Operator Manual for Profibus

Transcription

1 PROCESS ANALYSERS SERVOPRO MultiExact Operator Manual for Profibus Part Number: Revision: Language: A 0 UK English

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3 LIST OF CONTENTS Section Page 1. DESCRIPTION AND DEFINITIONS Scope of this Manual Safety information Description ELECTRICAL INSTALLATION PROFIBUS SETTINGS Selecting Profibus as the Communications Method Setting the Profibus Address Monitoring profibus line Status PROFIBUS DPV0 FEATURES DPv0 Modules Profibus Master Device Configuration Data Format Measurement One & Measurement Two Module Data Map Measurement One Status & Measurement Two Status Data Map Sample Stream Output Module Extended Diagnostic Bits DPV1 COMMUNICATIONS TROUBLESHOOTING The analyzer is not detected by the profibus master device The communication starts, but there are frequent line drops

4 1. DESCRIPTION AND DEFINITIONS 1.1. Scope of this Manual This manual is a supplement for the MultiExact Operators Manual, it contains installation/operation instructions and data tables available with the Profibus option. The MultiExact Operators Manual must be read, before referring to this manual Safety information Read this manual and ensure that you fully understand its content before you attempt to install, use or maintain the analyser. Important safety information is highlighted in this manual as WARNINGs and CAUTIONs, which are used as follows: WARNING Warnings highlight specific hazards which, if not taken into account, may result in personal injury or death. CAUTION Cautions highlight hazards which, if not taken into account, can result in damage to the analyser or to other equipment or property Description WARNING Read the MultiExact Operators Manual, before referring to this manual. The Profibus option adds DPv0 synchronous and DPv1 asynchronous communication capabilities to the Multiexact Analyser. The option also provides digital outputs for an external sample stream switching valve block, which can be controlled by a profibus master device. The Profibus option board provides the following features: Supports DPv0/DPv1 profibus communication with RS485 transmission. DPv1 communications with class I and class II Master devices Separate DPv0 modules to optimize bus load Profibus Address can be set from the User Interface. External output for the Sample Stream Switching Module. 3

5 2. ELECTRICAL INSTALLATION WARNING The Profibus connection should follow the Profibus Installation Guidelines. CAUTION There are no internal termination resistors, if the device is at the end of the segment, termination resistors should be on the connector, or the segment should have an active termination unit. 1. Use recommended Profibus cable, optimized for RS485 transmission. 2. Standard Profibus 9-pin sub-d connector is used for profibus, the connector is labelled as Comms 1 on the back of the analyser. Profibus Connector (Comms 1) Pin No Signal Definition 3 TxD-P Data line plus (B-Line) 4 RTS PROFIBUS Ready To Send signal 5 DGND Data Ground 6 VP +5V supply for terminating resistors 8 TxD-N Data line minus (A-Line) Case Shield Ground Connection 3. To ensure correct operation follow the Profibus Installation Guidelines. For information on the profibus installation guidelines, refer to 4. The Profibus option board also provides an external output which can be used to control the Sample Stream Switching Module. This output is labelled as Comms 2 on the back of the analyser. 4

6 3. PROFIBUS SETTINGS Selecting Profibus as the Communications Method Select Setup Comms type Use the and soft keys to highlight profibus and then press the soft key Setting the Profibus Address The default profibus address for the analyser is set to 126. Use the following feature to change the profibus address of the analyser. Select Settings Comms parameters Edit the displayed time as described in Section of the operator manual Monitoring profibus line Status The user interface provides information on the profibus line status. There are three reports available: Wait for parameterization : There are no communications between the analyser and the profibus master device. Wait for configuration : Initial parameterization message received, waiting for configuration data from the profibus master. Data exchange : The analyser and the profibus master device are communicating, using DPv0 cyclic messages. To review the profibus line status: Select Settings Comms parameters Scroll down using the the profibus line status. soft key to view 5

