Field IT. PROFIBUS DP/PA Linking Device LD 800P. User Instructions

Transcription

1 Field IT PROFIBUS DP/PA Linking Device LD 800P User Instructions

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3 Field IT PROFIBUS DP/PA Linking Device LD 800P User Instructions

4 NOTICE The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABBbe liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. This product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage Directive 72/23/EEC. Copyright 2001 ABB All rights reserved. Release: Document number: 3BDD011704R0101 TRADEMARKS Registrations and trademarks used in this document include: Windows Field IT Registered trademark of Microsoft Corporation. Trademark of ABB.

5 TABLE OF CONTENTS Safety Summary Intended use...9 Commissioning and installation in connection with Ex areas...11 Installation of LD 800P modules outside the Ex area...11 Installation of LD 800P modules within Zone 2 of the Ex area...12 Grounding / shielding...14 Hard grounding to both ends of the transmission line Capacitive grounding in the non potentially explosive area...14 Mounting and dismounting...14 Maintenance...15 Fault elimination...15 Ambient conditions...15 Isolation coordinates for devices Ex certificate in accordance with EN Isolation coordinates for information on galvanic separation in accordance with EN and EN Disposal...16 About This Book General...17 Use of Warning, Caution, Information, and Tip Icons...17 Terminology...18 Related Documentation BDD011704R0101 5

6 Table of Contents Section 1 - Introduction Range of application of the Linking Device...19 Section 2 - Installation Quick Comissioning LD 800P...23 Commissioning LD 800P...27 Mounting the Linking Device LD 800P...27 Mounting in Zone Connections...27 Bus termination...29 Grounding...30 Commissioning of communication...31 The startup phase of the Linking Device LD 800P...32 Configuration of PROFIBUS PA slaves...33 Effect of the GSE converter software on field device functionality...34 Use of the "GSD Converter software...35 Setting the PA slave watchdog time...37 Information for determining the Watch Dog Time TWD...37 Determining the parameter TWD...38 Details for calculating the TWD parameter...39 Modification of the LD 800P watch dog time settings by using the service tool...39 Redundancy...41 Redundancy monitoring with AC 800M / CI Redundancy monitoring with AC 800F / Freelance...42 Redundancy monitoring with Symphony Melody...42 Usage of Device Type Manager (DTM)...43 Specialties when using a PA slave DTM...44 Specialties with Symphony Melody...44 Specialties with Freelance (AC 800F)...45 Using with externally safed GSE file...45 Handling with DTM, that require the original GSE-file name BDD011704R0101

7 Table of Contents Section 3 - Planning for a PROFIBUS PA application Planning of a PROFIBUS PA application with LD 800P...52 PROFIBUS DP time behaviour...54 Dimensioning of a PROFIBUS PA segment...56 Current calculation...56 Voltage calculation and line length...57 Mechanical dimensions of LD 800P...60 Voltage supply...62 Section 4 - Maintenance Displays and error messages...63 Power Link Module LEDs...66 Appendix A - Introduction to intrinsic safety for field bus systems (FISCO model) Appendix B - PROFIBUS-PA topologies and lines Appendix C - Specification of the service cable 3BDD011704R0101 7

8 Table of Contents 8 3BDD011704R0101

9 Safety Summary Intended use This instruction manual is valid in combination with the corresponding data sheets. The data sheets can be retrieved under The company who operates the plant, bears the responsibility regarding planning, mechanical installation, commissioning, operation and maintenance, specially in connection with applications in potentially explosive environments. The Linking Device LD 800P is the interface between PROFIBUS DP and PROFIBUS PA and ensures among other things the galvanic separation between PROFIBUS DP and PROFIBUS PA. The PROFIBUS PA is the PROFIBUS DP with the addition of transmission elements in accordance with IEC , which can be used in areas subject to the danger of explosions. For further information please see the section introduction. A Linking Device LD 800P with an intrinsically safe PROFIBUS PA interface is used to operate intrinsically safe PROFIBUS PA field devices within areas subject to the danger of explosions. Data sheets for the LD 800P modules contain the electrical data of the EC Declaration of conformity and are considered an integral part of the instruction manual. The data sheets can be retrieved under Linking Devices that are operated in general electrical systems must not be operated in electrical systems that are connected with areas subject to the danger of explosions. Laws and/or regulations governing the use or intended usage goal must be observed. 3BDD011704R0101 9

10 Intended use Safety Summary The Linking Device LD 800P is only approved for proper professional usage in accordance with the intended purposes. Improper handling will void any claim made under the warrantee and any manufacturer's liability. Protection of operating personnel and the system is not ensured if the module is not used in accordance with its intended purpose. The device must be operated by authorised specialist personnel only in accordance with these operating instructions. 10 3BDD011704R0101

11 Safety Summary Commissioning and installation in connection with Ex areas Commissioning and installation in connection with Ex areas Commissioning and installation must only be performed by specialists who are trained specifically for this purpose. Installation of LD 800P modules outside the Ex area The Linking Device modules are designed in the IP20 protection class in accordance with EN and must be appropriately protected against adverse environmental conditions such as splashed water or dirt beyond accumulation level 2. The Linking Device LD 800P is allowed to be installed in zone 2 of the area subject to the danger of explosion! The intrinsically safe PROFIBUS PA may be introduced into the area subject to the danger of explosion with due consideration to the explosion group and category. Special care should be taken in this case to ensure a safe separation from all nonintrinsically safe circuits. The installation of the intrinsically safe circuits is to be conducted in accordance with the relevant installation regulations. The intrinsically safe PROFIBUS PA should only be connected with the blue removable connection terminals of power link module PL 890. When interconnecting intrinsically safe field devices with the intrinsically safe PROFIBUS PA connection of the LD 800P, the respective maximum values of the field devices and power link module PL 890 in accordance with the EC Declaration of conformity must be observed (Proof of Intrinsic Safety). EN /IEC should be observed in this regard. For the Federal Republic of Germany, the "National Foreword" of DIN EN /VDE 0165 Part 1 and the FISCO model (PTB Report W-53) must be observed in addition When using intrinsically safe circuits in the dust Ex area "D", only field devices certified for this purpose may be connected. 3BDD011704R

12 Commissioning and installation in connection with Ex areas Safety Summary If Power Link Modules PL 890 with an intrinsically safe interface are used for the LD 800P, care should be taken that there is a straight-line distance of 50 mm between the PROFIBUS DP connection of the head station and the intrinsically safe terminals of the Power Link Module PL 890. When Power Link Modules PL 890 with intrinsically safe PROFIBUS PA are being installed and operated, the EC Declaration of conformity must be observed. Especially important is the obseration of the 'special conditions' that may be included. Installation of LD 800P modules within Zone 2 of the Ex area Devices can only be installed in Zone 2 if corresponding conformity information of a named center or a declaration of conformity of the manufacturer is on file. This is the case for all modules of LD 800P. The devices should be installed in a switch or junction box to IP54 or better, in accordance with EN The intrinsically safe PROFIBUS PA may be introduced into the area subject to the danger of explosion with due consideration to the explosion group and category. Special care should be taken in this case to ensure a secure separation from all nonintrinsically safe circuits. The installation of the intrinsically safe circuits is to be conducted in accordance with the relevant installation regulations. The connection of the intrinsically safe PROFIBUS PA is carried out exclusively via the blue, removable PL 890 connector terminals. When interconnecting intrinsically safe field devices with the intrinsically safe PROFIBUS PA connection of LD 800P, the respective maximum values of the field devices and PL 890 in accordance with the EC Declaration of conformity must be observed (Proof of Intrinsic Safety). EN /IEC should be observed in this regard. For the Federal Republic of Germany, the "National Foreword" of DIN EN /VDE 0165 Part 1 and the FISCO model (PTB Report W-53) must be observed in addition When using intrinsically safe circuits in the dust Ex area "D", only field devices certified for this purpose may be connected. 12 3BDD011704R0101

13 Safety Summary Commissioning and installation in connection with Ex areas If Power Link Modules PL 890 with an intrinsically safe interface are used, care should be taken that there is a straight-line distance of 50 mm between the PROFIBUS DP connection of the head station and the intrinsically safe terminals of the Power Link Module. When Power Link Modules PL 890 with intrinsically safe PROFIBUS PA are being installed and operated, the EC Prototype test certificates and EC Conformity information or Declaration of conformity must be observed. Especially important is the obseration of the 'special conditions' that may be included. 3BDD011704R

