. The bus coupler is now in the appropriate poThe following PC-internal settings apply: Port COM COM COM COM 1 2 3 4 HEX Address 3F8 2F8 2A0 2A8 Interrupt 4 3 12 15

Fig. 14

For this, normal commercially available interface converters should be used (see accessories). The interface converters require an automatic baud rate recognition and an automatic direction changeover in order to fulfil all requirements.

1.7 Configuring of Module Data 1.7.1 Maintenance

Select the menu item MODULE DATA / EDIT MODULE DATA to change from the Main Menu to the Module Data Menu (Fig. 15). With the Module Data Window you can configure the station and the individual I/O modules or load and save data, either in the field station or on the hard disk. The configuring of module data could not be simpler. You can set or change the data of a module after double-clicking the slot you want to configure with the mouse. The setting of a module that has already been configured will then appear in a window that corresponds to the check sheet of the slot and shows all the set parameters. If you wish to occupy a new slot, the process is similar. By double-clicking a blank position you will receive the list of modules available (Fig 16). Choose the I/O unit you want and click the OK button or double-click the desired module directly. You will then see the parameter window for this module and you can now configure the module according to your own requirements. Fig. 16 By double-clicking a free slot, you will obtain a list of available modules. In this way you can place up to 48 I/O modules. The mains units FB 92XX cannot be configured and, therefore, they cannot be selected. The settings are determined automatically by the programme. You can merely enter the mains voltage being used. A list of the available slots (Fig. 17) appears in the menu window (Fig. 18) when the complete station is configured. The basic position of any module type can be saved in a Default File. This facilitates the setting of many plugging positions of the same form (see file Load Module Data, Save Module Data).

Fig. 15

Fig. 17 The configuration of modules can be transferred to other slots using the COPY

Fig. 18

10

2 Hardware
The FB Remote I/O modules can be positioned on the backplane in any order de-sired following the bus coupler on the left hand side of the first segment. A mains unit is needed for each segment of 24 I/O de-vices to stabilize the internal supply voltages and monitor the modules. All modules can be exchanged during operation. This also applies for mains units and bus couplers. The enclosure connection terminals are only accessible in a volt free state after removing the perspex cover. The intrinsically safe module terminals can also be plugged or screwed in during operation if the conditions applicable for intrinsically safe circuits are observed. Each bus coupler features 2 galvanically isolated serial interfaces. One bus connection is for the connection to the DCS or PLC. The second bus connection serves as a service bus during commissioning and maintenance activities, as well as for the HART communication. Note: The system bus and service bus should be laid seperately. The bus coupler features a dual port RAM which shows the complete status and data situation of the I/O modules connected to the bus coupler at any one moment in time. This enables the DCS or PLC to access data at any time without delay. Data for as many as 48 I/O modules in the dual port RAM is updated every 5ms. The PLC or DCS does not have to wait for the analogue to digital conversion of the channels to be performed. The bus coupler also collects the status information of each I/O module. In the event of a fault in one of the I/O modules, this information can be transmitted via the field bus. The service bus enables you to analyse faults in detail. Knowing the position of the unit which has reported the fault, you can address the point and look at it on your monitor during operation. In this way it is, for example, possible to find out if a line fault has occurred on a pressure transmitter loop (0 mA < I < 1 mA), or if the transmitter is faulty (1 mA < current < 3.6 mA), or the loop has been shorted (current > 21 mA).

2.1 Bus Couplers

Various bus couplers are available to accommodate the various PLC systems or controls. 1) MODBUS 2) PROFIBUS RTU, ASCII, MODICON FMS, DP

Successful couplings are already in operation with the following systems: ABB Advant ABB MOD 300 AEG MODICON ALFA LAVAL Allen Bradley Babel Box Bailey Fisher&Porter DCI SIX Fisher Rosemount RS3 and PROVOX FOXBORO Eckardt Micro I/A FOXBORO Eckardt PLS 80 GE FANUC Hartmann&Braun Digimatik/FREELANCE Hartmann&Braun Symphony Hilscher HIMA Hitachi HMS Honeywell Intellution FIXDMACS Matsushita Siemens S5, S7, Teleperm AS235 Softing Trebel&Himstedt Wonderware Yokogawa More bus couplings are in preparation. Changing the bus coupler does not effect the explosion protection. BUS MODBUS PROFIBUS FMS, DP PROFIBUS FMS, DP PROFIBUS FMS, DP PROFIBUS FMS, DP PROFIBUS PA, H1 Service bus Fig. 19 Data transmission rate 19.2 kBit/s, 38.4 kBit/s 1.5 Mio bit/s 500 kBit/s 187.5 kBit/s 93.75 kBit/s, 19.2 kBit/s, 9.6 kBit/s 31.25 kBit/s 9 600 bit/s Cable length, max. 1200 m 200 m 400 m 1000 m 1200 m 1900 m 1200 m

2.1.1 System Speed - Cable Length 2.1.1.1 Fundamental Principles

The different transmission rates are recognized by the bus coupler automatically. The standardized interfaces determine the possible cable types and bus lengths. You should use screened twisted cables for the bus. The installation requirements according to VDE 0165 must be taken into account for wiring in hazardous areas. The bus connections are generally fitted with standard RS 485 hardware. This guarantees a reliable communication link. Commercially available components can be used to adapt them for fibre optic links or other media (e.g. telephone modems). The technical data (Fig.19) applies to type A cables for standard applications to DIN19245 Part 3 or EN 50 170.

11

Line 11 Linie

MASTER

Station 1

Station30

Repeater

Off-the-shelf repeaters (amplifiers) allow you to increase the cable length even further (Fig. 20). Installation of repeaters in the hazardous area on request, e.g. using flameproof enclosures.

Line 22 Linie

2.1.1.2 PROFIBUS Speed

Station 1

Station 2

Station30

Station31

Abschluwiderstand Termination impedance

Fig. 20

The system reaction time for a PROFIBUS system is basically dependent on the following factors: the reaction time in which a participant can respond, the selected transmission rate (Baudrate), the Min_Slave_Interval, the net data length agreed on. The following simplified example can be used as an estimate: 1 master and 5 slaves are connected to the Profibus DP. 10 bytes output data and 20 bytes input data are to be transmitted per slave. The transmission rate is, for example, 1.5 MBaud. Thus: 1 bit at 1.5 MBaud = 1 / 1.5 Mio bits/s = 0.67 ms = 670 ns 1 symbol consists of 11 bits (1 start bit, 1 stop bit, 1 parity bit, 8 data bits) Therefore 1 symbol requires 11 x 670 ns = 7.33 ms The basic requirement for an information cycle results from the addition of the bus times and the telegram header. TMC = 2 x length header (bytes) x 11 bit + TSDR + TSYN + Tidi (Fig. 21 and 22) In the data exchange the header comprises 9 bytes. The bus time-out times for the synchronization are to be taken as being TSYN = 33 bit and Tidi 36 bit (at 1.5 MBaud). The delay times of the signals at the bus are negligible. A typical value for an ASIC is TSDR = 30 bit. Thus: TMC / bit = 2 x 9 x 11 + 30 +33 + 36 = 300 or 300 x 670 ns = 201 ms. Thus, the approximate time for an information cycle is: 201 ms + quantity of net data (e.g. 10 output bytes + 20 input bytes) 201 ms + 30 x 7.33 ms = 420.9 ms per slave or ca. 2.1 ms with 5 slave stations.

Principle of informative data traffic

Call-up telegram
Closing Info

Output data

Heading-Info

Response telegram
Heading-Info

Input data

Closing-Info

Telegram formats
SRD-Request, variable information field length

SRD-Response, variable Information field length

Fig 21

Bus cycle time of a PROFIBUS-DP Mono-Master System

Bus cycle time

2.1.1.3 MODBUS Speed

The reaction time to Modbus telegrams is approximately 3.5 Character Times + 2 ms. This results in the following reaction times depending on the baud rate: baud rate 9600 = > 19200 = > 38400 = > approx. 6 ms approx. 4 ms approx. 3 ms

Initial conditions:

Each slave has 2 byte input and 2 byte output data The minimal slave-interval-time is 200 microseconds Tsdi=37 bit times, Tsdr=11 bit times

DP-Slaves

Fig. 22

An interrogation of 48 analogue values would be seen as follows in the MODBUS: Request : 1, 4, 0, 0, 0, 48 (Address, Function, Register, Quantity) Answer: 1, 4, 96, x1, x2, ..., x95, x96 (Address, Function, Quantity, Values)

12

baud rate 9600: request 8 ms, pause 6 ms, response 100 ms = 114 ms baud rate 19200: request 4 ms, pause 4 ms, response 50 ms = 58 ms baud rate 38400: request 2 ms, pause 3 ms, response 25 ms = 30 ms

Terminal X2.4 = RxD/TxD-P X2.3 = DGND X2.6 = + 5 V X2.5 = RxD/TxD-N

Function receive/transmitdata-P reference potential only at cable end receive/transmitdata-N

2.1.2 RS 485 Bus 2.1.2.1 Fundamental Principles

The bus connection to the DCS or PLC features the same RS 485 hardware standard as the service bus. The following properties in accordance with the European standard EN 50170 must be taken into consideration: Bus structure Lines to be terminated at both ends with the characteristic impedance. No branch lines. Branches to participants <0.3 m. Screened, twisted pair. Characteristic impedance 100-130 W . Cross section > 0.22 mm, ca. 60 pF/m. 1200 m max., depending on the data transmission rate. 32 active or passive participants and repeaters.

So-called T-junctions should be used for the connection of the bus cable segments to the stations, i.e. double terminals (Fig. 23). Branch lines for avoiding reflections must not be longer than 0.3 m. RD dependent on the cable type, specified to EN 50 170. So it should be distinguished RD = 220 W (Type A to 12 MBaud) RD = 150 W (Type B to 0.5 MBaud). Do not use Type B when it is possible. (RD = 120 W for MODBUS).

2.1.2.2 Bus Interface Connection in Zone 1

Medium

Cable length

The same regulations apply when wiring the bus cables as with the power cables. In hazardous locations where there is a risk of explosion, the assembly regulations in accordance with VDE 0165 are to be observed. E.g. section 5.6.1.1: Cables must be chosen that meet the mechanical, chemical and thermal demands. 5.6.1.2: Any cables that are not being laid in the ground or in sand filled channels or are not otherwise protected against fire entrainment must have the fire characteristics proven... 5.6.3.1: Duct openings for cables and wiring to non-hazardous locations must be sufficiently sealed e.g. by sand bags, mortar filling. 5.6.3.3: Cables that lead through locations that are particularly subject to thermal, mechanical or chemical demands need to be protected, e.g. by laying protective pipes, plastic hosing, metal hosing with side protection (terminal sleeves) or by covers...

Bus participants

The cable length can be increased using bidirectional amplifiers (repeaters). A maximum of 3 repeaters may be inserted between 2 participants. The following limitations must be observed at < 93.75 kBit/s with serially connected data lines: 0 Repeater 1.2 km one master plus 31 participants with 48 I/O modules each (1488 modules). 2.4 km and 62 participants (2928 modules).

1 Repeater

The participants are connected to the bus by means of a double terminal in the form of a T-connection. The terminal assignment is as follows:
X 1 .4 + 5V X 1 X2.2 .2 D aB1n te X 1 .5 X2.1 An D a te1 390 X 1 .3 DGND

2.1.2.3 Earthing and Screening

RS 485/2
390

X 1 .4 X2.6 + +V V 55 X 1 .2 X2.5 D a te n Data

RS 485/1
39 W 390 0

RD

120 0 12 W

RD

220 0 12 W

X2.4 X 1 .5 Data D a te n Service bus

X 1 .3 X2.3 DGND ISO_GND2

3900 39 W System bus

Terminal assignment for bus termination B u s a b s c h lu K le m m e n b e le g u n g Fig. 23

B u s a b s c h lu K le m m e n b e le g u n g

Wiring and cable screens are, depending on the application, to be earthed at one or both ends. Earthing at both ends is not permitted if earth loops could occur, or if the screen is being used as a return line. Large scale earthing of the screens in the CEAG field stations is provided by means of the metal screw fittings. The screen end of the input/ output lines are thus connected via the metal casing or metal-coated part of the plastic casing to the earthing point X1.3 (refer to operating instruction FB 92XX). This earthing connection is to be connected with the equipotential bonding for applications in ZONE 1.

13

There is no earthing of the screens on separate screen bars in the casings as electromagnetic noise fields could gain entrance into the inner casing this way. The screening effect must therefore be guaranteed and all wires and cables including the network and bus connections must be screened. For Profibus screening also see the literature offered by the Profibus User Group.

2.1.3 System Expansion

In order to be able to set up additional bus stations during operation, it is advisable to fit empty stations at the positions provided at the initial installation stage. A station can then be connected there at a later point in time (Fig. 24). Substations can be extended during operation if the necessary measures were taken during initial commissioning. An extension of the bus line during operational running would require the removal of the bus termination resistor. In this case, operational running can only be maintained by means of redundant stations.

co-exist. CEAG already offers the HART protocol via the service bus. In the future, with the assistance of the PROFIBUS DPV1, it will be possible to allow HART communications via the system bus and to carry out the configuration and parameterisation of the field stations. PROFIBUS PA devices are fed via the bus as intrinsically safe participants and the parameters can be remotely set just like HART devices. They work at a data rate of 31,25 kBaud that is much lower than the normal bus speed used for the PROFIBUS which is 1500 kBaud. PA field devices are fed intrinsically safe via segment couplers. At the same time the segment couplers are used to increase the data rate to 93,75 kBaud in order to make the connection with a PROFIBUS Master possible. Alternatively PA field devices can be coupled directly to the PROFIBUS DP via LINKs and Exi-feed buffers. These LINKs allow shared use of the bus for CEAG field stations and PA field devices of any manufacturer. Normal structural components are used in the process (Fig. 25).

2.1.4 PROFIBUS PA and DPV1

2.1.5 Redundancy

Ever increasing field device manufacturers are offering PROFIBUS PA devices that offer the user additional advantages that were previously only offered by HART devices. PA devices allow parameters to be set via the bus and to carry out diagnostic and repair work. In the coming years the technologies of both HART and PA will

Redundant bus couplers must be connected together via Exi-lines on the front panel. Active redundant couplers have flashing green LEDs on the front panel. Passive redundant couplers can be detected by a steady green light on the front panel.

2.1.5.1 Introduction

Station 1

Free station

Station 2

Station 3
with with Bus termination

Redundancy is used to make sure that the operation of a bus station continues even if a bus coupler is faulty. FB Remote I/O provides redundant buses and redundant bus couplers. If a bus line or a bus coupler fails, the higher ranking system switches to the redundant bus line. The redundant coupler has the same configuration as the primary coupler and continuously receives the same data that is also processed in the primary coupler. Because of that a bumpless change-over is possible when the bus line or bus coupler fails. Bus couplers are SLAVES to the bus and wait for a data request from the digital control center (DCS) or from programmable logic control system (PLC). The bus coupler interfaces the field bus with the DCS or PLC (master). A maximum of 31 bus couplers can be linked in parallel to the bus segment. If repeaters are used, a maximum of 126 (when using PROFIBUS) or 247 (when using MODBUS) FB-stations per master are possible. Every bus coupler has 2 serial interfaces, which are galvanically isolated: one bus link is for communication with the higher ranking system, PLC or DCS, the other bus link can be used as a service bus during commissioning, during maintenance or for transmitting the HART protocol.

Bus end

Fig. 24

heute verfgbare Lsung Possible solution PROFIBUS DP 1,5 Mbaud 93,75 kbaud Exi Exi Exi Exi L I N K 31,25 kbaud

ZONE 1 PA PA PA PA PA PA 31,25 kbaud PA PA 31,25 kbaud PA PA PA PA PA PA

.
Fig. 25

14

Each station supports 48 I/O modules. Without an additional amplifier 31 x 48 analogue circuits or 31 x 144 binary inputs or an arbitrary combination of inputs and outputs can be operated on one bus line.

2.1.5.2 Redundancy Concept

The primary coupler continuously checks the redundant coupler . For the master can constantly obtain the status information about the state of both couplers. When the master determines a communication fault communication, it changes over to the redundant bus within 200 ms and transmits the settings for the outputs. In the event of an internal failure or if the communication with its master is interrupted, the active bus coupler is switched to passive status automatically. It does not try to set outputs. In passive mode, the data from the I/O modules on the internal bus is only monitored, the addressing lines are in high impedance mode (tristate outputs). The redundant coupler then assumes the bumpfree control via the internal bus. If neither the primary coupler nor the redundancy coupler are connected to the Masters and the LB-/ FB-station, then the output modules are switched to a safe OFF status. Faults can be caused by faulty selectors, faulty power supply units, faulty I/O modules or faulty internal bus coupler components. All faults emit a collective alarm within the bus coupler. If the master detects such an alarm or if it cannot establish a connection with the bus coupler, it then addresses the redundancy coupler. Unclear change-over status can be monitored by a plausibility check in the master and can be verified by comparing it with the redundancy coupler. A malfunction in the redundancy coupler on the internal bus is also signalled by the status register of the primary coupler (Error 12, synchronisation fault). To check the complete functionality of both bus couplers, the functions of the primary and redundant couplers can be switched around; e.g. every 24 hours. The master needs to send the 0xF5 command to the primary coupler to switch the redundancy around. In a PROFIBUS operation, the values of both output bytes for the command/status pseudo module need to be changed to 0x00 and 0xF5.

Depending on the redundancy concept of the master, several options are possible: Redundancy concept A The simplest way of achieving redundancy envisages 1 bus cable and 2 bus couplers per station in which different bus addresses need to be used. That concept is not ideal because in the event of a bus failure (e.g. cable, master, etc.) not only one complete slave fails, but the complete bus line, i.e. up to 15 x 48 analogue circuits or 15 x 144 binary inputs or any combination of inputs and outputs (without repeater). Redundancy concept B The best form of redundancy envisages 2 bus cables and 2 bus couplers per station. That concept ensures that the function of the system is maintained even if a bus coupler fails.