7 4. PROFIBUS DPV0 FEATURES 4.1. DPv0 Modules The synchronous messaging structure of the DPv0 network requires all variables to be repeated in every message. This means the PLC has to be programmed to parse incoming and outgoing messages to extract required data. These protocol limitations mean that only frequently required parameters, which are important to be remotely accessible, are made available for DPv0 access. The MultiExact is capable to operate with different module configurations enabling the user to optimize network traffic. For example, if detailed status information is not required, the user can choose to omit the Measurement Status modules in the configuration. The analyser can support up to 5 modules, and the user can choose to include these modules in any order. Only one Sample Stream Output Module can be included in the configuration. The Profibus master can configure the MultiExact to include the following modules: Module Name Type Size Measurement One Input and Output 6 Input, 2 Output Bytes Measurement Two Input and Output 6 Input, 2 Output Bytes Measurement One Status Input 10 Input Bytes Measurement Two Status Input 10 Input Bytes Sample Stream Output Output 2 Output Bytes Example Configuration 1: Slot Module Input Byte Data Offset Output Byte Data Offset 1 Measurement One Measurement One Status 6-3 Sample Stream Output - 2 Example Configuration 2: Slot Module Input Byte Data Offset Output Byte Data Offset 1 Sample Stream Output Measurement One Measurement One Status 6-4 Measurement Two Measurement Two Status Profibus Master Device Configuration Refer to your profibus master device s operator manual to configure DPv0 communications with the MultiExact. SVMX0C58.gsd can be used as the GSD file to configure the master device. A CD, which contains this file, is provided with the analysers that include the profibus option. The file can also be downloaded from Data Format Endianness: All data transfers are word aligned, and the analyser uses Big-Endian order, as specified in profibus standards. In Big-Endian order, the Most Significant Byte (HI) comes before the Least Significant Byte (). Bit order follows the same rule and bit 0, is the least significant bit. 6

8 Floating Point Numbers: All floating point numbers (e.g , , etc.), are digitally represented using the IEEE-754 format. Single precision floating point numbers are used throughout and since they require 32 bits of data, they occupy 2 words. The most significant word is transferred first. Low/Hi Byte: The byte of a word is the least significant byte. The Most significant Byte is called the HIGH Byte Measurement One & Measurement Two Module Data Map Measurement One and Measurement Two modules contain measurement data related to the measurement modules. Both of the module mappings are the same. Profibus DPv0 Inputs Word # Word R/W Name 0 2 R Measurement as seen on the measurement display. Floating point data in IEEE-754 format. 2 1 R Status Word (See Below) Profibus DPv0 Outputs Word Byte Bit R/W Name 0 W Transducer Service In Progress 0 HI 1 W Calibration mode on/off 2 W Switch to Low calibration gas 3 W Switch to High calibration gas 4 W Low calibrate 5 W High calibrate 6 W Start auto validation 7 W Stop auto validation 0 W Auto validation/ Auto calibration mode (0 = Validate, 1 = Calibrate) 1-7 W Reserved Status Word Byte bit Name Definition 0 Warming State 0= Not warming, 1= Warming. 1 Alarm 1 Alarm 1 is active or latched. 2 Alarm 2 Alarm 2 is active or latched. 3 Range Active analogue output range 0=Range 1, =Range 2 4 Fault A transducer fault exists. 5 Maintenance required A transducer maintenance required status exists. 6 Service in progress A transducer service in progress status exists. 7 Reserved Reserved HI 0-7 Reserved Reserved 7

