ManualFB Remote I/Ofor mounting in Zone 1

GHG 210 7003 P0041 (B)

2

Table of Contents

1 Configuration Software.....................................................................................1.1 PC to run FB Remote I/O Configuration Service.....................................................1.2 Instructions for the Installation of Software.............................................................1.3 FB Remote I/O Configuration Software...................................................................1.3.1 How to Use the FB Remote I/O Configuration Software..........................................1.4 Password Protection...............................................................................................1.5 Establishing Connections........................................................................................1.6 Options / Communication Set-up............................................................................1.7 Configuring of Module Data.....................................................................................1.7.1 Maintenance............................................................................................................

2 Hardware..............................................................................................................2.1 Bus Couplers..........................................................................................................2.1.1 System Speed - Cable Length................................................................................2.1.1.1 Fundamental Principles...........................................................................................2.1.1.2 PROFIBUS Speed...................................................................................................2.1.1.3 MODBUS Speed.....................................................................................................2.1.2 RS 485 Bus.............................................................................................................2.1.2.1 Fundamental Principles...........................................................................................2.1.2.2 Bus Interface Connection in Zone 1........................................................................2.1.2.3 Earthing and Screening...........................................................................................2.1.3 System Expansion..................................................................................................2.1.4 PROFIBUS DA and DPV1.......................................................................................2.1.5 Redundancy............................................................................................................2.1.5.1 Introduction.............................................................................................................2.1.5.2 Redundancy Concept.............................................................................................2.1.5.3 Redundancy Function.............................................................................................2.1.5.4 HART Communication in Case of Redundancy.......................................................2.1.5.5 Redundant Power Supply.......................................................................................2.1.5.6 Segments................................................................................................................2.1.5.7 Cabeling in Case of Redundancy...........................................................................2.1.5.8 Configure Redundancy...........................................................................................2.1.5.9 Initial Configuration for Redundant Operation.........................................................2.1.5.10 Retrofitting of Redundancy......................................................................................2.1.6 Bus Change-over....................................................................................................2.1.7 Self-Monitoring Features.........................................................................................2.1.8 Collective Alarm.......................................................................................................2.1.9 Time Out..................................................................................................................2.1.10 Safety......................................................................................................................2.2 System Configuration..............................................................................................2.2.1 ON-LINE..................................................................................................................2.2.2 OFF-LINE.................................................................................................................2.3 Self-Documenting....................................................................................................2.3.1 Station Layout..........................................................................................................2.3.2 Printing TAG Numbers.............................................................................................2.3.3 Terminal Plans.........................................................................................................2.3.4 Configuration Data...................................................................................................2.3.5 Data Structure.........................................................................................................2.3.6 Importing-Exporting of Data....................................................................................2.3.6.1 Format of the Import / Export File...........................................................................2.3.6.2 Example for Importing / Exporting of Data..............................................................2.3.7 Power Failure Protection..........................................................................................2.4 Station Set-up..........................................................................................................2.4.1 Field Wiring - Mechanical Coding............................................................................2.4.2 Power Consumption................................................................................................2.5 Local Connections...................................................................................................2.6 Commissioning - Maintenance................................................................................2.6.1 Commissioning Information.....................................................................................

3 How to Configure I/O Modules.........................................................................3.01 Introduction.............................................................................................................3.02 Module Replacement..............................................................................................3.03 Signal Processing....................................................................................................3.04 Functional Safety.....................................................................................................3.1 FB 1201 Digital Input...............................................................................................3.1.1 How to Configure Digital Inputs...............................................................................3.2 FB 1202 Digital Input...............................................................................................3.2.1 How to Configure Digital Inputs...............................................................................3.3 FB 1203 Digital Input...............................................................................................3.3.1 How to Configure Digital Inputs...............................................................................