2.1.5.3 Redundancy Function

The bus coupler controls the I/O modules via an internal bus. The 48 linkable I/O modules are addressed via the backplane segments. Redundant selectors are present for this purpose, which switch the respective internal bus through to the I/O modules. The selectors are each responsible for operating a segment of 12 I/O modules. The internal buses for the two couplers are connected to one another via a resistor to enable the primary coupler to use the redundant coupler as an additional module and to also enable the redundant coupler to read the data. The primary coupler and the redundant coupler have access to the I/O modules via the selectors and the data line. Both couplers constantly read all the incoming data. However, only one of the two couplers can set activated outputs. During commissioning, a fixed Timeout is used to decide between the two bus couplers with regard to who will be given access to the outputs. Subsequently, the Master determines which of the two couplers will be linked to the outputs. The redundant coupler receives identical field information by reading the data between the active coupler and the I/O modules on the internal bus. As a result, a bumpless change-over is made possible in the event of the failure of a coupler.

2.1.5.4 HART Communication in the event of redundancy

During HART communication, no continuous redundancy change-over should take place between the primary coupler and the redundant coupler, because the field units transmit their HART telegrams independent of the data transmission during redundancy. If the primary coupler diverts the HART telegram to the redundant coupler in the middle of a redundancy change-over, the primary coupler, which has sent the HART telegram, remains in stand-by mode. This type of situation should be avoided by making sure no redundancy change-over takes place during HART communication.

15

2.1.5.5 Power supply redundancy

The bus couplers get their power supply from the FB 9204 or FB 9215 power supply modules. During redundancy operation, the 2 power supply modules are individually able to supply the bus coupler and 24 I/O modules. The necessary wiring is already contained in the BACKPLANE segment. Should one of the power supplies fail, then the second power supply assumes the operation without any interruption. An error bit allows you to signal this fault in the process control room. NOTE: Each comm unit is supplied by one power supply. In case of redundancy the failure of a power supply will shut down the corresponding comm unit. The other one will maintain full operation.

2.1.5.6 Segmenting

The 48 I/O modules in a station are partitioned into 4 segments containing 12 modules each. Any 2 segments are supplied by a separate power supply in the case of redundancy and are independently linked to the bus coupler. The failure of a segment does not influence the other segments (Fig. 26).

2.1.5.7 Wiring in event of redundancy

Ex-i Modules
PROFIBUS MODBUS Bus1 Bus2 1 12 Selektor 1 memory comm 1 memory comm 2
Data Daten

Feldgerte Ex-i

The wiring of the redundant stations is similar to that of the standard bus configurations. Both buses are treated equally. You could operate 31 bus couplers on one bus line without a repeater (Fig. 27). Every station is linked to the next station via a Tpiece (installed double terminals). A bus terminating resistor is mounted at the last station. If you are pursuing redundancy concept A with only one bus, please remember that the 15 redundant stations have already been equipped with 30 bus couplers.

2.1.5.8 Configuring redundancy

13-24 Selektor 2

The task: bus couplers are to be configured with redundant service bus address N. Assumption: bus couplers (BK) are already set to the service bus address N. All bus couplers are supplied with the address N = 1 when they are shipped.

2.1.5.9 Initial configuration for redundancy operation

Segment 1 Segment 2 Segment 3-4

Fig. 26 Partitioning into 4 segments which are individually linked to the bus couplers
Master
Primary bus Primrbus redundant bus Redundanzbus

Proceed as follows for the initial configuration of a redundant station: The configuration of the field stations can be carried out under the following ambient conditions: - In the office with the help of configuration kit FB 9250, - In Zone 1 via the service bus, - In Zone 1 with hot work permit. Plug the redundant bus coupler into its slot in the redundancy rack if the primary coupler is missing (Fig. 28) and start communication by the communication interface.

Station 1

Station N

Station 31

Fig. 27 Redundant coupler Primary coupler

Fig. 28

16

Fig. 29: ( 1 ) Set the service bus address N + 128 (e.g. 130 for N = 2) in the device data window. ( 2 ) Select Save and confirm the option Save data in module with OK. After transmission, re- confirm with OK once again. Fig. 30: ( 1 ) Add the second bus coupler (primary coupler) to the appropriate slot. Establish communication with the primary coupler with the address N (e.g. N = 2). (2) Open the device data window for the primary coupler by double clicking on it. Mark the checkbox include redundant comm unit. The primary coupler and the redundant coupler can now be accessed as a pair and can be parameterised at the same time. Before to activating the redundancy the warning shown in Fig. 31 will appear. (3) Now you can also set other parameters, e.g. the bus address for communicating with the master, the type of protocol (MODBUS; PROFIBUS). Click the button Parameters to access the parameters of the redundant coupler. ( 4 ) When finished, press the button Save and send the station data to the bus couplers. Both bus couplers will receive their respective data.

Fig. 29 Configure the redundant coupler first.

The bus couplers now are passive and redundant at the internal bus of the station. The coupler with the service bus address N becomes active first. The second coupler will only activated when the first coupler fails or if a change-over command is issued via a bus telegram. For this purpose, it is necessary that the master transmit the 0xF5 command. It is now possible to configure the I/O modules (see Chapter 3). Caution: Bus monitoring is automatically set to 200 ms by the system. This minimum time is frequently exceeded by the Masters polling cycle. It should therefore be set to a realistic value, so that it is longer than the polling cycle duration which is needed by the master to address the corresponding station (e. g. > 5 sec). During configuration, you will come across the following warning (Fig. 32).

Fig. 30 Configure the primary coupler after the redundant coupler.

2.1.5.10 Retrofitting of Redundancy

The configuration of the field stations can be made under the following ambient conditions: Fig. 31 In the office with the help of configuration kit FB 9250, - In Zone 1 via the service bus, - In Zone 1 with the hot work permit. Procedure for refitting redundancy in previously configured stations (in the system, see Fig. 28): Fig. 32

17

Fig. 33

1. Remove the previously used primary coupler with the address N. 2. If there is no primary coupler, plug re dundant bus coupler into the slot in the redundancy rack and establish communi cation with the communication interface. 3. Set the service bus address N + 128 (e.g. 130 for N = 2) in the device data dialogue box. Select Save and confirm the option Save data in module with OK. After transmission, re-confirm with OK (see Chapter 2.1.5.9). Steps 2 and 3 could be prepared using the configuration kit. In that case it is not necessary to remove the primary coupler. 4. Add the primary coupler to the basic rack. Establish communication with the primary coupler with the address N (e.g. N = 2). 5. Load the existing configuration of this station from primary coupler (Fig. 33). The existing configuration is now present in the main memory. 6. Open the device data window for the primary coupler by double clicking on it. Mark the checkbox include redundant comm unit. The primary coupler and the redundant coupler can now be accessed as a pair and can be parameterised at the same time. 7. Click the button Parameters to access the parameters of the redundant coupler. (e. g. the address of the redundant coupler to be addressed by the master). 8. After completion, press the button OK and then select Save station in field in the Device dialogue window. The station data is now stored in both bus couplers. 9. The bus coupler now are passive and redundant at the internal bus of the station. The coupler with the service bus address N becomes activated at first. The second coupler will become activated once the first coupler fails or if a change-over command is given via a bus telegram. It now has a copy of all the I/O modules in order to ensure a smooth change-over possible at any time. For this purpose, the master must transmit the 0xF5 command. Caution: The bus monitoring is automatically set to 200 ms by the system. This minimum time is frequently exceeded by the Masters polling cycle. It should therefore be set to a realistic value, so that it is longer than the polling cycle duration which is needed by the master to address the corresponding station (e. g. > 5 sec). During configuration, you will come across the following warning (Fig. 32, previous page).

2.1.6 Bus Change-over

The redundant bus couplers are interconnected to each other via an intrinsically safe line that supplies the secondary coupler with the information from the primary coupler. If, the positive status signal of the primary coupler is not available because it displays a fault, an error signal is transmitted to the higher-ranking system via the system bus. The higher-ranking system must then transmit a change-over command.

2.1.7 Self-monitoring features

The I/O modules need no redundancy, because even with conventional technology, one assumes that modules with 1 to 4 channels have a high availability. In addition, all modules are self-monitoring and the incoming wires are monitored for interruptions or short circuits. The outputs switch over to a safe OFF status in the event of a fault. The time is set up in such a way, that the redundant coupler can take the control at the right time. A failure criteria is a lack of internal communication with one or both of the bus couplers. Every I/O module is equipped with selfmonitoring. Light emitting diodes (LED) on the front indicate the status of the module. The green LED lights up when the module correctly supplies secondary power and the module fuse is intact. The red LEDs display the monitoring status of the field circuits. All input and output circuits from the temperature sensor, the transmitter power supply circuits, binary inputs, valve outputs e.g. are monitored for cable breakage or shortcircuits. The yellow LEDs display the switch status of the binary inputs and outputs. The LEDs are largely visible through a round window on the front of every module. The internal data transmission between the modules and the bus coupler is protected by the Manchester code. In the case of erroneous data from an I/O module, 4 subsequent polling cycles will be attempted to obtain the correct information from the faulty module. If all attempts are unsuccessful, this triggers an error message. The selectors are equipped in such a way that they separate any faulty I/O modules from the bus, to avoid faults in neighbouring circuits. Malfunctions are stored as error codes in the bus coupler and could be read together with the measuring data by the mainframe. Every fault triggers a collective alarm in the bus coupler. The collective alarm and the red LED for the bus coupler are NOT automatically reset. An acknowledge command has to be issued by the system or via the service bus once all the alarm conditions have been rectified (see Chapter 7).

18

2.1.8 Collective alarm

Fig. 34 MODBUS Parameter

The bus coupler generates a collective alarm if one of the following error conditions exists: 1. I/O module line break 2. Incorrect or missing component device in an I/O plug-in slot 3. Defective I/O module 4. 4 communication errors in succession between the bus coupler and an I/O module. 5. Internal fault within the control processor of the internal bus. 6. Fault in the control processor of the PROFIBUS/MODBUS interface. Detailed error codes are listed in Chapter 6.1.5.1

one. Once the individual addresses have been set, the bus couplers can be connected to each other via the bus line. Starting from the main menu, the sequence of commands for establishing communications via the service bus is as follows: Headline Options Window Communication set-up

Set the communications port of your LAPTOP or PC (usually COM1). The baud- rate for the service bus is set at 9600 ex works. Bus couplers can also be configured by authorized users via the service bus. It is also possible to carry out the configuration in the office using the FB 9250 configurator KIT. . Starting from the main menu, the sequence of commands is as follows: Headline Module data Headline File Window Process module data Window Configure bus coupler

Fig. 35 PROFIBUS Parameter

2.1.9 Time Out

Fig. 36

The Master and Slave are both able to monitor the system bus data traffic. For this purpose a response monitoring time in the Slave and/or Master is activated. These times often lead to conflicts if the polling cycles are not adapted to the monitor periods. If the response monitoring time is ZERO, then both CEAG outputs remain frozen if there is an interruption in the data traffic. In order to achieve smooth resumption of traffic, measures must be in place to ensure that the Master does not set all the outputs to ZERO when it establishes a connection with the Slave. In the event of a failure in the internal data traffic between the bus coupler and the output module, the output switches to ZERO after approximately 0.5 seconds. The response monitoring period for the master should be considerably longer than the longest polling cycle. If in doubt, deactivate the monitoring function.

Process control systems or controls that are capable of setting parameters via the system bus can exercise direct access to the appropriate memory cells in the bus coupler. Should you have any questions, you can reach us via our HOTLINE (see READ ME file on the disk / CD-Rom supplied). Depending upon the desired system bus, further parameters can be set in the configuration window for the bus parameters (Fig. 34 and 35). Provided that the PLC and DCS support this high speed, a baud rate of 38.4 kBaud can be set for the MODBUS. At present transmission rates of up to 1.5 miobit/s are available for the PROFIBUS (see window at Fig. 37 next page). Further adaptations to the main system are possible with the PROFIBUS. In each case it is necessary to refer to the manuals for the DCS and PLC systems, as they contain details that are specific to the respective manufacturers and these allow optimum adaptation to the FB Remote I/O. Here the settings available with the FB Remote I/O for marshalling (packing) data, scaling analogue values, etc. are particularly useful, as the standard for DCS and PLC systems is used in various ways (see Fig. 36 and Software Marshalling).

2.1.10 Safety

Applications relevant to safety (e.g. Zcircuits or EZA) can be achieved with the help of the FB Remote I/O components with a separate signal path. Details for this can be provided upon request.

2.2 Configuration

The baud-rate and the bus address can be set via the service bus. Unless otherwise agreed in advance, the bus couplers have an address of 1 and a baud-rate of 9600 when they are delivered from the factory. During commissioning you can set the address to suit the system requirements. If all bus couplers have the same factory setting, initially only one bus coupler should be connected. Then all the other bus couplers are allocated an address one by one.

19

( 1 ) The model number of the module is entered automatically. For updates please see the READ ME file on the disk supplied. (2) The number of the firmware version. (3) TAG-No. or device identification no. with up to 20 characters. (4) Name of project or part of installation for which the bus coupler is responsible. ( 5 ) Description of the device for which the bus coupler is responsible.

1 2 3 4 5 6 7 9 11 10 14 15 16 17 18 8

12

13 Fig. 37

( 6 ) Unpacked data is transmitted following the module structure. - Data of I/O circuits can be packed to compress it into words. - Data can be packed in a user defined manner to group them into words. ( 7 ) Suppress consequences of alarm. ( 8 ) Temperature Class fixes values for installable power consumption, e.g. number of I/O modules. Pay attention to the user instruction of FB 92XX. ( 9 ) Installation of redundant bus coupler. After marking a new button parameter appears (see little menu). Click parameter to open menu for redundant bus coupler. Here you have the possibility to set only those values, which are marked by X in the menu Fig. 38; TAG-No. and bus address. (10) The bus time-out defines the period which will elapse before all outputs are set to ZERO following a total breakdown of communications on the bus. If this time-out period is ZERO, the station can also be operated without bus. Then a failure of the bus transmission is not used for disconnecting the outputs. (11) The bus connections are activated individually. (12) Bus addresses must range between 1-255 for MODBUS and 1-126 for PROFIBUS. The address 0 is blocked. (13) Open a window to configure further data for authorized users. Bus couplers can be configured for MODBUS and PROFIBUS applications. (14) Press the OK button after completion of the coupler specification. (15) Use CANCEL if you wish to abort all changes and return to the original setting. This button will return you to the main menu without carrying out any changes. (16) After configuration save the setting in the bus coupler. (17) Call up the works setting. (18) Call up HELP. MODBUS note: From software version 2.52/2.45 onwards there is an additional selection box under redundancy. Transparent Mode If this mode is activated then the passively switched primary coupler acts as a relay point. Here, the bus telegrams are exchanged via the intrinsically safe front connector of both bus couplers!

Fig. 38 Dialogue window in case of redundancy

20

2.2.1 ON-LINE

The system can now be configured station by station. You can do so ON-LINE or OFFLINE. For ON-LINE configurations simply place the I/O modules on the backplane in the desired order. Next use the command LOAD ALL FROM FIELD UNIT to load the hardware configuration from the station to be processed. Next double-click module position by module position and carry out the individual I/ O settings with the aid of the menu. Starting with the main menu, the sequence of commands is as follows: Headline Module data Headline Module Window Process data Window Load all from field unit

2.2.2 OFF-LINE

You can engineer a system using OFF-LINE configurations without actually having the hardware in your possession. You can store the configuration of each station on disk. The files can be loaded on to the hardware later. During this storage process the system will automatically check that the arrangement of the I/O modules with regard to type and sequence coincides with the configuration chosen during engineering. This gives the user complete support during the commissioning stages as mounting errors are automatically detected and indicated. For OFF-LINE configurations use the following commands starting with the main menu: Headline Module data Headline File Window Edit module data Window Edit

Caution! Check if the control system or the PLC will allow an ON-LINE configuration to be carried out. With some Master functions the bus station will run down temporarily after a change has been made. CEAG bus stations can be frozen for the time needed to reconnect, see 2.1.9. The Master must ensure that not all data is set to ZERO on detection of the new configuration.

A window (Fig. 39) will now display the first 6 I/O slots. By double-clicking the slot to be configured you will receive the list of standard modules available. Choose the type of module required from the list of standard modules. The exact type of module can be determined in the adjacent window (Fig. 40). Once you have double-clicked the module of your choice, the associated data spec sheet opens auto-matically for you to configure it. Once this task has been completed, the service programme returns to the selection window to choose additional I/O modules. Use the COPY button to make identical copies of the last I/O module you configured in any slot. After switching off the COPY mode you can proceed as initially described.

Fig. 39 Example: Module in slot 8 -Exi-temperature converter type FB 5202

Fig. 40 list of standard modules, select the desired module type. In the right dialogue window you can determine the module type.

21

2.3 Self-Documenting

As soon as you leave the configuration window the I/O modules will appear on the screen in the order which you have chosen on the BACKPLANE. This gives you an immediate document of the work you have carried out. You can also use this tool to establish your wiring diagrams. Use the following commands starting with the main menu: Headline Window Module data Edit module data Headline Services Window Set additional parameters

Display Headline Options Print Headline Options

Window Print preview Window Print

First of all you will see the window with the station set-up. Click CONTINUE to display a window in which the target designations of cable connections are listed. You can now create your cable wiring plans module by module. In addition to this, this file can be exported and can be used as an ASCII file in other software tools, e.g. AUTOCAD. The reverse is also possible, thus enabling you to import data from other programmes employing ASCII files. To do this use the following commands starting with the main menu: Headline Module data Headline File Window Edit module data Window Import

Fig. 41 appears: ( 1 ) Name of station or project using 20 alphanumeric characters. ( 2 ) Choose the desired field or main cable. ( 3 ) Selected I/O module. Define all slots one by one. (4) (5) (6) (7) Enter the target terminals Mx:y adding a description if necessary ( 8 ) Click a line in section 4-7 to make your entries. Enter the data in the columns of line 8. Again click the desired line in columns 4-7 to accept the data. ( 9 ) Continue to next window. (10) Abort session without accepting any changes. (11) Call up HELP. All the parameter settings carried out with the bus coupler are registered automatically and can be printed out. To do so use the following commands starting with the main menu:

The resulting documentation will print a station layout which the field engineer can use to assemble the station hardware. It also documents the configuration of each individual module so that you can check on the measuring ranges and additional parameters. These settings, including the additional texts per measuring point, can be stored in a file (FILENAME.Ibu). Any notes and device specific comments can be stored on file. However the information will not be stored in the comm unit. It can be reassigned to the substation at a later stage when loading data from the comm unit. During that process you will be asked whether data should be added from an existing file.