9 4.2.3 Measurement One Status & Measurement Two Status Data Map Measurement One Status and Measurement Two Status modules, contains status data related to measurement one and two. Both of the module mappings are the same. Profibus DPv0 Inputs Word Offset # Words Read/Write Name 0 1 Read Calibration and Validation Word (See Table Below) 1 1 Read Flow (Integer number) 2 1 Read Fault and Alarm Word 1 (See Table Below) 3 1 Read Fault and Alarm Word 2 (See Table Below) 4 1 Read Fault and Alarm Word 3 (See Table Below) Calibration and Validation Word Byte bit Name Definition 0-2 Auto Validation State 000=Idle, 001=Pre-warning, 010=Inerting, 011=Flushing, 100=Validating 3 Auto Validation finishing 0=Not finishing, 1=Finishing HI 4 Auto Validation fail state 0=Auto validation OK, 1=Auto validation failed 5 Calibration mode on/off 0= off (normal), 1= on (alarms masked, jamming etc). 6 Low calibration gas 0= Sample gas active, 1= Low calibration gas active. 7 High calibration gas 0= Sample gas active, 1= High calibration gas active. 0 Low calibrate 0= Idle, 1= Low calibration in progress. 1 High calibrate 0= Idle, 1= High calibration in progress. 2 Start auto Validation 0= Idle, 1= Auto validation in progress. 3 Stop auto Validation 0= Auto validation in progress and can be stopped, 1= Stop N/A. 4-7 Reserved Reserved Fault and Alarm Word 1 Byte bit Name Definition 0 Alarm 1 Alarm 1 is active or latched. 1 Alarm 2 Alarm 2 is active or latched. HI 2 Fault A transducer fault exists. 3 Maintenance required A maintenance required status exists. 4 Service in progress A service in progress status exists. 5 Transducer maintenance fault Internal transducer fault. 6 Transducer error Internal transducer fault. 7 Transducer fatal fault Internal transducer fault. 0 Heater fault Transducer heating has failed. 1 Sample heater fault Transducer sample heating has failed. 2 Calibration fault Transducer needs calibrating. 3 Communication fail Transducer is not responding. 4 Incorrect transducer type Wrong sort of transducer fitted. 5 Transducer not detected Transducer is unplugged or broken. 6 Low calibration fail Auto calibration low failed. 7 High calibration fail Auto calibration high failed. 8

10 Fault and Alarm Word 2 Byte bit Name Definition 0 Low validation fail Auto Validation low failed. 1 High validation fail Auto Validation high failed. HI 2 Remote low calibration denied Remote low calibration was not allowed. 3 Remote high calibration denied Remote high calibration was not allowed. 4 Milliamp fault Hardware fault detected. 5 Milliamp not detected Card is missing or the wrong type fitted. 6 Milliamp reset A timeout occurred on the milliamp card. 7 Volt fault Hardware fault detected. 0 Volt not detected Card is missing or the wrong type fitted. 1 Volt reset A timeout occurred on the volt card. 2 Pressure calibration Pressure transducer needs calibrating. 3 Pressure fail Hardware fault detected on pressure transducer. 4 Pressure low Pressure transducer low fault. 5 Pressure high Pressure transducer high fault. 6 Relay not detected Card is missing or the wrong type fitted. 7 Switch input not detected Card is missing or the wrong type fitted. Fault and Alarm Word 3 Byte bit Name Definition HI 0 Flow fail Hardware fault detected. 1 Low flow Flow has fallen to maintenance required level. 2 Very low flow Flow has fallen to fault level. 3 Remote service in progress Switch input has activated service in progress. 4 Transducer calibration mode Calibration mode is active. 5 Auto validation/calibration Service in progress 6 Milliamp service in progress Milliamp service in progress with the user interface. 7 Volt service in progress Service in progress 0 Pressure service in progress Service in progress 1 Relay service in progress Service in progress 2 Flow service in progress Service in progress 3 Reserved Reserved 4 Reserved Reserved 5 Reserved Reserved 6 Reserved Reserved 7 Reserved Reserved Sample Stream Output Module This module controls the analyser sample stream output. The output can be connected to a sample stream switching module, available from Servomex. The data mapping will be provided in the module manual. 9