14 Grounding / shielding Safety Summary Grounding / shielding If a screen is required and the latter has to be grounded due to EMC reasons, chapter of the EN and chapter of of the PNO guide PROFIBUS PA always have to be observed. Preferably, the following possibilities should be used. Hard grounding to both ends of the transmission line. This procedure, which is optimal for electromagnetic compatibility and personal protection, can be used in accordance with EN , Sect without restriction in systems with potential compensation that is "assured to a high level" throughout the entire course of the fieldbus installation. Capacitive grounding in the non potentially explosive area The following requirements are placed on the isolating capacitor: Fixed dielectric, for example ceramic C < 10nF Test voltage >1500V Mounting and dismounting LD 800P is normally mounted on a 35-mm top hat section rail in accordance with DIN EN Recognized rules of the technology and setup requirements must be maintained during mounting and dismounting. Especially for tasks on electrical systems, special safety requirements must be observed. Mounting and dismounting must only be performed by specialists who are specially trained and authorized for the task. 14 3BDD011704R0101

15 Safety Summary Maintenance Maintenance Fault elimination The transmission behavior of the Linking Device LD 800P is stable even over long periods of time. There is thus no need for regular adjustments or similar tasks. Maintenance is therefore not required. No changes must be made to LD 800P devices that are operated in connection with areas subject to the danger of explosion. Repairs made to LD 800P modules must only be performed by the manufacturer. Ambient conditions Ambient temperature Storage temperature Relative humidity C ( ) K C ( ) K max. 75 % rel. humidity without moisture condensation Isolation coordinates for devices Ex certificate in accordance with EN LD 800P is dimensioned for use in accumulation level 2, in accordance with EN Isolation coordinates for information on galvanic separation in accordance with EN and EN LD 800P is a built-in device or electronic equipment for use in closed electrical operating locations to which only electrical specialists or persons trained in electrotechnology are granted admission or access. The devices are dimensioned for use in accumulation level 2, in accordance with EN BDD011704R

16 Disposal Safety Summary Disposal Disposal of the packaging and Linking Device LD 800P must only take place in accordance with the requirements of the country in which the LD 800P is installed. The LD 800P does not contain any batteries that must be disposed of separately from the Linking Device. 16 3BDD011704R0101

17 About This Book General Use this subsection to summarize the content of the book and the content of this section. Use this section as a guide to the conventions and terminology used throughout this book. Use of Warning, Caution, Information, and Tip Icons This publication includes Warning, Caution, and Information where appropriate to point out safety related or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols should be interpreted as follows: Electrical warning icon indicates the presence of a hazard which could result in electrical shock. Warning icon indicates the presence of a hazard which could result in personal injury. Caution icon indicates important information or warning related to the concept disussed in the text. It might indicate the presence of a hazard which could result in corruption of software or damage to equipment/property. Information icon alerts the reader to pertinent facts and conditions. Tip icon indicates advice on, for example, how to design your project or how to use a certain function 3BDD011704R

18 Terminology About This Book Terminology Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices. The following is a list of terms associated with the Linking Device that you should be familiar with. The list contains terms and abbreviations that are unique to ABB or have a usage or definition that is different from standard industry usage. HCIR Term Hot Configuration in Run Description Related Documentation The following is a listing of documentation related to LD 800P. Category Title Description Hardware Data Sheet PL 810 Data sheet for the non-intrinsically safe Power Link Module Data Sheet PL 890 Data Sheet HS 810 Data Sheet HS 820 Data Sheet HS 840 Data sheet for the intrinsically safe Power Link Module Data sheet of the 1 channel head station Data sheet of the 2 channel head station Data sheet of the 4 channel head station 18 3BDD011704R0101

19 Section 1 Introduction Range of application of the Linking Device The Linking Device LD 800P is the interface between the PROFIBUS DP and the PROFIBUS PA. PROFIBUS PA extends the PROFIBUS DP with a transmission technology (Manchester Bus Powered MBP) in accordance with IEC which can be used in areas subject to the danger of explosions. Both systems are communication-compatible, so that a data exchange between both systems is possible without any problem. The advantage of the physical transmission arrangement in accordance with IEC is that power can be supplied to field bus stations from the transmission line. The power supply current required for this is made available by the Linking Devices. If an intrinsically safe PROFIBUS PA segment is used, the Power Link Module PL 890 with an intrinsically safe interface has to be used. One task of the intrinsically safe power link module is then to ensure the intrinsic safety of the PROFIBUS PA segment. To this end, the maximum amount of power in the explosive area available in the event of an error is limited to an amount that is not suitable for bringing the surrounding atmosphere to the ignition point. This is achieved by limiting the voltage (in this case 12.6 V V) and limiting the current (in this case I < 100 ma). Everthing else is regulated by the FISCO model (An explanation of the FISCO model is part of appendix A). 3BDD011704R

20 Range of application of the Linking Device Section 1 Introduction The following illustration shows a typical PROFIBUS structure: 20 3BDD011704R0101

21 Section 1 Introduction Range of application of the Linking Device LD 800P performs the following tasks: Potential separation between the PROFIBUS DP and the PROFIBUS PA Conversion of the RS 485 physical arrangement of the PROFIBUS DP to the physical arrangement based on IEC of the PROFIBUS PA. Adapting the PROFIBUS DP transfer rate to the PROFIBUS PA transfer rate of kbd. Power supply of PROFIBUS PA stations over the bus line. Diagnostics via LEDs. Ensuring intrinsic safety if the PL 890 power link module with an intrinsically safe interface is used. A PROFIBUS DP master (class 1 master), which organizes the exchange of process data, is contained in the controller (PLC/PCS). Moreover, a configuration tool, usually a PC, can be connected as class 2 master to the PROFIBUS DP. Parameterization and configuration of the bus elements usually takes place by means of this configuration tool - even during operation. This is performed using the acyclic channel of the PROFIBUS DP or PROFIBUS PA. LD 800P supports both cyclic as well as acyclic PROFIBUS communication. The way in which LD 800P works is essentially transparent. This means that PROFIBUS DP masters have direct access to PROFIBUS PA slaves. This offers the following advantages: No configuration of the Linking Device is required PROFIBUS PA slaves can be treated like PROFIBUS DP slaves There is no PROFIBUS DP address setting on the Linking Device Because of this, there is no restriction on the amount of data to 244 bytes of I/O data per PROFIBUS PA segment for the PROFIBUS PA. 3BDD011704R

22 Range of application of the Linking Device Section 1 Introduction With the power link module PL 890 the Linking Device has an intrinsically safe interface on the PROFIBUS PA side. The differences between the power link modules with intrinsically safe and non-intrinsically safe interfaces are illustrated in the following table: Table 1. PL 890 (intrinsically safe) PL 810 (nonintrinsically safe) Measurement voltage 12,8 V... 13,4 V 24 V V Measurement current < 100 ma < 400 ma max. PROFIBUS PA slaves a max. line length b 1000 m 1900 m a The actual number of bus elements on a PROFIBUS PA segment is dependent on the actual current drain of the PROFIBUS PA slalves. b The actual line length is dependent, on among other factors, on the cable used. The actual number of bus elements which can be connected to a PROFIBUS PA segment depends on the current consumption of each bus element and the Fault Disconnection Electronics (FDE). This FDE includes electronic current limiting, which limits the maximum current which flows in the event of malfunction. This refers to an electronic current limit that restricts the maximum additional current I FDE that can flow in the event of an error. I FDE can be derived specifically for each device from the corresponding data sheet. In an extreme case, the I FDE current is 9 ma, i. e. the maximum current consumption is the basic current (current consumption according to the data sheet) + I FDE. 22 3BDD011704R0101

23 Section 2 Installation Quick Comissioning LD 800P This chapter describes in brief outlines how to put into operation the LD 800P. It is intended for employees who have experience in commissioning PROFIBUS. For detailed information please refer to paragraph comissioning LD 800P. If you have not done so already, mount the top hat section rails at the installation location on the Linking Device. Snap the Head Station and the Power Link Modules of the channel 1 as well as the power supply unit onto the corresponding DIN Rail segment. Please note that the distance between the PROFIBUS DP socket of the head station and an intrinsically safe PROFIBUS PA connection of the Power Link Module PL 890 must be at least 50 mm measured straight. If a 2- or 4-channel head station (HS 820 or HS 840) is being used snap the Power Link Modules of the channels 2 to 4 as well as the power supply units onto the correponding DIN rail segments. Connect the power supply to the LD 800P modules. Connect the PROFIBUS DP transfer line to the head station. If it is being used, connect the redundant PROFIBUS DP transfer line to the head station (HS 840). Add the external bus termination if the head station is the last station on the PROFIBUS DP segment. 3BDD011704R