1 2

10 11

Fig. 41

22

2.3.1 Station Layout

The automatic documentation provides a general plan showing all the modules that have been configured (Fig. 42). With this

plan the field engineer can install the modules on the backplane segments in the correct order. An error signal is given if a module is not in the correct position.

FB Remote I/O Unit

Fig. 42 Automatic documentation

23

2.3.2 Printing TAG Numbers

The configuration software allows you to print device identification labels (TAG numbers). Starting with the main menu select OPTIONS. Next activate PRINT TAG LABELS. Fig. 43 appears. Print on blank paper first before using the sheet of blank labels provided. Adjust the settings suggested in the window to the millimetre to match your printer. The setting is stored. Print a test page with the offset setting at 0. Insert the difference between the measured offsets to the set point offsets in the corresponding parameter box. The set point offsets in diagram 44 are to be taken into account. Fig. 43

The labels are also suited for labelling the carrier plates of the backplane segments. The labels should be affixed after printing (see 2.4 Station Set-up). TAG numbers or measuring point designations can comprise up to 20 characters. This does, however, influence the size of the lettering, as the lettering space for narrow modules is only small. With multi-channel modules it is advisable to limit the number of characters per channel to 4, e.g. PTIC 1234 3781 5783 (3-channel). Please print out the labels in duplicate. Affix the labels as shown in Fig. 45 and 46.

32.0

23.0

13.5

Fig. 44 Test page (dimensions in mm)

Space for Platz fr TAG Nr. TAG No

Fig. 45 I/O modules

10.0
TAG TAG

Fig. 46 TAG numbers for backplane

24

2.3.3 Terminal Plans

The software draws up the terminal plans for each station from the configuration data

for the I/O modules that you enter (Fig. 47).

Fig. 47

2.3.4 Configuration Data

The software draws up plans according to slots based on the module related data for

each station from the configuration data for the I/O modules (Fig. 48).

Fig. 48

25

2.3.5 Data Structure

When the software marshalling mode for the I/O modules is activated, the documentation software draws up a list of the marshalling addresses of each station (Fig. 49). To insert your own logo replace the Localbus.wmf file or .emf at 32 Bit compu-

ters with one of your own that has the same format. To do this open the file with a suitable graphics program and replace the CEAG logo. The file must be stored under the name Localbus.wmf or Localbus.emf.

Fig. 49

26

2.3.6 Importing - Exporting of Data

Having created your cable wiring plans module by module, you can export this file and use it as an ASCII file in other engineering programmes, e.g. AUTOCAD. The reverse is also possible, thus enabling you to import data from other programmes employing ASCII files. To do this use the following commands starting with the main menu. Headline Window Module data Edit module data Headline File Window Import

FB 1202: Line monitoring channel 1 (on/off); Line monitoring channel 2 (on/off); Line monitoring channel 3 (on/off); 6* terminal data: Cable from (14 characters); Terminal specification (20 characters); Wire-No. (5 characters); Cable name (15 characters); FB 1203: Line monitoring channel 1 (on/off); Burn-out drive (-20% = 0, 0% = 1, 100% = 2, freeze = 3), Break delay (1 - 255 * cycle time); Measurement mode; Counting direction for pulse measurement (no significance); Action triggering for pulse measurement (no significance); Beginning of range (frequency measurement); End of range (frequency measurement); Prescaler (pulse measurement); Counter limit (pulse measurement); Input filter (0-4), 4 * terminal data: Cable from (14 characters); Terminal specification (20 characters); Wire-No. (5 characters); Cable name (15 characters); FB 2201 - FB 2213: Line monitoring channel 1 (on/off); Line monitoring channel 2 (on/off); Line monitoring valve (on/off); Local connection (LC) (inactive = 0, active = 1); Type of LC (digital = 0, analogue = 1); Type of LC (normal = 0, inverse = 1); LC with module at slot (1-48); and with channel (1-3); Limit value (0-100%); Hysteresis (0.0-10.0% = 0-100); 6 * terminal data: Cable from (14 characters); Terminal specification (20 characters); Wire-No. (5 characters); Cable name (15 characters); FB 3201-FB 3203: Line monitoring channel 1 (on/off); Burn-out drive; Limit for wire break (0.00-25.99); Limit for short circuit (limit FB-26.00); 3 * terminal data: Cable from (14 characters); Terminal specification (20 characters); Wire-No. (5 characters); Cable name (15 characters); FB 4201 - FB 4203: Line monitoring channel 1 (on/off); Local connection (inactive=0, active=1); LC with module at slot (1-48); 2 * terminal data: Cable from (14 characters); Terminal specification (20 characters); Wire-No. (5 characters); Cable name (15 characters); Minimum current;

The data in this file is arranged in the order of the modules. The configuration of the individual modules is stored in the file as in the following text described. This way, the configuration drawn up in the PLS can be transferred correctly to the hardware of the field stations.

2.3.6.1 Format of the Import / Export File

The character lengths stated are maximum character lengths

Line 1, 1st character: The first character in the first line of the file contains the separator for the data (e.g. semicolon). Further characters up to the first new line are arbitrary. 2nd to last line: One line corresponds to one module. The format of the line is specific to each module. General: Applies for all modules Type (e.g. 8201/8202, 1201,1202,...,5201); Type extension, currently not in use (all information included in type code); Slot number; Communication status (active = 1, passive = 0); TAG-No. (20 characters); Software marshalling parameters (per channel, analogue modules = 1 channel): Marshalling active (inactive = 0, active = 1, not in 82XX); Normal / inverted (0/1); Register address, Bit address (of no significance for analogue modules, !! however, the position must, for example, be assigned with BLANK as otherwise the data structure would be destroyed !!); FB 1201: Line monitoring channel 1 (on/off); Line monitoring channel 2 (on/off); 4* terminal data: Cable from (14 characters); Terminal specification (20 characters); Wire-No. (5 characters); Cable name (15 characters);

27

FB 5201 - FB 5202: Line monitoring channel 1 (on/off); Burn-out drive (-20% = 0, 0% = 1, 100% = 2, freeze = 3); Break delay (1-255 * cycle time); Cycle time in ms; Mains filter (50 Hz = 0, 60 Hz = 1); Temperature unit (C = 0, F = 1); Measurement mode; Measurement sensor; Start of measurement; End of measurement; Reference junction value; Input filter (0-4); 4 * terminal data: Cable from (14 characters); Terminal specification (20 characters); Wire-No. (5 characters); Cable name (15 characters); for FB 5202 only: Duty cycle of PT 100: TC sensor for internal VST (1-255); FB 820X: Name of project (20 characters); Field bus connection 1 (inact.=0, act.=1); Field bus connection 2 (inact.=0, act.=1); Bus address (1-255); Address FBA 1; Address FBA 2; Data format; Type of cable (22 characters); Description of measuring point (25 characters); Baud rate PC, (of no significance: setting = 9600); Baud rate FBA 1, (of no signif. for PROFIBUS); Baud rate FBA 2, (of no signif. for PROFIBUS); Parity PC, (of no signif., no settings); Parity FBA1, (of no signif. for PROFIBUS); Parity FBA2, (of no signif: for PROFIBUS); Bus time-out time (in s); Bus type (Modbus-Modbus (0), Modbus redundant (1), ProfibusModbus (2), Profibus redundant (3)), Profibus type (DP (0), FMS (1), DP/FMS (2), PA (3)); Profibus-DP parameters: Modus, Meanings of bits (0 = no, 1 = yes) Bit0: Module status range Bit1: Status/command word Bit2: Outputs scaled separately Bit3: Inputs/outputs scaled Bit4: packed (data from Xchange range) Bit5: Block / modular Bit6 = 1 (reserved) Bit7 = 1 (reserved) Factor for input scaling, (0.002...1.999) Offset for input scaling, (0.002...1.999) Factor for overall output scaling, (0.002...1.999) Offset for overall output scaling, (0.002...1.999) Redundancy (master = 1, slave = 2 (is 2nd coupler)); Deactivate alarm (0 = no, 1 = yes); Temperature class ( 0 =T4, 1 = T6) additionaly activate bus monitoring (0 = no, 1 = yes); Offset for datas of local access (0-38);

2.3.6.2 Example for Importing/Exporting of Data

A redundant system consisting of two redundant bus couplers is exported (not a I/O module). Similar to this example are the data of the other I/O modules. First bus coupler: ;; 8202; 0; 0; 1; FB 820X-m; 0; red; 1; 0; 1; 2; 0; 1;; Bus coupler; 4; 4; 0; 0;0;0; 0; 1;0; 224; 1.1;1;0.9;2; 1; 1;1;1; 0;0;0;0; semicolon type extension slot active TAG-No. no marshalling parameter name of project FBA1 active PC-address address FBA1 address FBA2 format of data unpacked baud rate FBA1 FBA2 parity bus time-out DP-parameter redundant (master = 1st coupler) PLC-parameter

2nd bus coupler: 8202;0;0;1;FB-820X-s;0;red;1;0;1;1;0;1;; bus coupler;4;4;0;0;0;0;0;1;0;224;1.1;1;0.9;2; 2;1;1;1;0;0;0;0; slave when redundancy (is 2nd coupler) Notes to the example: baud rate 1 = 1200 2 = 2400 3 = 4800 4 = 9600 5 = 19200 6 = 38400 parity 0 = non 1 = even 3 = uneven DP-parameter 247 = 11110111 (bit7 ... bit0) The possible settings in the menu bus coupler FB 8201/2 and redundant bus coupler FB 8201/2 are written in chapter 2.2.

2.3.7 Power Failure Protection

An EEPROM secures all data in the event of a power failure. However, it is advisable to save a BACKUP file on disk or hard disk as this data can be used to produce duplicate copies of the bus coupler. The memory is designed for 10 000 write cycles.

28

2.4 Station Set-up

Buskoppler

bus coupler /

Each bus station consists of a bus coupler and various I/O modules. The stations are prefabricated ex works and feature slots for 24 or 48 modules and terminals for the bus connection and power supply (Fig.50). You may also use two separate redundant power supplies (e.g. battery back-up) as these are decoupled by diodes at the supply point. The bus coupler occupies the first slot on the left (Fig. 51). It is the link between the DCS or PLC and the I/O modules that are plugged into the BACKPLANE segments. Each BACKPLANE segment features 12

Field wires are connected to the I/O modules via front screw terminals using the plugin PHOENIX COMBICON system (Fig. 52). The connectors are designed for wires up to 1.5 mm in diameter. However, it is advisable not to use wires of more than 0.75 mm (Fig. 53). Plugs can be mechanically coded to avoid any confusion regarding connections. To do this you can remove one or more of the 6 plastic pins provided on the plugs. Accordingly, small plastic inserts are placed in the front sockets of the I/O modules in the corresponding positions. This gives you 26 =64 combination possibilities (see Fig. 54). A COMBICON plug with housing and integral Pt100 sensor is provided for cold junction compensation in thermocouple measurements (see Fig. 55, next page).

2.4.1 Field Wiring - Mechanical Coding

power supply /

Fig. 50

Netzteil

power supply/

bus coupler/

bus coupler/

Buskoppler

Buskoppler

Netzteil

2.4.2 Power Consumption

power supply/ power supply/ power supply/

Netzteil

Netzteil

Fig. 51 Redundancy station with 48 slots FB 9249

Plug-in screw connector with enclosure for FB remote I/O FIELD BUS on request only Enclosure Plug-in screw connector Plug-in screw connector

Netzteil

The power consumption and the power dissipation of the FB Remote I/O modules are written in the operating instructions FB 9225 to FB 9249.

2.5 Local Connections

6 5 4 3 2 1

Analogue and digital I/O modules can be interconnected locally. In addition to the transmission of data to the DCS or PLC system, input signals are then also used to drive outputs. This feature opens up the applications Fig. 56, next page. An output used locally is not accessible to the DCS or PLC system. Should the bus link fail, a locally driven output does not drive down to ZERO, but continues to follow the instructions given by the input to which it is connected. In addition to the local connection, there is a software tool available that opens up the possibility of mathematical functions, conditional transfers, control algorithms, logical configurations and many other functions that relieve the bus and provide the bus station with even more intelligence (Disk available on request).

Multi-core cable

Fig. 52 slots for I/O modules. A supply modules FB 92XX is required for every 24 slots. An additional BACKPLANE segment is provided when a redundancy coupler is used. This is accommodated in a redundancy enclosure (see catalogue). Unused slots can be left empty for future extensions.

coding piece
Fig. 53 Screw plug-in connectors PHOENIX COMBICON MC 1.5/6-STF-3.81 with fixing screws of the type FB 9107 (recommended type) The TAG-No. or measuring point number can be printed using the configuration software.
TAG Nr.

6 5 4 3 2 1

Kodierfahne

coding piece
Example of a coding piece and pin assignment.

Fig. 54 Example of an I/O module

29

COMBICON plug COMBICON Stecker

Pt100 Vergleichstellenmodul Cold junction module for measurement with thermocouple fr Thermoelementmessungen FB 9112
Fig. 55

Example of a local connection (Fig. 57) ( 1 ) The module type is entered automatically. ( 2 ) TAG-No. or measuring point number with up to 20 characters. ( 3 ) Number of the slot currently being processed. ( 4 ) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the query. The actual state of the module is shown. In the above example the simulation mode is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). ( 5 ) Line monitoring (LFD) On/Off. ( 6 ) Here you activate the local connection. ( 7 ) Local connection with slot 1 (example). ( 8 ) Space for notes. ( 9 ) Click OK after completing the description of the measuring point. (10) Press CANCEL if you want to restore the original setting ignoring the changes

that have just been entered. This command returns you to the main menu without registering any changes. (11) You can load any I/O configurations that already exist from disks or from the hardware. (12) You can save the entries made on disks or in the hardware. (13) You can recall the original setting status, but remain in the current configuration window. (14) Set input and status values for testing purposes during service and commissioning. (15) Call up HELP.

2.6 Commissioning - Maintenance

Output Analogue output

Connected to Transmitter supply Temperature input Temperature input Transmitter supply Digital input FB 1203 Temperature input Transmitter supply Digital input FB 1203

Application Field display Signal duplication Discrete controllers Connection to second DCS Trip amplifier Trip amplifier Switch amplifier Dosing system 2 point controller Acoustic sounders Lamp driver Dosing system

During commissioning it is possible to test each field circuit via the service bus without having to use the DCS or PLC system. The mounting position of each module can be taken from the documentation which is automatically generated while you configure your station. When you commission a system, you simply transfer the configuration from file to the bus coupler. An automatic check is carried out comparing the configuration of the station with the hardware installed by your members of staff. Any discrepancies will be displayed on your LAPTOP so that you can take corrective action immediately. Either you replace the wrongly placed I/O module or you change the configuration. During servicing it is possible to replace faulty modules on-line while the rest of the system continues to operate. Modules taken from stock need not be reconfigured. Calibration is not necessary. Once you plug the correct module into position to replace its identical predecessor, it will automatically receive the same parameter settings as this predecessor - from measuring range to burn-out drive. In order to transfer a station configuration to a bus coupler use the following commands starting from the main menu. Headline Module data Headline File Window Edit module data Window Open file

Solenoid valve driver

Fig. 56

1 2 4 5 6 7 3

9 10 11 12 13 14

The station data has now been transferred from the file to LAPTOP memory. Headline Device Window Store all in field

15

The configuration is now transferred to the station. Then, as explained above, an automatic check of the configuration against the hardware is carried out.

Fig. 57 The parameters can be set after the module data for the output module has been called up.

30

From version 2.52/2.45 onwards there is an additional menu with the following choices: Device Store station in display with restart of the bus coupler without restart of the bus coupler Caution! A restart will temporarily set all outputs to ZERO. A restart is necessary when address sections are being shifted in the packed mode. A restart is not necessary when working in the packed mode if things are only being deleted or if adding information into empty locations. Caution! Carrying out several changes at various times may make it necessary to perform a restart. A restart is not necessary if reconfiguring in the unpacked mode. Once the data transfer has been completed, you can check the system loop by loop. An explanation of how to handle each I/O is given in the description of the individual modules.

the PLC or DCS being used (see 6.3 FB 8202 MODBUS Data Interface). With the PROFIBUS a GSD (basic device data) file allows a high speed connection to your system. The identification number of the FB Remote I/O BUS file that was issued to CEAG by the PROFIBUS User Organisation to allow the unmistakable identification of SLAVES from several manufacturers during operation is: 0710 HEX (file CEAG0710.GSD). The PROFIBUS knows 3 protocols. The PROFIBUS DP is designed for the high speed data exchange from the sensor / actuator level to MASTER / SLAVE operation. A multi-master operation is only possible if they form independent subsystems that are allocated to a DPM1 master. The PROFIBUS FMS (field message specification) allows the intercommunication of automation devices, as well as the communication of automation devices with intelligent field devices. Multi-master operation is possible here. The multi-master capacity requires a protocol structure that is considerably more extensive than that of the PROFIBUS DP and, therefore, with the same timing-pulse rate on the bus, it results in longer cycle times. PROFIBUS PA with intrinsically safe field bus devices requires an appropriate intrinsically safe supply unit. However, due to the explosion protection, the transmission rate for the Exi field bus and the number of participants is extremely low. During commissioning it is advisable not to commission all the SLAVES at one time, but to connect the participants with the master one after the other. A commercially available bus monitor that can listen in on the bus telegrams as a passive participant is recommended for error analysis. FB Remote I/O BUS stations receive their addresses via the service bus (works setting Address 1). The I/O modules are to be determined relative to the station address in accordance with the annex. LEDs on the front of the bus coupler indicate data transmission. If, when a SLAVE is called up, no yellow LED of the bus coupler lights up (blinks), the transmission line of the master is interrupted (interface fault in the master or cable fault). If communication cannot be established, it is possible that the wrong station address was given. It is also possible that the terminating resistor of the bus is not connected, or that non-approved branch lines were installed instead of short T-junctions. When installing the bus, take care that there is no confusion of the transmitting and the receiving lines RTD-P and RTD-N (see 2.1.2 RS 485 Bus). The result of this could be that this SLAVE cannot be reached, but all others. If confusion occurs during the looping of terminals, all the subsequent participants also cannot be reached. Pay attention to the fact that the parameters or configuration of the MASTER and SLAVE match and that the correct identification number has been selected. In the case of PROFIBUS applica-

2.6.1 Commissioning Information

It is only possible for us to give limited important information regarding the use of the bus interfaces here. Additional information on various system couplings is available on the CD ROM. Detailed information on the MODBUS and PROFIBUS can be found in the specialized literature, e.g. MODBUS Protocol Reference Guide (from: AEG Schneider Automation Essen), PROFIBUS DP Schnelleinstieg or the Technische Druckschrift PROFIBUS (from: PROFIBUS Nutzerorganisation Karlsruhe). GSD (basic device data) files that allow a high speed linkage of the SLAVES from various manufacturers with the PLC or DCS are supplied for the FB Remote I/O BUS and can be called up via Internet from the PROFIBUS User Organisation. Address: Http://www.PROFIBUS.com For Siemens systems we also supply a TYPE file. That file should be deleted for PCS 7, because the GSD file will be more comfortable for the operator. Bus protocols define the structure of the data packets that, independent of the bus participants, are recognized by the transfer paths being used. They describe the way in which processors request data from other devices how they react to these requests, and how errors are detected and reported. MASTER / SLAVE techniques are used here. The MASTER is the only bus partici-pant that can request data from others or issue commands. The bus protocol deter-mines the set-up of the command struc-tures. The setup of the data packets for MODBUS and PROFIBUS data protocols are described in the annex to this manual. Please note that the MODBUS has 2 addressing modes, namely the MODBUS and the MODICON addressing modes. The I/O addresses of the FB Remote I/O BUS modules described in the chapter MODBUS Addressing must be called up according to

31

tions, the FB Remote I/O helps you to set the correct configuration if you call up the DP configuration string in the menu (Fig. 58). The definitions listed in the annex apply here, e.g. 10 = digital input, 51 = count input, 60 = analogue input, etc. Set the station configuration with your master configuration soft-ware with the aid of the GSD (basic device data) file. With Siemens systems you can use the TYPE file supplied together with the FB Remote I/O Manual. That file should be deleted for PCS7, because the GSD file is more comfortable for the operator. A common cause of faults is the absence of terminating resistors at the start and the end of the bus (accessories: terminating resistors). It is also important that the polling cycle of the master and the time-out (watch-dog) of the slave match. (Set time-out of PLC or DCS). The various process control and programmable control systems have their own data structures that can be adapted in an optimum way to the FB Remote I/O slaves with the aid of software marshalling (see Section 5 Software Marshalling). Siemens TELEPERM systems can, for example, process only 32 bytes input data and 32 bytes output data per SLAVE.