11 4.3. Extended Diagnostic Bits The analyser will report all diagnostic information in the extended diagnostics (device related) part of the profibus diagnostics telegram. The diagnostics telegrams are only sent when there are updates on diagnostic flags. The Extended diagnostic flags are associated with text strings in the.gsd file. If the master device is capable of decoding this information, the user will be able to read the text explanations when the diagnostic flag is raised. Diagnostics Telegram Standard Diagnostics (6 Bytes) Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Extended Diagnostics (3 Bytes) Byte 0 Byte 1 Byte 2 b7 b6 b5 b4 b3 b2 b1 b0 b0: Slave doesn t exist b1: Slave not ready for data exchange b2: Configuration fault b3: Slave has extended diagnostics data b4: Slave does not support parameter function b5: Invalid slave response b6: Parameterisation fault b7: Slave locked by another master b7 b6 b5 b4 b3 b2 b1 b0 b0: Slave to be parameterised b1:static-diagnostic b2: Always set to 1 b3: Watchdog active b4: Slave in freeze mode b5: Slave is in sync mode b6: Reserved b7: Slave deactivated See Extended Diagnostics Table below Profibus Id Code LSB Profibus Id Code MSB Address of Controlling Master b7 b6 b5 b4 b3 b2 b1 b0-b6: Reserved b7: Ext. Diagnostics Overflow b0 Byte bit Extended Diagnostics Table 0-5 Length of Extended Diagnostics 6-7 (00) Device Related Diagnostics 0 Pump fault Pump fault exists. 1 Solenoid fault Solenoid fault exists. 2 Power configuration fault Wrong power type configured. 3 Static RAM fault A fault in the internal memory has been detected. 4 7 Reserved Reserved 0 System Fault Set, if any system fault exists. 1 System Maintenance required Set, if any system maintenance required status exists. 2 System Service in progress Set, if any system service in progress status exists. 3 Reserved Reserved. 4 Date/Time invalid System clock needs setting. 5 Code fault The programmed software has become corrupted. 6 Database fault A fault occurred when using the database. 7 Reserved Reserved. 10

12 5. DPV1 COMMUNICATIONS The analyser is able to communicate using DPv1 asynchronous profibus communications with Class I and Class II masters. The following table shows the available data for DPv1 communication with Index and Slot numbers. The user module/slot configuration on the profibus master device will not affect the DPv1 slot numbers, only Slot 1 is used. Write requests are only accepted if the specified data lengths in the requests are same as the data lengths defined in slot/index table. Slot Index R/W # Words Data 1 1 R 22 Measurement One Data 1 2 R 3 Measurement One Fault and Alarm 1 3 R/W 18 Measurement One Setup Block One 1 4 R/W 25 Measurement One Setup Block Two 1 5 R/W 15 Measurement One Setup Block Three 1 6 R/W 2 Measurement One Control 1 11 R 22 Measurement Two Data 1 12 R 3 Measurement Two Fault and Alarm 1 13 R/W 18 Measurement Two Setup Block One 1 14 R/W 25 Measurement Two Setup Block Two 1 15 R/W 15 Measurement Two Setup Block Three 1 16 R/W 2 Measurement Two Control R/W 8 System Setup R 1 System Fault Data Measurement One Data (Slot 1, Index 1) Measurement Two Data (Slot 1, Index 11) Word Name Comments 0-1 Measurement As seen on the measurement display. Floating point number. 2-3 Filtered Measurement Basic measurement, filtered. Floating point number. 4-5 Pressure Compensated Measurement Filtered and pressure compensated measurement. Floating point number. 6-7 PMR Primary measurement range. Floating point number. 8 Warming state 0= Not warming, 1= Warming Formula Gas formula. ASCII text, 5 characters max, terminated by a zero Units Measurement units. ASCII text, 7 characters max, terminated by a zero. 16 Auto validation state 0=Idle, 1=Pre-warning, 2=Inerting, 3=Flushing, 4=Validating 17 Auto validation gas 0=Low gas, 1=High gas, 2=Sample gas 18 Auto validation finishing 0=Not finishing, 1=Finishing 19 Auto validation fail state 0=Auto validation OK, 1=Auto validation failed 20 Active analogue output range 0=Range 1, =Range 2 21 Flow Current flow rate in percent 11