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3.4.1 Calculation of a Valve Circuit...................................................................................3.4.2 How to Configure Digital Outputs............................................................................3.4.3 Dosing System using Valves...................................................................................3.4.4 Interconnection with an LED signal lamp.................................................................3.5 FB 3201 Analogue Input, Transmitter Power Supply, Input Isolator........................3.5.1 How to Configure Analogue Inputs..........................................................................3.6 FB 3202 Analogue Input, HART Transmitter Power Supply, Input Isolator..............3.6.1 HART Communication for FB 3202..........................................................................3.6.2 How to Configure Analogue Inputs..........................................................................3.7 FB 3203 Analogue Input, HART Transmitter Power Supply, Input Isolator..............3.7.1 HART Communication for FB 3203..........................................................................3.7.2 How to Configure Analogue Inputs..........................................................................3.8 FB 4201 Analogue Output.......................................................................................3.8.1 Local Connections for FB 4201...............................................................................3.8.2 Strain Gauge Measurement....................................................................................3.8.3 How to Configure Analogue Outputs.......................................................................3.9 FB 4202 Analogue Output, HART Output Isolator....................................................3.9.1 HART Communication for FB 4202..........................................................................3.9.2 Local Connections for FB 4202...............................................................................3.9.3 How to Configure Analogue Outputs.......................................................................3.10 FB 4203 Analogue Output.......................................................................................3.10.1 Local Connections for FB 4203...............................................................................3.10.2 How to Configure Analogue Outputs.......................................................................3.11 FB 5201 Temperature Converter.............................................................................3.11.1 Line Resistance.......................................................................................................3.11.2 How to Configure Temperature Inputs....................................................................3.12 FB 5202 Temperature Converter.............................................................................3.12.1 How to Configure Temperature Inputs....................................................................3.12.2 Cold Junction Compensation..................................................................................

4 HART communication.........................................................................................

5 Software - Marshalling...................................................................................5.1 Automatic Marshalling.............................................................................................5.2 Manual Marshalling.................................................................................................5.3 Software Marshalling by means of Table Imports...................................................5.3.1 Description of Format..............................................................................................5.3.2 Conversion of Tables..............................................................................................5.3.3 Explanation for Importing/Exporting of Data...........................................................

6 How to Address from the PLC or DCS............................................................6.1 PROFIBUS DP.........................................................................................................6.1.1 GSD File...................................................................................................................6.1.2 PROFIBUS DP Configuration..................................................................................6.1.2.1 Bus coupler Configuration.......................................................................................6.1.2.2 Control System Configuration..................................................................................6.1.2.3 PROFIBUS Configuration String..............................................................................6.1.2.4 Data Parcel..............................................................................................................6.1.3 Modul Status and Commando Register..................................................................6.1.3.1 Error Codes............................................................................................................6.1.3.2 Module Related Error Codes FB 520X...................................................................6.1.3.3 Command Register..................................................................................................6.1.3.4 Commands..............................................................................................................6.1.4 Data Format.............................................................................................................6.1.4.1 Analogue Data.........................................................................................................6.1.4.2 Binary Input.............................................................................................................6.1.4.3 Binary Outputs........................................................................................................6.2 PROFIBUS FMS......................................................................................................6.3 FB 8202 MODBUS Interface...................................................................................6.3.1 Status Register........................................................................................................6.3.2 MODBUS System Addresses................................................................................6.3.2.1 Elsag Bailey (H+B)..................................................................................................6.3.2.2 Fisher Rosemount RS3...........................................................................................6.3.2.3 HIMA.................................................................................................................... ...

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7 Troubleshooting.................................................................................................7.1 Communication........................................................................................................7.2 Faulty Power Supply Units......................................................................................7.3 Faulty Modules........................................................................................................7.4 Red LEDs................................................................................................................7.5 Searching for Errors................................................................................................7.6 Check List at Failure of Signals...............................................................................

8 Literary References...........................................................................................

9 Index of Keywords..............................................................................................

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1.1 PC to run FB Remote I/OConfiguration ServiceYour personal computer or LAPTOP mustfulfil the following minimum specifications torun the configuration software:

Processor 80486 DX, 33 MHz or higher;8 MB RAM minimum;3 ½ floppy-disk drive (CD-Rom);ca. 2 MB hard disk space required;uses Windows 3.1, Windows 3.11, orWindows 95, NT version;

You will obtain information about your hard-ware using the DOS command MSD.Leave WINDOWS* completely. Do not usethe MSDOS prompt in WINDOWS but restartyour computer under DOS. Then enterMSD.