However, the accuracy of analogue circuits requires the transfer of 2 bytes per channel, i.e. in this case only 16 analogue inputs can be used in a FB Remote I/O station. Mixed installations can be planned with the aid of the data in the annex. The data volume required per module is described in Section 5 Software Marshalling. For communication via serial interfaces Fisher Rosemount forms 31 data blocks that can be adapted to the station set-up. The FB Remote I/O software marshalling can be used to utilize these 31 blocks to the full, as this makes it possible to combine analogue and digital circuits. Without this software marshalling it would be necessary to form 4 groups made up of analogue inputs, analogue outputs, digital inputs and digital outputs within the hardware of a bus station. The sequence of the modules of a station would then no longer be arbitrary in the way that is actually made possible by the FB Remote I/O. NOTE: If you use the software marshalling, you should assign free spaces for later extensions. Otherwise, when new modules are added, the marshalling addresses shift and make it necessary to change the parameter settings of the PLC or DCS.

Fig. 58

32

3 How to Configure I/O Modules

Below, the adaptation of the module and output signals is described in detail with the help of standard bus systems which have already been successfully coupled in many installa-tions with different systems via PROFIBUS DP and MODBUS. In the case of digital inputs which are located in the same station with digital outputs you can use the economically priced combimodule FB21XX which offers inputs and outputs at one plug position. On request, both a double bus coupler and a double power supply for the bus coupler are available. This is a special advantage of the CEAG concept. All I/O modules have the monitoring connections for lead breakages and short circuits stated in the data leaflet. Disturbances of the transmitter which can be recognised by leaving the measuring range, are also recorded. The status information can be called up via the bus. The terminals for the input/output circuits have been developed as screw-plug connectors of the PHOENIX COMBICON systems. On request, terminals with cage clamp connectors are available. All types as per norm DIN 19245 are suitable as bus cables.

3.01 Introduction

sonnel by means of assistance information on the nature of a defect. The modularity of the system allows simple extendibility even in small units. An extension of the installation is possible during operation if this function is supported by the master system or by the memory programmed control system. Further technical data are contained in the handbook and the catalogue. All I/O modules can be adapted to specific tasks. When a module is replaced, the setting of the predecessor is automatically transferred to the new unit. Therefore adjustments or recalibration have become a thing of the past (no address settings required). Therefore modules cannot be mounted in the wrong position. Additional information can be entered for each module. This data can only be stored on file, not in the bus coupler or the I/O module. However, when the station is being loaded from the field, it can be reallocated to the original configuration per file access.

3.03 Signal Processing

3.02 Module Replacement

All modules can be replaced during operation. Status information on binary inputs and outputs is recognisable by front LEDs on the modules. The components are to a major extent maintenance free. Replacement devices are pluggable and self configurating. Alignment and address setting are not necessary. The software supports the maintenance perInput / output Binary input Binary output Analogue input Analogue output Temperature Fig. 59 Signal Switching position, valve position, etc. Solenoid valve, detector, etc Pressure, head mounted transmitters, Throughflow, analysis, etc. I/P converter, position regulator Pt100, thermocouples Form of signal NAMUR, contact active, V, mA 4-20mA 4-20mA W , mV

The measured values are kept available with a high data rate in a memory for delay free call up by the master system. The refreshing of the data is carried out with a station fully equipped with 48 plug positions according to figure 59. Details can be seen in the descriptions of the individual modules. The signal processing is carried out more or less simultaneously for all modules, however not synchronised. Monitoring for wire breakage and short circuits can be activated per input and output. Typical conversion < 5ms < 5 ms < 20 ms < 20 ms < 100 ms

33

If required, bus couplers are supplied with redundant auxiliary energy. For each I/O module a feed component is available. In this way a high availability is ensured. The structural components can be assembled horizontally or vertically. The failure of one bus station does not impede other bus stations. After return of the auxiliary energy of a bus station this is auto-

3.04 Functional Safety

matically reset and restarted. All structural components are earth free. There is a secure galvanic separation to the field side and to the mains. The I/O circuits are decoupled against earth and against EMC effects by suppressor capacitors. The devices bear the CE identification. A double power supply is possible (Figs. 60 and 61).

Field station with 48 slots

with redundancy

Power and bus connection terminals are double terminals, therefore the connection to the next station can be fixed there.

mains supply

buscoupler

mains supply

L(+) x1.2 N(-) X1.1 PE x1.3

+
Fig. 60

24 VDC redundancy common zero line

- 24 VDC
basis station common zero line

- x 24 VDC 2
extention station common zero line

Field station with 48 slots

with redundancy

Power and bus connection terminals are double terminals, therefore the connection to the next station can be fixed there.

mains supply

buscoupler

mains supply

L(+) x1.2 N(-) X1.1 PE x1.3

230 V redundancy

230 V basis station

2 x 230 V extention station

Fig. 61

mains supply

mains supply

buscoupler

mains supply

mains supply

buscoupler

34

10kW 2.2kW

The digital input module FB 1201 interfaces the process signals of mechanical contacts, NAMUR initiators, or opto-couplers with the DCS or PLC. The device features 2 channels that are independent of the bus and galvanically isolated from each other. Each channel is individually fitted with a line monitoring feature to test for open or short circuits. This monitoring function can be deactivated with the software. With mechanical contacts either the line monitoring is deactivated or the switch must be wired to a resistor combination to emulate a NAMUR initiator. Only then is it possible for the electronics to distinguish between a closed contact and a short circuit (see figure 62). The resistor network is available as an accessory. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs indicate the state of the field cables. They light up in the event of a short or open circuit. Yellow LEDs indicate the switching status of digital inputs. The green LED, the red LED of channel 1 and, if applicable, the yellow LED of channel 1 are visible in the front window of the modules. For explosion protection reasons it is not possible to display more LEDs. The maximum input frequency is 100 Hz per channel if supported by the master. For frequency measurements see FB 1203.

3.1 FB 1201 Digital Input

FB Remote I/O Fig. 62

3.1.1 How to Configure Digital Inputs

When you select the input module FB 1201 you will see the following device spec sheet (Fig. 63). The module can now be configured.

1 3 2 4 5 6 7 18 9

10 11 12 13 14 16 17

Notes for menu Switch Amplifier FB 1201 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) in channel1 indicating the status of the field wiring (OK or fault). (6) Line monitoring (LFD) in channel2 indicating the status of the field wiring (OK or fault). (7) Here you can activate or deactivate the line monitoring (LFD) feature. (8) Space for notes and remarks concerning the respective measuring point. (9) Number of the slot which is currently being configured. (10) Press OK to store the parameter setting. (11) Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. (12) LOAD allows you to load existing configurations from the disk or the hardware. (13) SAVE allows you to store configurations on a disk or in the hardware. (14) RESET allows you to restore the original parameter settings while staying with the present configuration window. (15) Call up HELP. (16) Interpretation of the input contact as logical 0 or 1. (17) Set input and status values for test purposes during service and commissio ning. (18) TAG no. per channel.

8 15 Fig. 63

35

3.2 FB 1202 Digital Input

10kW

2.2kW

The digital input module FB 1202 interfaces the process signals of mechanical contacts, NAMUR initiators, or opto-couplers with the DCS or PLC. The device features 3 channels that are independent of the bus and are galvanically isolated. The field circuits have a common negative potential. Each channel is individually fitted with a line monitoring feature to test for open or short circuits. This monitoring function can be deactivated with the software. With mechanical contacts either the line monitoring is deactivated or the switch must be wired to a resistor combination to emulate a NAMUR initiator. Only then is it possible for the electronics to distinguish between a closed contact and a short circuit (see figure 64). The resistor network is available as an accessory. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs indicate the state of the field cables. They light up in the event of a short or open circuit. Yellow LEDs indicate the switching status of digital inputs. The green LED, the red LED of channel 1 and, if applicable, the yellow LED of channel 1 are visible in the front window of the modules. For explosion protection reasons it is not possible to display more LEDs. The maximum input frequency is 100 Hz per channel if supported by the master. For frequency measurements see FB 1203.

3.2.1 How to Configure Digital Inputs

When you select the input module FB 1202 you will see the following device spec sheet (Fig. 65). The module can now be configured. Notes for Switch Amplifier FB 1202 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) in channel1 indicating the status of the field wiring (OK or fault). (6) Line monitoring (LFD) in channel2 indicating the status of the field wiring (OK or fault). (7) Line monitoring (LFD) in channel3 indicating the status of the field wiring (OK or fault). (8) Here you can activate or deactivate the line monitoring (LFD) feature for channel 1, 2 or 3. (9) Space for notes and remarks concerning the respective measuring point. (10) Number of the slot which is currently being configured. (11) Press OK to store the parameter setting. (12) Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. (13) LOAD allows you to load existing configurations from the disk or the hardware. (14) SAVE allows you to store configurations on a disk or in the hardware. (15) RESET allows you to restore the original parameter settings while staying with the present configuration window. (16) Call up HELP. (17) Interpretation of the input contact as logical 0 or 1. (18) Set input and status values for test purposes during service and commissio ning. (19) TAG no. per channel.

FB Remote I/O Fig. 64

1 3 2 19 10

11 12 13 4 5 6 7 14 15 18

8 17

9 Fig. 65

16

36

3.3 FB1203 Digital Input

CH 1
Direction Richtung 10kW 2.2kW

The digital input module FB 1203 interfaces the process signals of mechanical contacts, NAMUR initiators, or opto-couplers with the DCS or PLC. The device features 2 channels. One channel is designed to determine the direction of rotation or the direction of counting - up or down. The device can be used to perform the following tasks: 1) Frequency measurements up to 15 kHz. 2) Frequency measurements with pulse counting to 50 Hz. 3) Frequency measurements with determining direction of rotation to 15 kHz. 4) Frequency measurements with determining direction of rotation and pulse counting to 50 Hz. 5) Pulse counting to 15 kHz (109). 6) Pulse counting with determining direction of rotation ( counter forward and backward to 15 kHz). The module features a line monitoring feature to test for open or short circuits. This option can be deactivated in the software. With mechanical contacts either the line monitoring is deactivated or the switch must be wired to a resistor combination to emulate a NAMUR initiator. Only then is it possible for the electronics to distinguish between a closed contact and a short circuit (see figure 66). The input is interrupt-controlled so that no pulse is lost. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs indicate the state of the field cables. They light up in the event of a short or open circuit.

1 2 3 4

5 6

Frequency Measurements Frequencies from 1mHz to 15 kHz are measured. The result of the frequency measurement is transferred as an integer value with 0.1 % accuracy to the bus coupler. Depending on the frequency measured, new results are registered here from every 5 ms (200 Hz) to every 1000 ms (1 Hz). The frequency is measured using the internal 16 MHz quartz crystal to measure the time that elapses between 2 pulses. The shortest pulse duration is 20 ms. Direction of Rotation (Up / down counter) The second digital input allows you to detect direction of rotation by registering the phase shift between the 2 pulses. The result is transferred to the bus coupler as a status bit. In this respect the maximum counting frequency is 1000 Hz. In figure 67 function 5 is explained when two sensors transmit a phase displaced signal to the module. If the channel 1 impuls input is logical 1 and at the same time the direction of rotation input is logical 0, than counting goes forward. If the channel 1 impuls input is logical 1 and the direction of rotation input is logical 1, than counting goes backward. Pulse Counter The counting direction is determined by the switch position of input 2: Contact closed = upwards, Contact open = downwards. When configured as a pulse counter the module has a 4 byte counter to count up to 109 with pulse rates up to 15000 pulses per second. You can pre-set the counter at a given value using the system bus. When the START bit is set, the counter starts to work, starting from 0. A status bit will tell you when the preset value has been reached. The status bit is not reset until the counter is restarted via the bus. This allows you to build dosing systems (FB 220X). The frequency can be measured at the same time and transmitted as measured value. Remark: In redundant systems both comm units will register the pulse count. However if you remove or power down one of them the memory contents of the counter in that comm unit will be lost.

FB Remote I/O Local Bus Fig. 66

Direction of rotation Binary input LB / FB 1X03

direction 10 kW

2.2 kW

ch1

Rtg.

forward

ch1 1 Rtg.
Fig. 67 NOTE: In the frequency mode the measured value will be zero until the first two pulses have been registered. In live zero systems (ranges 10 000 - 50 000) this will lead to a negative result.

backward

37

3.3.1 How to Configure Digital Inputs

(8)

When you select the input module FB 1203 you will see the following device spec sheet (Fig. 68). The module can now be configured. Notes for menu Counter / Frequency Converter FB 1203 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE config.). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty). (6) The number of the slot being configured. (7) Here you can activate or deactivate the line monitoring (LFD) feature.

(9) (10) (11) (12) (13) (14) (15)

(16) (17) (18) (19)

Set the delay to elapse until a line fault has been accepted as rectified. Determination of the measured value (burn-out drive). Selection of the operating mode (frequency measurement, determination of direction of rotation, pulse counter) Start and end of measurement for frequency measurement. Counter value for setting the status bit (dosing). Activates the time filter. Press OK to store the parameter setting. LOAD allows you to load existing configurations from the disk or the hardware. RESET allows you to restore the original parameter settings while staying with the present configuration window. Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. SAVE allows you to store configurations on a disk or in the hardware. Call up HELP. Space for notes and remarks concerning the measuring point. Set input and status values for test purposes during service and commissioning.

1 2 3 4 5 7 8 9 6

12 13 14 19

15 16

17

10 11 Fig. 68

18

38

3.4 FB 220X Digital Output

10kW 2.2kW

The digital output FB 220X interfaces the DCS and PLC systems with solenoid valves, acoustic sounders or optical alarms (LEDs). The module features 1 output channel and 2 status inputs which respond in the same way as those of the digital input module FB 1202. The module can be used for the following purposes: - Solenoid valve driver - Lamps and acoustic alarms - Processing digital inputs for NAMUR or mechanical contacts independent of the valve circuit. The valve driver and the digital inputs feature a line monitoring mode for indicating open or short circuits. The option can be deactivated in the software. With mechanical contacts you can either deactivate the line monitoring mode or the contact can be connected to a resistor combination to emulate a NAMUR initiator. This is to enable the electronics to distinguish between a closed contact and a short (Fig. 69). The valve circuit is monitored by means of a current pulse that is so short that a connected valve does not respond. The monitoring of the valve circuit is not possible in all cases if booster valves are used since these valves have a storage capacitor which constitutes a short circuit when switched off. In such cases depending on the valve, a parallel resistance of 10 kW can open line monitoring even for booster valves. Should the line monitor continue to indicate a fault it must be deactivated. Dedicated digital outputs are available to drive LED displays (see order code). Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. A red LED indicates the monitoring status of the field cables. It lights up in the event of faults in the field cables. Yellow LEDs indicate the status of the digital inputs. For explosion protection reasons the yellow LEDs cannot be displayed in every case. There are 14 device options for operating intrinsically safe solenoid valves. These cover more than 100 different commercially available valves from various manufacturers including: SAMSON, HERION, SEITZ, BRKERT, TELEKTRON, HONEYWELL, ASCO, RGS etc. The digital output can be assigned locally to analogue or digital inputs for the following

applications: - Local connection to a temperature input or converter /supply circuit, e.g. for twoposition control. - Local connection to a binary input for signal amplification. - Local connection to the pulse counter FB 1203 for creating a dosing system. You determine which slot the digital output is to be connected to locally and what kind of connection you want it to be, analogue or digital. Analogue connections allow you to set a switching point. Digital connections allow you to activate the line monitoring feature of an input, the live ZERO monitor or other status bits. A local connection has priority over controls from the DCS or PLC system. With active local connections a setting of the out-put for service purposes is also blocked.