13 Measurement One Fault and Alarm Data (Slot 1, Index 2) Measurement Two Fault and Alarm Data (Slot 1, Index 12) Word Byte Bit Name Comments 0 Alarm 1 Alarm 1 is active or latched HIGH HIGH HIGH 1 Alarm 2 Alarm 2 is active or latched. 2 Fault A transducer fault exists. 3 Maintenance required A maintenance required status exists. 4 Service in progress A service in progress status exists. 5 Transducer maintenance fault Internal transducer fault. 6 Transducer error Internal transducer fault. 7 Transducer fatal fault Internal transducer fault. 0 Heater fault Transducer heating has failed. 1 Sample heater fault Transducer sample heating has failed. 2 Calibration fault Transducer needs calibrating. 3 Communication fail Transducer is not responding. 4 Incorrect transducer type Wrong sort of transducer fitted. 5 Transducer not detected Transducer is unplugged or broken. 6 Low calibration fail Auto calibration low failed. 7 High calibration fail Auto calibration high failed. 0 Low validation fail Auto validation low failed. 1 High validation fail Auto validation high failed. 2 Remote low cal.denied Remote low calibration was not allowed. 3 Remote high cal. denied Remote high calibration was not allowed. 4 Milliamp fault Hardware fault detected. 5 Milliamp not detected Card missing or the wrong type has been fitted. 6 Milliamp reset A timeout occurred on the milliamp card. 7 Volt fault Hardware fault detected. 0 Volt not detected Card missing or the wrong type has been fitted. 1 Volt reset A timeout occurred on the voltage output. 2 Pressure calibration Pressure needs calibrating. 3 Pressure fail Hardware fault detected. 4 Pressure low Pressure low fault. 5 Pressure high Pressure high fault. 6 Relay not detected Card missing or the wrong type has been fitted. 7 Switch input not detected Card missing or the wrong type has been fitted. 0 Flow fail Hardware fault detected. 1 Low flow Flow has fallen to maintenance required level. 2 Very low flow Flow has fallen to fault level. 3 Remote service in progress Switch input has activated service in progress. 4 Transducer calibration mode Calibration mode is active. 5 Auto validation/calibration Service in progress 6 Milliamp service in progress Service in progress. 7 Volt service in progress Service in progress. 0 Pressure service in progress Service in progress. 1 Relay service in progress Service in progress. 2 Flow service in progress Service in progress. 3-7 Reserved Reserved 12

14 Measurement One Setup Block One (Slot 1, Index 3) Measurement Two Setup Block One (Slot 1, Index 13) Word Name Comments Analogue Output 0-1 Range 1 low Range 1, lowest sample measurement. Float 2-3 Range 1 high The Range 1 highest sample measurement. Float 4-5 Range 2 low Range 2, lowest sample measurement. Float 6-7 Range 2 high The Range 2 highest sample measurement. Float 8 Range mode 0=Range 1, 1=Range 2, 2=Auto range 9 Freeze 0=Follow, 1=Freeze 10 Jam 0=None, 1=Low, 2=High 11 Output range 0=0-20mA (0-10v), 1=4-20mA Under range Any value below 4 ma. Float Range change point The range change point. Float Hysteresis The range change hysteresis. Float Measurement One Setup Block Two (Slot 1, Index 4) Measurement Two Setup Block Two (Slot 1, Index 14) Word Name Comments Cross Interference 0-1 Offset Float Auto validation 2-3 Low target Float. Also calibration target. 4-5 Low tolerance Float 6-7 High target Float. Also calibration target. 8-9 High tolerance Float 10 Type 0=Low val, 1=High val, 2=Low & high val, 3=High & low val 11 Mode 0=Validate, 1=Calibrate 12 Pre warning phase 0=No, 1=Yes 13 Pre warning seconds Integer 14 Inerting phase 0=No, 1=Yes 15 Inert gas 0=Low, 1=High 16 Inert seconds Integer 17 Flush seconds Integer 18 Timer 0=Off, 1=On 19 Start year Start month Start date Start hour Start minute Repeat hours Integer 13

15 Measurement One Setup Block Three (Slot 1, Index 5) Measurement Two Setup Block Three (Slot 1, Index 15) Word Name Comments Pressure 0 Compensating 0=No, 1=Yes Alarm set up 1 Alarm 1 mode 0=None, 1=Low, 2=High 2 Alarm 1 latching 0=No, 1=Yes 3-4 Alarm 1 level Float 5-6 Alarm 1 hysteresis Float 7 Alarm 2 mode 0=None, 1=Low, 2=High 8 Alarm 2 latching 0=No, 1=Yes 9-10 Alarm 2 level Float Alarm 2 hysteresis Float Flow Alarm 13 Maintenance level Maintenance req. status will be raised if flow falls to this level 14 Fault level A fault status will be raised if flow falls to this level 14