24 Quick Comissioning LD 800P Section 2 Installation Connect the PROFIBUS PA transfer lines with the Power Link Modules provided for this purpose. The terminal resistances for the PROFIBUS PA segments are integrated into the Power Link Modules. Table 2. Function PL 810 PL 890 Shield PROFIBUS PA 1S and 13S 1S and 16S PROFIBUS PA - 2- and and 17- PROFIBUS PA + 3+ and and 18+ Connection to head station Connection to head station Functional earthing FE 46FE 58FE Design operating voltage Design operating voltage The terminals connection to the head station + and connection to the head station - have to be connected with the terminals PROFIBUS PA channel CHx + or PROFIBUS PA channel CHx -. The "x" designates the respective channel number 1 through BDD011704R0101

25 Section 2 Installation Quick Comissioning LD 800P Connect the outputs for channels 2 through 4 of the head station with the terminals "Connection to the head station" of one Power Link Module of the corresponding channel. Function Table 3. Connection to Power Link channel 1, + CH1, + Connection to Power Link channel 1, - CH1, - Connection to Power Link channel 2, + CH2, + Connection to Power Link channel 2, + CH2, - Connection to Power Link channel 3,+ CH3, + Connection to Power Link channel 3, - CH3, - Connection to Power Link channel 4, + CH4, + Connection to Power Link channel 4, - CH4, - Terminal Connect the PROFIBUS PA terminals of all power link modules of one channel. Connect the power pack. During configuration and when setting parameters for the PROFIBUS, make sure that DP-GSE files are used. When using DTM for devices it is required to use DTM providing either DP-GSE-file information or those DTM providing the GSE informationen out of the DTM. In the last case a GSE file converting 3BDD011704R

26 Quick Comissioning LD 800P Section 2 Installation ist required. For further information please refer to paragraph Commissioning LD 800P. The watch dog time T WD is set within the LD 800P to a default value of 5 sec.. This setting leads to a 5 sec. watchdog time of all underlying PA slave devices independent of the T WD settings within the PROFIBUS DP master. If a watchdog time adjustment of is not possible for the individual PA slave device there is a possibility to use a service tool and a serial connection to adjust the watchdog time for all PA slave devices within LD 800P. For further information please refer to paragraph Commissioning LD 800P. 26 3BDD011704R0101

27 Section 2 Installation Commissioning LD 800P Commissioning LD 800P Mounting the Linking Device LD 800P Mounting in Zone 2 Connections LD 800P is mounted on a 35 mm top hat rail in accordance with DIN EN The devices can simply be snapped vertically onto the top hat section rail. In no case should the module be mounted from the side so that it is slanted or tipped For information on mounting the LD 800P in Zone 2 of an area subject to the danger of explosion, please refer to the Safety Summary of these user instructions. For the pin assignment of the head station or power link modules, please refer to the following table: Table 4. Function Terminal Connection to Power Link channel 1, + CH1, + Connection to Power Link channel 1, - CH1, - Connection to Power Link channel 2, + CH2, + Connection to Power Link channel 2, + CH2, - Connection to Power Link channel 3,+ CH3, + Connection to Power Link channel 3, - CH3, - Connection to Power Link channel 4, + CH4, + Connection to Power Link channel 4, - CH4, - Function ground Operating voltage + Operating voltage - FE+ 3BDD011704R

28 Connections Section 2 Installation Table 4. Function Service interface (send line) Service interface (receive line) Service interface (reference ground) Terminal TxD RxD GND The service interface must only be used by authorized ABB service personel. Via service interface, a service tool is able to perform the following actions: Firmware download Adjustment of Watchdog time for subsequent PA-slave devices Adjustment of the parameters Max.Retry Limit The connection has to be realized with a two line service cable, connected via sub-d-plug with the serial interface of a notebook. For a detailed specification of the service cable please refer to appendix C. 28 3BDD011704R0101

29 Section 2 Installation Bus termination The terminal assignments for the Power Link modules are as follows: Table 5. Function PL 810 PL 890 Shield PROFIBUS PA 1S and 13S 1S and 16S PROFIBUS PA - 2- and and 17- PROFIBUS PA + 3+ and and 18+ Connection to head station Connection to head station Functional earthing FE 46FE 58FE Design operating voltage Design operating voltage The Power Link Module terminals connection to the head station CH + and connection to the head station CH - are to be connected with the head station connections Connection to Power Link channel CHx, + or Connection to Power Link channel CHx, -. The x marks the respective channel number 1 to 4. Bus termination As a transmission line between head station and Power Link Modules a standard PROFIBUS DP cable type A is recommended (see also appendix B). Each PROFIBUS PA segment must be terminated at the end of the line (R = 100 Ω + 2%; C = µf + 20%). The terminating resistance required for the Linking Device LD 800P is integrated into the power link modules PL 810 and PL BDD011704R

30 Grounding Section 2 Installation Grounding The PROFIBUS PA commissioning manual specifies 4 types of cable, of which cable types A and B have a shield. This shield must be grounded for reasons of EMC protection. This is possible in 2 ways: 1. Hard grounding at both ends of the PROFIBUS PA transmission line. This requires laying a potential compensateion line. 2. Hard grounding on all field devices, potential compensation in the field, capacitive grounding on the Linking Device. Different companies offer terminals with an integrated capacitor (e.g. Phoenix Contact, Wago,...). A sample wiring diagram is shown in the following illustration. Screen - + PROFIBUS PA Shield - + Bus connection Field device Power Link Module PL 810 or PL 890 PROFIBUS DP RxD/TxD-N RxD/TxD-P Shield/FE Shield/FE - DC 24 V + DC 24 V 30 3BDD011704R0101

31 Section 2 Installation Commissioning of communication For PROFIBUS PA only shielded wires should be used. The shield should be hard-grounded at the Linking Device or the power link module and on all field devices. For intrinsically safe applications a potential compensation between the safe and hazardous areas is required. If there is no potential compensation between the safe and hazardous areas, there is a possibility of capacitive grounding on the Linking Device/Power Link Module. The capacitor which is used must have a fixed dielectric. The following applies to the capacitance of the capacitor: C < 10 nf. In addition, the capacitor must be designed for a test oltage of > 1500 V. Commissioning of communication The Linking Device LD 800P works transparently. This means that the LD 800P is not perceived either from the point of view of PROFIBUS DP or PROFIBUS PA as a station (no addressing, configuration or parameter setting of the Linking Device required). The following image shows the highly simplified structure of a head station using the HS 840 as an example. HS 840 PA master 1 channel 1 PROFIBUS DP DP slave Buffer PA master 2 channel 2 PROFIBUS DP media redundant Connection PA master 3 PA master 4 channel 3 channel 4 3BDD011704R

32 Commissioning of communication Section 2 Installation PROFIBUS PA masters work independently of each other. The result of this is that individual PROFIBUS PA channels generally have differing bus cycle times. PROFIBUS PA masters store all data of the corresponding channel in a common data area (buffer) of the head station. The startup phase of the Linking Device LD 800P The common data area serves as a buffer between the PROFIBUS DP and the PROFIBUS PA. Data is stored temporarily in reference to the PROFIBUS PA address. If the power supply voltage of the Linking Device is turned on, the PA masters check which addresses are available on the respective channels and generate a reference list with all existing PROFIBUS PA slave addresses During the startup phase, LD 800P responds to no PROFIBUS DP telegrams. If the check reveals that the same addresses are present on different channels, LEDs CH x (x = 1, 2, 3 or 4) of the channels in question will flash red (see paragraph Displays and error messages in the section Maintenance ). Master requests from the PROFIBUS DP master to these doubled addresses will not be answered by the Linking Device. This will also result in an error message in the higher level control system. As soon as the error has been eliminated, the LEDs go out automatically and the corresponding master requests are answered. This requires the slave that is still present to have been previously configured correctly in the control system. 32 3BDD011704R0101