FB Remote I/O Fig. 69

3.4.1 Calculation of a Valve Circuit

329 = Ra 458 25,3 V = Uo

When connecting the valve control module to the solenoid valve from one of the manufacturers named above, it is necessary to carry out calculations based on both measurement technique and safety factors. Example 1: HERION 2035: The internal resistance of the valve at an ambient temperature of 65 C is 458 W. A minimum of 13.8 V are necessary for activation. In accordance with PTB No. Ex-95.D.2178 the safety ratings are 28 V and 120 mA . The valve control module FB 2112 has a noload voltage during operation of 25.3 V and an internal resistance of 329 W . In accordance with PTB No. Ex-95.D.2163 the safety ratings are 27.8 V and 110 mA. Therefore, the safety data allow an interconnection. The basic circuit layout is shown in figure 70. The operating current is I = 25.3 V / (329 + 458) W = 32 mA The voltage drop at the internal resistor of the valve control module allows a control voltage of U = 32 x 458 mV = 14.7 V Therefore, with regard to measurement technique factors, interconnection is possible as a minimum voltage of 13.8 V is required. These considerations can be repeated for other valves.

Fig. 70

39

3.4.2 How to Configure Digital Outputs

(8) (9)

When you select the output module FB 220X you will see the following device spec sheet (Fig. 71). The module can now be configured. Notes for Solenoid Valve Driver FB 2212 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (digital inputs/ outputs OK or faulty). (6) Here you can activate or deactivate the line monitoring (LFD) feature. (7) Here you can activate a local connection to an input module.

(10) (11) (12) (13) (14) (15)

(16) (17) (18) (19) (20)

Space for notes and remarks concerning the measuring point. With a local connection you can determine whether an analogue value or a digital input is to be responsible for activating the valve control output and whether it is normal or inverse. For connections with an analogue value set the switching point here. The number of the slot being configured. Press OK to store the parameter setting. LOAD allows you to load existing configurations from the disk or the hardware. RESET allows you to restore the original parameter settings while staying with the present configuration window. Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. SAVE allows you to store configurations on a disk or in the hardware. Call up HELP. Set input and status values for testing purposes during servicing and commissioning. Interpretation of the input contact as logical 0 or 1. TAG no. per channel.

1 3 2 4 5 11

12 13 14 18

15 16

17

19

9 10

8 Fig. 71

40

1 2

LB1103
FB 1203

3.4.3 Dosing System using Valves

LB2101 FB 2201 5

(1+2x5+3)ms

(1+2x5+3)ms

Fig. 72

When using the valve control output for building dosing system, the following time sequence results: 1) Set the START bit and reset the counter using the bus in module FB 1203. 2) Release of the valve after recognition of the status bit in FB 1203 by the valve module. 3) Integration of the counter pulses in module FB 1203. 4) The preset counter value has been reached and the status bit set. 5) Cutting-off of the valve after recognition of the status bit in FB 1203 by the valve control module. When fitted with 48 I/O modules and in the worst case condition, the valve control module cuts off the valve with a maximum time delay of 14 ms (Fig. 72). This results in an overlap of 3 pulses at 200 Hz. In the case of a station that is only fitted with 24 modules, the time delay is reduced to (1+2x2+3)ms=8ms. The time delay is based on: a response time of 1 ms for module FB 1103, plus 2 bus cycles at 5 ms each with 48 participants, plus a reaction time of 3 ms for the valve control module. The counter of the input module FB 1103 has a counting range up to109 that can be read by the valve control module. The bus coupler itself can only count up to 216. If the dosing is not local but controlled via the system bus, the bus coupler must be interrogated by the master often enough. The response time and, therefore, the accuracy of the dosing is clearly better with a local connection.

3.4.4 Interconnection with an LED signal lamp

The LED indicators GHG 418 2101 R 0001 are passive, intrinsically safe components to EN 50020. Components of this nature require no special official admission if the intrinsic safety of the circuit is guaranteed. The interconnection with our binary output modules FB 2204 and FB 2213, which contain module LB 2101 and LB 2104 certified to Ex-95.D.2163 is admissible. In the Instruction Manual FB 92. of the field bus devices you will find the ratings for the intrinsic safety. In accordance with EC design examination certificate PTB 97 ATEX 1074 U, the structural components are set out and certified. The following calculations figure 73 apply. The resistance incorporated in the signal lamps restricts the operating current to safe values. For the length of the leads, ratings of the binary output can be used since the passive I LED component does not S introduce any additional currents or voltages and no inductances and capacities into the circuit. The control components FB 2204 or FB 2213 are suitable for application with GHG 417 2101 R 0001 (Fig. 74). Note: valve control components send out a test impulse in second cycles for monitoring the lead. The switched off LED therefore flashes on briefly every second. This also applies if the lead monitoring is switched off. For this application use the component with the corresponding order number without lead monitoring. Here, the test impulse is switched off ex-works.

Operating data Inner resistance Maximum values of the binary output FB 2204 Operating values Operating current with LED signal

19 V 1 kW

25 mA

24.2 V 146 mA 22 V 220 W I = Uo / (Ri + R) I = 22 / (220 + 1000) = 18.03 mA U = 18.03 V 28.7 V 70 mA 26.7 V 509 W I = Uo / (Ri + R) I = 26.7 / (509 + 1000) = 17.69 mA U = 17.7 V

Maximum values of the binary output FB 2213 Operating values Operating current with LED signals

Fig. 73

Ri Uo Digital output FB 2XXX Fig. 74 LED signal lamps GHG 417 XXXX R XXXX

41

3.5 FB 3201 Analogue Input, Transmitter Power Supply, Input Isolator

The analogue input FB 3201 interfaces the PLC and DCS with the processing signals from pressure and differential pressure transmitters, sensor transmitters and remotely powered analysers, flow and level gauges etc. For transmitter supply applications use terminals 2 or 3(+) and 4 or 5(-). For transmitter supply applications involving 3-wire transmitters use terminals 2/3(+) (supply), 4/5(+) (return), 6(-). Applications as input isolators for remotely powered devices use terminals 4/5(+) and 6(-) (Fig. 75). The input resistance is 15 W. FB Remote I/O Fig. 75 HART hand control units with a Certificate of Conformity use terminals 3(+) and 4(-). Communication via the bus is also possible with the aid of the HART supply isolators types FB 3202 and FB 3203. Features: Supply voltage 14.5 V Open circuit voltage 24 V (Ex i) Short-circuit current 90 mA (Ex i) The unit offers a minimum supply voltage of 14.5 V at 20 mA. Up to this maximum value the voltage adapts itself to suit the require ments of the field device. Input signals of 0-25 mA are converted with a 12 Bit resolution. This results in an 11 Bit resolution for a signal range of 4-20 mA or 0-100 % (better 0.1 %). The conversion time for the suppression of ripple voltages is ca. 20 ms.

The device has a built-in line monitoring feature for the detection of open and short circuits. The feature can be activated or deactivated in the software. You can set the switch points at < 1 mA or > 21 mA. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs light up in the event of faults in the field cables. A yellow LEDs lights up when the input signal goes below the LIVE ZERO level. Due to explosion protection reasons the yellow LED cannot be displayed in every case.

3.5.1 How to Configure Analogue Inputs

When you select the input module FB 3201 you will see the following device spec sheet (Fig. 76). The module can now be configured.

1 2 3 4 5 6 9

10 11 12 13 14 16

8 15 Fig. 76

Notes for Transmitter Power Supply FB 3201 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty). (6) Status of the live zero signal (OK or faulty). (7) Here you can activate or deactivate the line monitoring (LFD) feature. (8) Space for notes and remarks concerning the measuring point. (9) The number of the slot being configured. (10) Press OK to store the parameter setting. (11) Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. (12) LOAD allows you to load existing configurations from the disk or the hardware. (13) SAVE allows you to store configurations on a disk or in the hardware. (14) RESET allows you to restore the original parameter settings while staying with the present configuration window. (15) Call up HELP. (16) Set input and status values for test purposes during servicing and commissioning.

42

HART

3.6 FB 3202 Analogue Input, HART Transmitter Power Supply, Input Isolator
The analogue input FB 3202 interfaces the PLC and DCS with the processing signals from pressure and differential pressure transmitters, sensor transmitters and remotely powered analysers, flow and level gauges etc. Fig. 77: (1) For transmitter supply applications use terminals 2 or 3(+) and 4 or 5(-). (2) For transmitter supply applications involving 3-wire transmitters use terminals 2/3(+) (supply), 4/5(+) (return), 6(-). (3) For applications as input isolators for active signals from the field use terminals 4/5(+) and 6(-). The input resistance is 15 W . HART hand control units with a Certificate of Conformity can be connected at terminals 3(+) and 4(-). Communication is also possible using the service bus. The 250 W communication resistance is built in. (4) HART field devices which are externally powered and produce active 20 mA, have to be connected to the terminals 1(+) and 6(-). The 250 W communication resistance is built in. Input resistance 265 W. Features: Supply voltage 16.5 V Open circuit voltage 27.1 V (Ex i) Short-circuit current 93 mA (Ex i) The unit offers a supply voltage of 16.5 V at 20 mA. The voltage adapts itself to suit the requirements of the field device. When the load is reduced to 4 mA, the supply voltage increases to about 22 V.

Input signals of 0 - 25 mA are converted with a 12 Bit resolution. This results in an 11 Bit resolution for a signal range from 4 - 20 mA or 0 - 100 % (better 0.1 %). The conversion time for the suppression of ripple voltages is ca. 20 ms. The device has a built-in line monitoring feature for the detection of open and short circuits. The feature can be activated or deactivated in the software. You can set the switch points at < 1mA or > 21mA. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs light up in the event of faults in the field cables. A yellow LEDs lights up when the input signal goes below the LIVE ZERO level. Due to explosion protection reasons the yellow LED cannot be displayed in every case.

FB Remote I/O Fig. 77

3.6.1 HART Communication for FB 3202

Field devices that can be remotely activated with the HART protocol can be addressed via the service bus. The software interfaces easily with the software supplied by the HART transmitter manufacturer. All the features available there are accessible with the HART protocol via the service bus. HART communication is also possible on the device terminals with the help of approved manual operation devices of the field device manufacturers (HHC). The 250 W communication resistance is built in. (Some Krohne transmitters use an inverse parity bit, this is not HART conform. They can only be set via Krohne manual operation devices. Following completion, a brief reset of the Krohne apparatus is necessary by inter-rupting the feed circuit.)

43

3.6.2 How to Configure Analogue Inputs (6) Status of the live zero signal (OK or
When you select the input module FB 3202 you will see the following device spec sheet (Fig. 78). The module can now be configured. (7) (8) (9) (10) (11)

Notes for Transmitter Power Supply FB 3202 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATIONMODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty).

(12) (13) (14) (15) (16)

faulty). Here you can activate or deactivate the line monitoring (LFD) feature. Space for notes and remarks concerning the measuring point. The number of the slot being configured. Press OK to store the parameter setting. Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. LOAD allows you to load existing configurations from the disk or the hardware. SAVE allows you to store configurations on a disk or in the hardware. RESET allows you to restore the original parameter settings while staying with the present configuration window. Call up HELP. Set input and status values for testing purposes during servicing and commissioning.

1 2 3 4 5 6 9

10 11 12 13 14 16

8 15 Fig. 78

44

HART

3.7 FB 3203 Analogue Input, HART Transmitter Power Supply, Input Isolator

The analogue input FB 3203 interfaces the PLC and DCS with the processing signals from pressure and differential pressure transmitters, sensor transmitters and remotely powered analysers, flow and level gauges etc. Fig. 79: (1) For transmitter supply applications use terminals 2 or 3(+) and 4 or 5(-). (2) For transmitter supply applications involving 3-wire transmitters use terminals 2/3(+) (supply), 4/5(+) (return), 6(-). (3) Applications as input isolators for active signals from the field use terminals 4/ 5(+) and 6(-). The input resistance is 15 W . HART hand control units with Certificate of Conformity can be connected at terminals 3(+) and 4(-). Communication is also possible via the bus. The 250 W communication resistance is built in. (4) HART field devices which are externally powered and produce active 20 mA, have to be connected to the terminals 1(+) and 6(-). The 250 W communication resistance is built in. Input resistance 265 W. Features: Supply voltage 14.5 V Open circuit voltage 24 V (Ex i) Short circuit current 74 mA (Ex i) The unit offers a minimum supply voltage of 14.5 V at 20 mA. The voltage adapts itself to suit the requirements of the field device.

Input signals of 0 - 25 mA are converted with a 12 Bit resolution. This results in an 11 Bit resolution for a signal range of 4 - 20 mA or 0 - 100 % (better 0.1 %). The conversion time for the suppression of ripple voltages is ca. 20 ms. The device has a built-in line monitoring feature for the detection of open or short circuits. The feature can be activated or deactivated in the software. You can set the switch points at < 1 mA or > 21 mA. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs light up in the event of faults in the field cables. A yellow LEDs lights up when the input signal goes below the LIVE ZERO level. Due to explosion protection reasons the yellow LED cannot be displayed in every case.

FB Remote I/O Fig. 79

3.7.1 HART Communication for FB 3203

Field devices that can be remotely activated with the HART protocol can be addressed via the service bus. The software interfaces easily with the software supplied by the HART transmitter manufacturer. All the features available there are accessible with the HART protocol via the service bus. HART communication is also possible on the device terminals with the help of approved manual operation devices of the field device manufacturers (HHC). The 250 W communication resistance is built in. (Some Krohne transmitters use an inverse parity bit, this is not HART conform. They can only be set via Krohne manual operation devices. Following completion, a brief reset of the Krohne apparatus is necessary by interrupting the feed circuit.)

45

3.7.2 How to Configure Analogue Inputs (7) Here you can activate or deactivate
When you select the input module FB 3203 you will see the following device spec sheet (Fig. 80). The module can now be configured. (8) (9) (10) (11)

Notes on Analogue Inputs FB 3203 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty). (6) Status of the live zero signal (OK or faulty).

(12) (13) (14)

(15) (16)

the line monitoring (LFD) feature. Space for notes and remarks concerning the measuring point. The number of the slot being configured. Press OK to store the parameter setting. Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. LOAD allows you to load existing configurations from the disk or the hardware. SAVE allows you to store configurations on a disk or in the hardware. RESET allows you to restore the original parameter settings while staying with the present configuration window. Call up HELP. Set input and status values for testing purposes during servicing and commissioning.

1 2 3 4 5 6 9

10 11 12 13 14 16

8 15 Fig. 80

46

3.8 FB 4201 Analogue Output

The analogue output FB 4201 interfaces PLC or DCS systems with the processing signals for positioners, I/P converters, proportional valves, and local indicators (Fig. 81). For output isolators use terminals 2 or 3(+) and 4 or 5(-). HART hand control units with Certificate of Conformity can be connected at terminals 3(+) and 4(-). Communication via the bus is also possible using the HART output isolators type FB 4202. Features: Output load 800 W Open circuit voltage 27.3 V (Ex i) Short circuit current 87 mA (Ex i) The unit offers a minimum supply voltage of 16 V at 20 mA. The voltage adapts itself to suit the requirements of the field device. Fig. 81
BUS FB5202 FB 5202 DMS Brcke Bridge

You decide which slot the analogue output is to be connected to locally. A local connection has priority over controls from the DCS or PLC system. With active local connections a setting of the output for service purposes is also blocked.

3.8.2 Strain Gauge Measurement

The FB Remote I/O modules FB 5202 and FB 420X are interconnected for SGB measurement. The output isolator is used here for producing a constant current, while the measurement input FB 5202 processes the millivolt signal of the bridge voltage produced. If required, the measurement can be transmitted to a DCS or PLC via a standardized bus. Alternatively, an additional module FB 4201 can produce an output signal proportional to the measured value of 4-20 mA. A constant current of 20 mA is suited for the supply of a 350 W bridge. A bridge voltage of 7 V results. With a bridge sensitivity of 2 mV/V the voltage at full load is 14 mV. Alternative with analogue output The modules named above are used. However, unlike the solution shown above, an additional analogue output is available here (Figure 82 - SGB measurement circuit with supply EExib IIC). Proof of interconnection according to PTB Report W39: You can calculate the new permitted external inductivities and capacities for class EExib IIC though graphical addition of the characteristic curves: FB 4201 Ik Uo Pmax La Ca 87 mA 27.3 V 594 mW 5.3 mH 70 nF FB 5202 21.6 mA 1.6 V Together Characteristic Characteristic

Output signals of 0 - 25 mA are converted with a 12 Bit resolution. This results in an 11 Bit resolution for a 4 - 20 mA signal corresponding to 0 - 100 % (better 0.1 %). The minimum current for LFD is 1 mA. The device has a built-in line monitoring feature for the detection of open circuits. The feature can be activated or deactivated in the software. Currents < 0.1 mA are interpreted as open circuits. A lead short circuit cannot be recorded due to the non-linear behaviour of the voltage requirement of modern HART positioners. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs light up in the event of open circuit in the field cables, or as long as the output current is < 0.1 mA. Due to explosion protection reasons the yellow LED cannot be displayed in every case.

mV

FB 4201

Power Speisung Supply

FB 4201

ResisBrde tance

Fig. 82 FB 5202 amplifier FB 4201 bridge supply

3.8.1 Local Connections for FB 4201

32.4 mW 664 mW 68 mH 200 F 1 mH 20 nF

Analogue outputs can be used to establish local connections: with a temperature input or a transmitter supply circuit, to indicate measured values locally or duplicate signals, to accommodate discrete controllers, or connect a second PLC.

47

3.8.3 How to Configure Analogue Outputs

(6) (7) (8) (9) (10) (11)

When you select the output module FB 4201 you will see the following device spec sheet (Fig. 83). The module can now be configured. Notes on Output Isolator FB 4201 (1) The model number of the module is entered automatically. Even though the inactive module is described, it does not exist physically or it is not to be included in the query. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while the inactive module is preconfigured but not physically present. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty).

(12) (13) (14) (15) (16)

Status of the live zero signal (OK or faulty). Here you can activate or deactivate the line monitoring (LFD) feature. Space for notes and remarks concerning the measuring point. The number of the slot being configured. Press OK to store the parameter setting. Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. LOAD allows you to load existing configurations from the disk or the hardware. SAVE allows you to store configurations on a disk or in the hardware. RESET allows you to restore the original parameter settings while staying with the present configuration window. You can set input and status values for servicing and commissioning purposes. Call up HELP.