16 Measurement One Control (Slot 1, Index 6) Measurement Two Control (Slot 1, Index 16) Word Byte Bit Name Comments 0 Calibration mode on/off 0= off (normal), 1= on (alarms masked, jamming etc). Write 1 to turn calibration mode on. 1 Low calibration gas 0= Sample gas, 1= Low calibration gas. 0 1 HIGH 2 High calibration gas 0= Sample gas, 1= High calibration gas. 3 Low calibrate 0= Idle, 1= Low calibration in progress. Write 1 to initiate a low calibration. 4 High calibrate 0= Idle, 1= High calibration in progress. Write 1 to initiate a high calibration. 5 Start auto val 0= Idle, 1= Auto validation in progress. Write 1 to start an auto validation/calibration. 6 Stop auto val 0= Auto validation in progress and can be stopped, 1= Stop N/A. Write 1 to stop an auto validation/calibration. Pressure 7 Calibrate pressure mode 0= Normal, 1= Calibrate mode 0 Calibrate pressure low 1= Calibrate 1 Calibrate pressure high 1= Calibrate Flow Alarm 2 Calibrate flow mode 0= Normal, 1= Calibrate mode 3 Calibrate zero flow 1=Calibrate at 0% flow 4 Calibrate normal flow 1=Calibrate at 100% flow Analogue Output 5 Calibration mode 0= Normal, 1= Calibration mode 6 Decrease output level 1= Step output down 7 Increase output level 1= Step output up Relays 0 Service mode 0= Normal, 1= Service mode 1 Relay state during service 0= De-energised, 1= Energised Remote service in progress 2 Remote service in progress 0= Inactive, 1= Active 3-7 Reserved Reserved HIGH 0-7 Reserved Reserved System Setup (Slot 1, Index 51) Word Name Comments 0 Year Month Date Hour Minute Second Linked 0=No, 1=Yes 7 Switch input function 0=Disabled, 1=Remote calibration, 2=Auto validation 15

17 System Fault Data (Slot 1, Index 52) Word Byte Bit Name Comments 0 Fault If any system fault exists. 1 Maintenance required If any system maintenance required status exists. Service in 2 If any system service in progress status exists. progress 3 Reserved Reserved 4 Date/Time invalid System clock needs setting. 0 HIGH 5 Code fault The programmed software has become corrupted. 6 Database fault A fault occurred when using the database. 7 Reserved Reserved 0 Pump fault Pump fault exists. 1 Solenoid fault Solenoid fault exists. 2 Power configuration fault Wrong power type configured. 3 Static RAM fault A fault in the internal memory has been detected. 4-7 Reserved Reserved 16

18 6. TROUBLESHOOTING 6.1. The analyzer is not detected by the profibus master device. Check that the profibus cable is connected to the analyser, and the master device. Check that the termination resistors on the end points of the network are active. Using the Set Up menu on the analyser, make sure that the digital communications option is configured to use profibus. Set Up Comms Type Select Profibus Check that the analyser node address is set up correctly on the master device. Settings Comms Parameters Check that there are no other devices configured to use the same address as the analyser Make sure that if there is more than one master device on the system, the correct master device is configured and connected to the analyser. On the profibus master device, make sure that the correct gsd file has been used to configure the analyser, and at least one module is included in the configuration. Refer to your master device's manual to make sure all steps for the configuration have been followed. Some profibus master devices are configured to stop reporting cyclic data as soon as an extended diagnostic error message is received. In this case either these faults have to be cleared on the analyser, or the master device has to be configured to continue normal operation when diagnostic bits are reported. Make sure that the profibus baudrate selected at the profibus master device, is suitable for the cabling setup. Make sure that the profibus master is running. Using the Status menu on the analyser, make sure that there is no "Profibus card not detected" fault. This fault will require servicing of the analyser - Contact Servomex or your local Servomex representative The communication starts, but there are frequent line drops. Make sure that the "Profibus Cabling Guidelines" have been followed. Refer to for the latest guidelines. If possible decrease the network baudrate. 17