33 Section 2 Installation Configuration of PROFIBUS PA slaves Configuration of PROFIBUS PA slaves Since the LD 800P works transparently, PROFIBUS PA stations are treated by the PROFIBUS DP master like PROFIBUS DP slaves. This also applies to commissioning and configuration. To make it possible for a PROFIBUS PA slave to be placed in operation and be configured by a configuration tool, the GSE file of the slave must have been integrated into the configuration tool. In principle, the following distinctions must be made with GSE files for PROFIBUS PA slaves: Is the GSE a profile GSE or a manufacturer-specific GSE? Is the GSE designed for communication over the RS 485 interface (DP-GSE) or over the interface based on IEC (PA-GSE)? If a Linking Device is used, independently of whether or not it is a manufacturerspecific or profile GSE, always use the DP-GSE If a profile GSE is used, you can tell by the filename whether the file is a DP-GSE file or a PA-GSE file. As a rule, profile GSEs are integrated into the configuration tool. For example, the file PA gse is a profile GSE for 4 binary outputs. The "PA" in the filename means that the device in question is a PROFIBUS PA slave. The "0" after the PA indicates that it is a DP-GSE. The filename of the PA-GSE for the same profile is PA The "1 after the abbreviation PA indicates that it is a PA-GSE. If manufacturer-specific GSEs are used, for example to use functionality that falls outside the profile, you can tell whether it is a DP-GSE or a PA-GSE in the following manner: If you have not done so already, integrate the GSE into your configuration tool. Check the baud rates that are supported in your configuration tool. 3BDD011704R

34 Configuration of PROFIBUS PA slaves Section 2 Installation If the baud rate kbd is supported, it is a PA-GSE. Normally, only baud rates of kbd, kbd and kbd are supported by the PA-GSE. If the transfer rates based on PROFIBUS specification (EN 50170/-2) are supported, i. e. baud rates of 9.6 kbd to 1.5 MBd or 12 MBd, it is a DP-GSE. Some PROFIBUS PA field device manufacturers do not offer any PROFIBUS DP- GSEs. In this case, the existing PROFIBUS PA-GSE must be converted. An appropriate conversion software package (GSE converter) is available at no cost at The task of this conversion software is exclusively to enter the missing transfer rate and set specific bus parameters to values that allow for problem-free operation of the PROFIBUS DP. Important notes on the 'GSE Converter' conversion software. The advisory committee of the PROFIBUS user organization has agreed that certified GSE files that have been modified by the GSE converter software do not lose their certificate. Effect of the GSE converter software on field device functionality The conversion of the GSE file imposes the following restrictions if it was previously supported by the original GSE file: FREEZE and SYNC functionality is deactivated. These functions are used in PROFIBUS DP for synchronizing sensors/actuators. Since the system is working with transfer rates of up to 12 MBd on the PROFIBUS DP side (host side) and with a transfer rate of kbd on the PROFIBUS PA side (field side) it is not possible to ensure that this synchronization will work with no problems. A maximum of 4 master Class 2 connections (C2 connections) are supported for each slave. Some PROFIBUS functions are currently not supported. If the field device is supposed to support one or more of the following functions, a warning will inform 34 3BDD011704R0101

35 Section 2 Installation Configuration of PROFIBUS PA slaves the user that this is no longer the case after the conversion. This affects the following functions: Alarms based on PROFIBUS DP V1 The following functions of the PROFIBUS DP V2 Data Exchange Broadcast (Publisher/Subscriber) Time synchronization Isochronous mode, i. e. cycle-synchronous transfer Use of the "GSD Converter software After the program is started (abbgsdcv.exe) the following dialog appears: BDD011704R

36 Configuration of PROFIBUS PA slaves Section 2 Installation To convert a GSE file, proceed as follows: Switch to the directory in which the GSE files to be converted are located. Select the GSE files to be converted: You can select one or more files (using Ctrl or Shift) for conversion. Files with '+' before the file name are the result of a former conversion and generate an error message if you attempt to convert them again. Files with a '-' are not the result of a conversion and can be converted. You can open a file to view it and edit it by double clicking on it. Determine the version number of the GSE file to be converted: The name of a PROFIBUS GSE file always consists of 3 parts: The manufacturer-specific part (1-4 characters). An identification of the manufacturer, for example "ABB_ for ABB The ID number (4 characters) The file extension For GSE files of PROFIBUS PA devices that were converted for transparent segment couplers up to 12 Mbit/s, the Profibus User Organization (PNO) has determined the manufacturer-specific part of the name. It is composed of the character sequence "YP0 and a version number. You can select the version number using a drop-down box (revision) and thus generate different versions of GSE files for a field device (with the same ID number). Switch to the directory in which the converted GSE files will be stored. Convert the GSE files by clicking on the "Process GSD --> button. You can start the conversion process with this button. Another window appears in which you are informed of the results of the conversion process. 36 3BDD011704R0101

37 Section 2 Installation Setting the PA slave watchdog time Setting the PA slave watchdog time Information for determining the Watch Dog Time T WD PROFIBUS devices are able to activate a watchdog mechanism that monitors at each time interval of cyclic calls (data exchange) to make certain the PROFIBUS master is still active. The time measurement takes place in the PROFIBUS slave. If the watchdog is activated and the time T WD (Watch Dog Time) since the last cyclic call expires, the device leaves cyclic data exchange, goes into the original state (Wait_prm) and sets the outputs to the secure state. The value of the time T WD and the activation of the watch dog are transferred in the parameterizing telegram from the PROFIBUS Master to the PROFIBUS slave at startup (transition to the data exchange). In general, dimensioning of the time T WD is used-specific (not device-specific, not in the GSE). The value is bounded below by cycle times. As a rule, the configuration tool is used to enter the time T WD. There are configuration tools for which the watchdog time is set 1x per PROFIBUS master (e.g. for the ABB systems Symphony Melody, AC 800M) and other for which the watchdog time is set individually for each PROFIBUS PA station (e.g. for the ABB System Freelance). This does not change with the value of the watchdog time. For many tools, the time T WD is automatically calculated based on the cycle time of the master with a corresponding baudrate. At higher baud rates on the PROFIBUS DP side (for example 12 MBd) cycle times on the PA side may be longer by a factor of 300. If parameters were set directly for a PROFIBUS PA device at a baud rate (DP) for a time calculated for a higher master 3BDD011704R

38 Setting the PA slave watchdog time Section 2 Installation T WD, it would generally be less than the PA cycle and the device would not enter into the data exchange.. Behavior of LD 800P To ensure reliable operation of the PROFIBUS the following bus parameters should be used: - Transfer rate 45,45 kbd MBd - Watchdog time T WD = 5 s - PROFIBUS DP Standard If there are a large number of PROFIBUS PA stations per channel of the Linking Device, the watchdog time T WD should be verified. The limit value is about 32 stations, but depends on the volume of data to be transferred. The Linking Device LD 800P is able to set the watch dog time TWD for all underlying PROFIBUS PA slave devices. The default setting for the watch dog time TWD is 5 s. Determining the parameter T WD The watchdog time for the value above is a number based on experience, in other words one that usually works. If it turns out that the watchdog time is too long (slaves are not switching into the secure state quickly enough) or too short (slaves are switching into the secure state without the master ever having failed) this must be factored into the calculation and be set in the head station of LD 800P via service tool. Depending on the configuration tool you are using, you can set parameters for only one watchdog time T WD for the entire PROFIBUS system. In this case, the greatest delay time must be used as the basis for determining T WD. set parameters for a watchdog time T WD for each individual slave. 38 3BDD011704R0101

39 Section 2 Installation Setting the PA slave watchdog time The time T WD that is set (parameter) must be greater than the longest delay time T V_max that will occur. This is composed of a number of elements as follows: T V_max = T Cycle_DP + T Cycle_PA_channel where T Cycle_PA_channel = cycle time of the PROFIBUS PA channel = cycle time of the PROFIBUS DP. T Cycle_DP Recommendation: Adjust the time T WD three times the PROFIBUS PA cycle time. Details for calculating the T WD parameter The PA cycle time T Cycle_PA_channel depends on the number n of stations on a channel the effective data length L Σ (average of the total of input and output data of all devices [number of bytes (unitless)]): Cycle time can be calculated in an approximate manner as T Cycle_PA_channel = n * ( ms * L Σ + 12 ms ) + 40 ms For more information on calculating cycle time, please refer to paragraph PROFIBUS DP time behaviour in section Planning for a PROFIBUS PA application. Modification of the LD 800P watch dog time settings by using the service tool If the modification of the watch dog time TWD default settings is required this modification has to be done by using the service tool (LD800P.exe). For getting access to the Linking Device a direct connection via service cable is necessary connecting the serial interface of a notebook with the service interface of LD 800P. The service tool is part of the documentation CD and can be retrieved under For details concerning the service cable structure please see appendix C. A modification of the watch dog time parameter TWD can be done as follows: Connect the service cable with the serial interface of the notebook and the service terminals of the head station. 3BDD011704R