1 2 3 4 5 9

10 11 12 13 14 15

8 16 Fig. 83

48

3.9 FB 4202 Analogue Output, HART Output Isolator

The analogue output FB 4202 interfaces PLC or DCS systems with process control outputs for positioners, I/P converters, proportional valves, and local indicators (Fig. 84). Output isolators use terminals 2 or 3(+) and 4 or 5(-). HART hand control units with Certificate of Conformity can be connected at terminals 3(+) and 4(-). Communication is also possible via the service bus. Features: Output load 800 W Open circuit voltage 27.3 V (Ex i) Short-circuit current 87 mA (Ex i) The unit offers a minimum output voltage of 16 V at 20 mA. The voltage adapts itself to suit the requirements of the field device. Output signals of 0 - 25 mA are converted with a 12 Bit resolution. This results in an 11 Bit resolution for a 4 - 20 mA signal corresponding to 0 - 100 % (better 0.1 %). Minimum current is 1 mA. The device offers a built-in line monitoring feature for the detection of open circuits. The feature can be activated or de-activated in the software. Currents < 0.1 mA will be interpreted as open circuits. A lead short circuit cannot be recorded due to the non-linear behaviour of the voltage requirement of modern HART positioners.

Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. Red LEDs light up in the event of open circuits in the field cables or as long as the output current is < 0.1 mA.

3.9.1 HART Communication for FB 4202

You can address field devices which use the HART protocol via the service bus. The software interfaces easily with the software supplied by the HART transmitter manufacturer. All the features available there become accessible via the service bus with the HART protocol.

FB Remote I/O

3.9.2 Local Connections for FB 4202

Fig. 84

Analogue outputs can be used to establish local connections: with a temperature input or a transmitter supply circuit, to indicate measured values locally or duplicate signals, to accommodate discrete controllers, or connect a second PLC. You decide which slot the analogue output is to be connected to locally. A local connection has priority over controls from the DCS or PLC system. With active local con-nections a setting of the output for service purposes is also blocked.

49

3.9.3 How to Configure Analogue Outputs

(6) (7) (8) (9) (10) (11)

When you select the output module FB 4202 you will see the following device spec sheet (Fig. 85). The module can now be configured. Notes for Output Isolator FB 4202 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty).

(12) (13) (14) (15) (16)

Here you can activate or deactivate the line monitoring (LFD) feature. You can logic link the analog output with the analog input. Space for notes and remarks concerning the measuring point. The number of the slot being configured. Press OK to store the parameter setting. Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. LOAD allows you to load existing configurations from the disk or the hardware. SAVE allows you to store configurations on a disk or in the hardware. RESET allows you to restore the original parameter settings while staying with the present configuration window. You can set input and status values for servicing and commissioning purposes. Call up HELP.

1 2 3 4 5 9

10 11 12 13 14 15

16

Fig. 85

50

3.10 FB 4203 Analogue Output

The analogue output FB 4203 interfaces PLC or DCS systems with process control outputs for positioners, I/P converters, proportional valves, and local indicators (Fig. 86). Output isolators use terminals 2 or 3(+) and 4 or 5(-). HART hand control units can be connected at terminals 3(+) and 4(-). To realize HART communication via service bus please use FB 4202. Features: Output load 400 W Open circuit voltage 12.6 V (Ex i) Short circuit current 80 mA (Ex i) The unit offers a drive voltage of 8 V at 20 mA which is self regulating to the remote devices requirements. Output signals of 0 - 25 mA are converted with a 12 Bit resolution. This results in an 11 Bit resolution for a 4 - 20 mA signal corresponding to 0 - 100 % (better 0.1 %). The minimum current for LFD is 1 mA. The device offers a built-in line monitoring feature to detect open circuits. The feature can be activated or deactivated in software. Currents < 0.1 mA are interpreted as open circuits. Short circuits cannot be recorded due to the non-linear behaviour of the voltage requirement of modern HART positioners. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. A red LED lights up in the event of a fault in the field cables or as long as the output current is < 0.1 mA.

3.10.1Local Connections for FB 4203

Analogue outputs can be used to establish local connections: to repeat a temperature input or a transmitter supply circuit, to indicate measured values locally or duplicate signals, to accommodate discrete controllers, or connect a second PLC. You decide which slot the analogue output is to be connected to locally. A local connection has priority over controls from the DCS or PLC system. With active local connections a setting of the output for service purposes is also blocked.

FB Remote I/O

3.10.2 How to Configure Analogue Outputs

Fig. 86

When you select the output module FB 4203 you will see the following device spec sheet (Fig. 87). You can now choose the device specification. Notes for menu Output Isolator FB 4203 1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty). (6) Here you can activate or deactivate the line monitoring (LFD) feature. (7) You can logic link the analog output with the analog input. (8) Space for notes and remarks concerning the measuring point. (9) The number of the slot being configured. (10) Press OK to store the parameter setting. (11) Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. (12) LOAD allows you to load existing configurations from the disk or the hardware. (13) SAVE allows you to store configurations on a disk or in the hardware. (14) RESET allows you to restore the original parameter settings while staying with the present configuration window. (15) You can set the input and status values at a given value for servicing and commissioning purposes. (16) Call up HELP.
51

10 1 2 3 4 5 9 11 12 13 14 15

8 16 Fig. 87

3.11 FB 5201 Temperature Converter

suppress 50 Hz or 60 Hz noise. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. A red LED lights up in the event of faults in the field cables. NO adjustments need be made when replacing a module.

2 Ltr. 3 Ltr. 4 Ltr.

1 2 3 4 5 6

The Pt 100 transmitter FB 5201 interfaces RTD signals of 2(-), 3(-), and 4-wire sensors with the PLC or DCS system (Fig. 88). In 2-wire configuration use terminals 5and 6. In 3-wire configuration use terminals 1, 5 and 6. In 4-wire configuration use terminals 1and 2 as well as 5 and 6. Measuring range 0-400 W (0-600 W when line resistance is 0 W . ) Smallest span 20 W. Maximum cable resistance 100 W . Non linearity 0.1 % Sensor current 200 A.

3.11.1 Line Resistance

mV Local Bus FB Remote I/O

Fig. 88

Temperatures between -200 C and +850 C are measured with a resolution of 16 Bit. This leaves an 11 Bit resolution for the smallest span of 20 W for 0 - 100 % (better 0.1 %). Conversion rate, Cycle time: 20 ms without line monitor. 125 ms with line monitor. Measured values are sent to the bus coupler once every 5ms independent of the conversion rate. Input signals can be filtered using a digital PT1 filter adjustable in steps of: - Without line monitoring (LFD): 40 ms, 80 ms, 160 ms, 320 ms. - With line monitoring (LFD): 250 ms, 500 ms, 1000 ms, 2000 ms. The device has a line monitoring feature to indicate short or open circuits. The cable resistance does not lead to false measuring results. The line monitoring option can be deactivated in the software. Line faults can lead to the following values: 0 %, 20 % (4 mA), 100 % (20 mA). A burn-out (LFD) delay can be used to delay the acceptance of correct results after a burn-out in order to avoid continued changes between fault and normal conditions in case of loose contacts (1 - 250 cycles). The conversion method can be adjusted to

With 2-wire switching arrangements you can measure the line resistance by changing over to resistance measurement and shorting the PT100 sensor. To measure the resistance, call up the measured value display for the respective measuring point. Using the mouse click on to the input module. When the right mouse button is doubleclicked, the measured value display is active. Enter the line resistance measured in this way after the changeover to 2-wire measurement for PT100 into the parameter spaces for the line resistance. The maximum permissible line resistance is 100 W . As an alternative to the line balancing method described above, it is also possible to use the conventional method. Use a balancing terminal with built-in balancing resistor in the feed line to the converter. Set the measurement input FB 5201 for 2-wire Pt100 measurement. With the menu set the line resistance at 20 W . Now replace the Pt100 sensor at the location of measurement by a 100 W precision resistor. Measure the value by calling up the measured value display for the respective measuring point. Using the mouse click on to the input module. When the right mouse button is double-clicked, the measured value display is active. Now balance out the value shown to 0 C using the balancing potentiometer. Having done this, reconnect the Pt100 sensor. Line balancing is not necessary for 3-wire and 4-wire measurement.

52

3.11.2 How to Configure Temperature Inputs

(8) (9) (10) (11)

When you select the temperature module FB 5201 you will see the following device spec sheet (fig. 89). The module can now be configured. Notes for Converter FB 5201 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty). (6) Here you can activate or deactivate the line monitoring (LFD) feature. (7) Here you can set the output drive in a

(12) (13) (14) (15) (16) (17) (18) (19)

fault condition. Select the sensor, the measuring method with 2-, 3-, or 4-wire configuration and the measuring range. The number of the slot being configured. Press OK to store the parameter setting. Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. LOAD allows you to load existing configurations from the disk or the hardware. SAVE allows you to store configurations on a disk or in the hardware. RESET allows you to restore the original parameter settings while staying with the present configuration window. Call up HELP. Suppression of line noise. Temperature scale (F or C). Space for notes and remarks concerning the measuring point. Set input and status values for testing purposes during servicing and commissioning.

1 2 3 4 5 6 7 9

10 12 14 19

11 13

15 16

17 18

Fig. 89

53

3.12 FB 5202 Temperature Converter

The thermocouple transmitter FB 5202 interfaces all kinds of thermocouples and millivolt signals with the PLC or DCS system (Fig. 90).

C JC

Connect thermocouples at terminals 5and 6.

A burn-out delay can be used to delay the acceptance of correct results for a given time after a burn-out in order to avoid a continuous change-over between fault and normal conditions in the event of a loose contact (1 - 250 cycles). The conversion method can be adjusted to suppress 50 Hz or 60 Hz noise. Front LEDs indicate the module status. A green LED indicates that the unit is properly connected to the power supply and that the fuse of the module is intact. A red LED issues an alarm in case of faults in the field cables. It lights up in the event of a short or open circuits. No adjustments need be made when replacing a module.

+
1 2 3 4 5

For Pt100 cold junction compensation (CJC): use terminals 1 and 2. Measuring range -75 ... + 75 mV. Smallest span 5 mV. Maximum line resistance 1000 W. Non-linearity 0.1%. Sensor current of CJC sensor 200 A. Temperatures between -200 C and +1850 C are measured with a 16 Bit resolution. This leaves an 11 Bit resolution for the smallest range of 5 mV or 0-100 % (better 0.1 %). All the thermocouple characteristics are linearized. Conversion rate, Cycle time For external CJC: 20 ms without line monitoring, 80 ms with line monitoring. For internal CJC external mounting: 120 ms with line monitoring, + 120 ms for CJC. Measured values are sent to the COM unit once every 5 ms independent of the conversion rate. Input signals can be filtered using a digital PT1 filter adjustable in steps of: - Without line monitoring (LFD): 40 ms, 80 ms, 160 ms, 320 ms. - With line monitoring (LFD): 250 ms, 500 ms, 1000 ms, 2000 ms. The device has its own line monitoring feature to indicate shorts or open circuits. A line fault is indicated when the line resistance exceeds 1000 W. The option can be deactivated in the software. Line faults can lead to the following values: 0 %, 20 % (4 mA), 100 % (20 mA).

mV
FB o ca l B u s L Remote I/O Fig. 90

3.12.1 How to Configure Temperature Inputs

When you select the temperature module FB 5202 you will see the device spec sheet below (Fig. 91). You can now choose the device specification. Notes for Converter FB 5202 (1) The model number of the module is entered automatically. (2) TAG-No. or measuring point number with up to 20 characters. (3) With a non-active module it is possible for the complete station to function while, even though the inactive module is described, it does not exist physically or it is not to be included in the data acquisition cycle. (4) Indicates the actual module status. In the above example the SIMULATION MODE is active allowing a simulation of the I/O function. This enables you to look at the function of the I/O module when there is still no connection to the hardware (OFF-LINE configuration). (5) Line monitoring (LFD) indicating the status of the field wiring (OK or faulty). (6) Here you can activate or deactivate the line monitoring (LFD) feature. (7) Here you can set the output drive in a fault condition. (8) Select the sensor, the type of thermocouple and the measuring range. (9) The number of the slot being configured. (10) Press OK to store the parameter setting. (11) Press CANCEL if you want to restore the original setting ignoring the changes that have just been entered. This command returns you to the main menu without registering any changes. (12) LOAD allows you to load existing configurations from the disk or the hardware. (13) SAVE allows you to store configurations on a disk or in the hardware. (14) RESET allows you to restore the original parameter settings while staying with the present configuration window. (15) Call up HELP. (16) Suppression of line noise. (17) Temperature scale (F or C)

1 2 3 4 5 9

10 12 14 19

11 13

6 7 16

15

8 18

17

Fig. 91

54

(18) Space for notes and remarks concerning the measuring point. (19) Set input and status values for testing purposes during servicing and commissioning.

With measurements using thermocouples it is necessary that extension wires from the sensor are wired up to the measuring device or the cold junction in order to avoid measurement errors, because new thermocouples are formed at the junction between the extension wires and the copper cable. Thus, the thermocouple measurement is then dependent on the ambient temperature at the terminal point. This temperature dependence can be compensated in various ways. Cold Junction Thermostat A thermostat is usually used with external cold junctions. This keeps the transition point between the extension wires and the copper cable at a constant temperature of 50 C. In this case the external cold junction must be selected in the menu for the FB 5202. The cold junction value entered is a fixed value. This method allows exact measurements, but it is rather complicated. The alternative is temperature measurement at the cold junction. Cold Junction Cold junction measurement provides a good compromise between the rather complicated

3.12.2 Cold Junction Compensation

method described above and accuracy. For this the temperature measuring transmitter type 520X is set to Internal VST. The sensor is assembled externally in order to achieve the best possible level of accuracy. With FB Remote I/O BUS modules a PT100 sensor is used for the temperature measurement at the transition point between the copper cable and the extension wires. The temperature registered by this sensor at the terminal point is used by the FB 5202 for the compensation of ambient temperature influences. The COMBICON terminal FB 9112 with built-in Pt100 sensor was designed to achieve a good temperature constancy. When activating the internal cold junction, an additional parameter becomes accessible in the measuring point window of the device (see 3.12.1). You can set the pulse-duty factor for the measurement of the cold junction temperature for the measurement of the process tempe rature to between 1 and 255. With a pulse-duty factor of 1 : 1 a cold junction temperature is calculated on each measurement. The overall time for a measurement will double to approx. 250 ms. With a pulse-duty factor of 1 : 100 a new cold point temperature is only calculated on every 100th measurement (every 10 sec.). Thus the normal measuring cycle remains short (approx. 120 ms). To balance out the lead resistances in the measuring circle of the externally assembled internal cold junction a lead resistance can be entered.

55

(1)

4 HART Communication
Analogue inputs and outputs (FB 3202, FB 3203, FB 4202) are available for communication with intelligent field devices according to the HART protocol. These subassemblies receive the HART telegrams via the service bus from a bus coupler (FB 820X) that is also designed for HART communication. The bus coupler recognizes automatically whether service information or HART protocols are to be exchanged. This is made possible by the various transmission frequencies. The configuration and service functions operate with the MODBUS protocol at 9600 Baud. HART communication operates to the Bell standard by sending out frequency packets (1200 Hz = 1, 2200 Hz = 0). These are superimposed by the I/O modules in the FSK (frequency shift keying) mode on to the 20 mA signals. When using an interface converter which adapts the RS 232 interface of your PC or LAPTOP to the RS 485 bus, it must be observed that this interface requires an automatic Baud rate recognition (9600 Baud for configuring, 1200 Baud for the HART communication). Figure 92: (1) Communication with certified hand control units at the terminal of the I/O module. The 250 W communication resistor is included in all analogue I/O modules. (2) Communication via the bus coupler and I/O modules without additional devices. (3) Principle of HART / SMART communication by the susperimposing of currents with frequency packets. Communication via the service bus is possible with the software of any field device that is HART compatible. Thus, you work with user instruments you are already familiar with. Leave the service programme of the FB Remote I/O BUS and call up the HART programme of your field device manufacturer. This ensures that both programmes do not try to gain access to the serial interface at the same time. Transmitters supplied by manufacturers with the address ZERO must not all be connected at one time as this leads to address conflicts. Connect the first transmitter and establish connection with the field device with the user software of the transmitter manufacturer (e.g. SMARTVISION). Give the field device a so-called long address (e.g. ad-dressing using the TAG-No.). Then put the second device into operation, etc. When all the transmitters have been allocated a long address, they can all be connected to the system simultaneously. On request modern automation management systems can be fitted with a driver that allows the scanning of the connected HART devices. In this case it is not necessary to connect the field devices sequentially when putting into service for the first time. HART communication has been tested with various systems. These include IBIS, AMS, KSMART, SMARTVISION, SIMATIC PDM and Krohne. With all systems it is necessary to ensure that the field devices are allocated with addresses that are unmistakable, as the HART communication addresses all the field devices at once via the FB Remote I/O BUS, whereby the transmitter with the correct address answers. Our software package BUS-Tools can be a valuable aid when commissioning SMART devices, as it is capable of determining the device codes of the connected devices and listing them for entering SMARTVISION, for example, regardless of the capabilities of the HART software of the field device manufacturers. The tests revealed the following limitations: HART communication is possible with the transmitters for an operating range of 4 - 20 mA. When there is no input signal (open circuit), some transmitters go into overdrive (22 mA). In this state HART communication with this transmitter is often not possible. This also applies for hand control units. Krohne uses its own protocol, which does not correspond to the HART standard. Therefore, some Krohne transmitters cannot be remotely operated with the Krohne programme via the FB Remote I/O BUS. In the case of intrinsically safe hand control units from Krohne, communication is possible at the terminals of the FB Remote I/O BUS supply unit. After this, the Krohne device has to be RESET by briefly unplugging the plug-in connection to FB 320X.