* WINDOWS is a registered trade mark ofMicrosoft Corp.

1.2 Instructions for the Installation ofSoftwareYou can now install the disk supplied. Theconfiguration software is suited for ourLB Remote I/O product, as well as for theFB Remote I/O.

Change to the disk index using the file ma-nager. Carry out SETUP.The files are unzipped automatically. Spacerequirement on the hard disk: 2MB + pro-gramme size LOCBUS.EXE + manual file.

See the README file for importantinformation on the latest softwareversion.

CD-ROMVersion: hard disk installation

is not necessary.Dictionary: SOFT\16-BIT\Englisch\DEMO\Setup 16.exe:16 bit version for(Installation) WINDOWS 3.1,

WINDOWS 3.11 andWINDOWS 95.

Setup 32.exe:32 bit version for(Installation) WINDOWS NT 4.0

and WINDOWS 95.

NOTE: Only the 32 Bit version is kept up todate. 16 Bit versions are frozen in the V2.24status.

Configuration Software

IntroductionThe FB Remote I/O product line is designedfor the galvanic isolation and the conditioningof signals between the measured values of aproduction process and the process control(DCS) or programmable logic systems(PLC).

The new concept offers the followingadvantages:

Cost reductions.Simplified planning.PLC and DCS only use serial data links.Input / Output cards are no longerrequired.Various standard bus systems areavailable.HART communication possible via theservice bus.Multistage redundancy concept.Selfmonitoring feature for all themodules and field wiring.Reduced power dissipation and,therefore, less heat rise.Easy installation using plug-in modules.Modern backplane technology.Screw / plug-in connectors for all fieldcables.

This manual explains the function of eachmodule and tells you how to install and usethe configuration software. It also providesimportant tips on the assembly andcommissioning of field stations. For all ex-relevant data as well as for the assemblyand for commissioning see the operationinstruction FB 9224 - FB 9249.

1

ManualFB Remote I/O

Fig. 1

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Fig. 3 appears. After entering this key, youshould change the password for the super-visor to limit free access via this main key toyourself only. After this you can set up fur-ther user rights for your colleagues. Userswithout a password can break off the pass-word entering stage; however, then they canonly read data and call up measured val-ues. Without a password they cannot carryout any changes to the station setting.

With the main key you can:

Change the user:enter all user rights,

Settings:Read password (Fig. 4):Read own and all others of a lesserlevel (user rights).Change password (Fig.5):Change own and all others of alesser level (user rights).Set up users:Open for users with lesser userrights.

User Rights:

Main key:Set-up supervisor

=> Supervisor Level 3 has allrights

Setting-up of specialist=> Specialist Level 2

Setting-up of maintenance man=> Maintenance Level 1

Specialist:Clearance by supervisor

=> Specialist Level 2With the exception of accessto the passwords of otherspecialists, has all rights.Can install passwords formaintenance staff.

Maintenance:Clearance by specialist/supervisor

=> Maintenance staff Level 1Compared to specialists, thefollowing restrictions existregarding user rights:Maintenance person cannotset up new users and canonly read his own password;He cannot switch the buscoupler to the packed modeHe cannot look into theRamView memory;He cannot jump data.

Observer:Clearance by specialist/supervisor

=> Observer Level 0Has extremely restricteduser rights.Without a password he canonly load data and displaymeasured values.

1.3 FB Remote I/O ConfigurationSoftwareThe FB Remote I/O configuration softwarehas been designed according to the rules ofVDI/VDE 2187 (general design rules for PC-related software regarding display proper-ties and menu support for digital field de-vices). The software helps you to configureFB Remote I/O devices and shows measuredvalues and device status information duringcommissioning.