40 Setting the PA slave watchdog time Section 2 Installation Start the program LD800P.exe. Select the serial interface of your notebook and press Set Parameters Table 6. Settings of PA Watchdog Time Selection Transparent: Fixed Value: Meaning / possible settings The Linking Device LD 800P passes throught the calculated watchdog time from the DP Master to the PA slave devices. Watch dog times in the range of 0.2 sec up to 25 sec can be adjusted within LD 800P. In case of the setting Fixed Value LD 800P discards the watchdog time coming from the DP master and replaces these times by the manually via service tool adjusted watchdog times. Adjust the desired settings and confirm these. After having confirmed the settings a message appears: Do you want to restart the device? A confirmation of the question ( Do you want to restart the device? ) leads to the paramter download within the Linking Device and to a restart of LD 800P. During the parameter download and the restart there isn t any PROFIBUS communication via LD 800P! Observe that in case of an exchange of a head station with modified parameter settings the new module also needs to be modified the same way! Specialities concerning Symphony Melody: If you have selected Transparent for the PA Watchdog Time setting (passing through the watch dog time from PROFIBUS DP master) it has to be observed that the operation of LD 800P in common with HCIR capable devices on the same PROFIBUS DP line does not allow a manually adjustment of the automatically calculated watch dog times. 40 3BDD011704R0101

41 Section 2 Installation Redundancy Redundancy The head station HS 840 provides a non monitored PROFIBUS DP media redundancy. If there is the need for a PROFIBUS DP line monitoring then the line monitoring has to be realized by the PLC / the controller or by using additional devices. Redundancy monitoring with AC 800M / CI 854 AC 800M provides a PROFIBUS DP line monitoring, that can be enabled within the mask Setting of CI854. (For line monitoring the parameter Line redundancy must be enabled ) 3BDD011704R

42 Redundancy Section 2 Installation The setting Line redundancy enabled turns on the activity monitoring of the redundant PROFIBUS DP lines. If there is no activity on one line, e.g. in case of a line break, there is a status entry causing a colored marking of CI854 in the CBM- Tree. When selecting the so marked CI854 module (by double click) a message text appears. When using some special devices (e.g. CEAG remote I/O), that principally do not send on both lines it is necessary to disable the line monitoring ( Line redundancy disabled ). In this case the monitoring has to be done with external devices. Redundancy monitoring with AC 800F / Freelance PROFIBUS DP media redundancy is done by using an external RLM 01 for doubling the PROFIBUS DP lines. The RLM01 module has a line monitoring, that is accessible as a binary signal. This binary signal can be evaluated in the PLC and thus displayed as a text message. Redundancy monitoring with Symphony Melody Symphony Melody provides PROFIBUS DP redundancy without additional devices. The redundany line monitoring referring to LD 800P has to be realized e.g. by using of an additonal RLM 01 module. The RLM01 module has a line monitoring, that is accessible as a binary signal. This binary signal can be evaluated in the PLC and thus displayed as a text message. 42 3BDD011704R0101

43 Section 2 Installation Usage of Device Type Manager (DTM) Usage of Device Type Manager (DTM) The DTM is a software component, which is usually supplied by the manufacturer together with the intelligent field device. The DTM is familiar with the way the field device works (plausibility), offers graphical user dialogs, manages device configuration and diagnostics, and supplies the device-specific documentation. The Linking Device LD 800P works pricipally transparent so that DTM software can be used for PA devices. According to the FDT specification a DTM provides the GSE file information to the PROFIBUS DP master. To maintain the full PROFIBUS system capabilities with reference to transmission rate and reaction time it is important that the DTM provides the GSE information in form of a DP GSE. For the provision ot the DP-GSE information by a PA device-specific DTM there are two different ways: The DTM provides a DP-GSE file or The PA DTM saves the GSE file information as an accessible file to enable the GSE converter tool for converting the GSE file. ABB Automation Products GmbH provides DTM software for PROFIBUS PA devices with an accessible GSE file to pass on the PROFIBUS DP Master. This applies to all FDT Versions >= FDT BDD011704R

44 Specialties when using a PA slave DTM Section 2 Installation Specialties when using a PA slave DTM Specialties with Symphony Melody Using a default DTM The System has access to the default DTM GSE files by using the path name. Here is an example of a path for saved GSE files: drive:\dtm_sub folder\gse\abb\converter GSD LD 800P\... Using a DTM with externally safed GSE file The GSE files of ABB PROFIBUS PA devices are stored in the same path, i.e. that also the converted GSE files have to be stored within this directory. Example: c:\programs\smart_vision\... Operation of LD 800P parallel with segment coupler 1 of Pepperl+Fuchs The GSE file content is centrally saved. Because of the different GSE file content the parallel operation of LD 800P and SK1 (Pepperl + Fuchs) is not possible. Exchange of a segment coupler 1 with a LD 800P If a project was planned and loaded with a segment coupler 1 (Pepperl + Fuchs) then based on the different GSE file contents the following steps are necessary: Delete all loaded PA slaves incl. the belonging function plans Convert the GSE files with the GSE converter tool Save the converted GSE files in the necessary directories Plan all belonging PA-slave devices new. 44 3BDD011704R0101

45 Section 2 Installation Specialties when using a PA slave DTM Specialties with Freelance (AC 800F) Using a default DTM The System has access to the default DTM GSE files by using the path name. Here is an example of a path for saved GSE files: c:\industrial IT\Engineer IT\Control Builder F\gse\ABB\Converter GSD LD 800P\... Using with externally safed GSE file The GSE files of ABB PROFIBUS PA devices are stored in the same path, i.e. that also the converted GSE files have to be stored within this directory. Example: c:\programs\smart_vision\svddesc\com_dpv1\_0016 \_2_04c4\... Handling with DTM, that require the original GSE-file name For some DTM (e.g. device specific PA DTM delivered by ABB) it is necessary that the DTM exclusively work with GSE-files having the original manufacturers file name. Because the GSD converter tool changes the GSE file name it is necessary to rename the GSE file after ist conversion. (e.g.: ABB_040c4.gse -> conversion in YP0040c4.gse -> renaming in ABB_040c4.gse) 3BDD011704R

46 Specialties when using a PA slave DTM Section 2 Installation 46 3BDD011704R0101

47 Section 3 Planning for a PROFIBUS PA application A Linking Device fulfills among other features the following demands: No limits on the PROFIBUS PA data volume Support all PROFIBUS DP transmission rates (45.45 kbd,..., 12 MBd) Linking Devices must not affect PROFIBUS DP speed No addressing of the Linking Device, neither from the PROFIBUS DP side nor the PROFIBUS PA side Use without additional configuration (Plug n Play) PROFIBUS DP master must be able to directly access the PROFIBUS PA slave (transparency) Independent of the PROFIBUS DP master manufacturer Connection of as many PROFIBUS PA bus elements as possible. Installation in zone 2 The Linking Device LD 800P consists of one head station and at least one, no more than 20 Power Link Modules. Depending on the type, a head station can operate 1 (HS 810), 2 (HS 820) or 4 (HS 840) channels that are independent of each other. Up to 5 Power Link Modules can be connected on each channel. This results in the following maximum structure: 3BDD011704R