(2)

mA
logical 1 logisch 0 logical 10 logisch

(3)

2200 Hz

1200 Hz Amplitude +/- 0,5 mA

ms
Fig. 92

56

5 Software Marshalling
5.1 Automatic Marshalling
in the bus coupler window Transfer Data Format (Fig. 93). The resulting address occupation can be read out and printed via the menu point Options/Documentation. In the packed mode it is not possible to set analogue and digital signals to test values via the service bus. If you wish to use this operation mode, switch from the packed mode to the unpacked mode for the duration of the service tasks. However, the station is then not connected to the main system that expects packed data. After completion of the servicing tasks, switch back to the packed mode to reestablish the connection to the system (see read me file). NOTE: When using the software marshalling, you should occupy unused slots for later extensions. Otherwise, when you add new modules, the marshalling addresses shift and make it necessary to change the parameters in the DCS or PLC. Close the window of the bus coupler and select as shown in figure 94: Services \ I-/O-Data Marshalling

The structure of the data of a substation can be adapted to suit the requirements of the DCS or PLC. This allows the processing speed and the exploitation of the data formats offered by the systems to be supported in an optimum way. Even when the I/O modules are arranged on the backplane segments in any mixed order, with the software marshalling they can be sorted according to analogue and digital data currents. To do this switch from unpacked to packed

Fig. 93

Fig. 94

57

After you choose I-/O-Data Marshalling the window in figure 95 appears. The configuration programme works out the optimum register assignments. If you wish to reserve empty spaces in the registers for later extensions, you must adapt the number of registers accordingly. Fig. 95

Select Auto Marshalling and the programme automatically optimizes the register assignment (Fig. 96). You can pre-configure modules for later extensions and then deactivate them. The storage areas are then reserved, even if no module is available. The advantage of this is that, when extensions are made, it is not necessary to reset the parameters of the complete DCS /PLC, but merely to activate the section added.

5.2 Manual Marshalling

If you wish to carry out marshalling manually, you must proceed as shown in figure 97. Select the device in the top left window and double-click the register in the lower field or press the Enter-key. Continue in this way until all the registers or devices have been marshalled. Please make a very careful record of the manual marshalling as the storage areas must match the parameters set in the DCS / PLC. It is easier for our specialized staff to assist you over the phone with automatic marshalling rather than with manual marshalling. In the case of digital signals, please fill in the bit positions in the registers accordingly. When you have marshalled all the inputs / outputs, select Save station (see figure 97). Marshalling is then completed.

Fig. 96

Fig. 97

58

5.3 Software Marshalling by means of Table Imports

In the event of extensive marshalling activities, it might make sense to prepare a table with the marshalling data in advance and then import it into the configuration programme. There are various possible ways for preparing the table. By way of example the Microsoft Excel method is to be described below. The table must feature the format as shown in figure 98.

This is followed by the input-marshalling data. Start with the marshalling of the analogue devices (values in word structure) and then add the digital devices (values in byte structure). The column structure shown in the example must be kept to. The first column shows the register, the second the bit to be assigned during marshalling, the columns 4 and 5 are for user information (in the example shown for byte and bit in the Siemens S5 assignment). The existence of these columns is necessary, although their content is merely a comment and is ignored otherwise. Column 5 shows the slot (starting from 1) and column 6 the channel. Column 7 indicates the operation mode, 0 = normal, 1 = inverse.

5.3.1 Description of Format

The first two lines are ignored by the import filter to the FB, the next line must begin with an E for Eingnge or an I for Inputs. Further characters in this line are ignored (see also 2.3.6.1).

L B - R e g is t e r F E in g Inputs: n g e : 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 A u s g Outputs: n g e : 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6

B e l e g u nInputse and Outputs n d A u s g n g S5 and i s c h e n S i e m e n s S 5 u n d L B Connecting g d r E i n - u between Siemens e z w FB B it S 5 B y t e B i t L FB- - Slots k p l a t z B S te c Kchannell N o r m a l = 0 a n a A c t iv = 0 k In v e r s = 1 D e a c t iv = 1 k 8 6 4 0 1 2 0 0 9 6 4 1 1 3 0 0 1 0 6 4 2 3 1 0 0 1 1 6 4 3 1 1 0 0 1 2 6 4 4 2 3 0 0 1 3 6 4 5 3 2 0 0 1 4 6 4 6 0 0 1 5 6 4 7 0 0 0 6 5 0 6 3 0 0 1 6 5 1 6 1 0 0 2 6 5 2 6 2 0 0 3 6 5 3 5 3 0 0 4 6 5 4 5 1 0 0 5 6 5 5 5 2 0 0 6 6 5 6 0 0 7 6 5 7 0 0 8 6 6 0 3 3 0 0 9 6 6 1 4 1 0 0 1 0 6 6 2 4 3 0 0 1 1 6 6 3 2 2 0 0 1 2 6 6 4 2 1 0 0 1 3 6 6 5 4 2 0 0 1 4 6 6 6 0 0 1 5 6 6 7 0 0 0 0 8 6 4 0 3 8 1 0 0 9 6 4 1 3 9 1 0 0 1 0 6 4 2 4 0 1 0 0 1 1 6 4 3 0 0 1 2 6 4 4 0 0 1 3 6 4 5 0 0 1 4 6 4 6 0 0 1 5 6 4 7 0 0 0 6 5 0 1 1 2 0 0 1 6 5 1 1 0 2 0 0 2 6 5 2 1 1 1 0 0 3 6 5 3 1 0 1 0 0 4 6 5 4 9 1 0 0 5 6 5 5 9 2 0 0 6 6 5 6 0 0 7 6 5 7 0 0 8 6 6 0 1 2 2 0 0 9 6 6 1 1 4 2 0 0 1 0 6 6 2 1 4 1 0 0 1 1 6 6 3 1 3 2 0 0 1 2 6 6 4 1 6 2 0 0 1 3 6 6 5 1 5 1 0 0

Fig. 98

59

Column 8 shows whether the modules are activated = 0 or deactivated = 1. The columns 7 and 8 are not absolutely necessary. If the information in these 2 columns is missing, the modules are set permanently at 0 (operating mode normal and active). Once all the inputs have been marshalled, the outputs can follow. Once again you start with the analogue data and then add the digital data. The column structure is the same as that of the inputs. The output field starts with a line with the text outputs in the first column, whereby the import programme merely wants to see an A for Ausgnge or an O for outputs. Any other information in this line is ignored. The example on the previous page also shows that the arrangement of the bits in the registers must also be taken into consideration. For example, the bits 8-15 of the FB Remote I/O BUS inputs belong to the bits 0-7 of the register 64 for the Siemens S5. The bits 0-7 of the FB Remote I/O BUS inputs then belong to the bit 0-7 of the register 65 of the Siemens S5.

Fig. 99

5.3.2 Conversion of Tables

For operations using the FB Remote I/O BUS menu it is necessary to convert the EXCEL file into an ASCII format. Save your marshalling table in a file on your disk /hard disk using the Excel command File / Save. Mark one line in the table, call up Data / Text in columns. The text assistant will then appear on your screen. Click on Divided in the upper third (Fig. 99). Then enter the division mark in the next window (Fig. 100). By first clicking on the Semicolon and then End. You are now back in the table. Now under File /Save as call up the File type CSV (separator divided) and then press OK (Fig. 101). Excel now generates the actual import file for the FB Remote I/O BUS project. If you use other table calculation programmes, you must prepare the table in exactly the same way as described at the beginning. However, you must adapt the conversion into the import file according to the software being used. You must bear in mind that a semicolon is being used as the separator.

Fig. 100

Fig. 101 (Samples in german language.)

60

Once the import file has been completed, you can import it by clicking Import data in the Software-Marshalling window. Having imported the marshalling data you can then check the marshalling in the window (Fig. 102). If this is correct, save it by clicking Save station. Marshalling has now been completed.

5.3.3 Explanations for Importing / Exporting of Data

Order of data: 1. FB register 2. Bit for digital data (otherwise free) 3. Of no significance (e.g. byte of connected S5) 4. Of no significance (e.g. bit of the selected bytes of the connected S5) 5. Slot-No. of module 6. Channel to be marshalled (for multichannel digital modules, otherwise free) 7. Significance (normal = 0 or free/inverse = 1) 8. Active = 0 or free/inactive = 1 Example: ;;;;;; Semicolon acts as separator Inputs;;;;; 0;8;64;1;1;2;;1 0;9;64;2;1;3;1; 0;10;64;3;3;1;;1 0;11;64;4;1;1;1; 0;12;64;5;2;3;; 0;13;64;6;3;2;1;1 0;14;;;1; 0;15;;;;1 0;0;65;0;6;3;1; 0;1;65;1;6;1;1;1 0;2;65;2;6;2;; 0;3;65;3;5;3;;1 Outputs;;;;; 5;8;68;1;38;1;1;1 5;9;68;2;39;1;; 5;10;68;3;40;1;;1 5;11;;;; 5;12;;;; 5;13;;;; 5;14;;;; 5;15;;;; 5;0;69;0;11;2;; 5;1;69;1;10;2;1; 5;2;69;2;11;1;1;1 5;10;68;3;40;1;;1

The separator is the first character of the file. Any character desired can be used for the separator. Further characters in the first line can be used as a comment. Second line: first character E or I (Eingnge / Inputs) or A or O (Ausgnge / Outputs), if you do not wish to marshall any inputs.

This is then followed by the data for the marshalling of the inputs, whereby the order for the analogue and digital data is optional. However, the data area for analogue data always comes before that of digital data. The range for the outputs begins with the line in which A/O is the first character. The following data applies for the outputs.

Fig. 102

61

6 How to Address from the PLC or DCS

6.1 PROFIBUS DP 6.1.1 GSD File
The certified firmware version P 1.45 for FB Remote I/O CEAG has been allocated the Profibus ID 0710 (Hex) by the PNO. The previously used ID was 8101h. In order to now avoid problems in mixed applications with older installations and for the event of service (replacement), the ident number has been determined as an ajustable parameter which is accessible. There are two ways of adapting the ID via the configuration software. 1. Via the LBU file with an ASCII Editor: This is the only possibility for older software packages of carrying out conversions (on version 2.44 (16Bit) and smaller or 2.50 and 2.51). In this respect the desired ID (8101 or 0710) is allocated to the entry PB DP-ID=. 2. Upwards of the operating software vesion 2.45 (16Bit) / 2.52 (32Bit) the alteration can be made from the programme. For this purpose the desired ID can be set under the menu point Services\Alter Profibus-ID\ . Subsequently the station data in the file and in the bus coupler must be saved, in order to realise the alteration in an interconnected manner. You can check the set ID by changing into the dialogue of the DP parameters of the bus coupler. Replacement devices New bus couplers with the firmware P 1.45 can be used very easily even as replacement for existing stations. For this you simply have to build up the connection to the bus coupler, subsequently load the station data from the previously used configuration file for which the bus coupler is to be used as replacement and load these data down into the coupler. The Profibus-ID will then automatically be set to that of the old station. This does not require any alteration in the Master. New installations If you design new stations attention must be paid to the following: - operating software version 2.44 and smaller, 2.50 and 2.51 create stations with the ID 8101h. - as from version 2.45 / 2.52 stations with the ID 0710h are created. Should you already have determined a standard for the bus coupler (default file created with BK\save\in default file) bus couplers with the ID set there (8101) will continue to be generated. You should therefore now prepare a new standard by generating a new bus coupler with the existing default settings, altering the ident number (ID) as described above and then saving as default. In dependence on the selected ID the GSD files (Fig. 103) must be used for parameterising the master. The address occupation can be read out and printed via the menu point Options/Documentation.

Status new previously Fig. 103

Operating software as from 2.45, 2.52 2.44 and older, 2.50, 2.51

ID 0710 8101

file used CEAG0710.GSD CEAG8101.GSD

62

6.1.2 PROFIBUS DP Configuration 6.1.2.1 Bus Coupler Configuration

Connect the configuration computer at the service bus, run the configuration program, login acc. figure 104, establish Sevice bus connection (Fig. 105), edit module data (Fig. 106). After FB selection the COM unit configuration should appear. The COM unit configuration screen can always been opened by double-clicking the COM unit in the window (see 1.3). The screen in figure 107 will appear, select Profibus (1), define node address, click configure, figure 108 will appear, select DP (2), click DP-Parameter, figure 109 will appear,

Fig. 104

If hardware status information or commands (like freeze, start/stop counter,...) should be available, click checkbox status/command (3). If module status information should be available, click checkbox module status area. First dont work with packed data. Save the configuration (COM unit).

6.1.2.2 Control System Configuration

-

Fig. 105

Fig. 106

Load the GSD-file (see 6.1.1). Attach I/O to bus system I/O configuration: Status/command and Module status area act as virtual modules. If they have been activated in the FB system; they have to be called first! e.g.: slot 0: Status/command slot 1: Module status area slot 2: FB I/O module 1 slot 3: FB I/O module 2 ...

DCS/PLC FB Remote For startup, set timeouts as high as possible (or switch off). Save configuration.

} }

Fig. 107 2

Fig. 108 3

Fig. 109

63

6.1.2.3 PROFIBUS Configuration String

The FB Remote I/O BUS helps you set the right configuration for PROFIBUS application if you call up the DP configuration string (Fig. 110). The following configuration string results (Fig. 111). This corresponds to the sequence of the modules placed above, including the preceding status registers 31 and 15. The following applies here (Fig.112).

Warning! Depending on the configuration, the module FB1203 may have 2,4,6 Byte length. Module status (Fig. 113). The modul status range sets 6 bytes for a collective alarm per module. The 6 bytes input data follow the input data of the commando/status range, if that is active (see 6.1.5). The module status bit is 1 if the module concerned is active and in order. Otherwise the bit is = 0. With Siemens systems the hexadecimal numbers must be converted to decimal numbers in order to be able to set the parameters of the DCS with, for example, the aid of the ET200. When using software marshalling, the following can, for example, result: 1 OE 1 1E 2 2A Ident. No.Comment I-Addr O-Addr 065 065 P064 064 001 P068 128 064 P066

Whereby the identification number is calculated from the DP string data by converting the hexadecimal numbers into decimal numbers. The input and output addresses of the Siemens DCS can be generated automatically.

Fig. 110

Fig. 111 String 00 10 15 20 30 31 50 51 52 60 Fig. 112 Modul status: byte 1 2 bit 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 module 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 Fig. 113 3 4 0 7 6 5 4 3 2 1 0 ... 9 24 23 22 21 20 19 18 17 ... Decimal 00 16 21 32 48 49 80 81 82 96 Type N N OUT IN/OUT Length Byte Bytes Byte Byte IN Byte OUT Bytes IN Bytes OUT Word Words Words Word Meaning No assignment Digital input Module status (1 bit per module = 48 Bit = 6 Byte) Digital output Digital input/output (valve with back indication) Global status and command Analogue input (2 Byte) Frequency measurer and counter (6 Byte) Analogue output (2 Byte)

1 6 1 1 1 IN/OUT 2 2 IN 1 IN 2 IN 3 OUT 1

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6.1.2.4 Data Structure

Example with module status area: PROFIBUS DP configuration string 15 10 30 50 60 20 50

The configuring string gives information about the sequence of the data words relative to the bus coupler. Example: PROFIBUS DP configuring string 10 30 50 60 20 50 That means the arrangement of the following devices: 1X0X, 2XXX, 5X0X, 4X0X, 6X0X, 3X0X Look for the tables to see the sequence of input and output bits. 1 Byte Inputs, 1 Byte Inputs + 1 Byte Outputs, 1 Word Inputs, 1 Word Outputs, 1 Byte Outputs, 1 Word Inputs. Module arrangement 1X0X 2XXX 5X0X 4X0X 6X0X 3X0X

Arrangement of the device data as above. The module status area is however placed before the entrance area with a length of 6 Byte. Example with commando area and global status: PROFIBUS configuration string 31 10 30 50 60 20 50

1 2 3 4 5 6 7 ... Input bytes

1 2 3 4 5 6 ... Output bytes

Arrangement of the device data as above. The global status is placed before the entrance area with 2 Byte, the commando area is placed before the exit area with 2 Byte. Example Read/Write, write exits and read entrances see following tables:

Example read/write Plug-in location Typ Dp-config Significance Inputs in Byte Outputs in Byte Write outputs Byte Typ (Slot) Read inputs Byte Typ (Slot) 0 2XXX(2) 1 4XXX(4) 2 3 6XXX(5) 4 n. b. 5 n. b. 0 1X0X(1) 1 2XXX(2) 2 5X0X(3) 3 4 3X0X(6) 5 1 1X0X 10 1Byte In 1 2 2XXX 30 1Byte In 1 Byte Out 1 1 3 4 5 5X0X 4X0X 6X0X 50 60 20 1 Word In 1 Word Out 2 2 1 6 3X0X 50 1 Word In 1 Byte Out 2

Example of DP Scaling

The transmission of analogue data from the FB Remote I/O BUS is carried out using unsigned integer values. The following applies when the scaling is activated: 0% = 10000, 100% = 50000. Some systems can be optimized by scaling the data. If the scaling is activated, the scaling data applies for all inputs or all outputs. Input: DP Value = ( Factor x (FB Value + Offset) ) Whereby: FACT = round(Factor x 32768) DP Value = ( FACT x (FB Value + Offset) ) / 32768 Output signals can also be scaled: Output: FB Value = DP Value / Factor - Offset FB Value = (32768 x DP Value) / FACT - Offset The DP Value is the value that is transmitted via the Profibus DP to the PLC / DCS. The FB Value is the value that is used in the bus coupler for the internal data transfer. Example: Siemens PROFIBUS DP Calculation of the Offset: Measured value 0 mA measured FB Value = 0 desired DP Value = 0 Calculation: DP Value = (Factor x (FB Value + Offset) 0 = Factor x (0 + Offset) thus: Offset = 0
65

Calculation of the Factor: Measured value 20 mA Calculation: thus:

measured FB Value = 50000 desired DP Value = 8 x 2560 = 20480 DP Value = (Factor x (FB Value + Offset) 20480 = Factor x (50000 + Offset) Factor = 0.4096

Thus the integral factor used in the bus coupler is: FACT = round(Factor x 32768), i.e. FACT = round(0.4096 x 32768) = 13422 Error Analysis Input 4 mA measured FB Value = 10000 desired DP Value = 8 x 512 = 4096 DP Value = (FACT x (FB_Value + Offset)) / 32768 DP Value = (13422 x (10000 + 0)) / 32768 = 4096 Error = 0 measured FB Value = 50000 desired DP Value = 8 x 2560 = 20480 DP Value = (FACT x (FB Value + Offset)) / 32768 DP Value = (13422 x (50000 + 0)) / 32768 = 20480 Error = 0 transmitted DP Value = 8 x 512 = 4096 desired FB Value =10000 FB Value = DP Value / Factor - Offset FB Value = (32768 x 4096) / 13422 - 0 = 9999 Error = 0,02 % transmitted DP Value = 8 x 2560 = 20480 desired FB Value =50000 FB Value = DP Value / Factor - Offset FB Value = (32768 x 20480) / 13422 - 0 = 49999 Error = 0,02 %

thus: Input 20 mA

thus: Output 4 mA

thus: Output 20 mA

thus:

6.1.3 Modul Status and Command Register

Structure of the modul status (2 bytes) Those 2 bytes are transmitted with the following syntax: 15 14 13 12 11 10 9 fault code see table 8 7 6 5 4 3 2 1 extension 0

single fault internal advice multiple fault number of faults local calculation: 1=activ 0=not used

number of faults: 0 means 1 fault 1 means multiple fault type of fault: 0=general fault 1=modul fault fault: 0=no fault 1=fault

freeze: 0=no modules freezed 1=1 modul freezed at minimum bus coupler: 0=passive 1=active

66

6.1.3.1 Error Codes

13 12 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 x 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 118 x 0 1 2 3 4 5 6 7 8 9 A B C D E F n Device Status Register No error No error Memory error PIC (RAM) Memory error PIC (Register) Memory error PIC (FLASH) PIC internal error Command error (PIC) Module related error Power supply*) Memory error CPU32 (RAM) Memory error CPU32 (FLASH) CPU32 internal error CPU32 internal error Redundancy error Redundancy error Redundancy error Internal error Field bus communication error 0 = No error; 0 = General error; Error code Error Extension Active power supplies *) Active power supplies *) RAM adress Register adress FLASH page Error sub-code Module number Active power supplies *) RAM page FLASH page (Watchdog) (Arithmetic) Error sub-code (synch.) (Not activable) (Inconsistent param.) Reserved Module Status Register No error No error Time-out (= not installed) Answer too long Answer too short (incomplete) Answer with parity error Answer with wrong address Error telegram received Reserved Reserved Wrong type installed Local link (LFD) Device error Reserved Reserved Reserved Reserved see 1.1.1

Bit 13: Bit 12: Bit811:

1 = Error 1 = Module specific error

CPU32 = main CPU for data processing and fieldbus control PIC = second CPU for internal bus control *) only FB Example: By double clicking on the plug position of the bus coupler with the right hand mouse key you will receive the contents of the global status register e. g. A607 0 = general fault 12 0 11 0 0 = not freezed 14 0

1 = fault

15 1

1 = fault 13 1 A

10 1

9 1

8 0

7 0

6 0

5 0

4 0

3 0

2 1

1 1

0 1

6 device related

07 error in Module 7

67

6.1.3.2 Module Related Error Codes FB 520X

Bit 11 Bit 10 1 x x 1 x x x x Bit 9 x x 1 x Bit 8 x x x 1 Description Faulty parameter set (CRC) Faulty calibration data (CRC) Calibration data outside tolerance band (> 5%) Busy (Power up)

6.1.3.3 Command Register

Bit15Bit8 Parameter, e.g. plug position no.

Bit assignment of the command register. Bit7Bit0 Command

6.1.3.4 Commands
Code 1 2 3 4 5 6 7 8 Command register Deactivate module Activate module Freeze module Unfreeze all modules Delete collective alarm Refresh marshalling Stop counter Start counter parameter module slot no. module slot no. module slot no. module slot no. (0 = all module) 0 = delete, otherwise set module slot no. module slot no.

Command HEX 0X15 0XDA 0XDB 0XF5 0XF8 0XF9

Description BUS TOOLS Command* Activate HART communication Switch off HART communication Redundancy switch-over (passive) Cold start Warm start

Parameters 0=init, 1=done, 2=step, 3=run, 4=stop, 5=reset slot no. slot no. -

One command can be transferred for each cycle. *BUS TOOLS is a CEAG Software Product that offers you comprehensive additional uses for local signal processing. You can use the processor for a wide range of tasks from mathematical operations through to conditional branching (data leaflet available on request). Example: To reset the collective alarm send HEX Byte 1 Byte 2 0 5

6.1.4 Data Format

To transmit data by PROFIBUS DP see the following data format. This applies for LB Remote /FB Remote and in the same way for non-intrinsically safe modules.

6.1.4.1 Analogue Data

Meaning Beginning of range Full scale value

Analogue data are transmitted as Integer numbers without sign: Value 0 10000 50000 62500 Percent - 25 % 0% 100 % 131 % engineering unit 3X0X, 4X0X 0 mA 4 mA 20 mA 25 mA 1X03, 5X0X as parameterised

For 0-20 mA signal the lead monitoring should be switched off. The measured value is contained in the bits 4 to 15 (except 1X03 as counter).

68

Bit 0 to 3 contains the following information: Bit 3 2 1 0 Properties of 1X03 Counting direction on 1X03 1 = below preset value 1X03 Line monitor both inputs Input status 1X03 Properties of 3X0X 0=monitoring ok 1=fault 0 at >3.6 mA 1 at <3.6 mA Bit 3 2 1 0

In the counter mode 1X03 counts from 0...65535 as far as the overflow (16 Bit unsigned integer). When counting backwards the overflow occurs from 0 to 65535. In the extended counting mode 1X03 counts from 0...429967295 as far as the overflow (32 Bit unsigned integer). When counting backwards the overflow occurs from 0 to 4294967295. During parametization the Low Byte is transmitted first and then the High Byte. 7 6 5 4 3 2 1 0 8

15 14 13 12 11 10 9

If PLC or the DCS cannot calculate with large integer numbers, the values can be scaled. The scaling can be done separate for inputs and outputs. To do so set the relating storing cells in the bus coupler during DP parameterization. Scaling for Siemens Systems is usually done by the factor 0.4096. In that case the number 4096 represents the measured value 4 mA; the number 20480 represents 20 mA (see 6.1.4.3).

6.1.4.2 Binary Inputs

7 Bit 7 6 5 4 3 2 1 0 6 5 4 3

Binary inputs are transmitted as 8 Bit values. 2 1 0 2XXX empty empty LFD chan.2 channel 2 LFD chan.1 channel 1 LFD valve empty

1X01 empty empty empty empty LFD chan.2 channel 2 LFD chan.1 channel 1

1X02 empty empty LFD chan.3 channel 3 LFD chan.2 channel 2 LFD chan.1 channel 1

LFD = 0 no cable fault LFD = 1 cable breakage / short circuit channel = 0 if open contact channel = 1 if closed contact

depending on the phase reversal mode

The solenoid valve driver has binary inputs and outputs. The input byte has binary inputs. Option: phase reversal (see 3.1.1 and 3.2.1)

6.1.4.3 Binary Outputs

7 Bit 7 6 5 4 3 2 1 0 6 5 4 3 2

Binary Outputs are transmitted as 8 Bit values: 1 0

2XXX empty empty empty empty empty empty empty Valve

6X01 empty empty empty empty empty empty Relay 2 Relay 1

The solenoid valve driver has binary inputs and outputs. The output byte only has one valve driving bit: valve = 0 valve = 1 output voltage = 0 valve on.

Relay 1/2 0 = deenergized 1 = energized

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6.2 PROFIBUS FMS

Object Dictionary Index 0 1..14 15 50 51 60 61 62 63 64 65 66 70 71 72 73 74 75 80 81 101 ... 148 Type S U16 S U16 A U8 A U8 A A A A A A U16 U16 U16 S16 U16 U16 Dim 1 1 48 48 48 48 48 50 48 50 50 25 25 25 25 ) 1 )
1

Name Status0 Cmd Din Dout Ain Aout Status sData ID xChng1 xChng2 xData1 xData2 fData1 fData2 Dpln DpOut Para ... Para

A U16 A U32 A U32 AF AF A U8 A U8 R DS15 ... R DS15

Remark OD-header standard data types data structure definition for slot parameter (see) global status command binary input values; channel 1=Bit0,...; bit wise coded binary output values; channel 1=Bit0,... bit wise coded analog input value analog output value module status PLC integers module Identification data exchange region part 1: xChange 1 xChng[ 1..50] data exchange region part 2: xChange 2 xChng[51..100] data exchange region part 3: counters 1 xData[ 1..25] data exchange region part 4: counters 2 xData[26..50] data exchange region part 5: PLC floats 1 fData[ 1..25] data exchange region part 6: PLC floats 2 fData[26..50] DP data exchange input buffer DP data exchange output buffer parameter for slot 1 ... parameter for slot 48

see also EN 50170 EN 50170 config.doc 6.3.1 6.3.7 6.1.11.2 6.1.11.3 6.11.1 6.11.1 6.3.1 6.3.4 6.3 6.3 6.3 6.3 6.3 6.3 6.1.2 6.1.2 config.doc ... config.doc

S = simple variable A = array R = record (data structure) DSnn = data structure nn (record) U8 = unsigned8 U16 = unsigned16 U32 = unsigned32 S16 = signed16 F = floating point (Gleitkommastelle) 1 ) variable (length of DP data_exchange in/out data), depends on configuration

70

6.3 FB 8202 MODBUS Interface

The different manufacturers (PLC or DCS) use two different possibilities of MODBUS adressing (MODBUS RTU and MODICON). Both possibilities can be used by FB Remote I/O. The address occupation can be read out and printed via the menu point Options/Documentation. The following table shows the two modes. Length Type MODBUS Address 384 Bit 8x(Modul1) + Channel -1 Dout 384 Bit 8x(Module1) + Channel -1 48 Word Module-1 Ain Status0 1 Word 99 Status 48 Word 100+ Module - 1 ID 48 Word 200 + Module - 1 Aout Cmd0 SData Para 48 1 50 49 Word Module - 1 Word 49 Word 50 + Module - 1 *) 100xModule Name Din MODICON Reference 10000 + 8x(Module 1) + Channel 8x(Module1) + Channel 30000 + Module 30100 30100 + Module 30200 + Module 40000 + Module 40050 40050 + Module 40001 + 100xModule Remarks Channel 1 = Bit0,..; can be addressed bit by bit Channel 1 = Bit0,..; can be addressed bit by bit Analogue input value Device status (s.6.3.1) Module status (s. 6.3.1) Module identification (s.6.3.4) Analogue output value Global command (s. 6.3.5) Integer for PLC Parameters to FB 8202 Data exchange

Xchng 100 XData fData 96 900

Word 5000 45000 + index index (1-100) range (packed) Word 5100 + 2x (Modul-1) 45101 + 2x (Module -1) Long Integer 32 bits for counter Word 5200 + 2x (index -1) 45201 + 2x (index - 1) 32bit float for local index (1 - 450) calculation

Analog values: 10000 = 0 % and 50000 = 100 % *) Information for module settings (range of measurement, cable breakage etc.) on request (see also 6.1.11). NOTE: Modules refer to slot numbers.

Data type

Input bit Output bit Input register Output register Xchng,Xdata,fdata analogue 3 FC = function code

Type of signal digital digital analogue

FC read 2 1 4

FC write 5 6 single

FC write 15 16 multiple

MODBUS Address range 0...65535 0...65535 0...65535

MODICON Reference range 10000...19999 0...9999 30000...39999

0...65535 40000...49999 with FC-code without FC-code

Details of how to use the MODBUS can be found in the relevant literature (see Chapter 8, Literary References).

6.3.1 Status Register

Bit15 active Bit14 frozen

Bit distribution of the status register: Bit 138 error code Bit 7/6 chan. 4 *) Bit 5/4 Bit 3/2 Bit 1/0 chan. 3 *) chan. 2 *) chan. 1 *)

Channel info:

low ranking Bit: line status (digital module, 1=ON / 0=OFF); high ranking Bit: 1 = LFD. The channel info indicates the LED status.

MODBUS uses the same status registers, the same error codes, the same command codes and data format as PROFIBUS.

71

6.3.2 MODBUS System Addresses

The different system manufacturers use different methods for Modbus addressing.

6.3.2.1 Elsag Bailey (H+B)

Digital input Digital output Analogue input Analogue output Function Code 2 1 / 5 / 15 4 3 / 6 / 16 Address 8 x Slot + Channel 8 x Slot + Channel Slot Slot

6.3.2.2 Fisher Rosemount RS3

Digital input Digital output Analogue input Analogue output Address 1000 + 8 x (Slot - 1) + Channel 8 x (Slot - 1) + Channel 30000 + Slot 40000 + Slot

6.3.2.3 HIMA
Digital input Digital output Analogue input Analogue output Function Code 2 1 / 5 / 15 4 3 / 6 / 16 Address 8 x (Slot - 1) + Channel 8 x (Slot - 1) + Channel (Slot - 1) (Slot - 1)

Note: Many MODBUS systems only write into output registers when the status of at least one bit changes. In theses systems the bus monitoring function of the slave should be disabled so that the watch dog circuit does not drive the output to zero because of a lack of communications. When the output module is replaced it only receives the correct setting when the master sends a new write command.

72

7 Troubleshooting
7.1 Communication 7.3 Faulty Modules

If there is a fault in the communication with the DCS or PLC please check whether the cable connections are intact, the address selected matches the desired station address, the baud rate and the start and stop bits match, the bus terminating resistor is activated, the bus stations were accidentally starconnected to a branch point (inadmissible) and the address strings of master and slave match. In the caseof packed data particular attention must be paid to careful addressing. During troubleshooting the FB Remote I/O BUS pro vides help via the service bus, as in each case it indicates the first difference between the master string and the slave. If there is a fault in the communication via the service bus please check whether the cable connections are intact, the address selected matches the desired station address, the baud rate and the start and stop bits match, the bus terminating resistor is activated and the bus stations were accidentally star-connected to a branch point (inadmissible).

In the event of faults with a module please check whether the green LED of the module is on (if NOT, either there is no contact to the backplane, or the fuse is defect, or if the 24 modules of one segment fail, there is a fault in the voltage supply), the module can be activated via the service bus (if NOT, see 7.1), the display shows that the module is OK, i.e. in operation (if NOT, check whether the module in this slot is the correct module), the display shows that the module is active (if NOT, the module has been preconfigured for later extensions, but is not addressed by the DCS or PLC), the modules selected by clicking the mouse can indicate its measured value (if NOT, the reason could be a short or open circuit), an output module has a local connection (if this is the case, the module cannot be addressed by the DCS or PLC as the local connection has priority). In this case manual settings are also blocked.

7.4 Red LEDs

7.2 Faulty Power Supply Units

In the event of faults with the power supply FB 92XX please check whether the green LED of the module is on (if NOT, either there is no contact to the backplane, or the fuse is defect, or the supply is interrupted).

If the red LED of a module lights up, there is a fault in the field wiring. The red LED of a module lights up if there are problems with an I/O module of the station. The red LED of the bus coupler cannot be switched off by the system or via the service bus until all I/O modules function correctly. The collective alarm can be reset in the main menu of the configuration software with the menu item SERVICE in the headline. The menu item DP-RAM Flash Viewer, that is also accessible there, is reserved for the servicing engineer of the manufacturer.

73

7.5 Searching for Errors Error Corrective measures

Green LEDs of the modules do not light up. Check mains connection and mains part. 24V power supply fault. Yellow LEDs of the bus couplers do not flash during data transmission. Software cannot find bus coupler when connecting. Check if it has been operated on the correct mains. Check the connection of the configuration cable and of the adapter. Check if the yellow LEDs flash when the connection is made. Check if the service bus address is in the selected area (if necessary extend the search area). Check if the bus coupler is correctly plugged in. Check password. Bring bus coupler content in to the PC with the menu point device Load station from the field. The desired configuration has not been saved in the bus coupler. See menu point Device Save station in the field. Possibly no error. May be no modules are plugged in the configuration kit. The bus coupler has checked if the configured modules are present.

Bus coupler cannot be configurated.

When reading out the bus coupler the desired configuration is not recognisable. Bus coupler advises module error when reading back the saved data from configuration kit.

Communication disturbance after the Check the galvanic separation of the service successful establishment of the connection. bus. Operate the LAPTOP with a battery. Use a normal commercially available interface converter RS 232-RS 485 with automatic recognization of the baud rate and line direction changeover. No HART communication Check if HART input/output separators are present. Use interface converter with automatic Baud rate and direction recognition. Ensure that HART field devices are not overdriven (working range up to 20mA). Check if the correct address of the HART device was used. Check if the HART software has a driver for the field device used.

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7.6 Check list in the Event of Failure of Signals

Question How many stations are affected? Are all output signals of a station affected? Are the stations equipped with a mixture of inputs and outputs? Are analogue and binary outputs affected? Which module types are affected? In which plug positions are modules affected? Is it always the same plug position? On which plug rows are the modules situated? Can the outputs be switched back on by software? Do the modules have to be replaced? Is the address monitoring of the bus coupler active? How long is the programmed time? At which time intervals does a master communication take place? Are the stations structured redundant? Is the lead monitoring of the modules active? How does the master react to breakage of the lead? Which lunimous diodes of the disturbed modules are switched on? Are red, yellow or red and yellow LEDs switched on? Which master system is being used? Which bus protocol is being used? Are the bus leads earth free? (bus couplers are separated galvanically) Are the earth connections linked with equipotential bonding? Are the screen connections of the field leads linked to the housing via the metal glands? Does the wiring between the basis unit and the extension unit correspond to the connection plan? Which supply voltage do the stations receive? (at least 20 V DC incl. drops in voltage required. If necessary oscillograph) Is it possible to connect a bus monitor to the service bus? For this a PC with Windows 3.11 or Windows 95 with hard disk would be suitable. Please fill out and send to us. Answer

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8 Literary References
PROFIBUS Art. No. 4.001 PROFIBUS DP Rapid induction Art. No. 4.071 Modbus Protocol Reference Guide PI-MBUS-300 PROFIBUS User organization Haid-und-Neu-Strae 7 D-76131 Karlsruhe Tel ++ 721 9658 590 FAX ++ 721 9658 589 AEG Schneider Automation Steinheimer Str. 117 D-63500 Seligenstadt Tel ++ 6182 810 FAX ++ 6182 813 306 www.profibus.com www.CEAG.de

Internet

Index of Keywords

This hand book is available on the CD ROM as a file. There you can look for any keywords using the ADOBE ACROBAT READER software (scope of delivery).

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CEAG Apparatebau Hundsbach GmbH & Co. KG

P.O. Box 4999 Wolfs & 7th North Streets USA Syracuse, NY 1321 Phone + 1 315/477-7000 Fax + 1 315/477-5717 Internet http://www.crouse-hinds.com/worlwide/ Bumatten 10 - 12 77815 Bhl/Baden Telefon07223 9909-117 Fax 07223 9909-140 Internet http://www.ceag.de E-mail: Info@apparatebau-hundsbach.de

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