48 Section 3 Planning for a PROFIBUS PA application PROFIBUS DP redundant PROFIBUS DP PROFIBUS PA Segment 1 PROFIBUS PA Segment 2 PROFIBUS PA Segment 3 PROFIBUS PA Segment 4 PROFIBUS PA Segment 5 Head station HS 840 Power Link Module 1 Power Link Module 2 Power Link Module 3 Power Link Module 4 Power Link Module 5 channel 1 PROFIBUS PA Segment 6 PROFIBUS PA Segment 7 PROFIBUS PA Segment 8 PROFIBUS PA Segment 9 PROFIBUS PA Segment 10 Power Link Module 6 Power Link Module 7 Power Link Module 8 Power Link Module 9 Power Link Module 10 channel 2 PROFIBUS PA Segment 11 PROFIBUS PA Segment 12 PROFIBUS PA Segment 13 PROFIBUS PA Segment 14 PROFIBUS PA Segment 15 Power Link Module 11 Power Link Module 12 Power Link Module 13 Power Link Module 14 Power Link Module 15 channel 3 PROFIBUS PA Segment 16 PROFIBUS PA Segment 17 PROFIBUS PA Segment 18 PROFIBUS PA Segment 19 PROFIBUS PA Segment 20 Power Link Module 16 Power Link Module 17 Power Link Module 18 Power Link Module 19 Power Link Module 20 channel BDD011704R0101

49 Section 3 Planning for a PROFIBUS PA application The illustration below shows a realistic example of a Linking Device with one head station (HS 840) and 2 Power Link Modules (PL 810 and PL 890): Connection PROFIBUS DP redundant (optional) Connection PROFIBUS DP Connection PROFIBUS PA Segment non-intrinsically safe Connection PROFIBUS PA Segment intrinsically safeensicher Head station HS 840 Power Link Module PL 810 Power Link Module PL 890 The head station is used to convert the PROFIBUS DP protocol to the PROFIBUS PA protocol and back. The Power Link Modules switch the power supply to the PROFIBUS PA line. This makes the physical arrangement corresponding to IEC available on the output of a Power Link Module and opens up a PROFIBUS PA segment. As many as 5 Power Link Modules can be connected to a PROFIBUS PA channel. Each Power Link Module opens up a PROFIBUS PA segment. This means that when the system is fully expanded, 20 PROFIBUS PA segments can be operated. Up to 32 stations can be connected to each PROFIBUS PA segment with nonintrinsically safe Power Link Modules, and for Power Link Modules with an intrinsically safe PROFIBUS PA interface up to 10 station can be connected. 3BDD011704R

50 Section 3 Planning for a PROFIBUS PA application Altogether not more than 125 PROFIBUS addresses can be managed by a PROFIBUS DP Master one PROFIBUS DP line. Due to this PROFIBUS DP restriction the maximum possible number of PROFIBUS PA slaves, which can be operated at one LD 800P is limited to 125. Each PROFIBUS PA station is addressed directly by the PROFIBUS DP master of Class 1 or Class 2. This makes it possible among other things to plan for and configure PROFIBUS PA stations in the hazardous area from outside in the safe area. The Linking Device places a physical load of one bus element on the PROFIBUS DP side. This is to be taken into consideration when the PROFIBUS DP segment, to which the head station HS 8x0 is connected, is fully expanded with 32 bus elements. For reasons of transparency, make certain that the addresses of the PROFIBUS PA bus element are not used on the PROFIBUS DP branch and vice versa. Because of the independence of PA channels cycle times of individual PROFIBUS channels are generally different. The cycle time of one PROFIBUS PA channel depends on the number of the connected stations and the data volume that is supposed to be transferred. This independence makes it possible to adjust cycle times within certain limits. A multi-channel head station must be used for this adjustment. Stations with time-critical data are connected to a PROFIBUS PA channel on which only a few stations with a low data volume are present (in the extreme case 1 PROFIBUS PA station per channel). Stations with time-non-critical data are connected to a PROFIBUS PA channel with more stations and a higher data volume. This PROFIBUS PA channel may consist of several PROFIBUS PA segments, i.e. a number of Power Link Modules can be connected. Because PROFIBUS PA channels work independently of each other, the result is a shorter cycle time in the upper case and a longer cycle time in the lower case. PROFIBUS is able to address up to 125 stations. There is a possibility in this case of connecting up to 125 stations with the PROFIBUS DP through a head station by using Power Link Modules appropriately. 50 3BDD011704R0101

51 Section 3 Planning for a PROFIBUS PA application The Linking Device LD 800P supports all transmission rates on the PROFIBUS DP side in accordance with EN Part 2 starting at kbd. LD 800P supports all PROFIBUS DP und PROFIBUS DP V1 services (cyclic and acyclic) of EN Part 2 with the exception of PROFIBUS PA- mastermaster communication (MMAC1 and MMAC2). The head station HS 840 occupies a second PROFIBUS DP connection. This allows for the possibility of implementing media redundancy on the PROFIBUS DP side. The use of a redundant transfer line increases the availability of the system. Media redundancy refers exclusively to the transmission medium (in this case the PROFIBUS DP line). 3BDD011704R

52 Planning of a PROFIBUS PA application with LD 800P Section 3 Planning for a PROFIBUS PA Planning of a PROFIBUS PA application with LD 800P Determine the number of intrinsically safe PROFIBUS PA slaves and the number of non-intrinsically safe PROFIBUS PA slaves. Determine the number of the required Power Link Modules with intrinsically safe interface (PL 890) and without intrinsically safe interface (PL 810). Add to this all power supply currents of non-intrinsically safe PROFIBUS PA slaves and divide the current by 400 ma. Round the result off to the nearest whole number. The result is the number of PL 810 Modules without intrinsically safe interface, that is needed. Repeat the addition of power supply currents for the intrinsically safe PROFIBUS PA slaves, divide the total of the power supply currents by 100 ma and again round off to the next higher whole number. In general this calculation is represented as follows: n Σ I vers_pa_slave i i=1 Number PL 810 = Int ( ) ma n Σ I vers_pa_slave i i=1 Number PL 890 = Int ( ) ma with I vers_pa_slave i current consumption of slave i Determine a preliminary structure for the non-intrinsically safe PROFIBUS PA slaves (which slave is operated on which Power Link Module). When making this determination, make certain that a maximum 400 ma power supply current is available on a non-intrinsically safe PROFIBUS PA segment. Thus the sum of all needed supply current has to be < 400 ma. For more detailed information, please refer to paragraph Dimensioning of a PROFIBUS PA segment. Determine a preliminary structure for the intrinsically safe PROFIBUS PA slaves. When making this determination, make certain that a maximum 100 ma power supply current is available on an intrinsically safe PROFIBUS PA segment. The total of all required power supply currents must thus be less than 100 ma. For more detailed information, please refer to paragraph Dimensioning of a PROFIBUS PA segment. 52 3BDD011704R0101

53 Section 3 Planning for a PROFIBUS PA applicationplanning of a PROFIBUS PA application with LD Check whether the input voltage on the last PROFIBUS PA slave is > 9 V. For additional information on this subject, please refer to paragraph Dimensioning of a PROFIBUS PA segment. Each PROFIBUS PA segment must be provided with a fieldbus terminator in the field. Include a fieldbus terminator of this type in the planning for each PROFIBUS PA segment. Determine the least number of channels your head station must have. To do this, add the number of PL 890 Ex Power Link Modules and PL 810 non-ex Power Link Modules determined and divide the result by 5. This yields the minimum number of channels required. Specify which Power Link Modules you want to operate on which channel. Check whether the PROFIBUS PA cycle times resulting from these calculations are sufficient for your requirements. An approximate calculation of cycle times that occur on each channel is described in paragraph PROFIBUS DP time behaviour. If the cycle times that occur are too high, use a head station that has more channels than what you previously planned and determine the distribution of Power Link Modules again. Check the cycle times that occur again. The following rule applies in general: The smaller the volume of data to be transferred, the smaller will be the cycle times that occur. Especially time-critical data should be transferred over a channel on which the smallest possible number of PROFIBUS PA stations are connected. Plan the layout of your switch cabinet. For information regarding the mechanical dimensions, please refer to paragraph Mechanical dimenstions of LD 800P. Specify the addresses of the PROFIBUS PA slaves. Observe, that the addresses, which are assigned at a PROFIBUS PA segment, are assigned for all other PROFIBUS PA segments and for the PROFIBUS DP segment. Address 1 must not be assigned to any PROFIBUS PA slave or PROFIBUS DP slave. 3BDD011704R

54 PROFIBUS DP time behaviour Section 3 Planning for a PROFIBUS PA application PROFIBUS DP time behaviour The LD 800P supports both cyclic and acyclic data exchange of the PROFIBUS DP V1. Cyclic communication services are performed based on a specific time grid, which is referred to as the bus cycle time. A bus cycle time (or cycle time for short) means the time lapse that goes by under "worst case conditions to transfer the input data change of a PROFIBUS slave to the PROFIBUS master or the output data from the PROFIBUS master to the slave. All data that is to be updated cyclically is automatically updated in the common data area by the PROFIBUS PA master. The cycle time, this actualisation needs, depends on the data volume, that is transferred via the PROFIBUS PA channel. From the point of view of the PROFIBUS DP, the LD 800P represents a multislave. If the PROFIBUS DP Master sends a request to a slave address existing at the Linking Device, the head station answers directly on the request with the data, that are stored in the common data range. Because of this behavior, the PROFIBUS DP master does not need to wait for the PROFIBUS PA slave to respond. The result of this is that the cycle time of the entire system is composed as follows: t Cycle = t Cycle_PA-channel + t Cycle_DP The time t Cycle_PA-channel can be estimated as follows: t Cycle_PA-channel = 10 ms + n*10.5 ms ms*(l E + L A ) where n = the number of PROFIBUS PA slaves L E = total number of input bytes of all PROFIBUS PA slaves on the channel. L A = total number of all output bytes of all PROFIBUS PA slaves on the channel. 54 3BDD011704R0101

55 Section 3 Planning for a PROFIBUS PA application PROFIBUS DP time behaviour The time t Cycle_DP can be estimated as follows t cycle_dp = T Bit * n * *T Bit *(L E +L A ) where n = the number of PROFIBUS DP slaves L E = total number of input bytes of all PROFIBUS slaves L A = total number of output bytes of all PROFIBUS slaves T Bit = bit time = 1/transfer rate For the time t Cycle_DP a safety add-on of 10% should be included in the calculation in accordance with the Profibus User Organization. The equation above applies given the following pre-conditions: The PROFIBUS DP is operated as a monomaster system, i. e. there is only one master on the PROFIBUS DP. If you want to use a multimaster system, the token hold time and the corresponding pause times of the additional masters must be added to the total. Only acyclic data exchange takes place. If the master is also supposed to transfer acyclic telegrams, the time required for acyclic communication must be added in total. For additional information, please refer to EN 50170/-2. 3BDD011704R

56 Dimensioning of a PROFIBUS PA segment Section 3 Planning for a PROFIBUS PA application Dimensioning of a PROFIBUS PA segment Current calculation A Power Link Module of the Linking Device LD 800P opens up a PROFIBUS PA segment. The following section will illustrate how to dimension a PROFIBUS PA segment. The following section is based on the assumption that type A cable is being used. For the cable parameters, please refer to the table in the appendix B. Power is supplied to PROFIBUS PA stations from the bus. They represent a current sink. The current consumption of each station from the bus line must be at least 10 ma for Ex applications. There are no restrictions for non-ex applications. The Power Link Module limits the power supply current in the PROFIBUS PA segment to 100 ma for Ex applications and 400 ma for non-ex applications. You must ensure that the current consumption of all stations is less than the current the LD 800P is capable of providing. The following applies: I out_power Link Module > Σ I in_fielddevices The current consumption if field devices determines the maximum number of stations per segment. For example, if field devices with a current consumption of 22.8 ma are used, 4 stations can be connected to a segment for Ex applications. If the current consumption per station falls to 10 ma, 10 stations can be connected. Especially the dimensioning with 10 stations can be critical since it can happen in the event of an error (defect in a PROFIBUS PA slave) that this slave draws a higher current than the specified power supply current from the bus line. Under worst case conditions it may happen that the entire PROFIBUS PA segment can malfunction because of one defective slave. To avoid this situation, a few devices offer what is referred to as a Fault Disconnect Electronic (FDE). This is an electronic current limit that limits additional current consumption of a defective slave in a failure case. This I FDE can also vary between PROFIBUS PA slaves and must be obtained from the data sheet. If an error case is included in the current calculation, the situation described above changes as follows: I out_power Link Module > I FDE + Σ I in_fielddevices 56 3BDD011704R0101

57 Section 3 Planning for a PROFIBUS PA application Dimensioning of a PROFIBUS PA segment This means that taking into consideration an error and a current consumption of 10 ma per slave, another 9 stations can still be operated on a segment. Voltage calculation and line length The distribution of stations on the PROFIBUS PA segment can have a negative effects on the maximum possible line length in certain circumstances. The following example is intended to clarify this point: Linking Device/ Power Link Module i max U out R L U L > 9 V i 1 i2 i n R L = Line resistance of line segment x I x = Current consumption of PA station x The case in question is an Ex application. The result of the current calculation is that a maximum direct current including I FDE of 100 ma is flowing. Type A cable is being used with a resistance coating of 44 Ω/km. A requirement for a PROFIBUS PA slave to be able to function properly is that the input voltage on the bus line must be at least 9 V. The following therefore applies to the maximum voltage drop over the lead: U Lmax = U out - 9 V Currently U out for LD 800P with an Ex interface PL 890 is at least 12.8 V (12.8 V ). For the worst case consideration, U out should be set to 12.8 V. This results in a U Lmax of 3.8 V. Since all stations are connected at the end of the line, the maximum line resistance must be 38 Ω (U L /i max ). This corresponds to a resistance coating of 44 Ω/km for a line length of 863 m. 3BDD011704R

58 Dimensioning of a PROFIBUS PA segment Section 3 Planning for a PROFIBUS PA application Since in practice the stations are not all connected compactly at the end of the transmission line, the resulting structure is as follows: l n l 2 l 1 Linking Device U out R L1 R L2 i 1 i 2 i n > 9 V R Lx = Line resistance of line segment x I x = Current consumption of PA station x Each station causes a voltage drop on the length segment through which its power supply current flows. For the first station, this would be: U RL1 = i 1 *R L1 or U RL1 = i 1 * l 1 * r ; where r = the resistance coating of the line For the second station, this appears as follows: U RL2 = i 2 * (R L1 + R L2 ) or U RL2 = i 2 * l 2 * r In general, the equation for Ex applications is then as follows: n! U RL = r * Σ (i x * l x ) < U out - 9 V x=1 58 3BDD011704R0101

59 Section 3 Planning for a PROFIBUS PA application Dimensioning of a PROFIBUS PA segment If the condition described above is not fulfilled, a) the line has be shortened or b) a line with reduced resistance coating has to be used. When selecting the type of line, make certain that for Ex applications the requirements in terms of insulation voltage and single conductor insulation of EN Section 12 and the characteristic values in accordance with the FISCO model are maintained. Note that the length to be specified represents the length of the line between the terminals of the Linking Device and the respective station. 3BDD011704R

60 Mechanical dimensions of LD 800P Section 3 Planning for a PROFIBUS PA application Mechanical dimensions of LD 800P LD 800P has removable terminal blocks. Screw-in selfopening apparatus terminals suitable for a conductor crosssection of up to 2.5 mm² are integrated. In principle housings come in three shapes. For the dimensions of these housings, please refer to the following diagrams: The following illustration applies in regard to the mechanical dimensions for PL 810: 60 3BDD011704R0101

61 Section 3 Planning for a PROFIBUS PA application Mechanical dimensions of LD 800P The following illustration applies in regard to the mechanical dimensions for PL 890: The following illustration applies in regard to the mechanical dimensions for all head stations (HS 810, HS 820, HS 840): 3BDD011704R

62 Voltage supply Section 3 Planning for a PROFIBUS PA application Voltage supply Power is supplied to the Linking Device, consisting of a head station and a maximum of 5 Power Link Modules per PROFIBUS PA channel through the power supply terminals. For the total amount of current note that the Power Link modules PL 810 / PL 890 draw current for their own needs as well as well as the current required by all PROFIBUS PA bus elements connected to the Power Link Modules. Example: A LD 800P consists of one head station HS 810 with 5 connected Power Link modules PL 810. Under worst case conditions, i.e. the external voltage supply is DC 20 V, the PROFIBUS PA bus elements draw the maximum current from the PROFIBUS PA segment, the total current consumption is calculated as follows: Table 7. Current Number Product Total [ma] consumption 1 4-channel head station HS Power Link Module Total current 2350 The non-ex version PL 810 has a maximum current consumption of 790 ma. 62 3BDD011704R0101

63 Section 4 Maintenance Displays and error messages The following LEDs are present on the front side of the head station:: LED Red_CH3 LED Green_Power LED Red_CH1 LED Red_CH2 LED Red_CH4 LED Red_DP LED Red_DP red In normal operation, the LEDs should display the following state if there are no errors: Table 8. LED display green on Red CH x/err off Red_DP/Red_DP red; off Meaning power supply ok PROFIBUS PA communication ok PROFIBUS DP communication ok 3BDD011704R

64 Displays and error messages Section 4 Maintenance If errors occur on the PROFIBUS PA side, this will be indicated via the channel LED. These LED signal and specify the error. A single flashing for about 3 sec. means that at least one slave of a channel has not answered the master request in time. Possible reasons are: defective slave slave is physically disconnected from the bus problems with the quality of signal transmission Further errors will be signaled via flashing sequences. The flashing sequences consist of an error code and a pause. The structure is shown in the following illustration: 1 s pause Error code , 1 s pause with 2 Hz flashing Error code , with 2 Hz flashing 1 s pause one flashing sequence Only the LEDs of the channel that has an error will flash. The error code is indicated by the frequency of the flashing on the LED. The following example is intended to clarify this point: The CH2 LED flashes 3 times, followed by a pause of about 1 s. Then the CH2 LED flashes again 3 times, etc. This indicates that one of the errors that are described under error code 3 has occurred on PROFIBUS PA channel 2. For the meaning of the individual flashing sequences, please refer to the following table: 64 3BDD011704R0101

65 Section 4 Maintenance Displays and error messages Table 9. LED Error code Error description Red CH_x 2 One or more slaves have exited data exchange mode. Possible reasons: - Slave physically separated from the transmission medium - Watch Dog Time T WD too short - Defective slave Red CH_x 3 One or more slaves is not switching into data exchange mode. Possible reasons: - Incorrect slave parameter values - Watch Dog Time T WD too short Red CH_x 4 NO data exchange on the PA channel. Possible reasons: - lead breakage or short-circuit - all slaves have been removed physically Red CH_x and Red_DP / Red_DP red 5 2 identical addresses for different PA channels. Change one of the addresses that was assigned twice (note that no PROFIBUS PA slave must have the address 1). Red PA_x 6 The PA cycle time is close to or greater than the Watch Dog Time T WD. Increase the Watch Dog Time If the red LED DP or DP_red flashes continously at a frequency of about 1.4 Hz (1.4 times per second), this indicates that there is no data exchange on the PROFIBUS DP line or that the PROFIBUS DP cable is not connected If one or more LEDs are flashing at a frequency of 5 Hz, it is essential to send the device in to ABB Automation Products GmbH. 3BDD011704R

66 Displays and error messages Section 4 Maintenance Power Link Module LEDs The meanings of the LEDs for the Power Link Modules are as follow: Table 10. LED display Red CHK/ERR on Red COM/ERR; 2 Hz flashing Green PWR on Meaning Hardware error No activity on the PROFIBUS PA Segment Power supply OK 66 3BDD011704R0101

67 Appendix A Introduction to intrinsic safety for field bus systems (FISCO model) To render the proof of Intrinsic Safety as simple as possible, the so-called FISCO model was developed. FISCO stands for Fieldbus Intrinsically Safe COncept. The German Federal Physical Technical Institute (PTB) developed the FISCO model and has published it in Report PTB-W-53 "Examination of intrinsic safety for fieldbus systems. This model is based on the following prerequisites: To transmit power and data, the bus system uses the physical configuration defined by IEC This is the case for PROFIBUS PA. Only one active source is permitted on a bus segment (in this case the Linking Device). All other components work as passive current sinks. The basic current consumption of a bus station is at least 10 ma. It must be ensured for each bus station that U i > U o of the Linking Device/Power Link I i > I o of the Linking Device/Power Link P i > P o of the Linking Device/Power Link. Each bus station must fulfill the following requirement: C i < 5 nf L i < 10 µh The permissible line length for EEx ia IIC applications is 1000 m. The permissible stub line length for Ex applications is 30 m per stub line. The definition of the stub line must be observed in this connection. 3BDD011704R

68 Appendix A Introduction to intrinsic safety for field bus systems (FISCO model) The transmission line that is used must conform to the following cable parameters: resistor coating: 15 Ω/km < R < 150 Ω/km inductance coating: 0.4 mh/km < L < 1 mh/km capacitance coating: 80 nf/km < C < 200 nf/km (including the shield) Taking the shield into consideration, the capacitance coating is calculated as follows: C = C conductor/conductor * C conductor/shield if the bus line is potential free or C = C conductor/conductor + C conductor/shield if the shield is connected with a pole of the Linking Device/Power Link. The bus segment must be terminated on both ends of the line with a fieldbus terminator. A fieldbus terminator is integrated into the Power Link Module PL 890 so that an external bus termination is only required on the other end. According to the FISCO model the terminal bus resistance must conform to the following limits: 90 Ω < R < 100 Ω 0 µf < C < 2,2 µf On condition that the points 1 up to 9 are all satisfied, the proof of intrinsic safety has been provided by means of the FISCO model. Points 1, 3 and 5 are automatically satisfied if a product is certified in accordance with the FISCO model. The prerequisite for being allowed to bear the proof of intrinsic safety in accordance with the FISCO Model is, that the Linking Device and all fieldbus stations are certified according to FISCO. As a rule, a separate declaration of conformity is also required for the bus connection. Furthermore, the cable must meet the requirements of the FISCO model. The power link module PL890 is approved in accordance with the FISCO model. For the characteristic Ex values, please refer to the data sheet and the EC Declaration of Conformity PTB 02 ATEX The power link module PL 890 with an intrinsically safe interface provides a maximum basic current of 100 ma at a minimum output voltage of 12.8 V. Thus up to 10 bus stations can be supplied. 68 3BDD011704R0101

69 Appendix B PROFIBUS-PA topologies and lines Appendix B PROFIBUS-PA topologies and lines The PROFIBUS PA can be built up in the line or tree topology. The PROFIBUS PA commissioning guide recommends essentially two types of cables with the following characteristic cable values: Cable structure Table 11. Type A shielded twisted pair Type B one or more twisted pairs, complete shielding Conductor cross section (nominal) 0,8 mm² (AWG 18) 0,32 mm² (AWG 22) Loop resistor (direct current) 44 Ω/km 112 Ω/km Wave resistance at 31,25 khz 100 Ω + 20 % 100 Ω ± 30 % Wave attenuation at 39 khz 3 db/km 5 db/km Capacitive asymmetry 2 nf/km 2 nf/km Group runtime distortion (7, ) khz 1,7 µs Covering level of the shield 90% a Maximum extent of the network for nonintrinsically safe applications Maximum extent of the network for nonintrinsically safe applications a not specified b applies only to non-intrinsically safe applications 1900 m 1200 m b 1000 m a a 3BDD011704R

70 Appendix B PROFIBUS-PA topologies and lines The recommended extent of the network comprises the total of the main line and all stub lines. A PROFIBUS PA bus element works from an input voltage of 9 V, i. e. this value corresponds to the minimum input voltage. With an unfavorable distribution of stations, i.e. if all PROFIBUS PA stations are widely removed from the Linking Device, it can happen that the voltage drop along the line is so great that the voltage level at the end is insufficient. This results in a shortening of the transmission line or the necessity of using cable with a larger cross-section. Under the most unfavorable conditions, you can reach the following lengths with cable type A (0.8 mm² or AWG 18): Application EEx ia IIC ==> 860 m Non-Ex application ==> 852 m PROFIBUS PA allows stub lines. The length of each stub line is determined by the number of PROFIBUS PA bus elements and by the area of application. The following table offers an overview: Number of stub lines Table 12. Maximum length of a stub line Non-Ex 1 bis m 30 m 13 bis m 30 m 15 bis m 30 m 19 bis m 30 m EEx ia Please note that the permissible total line length (the total of the main line and all stub lines) must not be exceeded. For cable type B, multiple PROFIBUS PA segments can be carried in one cable. If cable types other than those recommended are used, or if an intrinsically safe PROFIBUS PA segment is set up, the permissible line lengths are reduced. 70 3BDD011704R0101

71 Appendix C Specification of the service cable Appendix C Specification of the service cable A RS 232 cable has to be connected to terminals 16,17, 18 (service interface)and to one COM port of the PC as shown: Table 13. Signal Sub-D9 Sub-D25 HS 8x0 RxD 3 3 RxD TxD 2 2 TxD GND 5 7 GND It is recommended to use a laptop for running the service tool of the Linking Device LD 800P to avoid problems with different connections to earth. If there is no laptop available, a power supply without connection to earth should be used for LD 800P. 3BDD011704R