1.3.1 How to Use the FB Remote I/OConfiguration SoftwareExecute LOCBUS.EXE under one of abovementioned Windows versions. You will re-ceive the opening menu fig.1, page before. Amenu will appear showing you the currentsoftware identification number. Click on theOK button to gain access to the mainwindow of the application. Select whetheryou wish to configure LB Remote I/O orFB Remote I/O stations. You will now see ablank BUS station with 48 I/O slots.

You now have the option of:- entering a password,- establishing a connection to the field

station,- changing to the device window of a

station to configure it,- displaying the status or the

measured values of preconfiguredmodules,

- setting the serial interface,- setting the printer options,- documenting the configured stations,- switching on or off of the simulation

mode,- changing the station configuration,- combining parameter strings to

perform optimum adaptation to thePLC or DCS (marshalling of zippeddata) or

- call upon HELP functions.

1.4 Password ProtectionTo protect station settings from unauthorizedusers, the setting parameters can be safe-guarded by passwords. Here it is possibleto set up various user levels.

When the configuration software is called upwith the command LOCBUS.EXE and themain menu has been acknowledged bypressing the OK key, the password inquiryappears (Fig. 2).

Enter the users name and the passwordhere. When putting into service for the firsttime, you can issue a list of user names andpasswords to allow your colleagues accessto the various levels. Therefore, do not enterthis information on the original disk supplied,but on your hard copy. Your original diskacts as a key if the main password shouldever get lost.

The main key reads as follows:Users name: CGDPassword: Safety

Fig. 2

Fig. 3

Fig. 4

Fig. 5

7

Fig. 6

to PC COM 1 or COM 2

CommercialRS232 - RS485

Converter FB Station 1

FB Station n

FB Station 31

HE

Adapter Configuration cable Configuration kitGHG139 0008C0000 FB 9250

to PC COM 1 or COM 2

Fig. 7 Service bus for the connection of several FB stations to the PC

Fig. 8

1.5 Establishing ConnectionsBus stations can be configured ONLINE viaa permanently installed service bus. Buscouplers can be set in the office with the aidof a configuration kit FB 9250 and thenplugged into the slot provided during opera-tion.

Configuration of a station in Zone 1is only permitted via the Servicebus or with a hot work permit orappropriate certified aids.

When the menu item Establish Connection isselected, the program searches for anystations that are connected. Please note thatthis menu item is only available when thedemo mode is turned off (Fig. 6).

Using the connector cable RS 232/485,connect the bus terminals of the configura-tion kit to a free COM port of the PC. Thecable is a component part of the configura-tion kit. In the case of a permanently in-stalled service bus, the cable must beconnected to a free RS 232 interface of thePC using a commercially available RS 232-RS 485 converter (Fig. 7). The connectionsare described in operating instructionFB 92XX.

During the permanent installation of theservice bus, the bus terminals, that areavailable in duplicate, are used as a T-con-nection in accordance with the RS 485standard. All stations of a bus are of equalstanding and are independent of each other.However, it is necessary to ensure that thebus terminating resistors are mounted at thelast station.

In addition to this, it is also necessary to en-sure that the settings to the port connectionsof the bus coupler FB 8201/2 match those ofthe PC. The bus couplers are supplied withthe following factory setting of the PC ports:BAUDRATE = 9600, PARITY = NONE (seealso Options/Communication Set-up).Address is 1. Address 0 is blocked. Settingof the address range to be searched isshown in Fig. 8. The setting from 0 to 0records all address areas.

8

Fig. 10 System bus in redundancy mode

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

Redundanzeinheit Basiseinheit BasiseinheitRedundanzeinheit

Der Servicebus wird von Station zu Stationjeweils von der Redundanzeinheit zurBasiseinheit mit Hilfe der vorhandenenDoppelklemmen verdrahtet. Am letztenKlemmenblock wird der Abschlusswiderstandmontiert.

The Service bus is wired from station to station in each case fromthe redundancy unit to the basis unit with the help of the existingdouble terminals. The termination resistors are assembled on thefinal terminal block.

Redundancy unit Base unit Redundancy unit Base unit

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

x2.6x2.5x2.4x2.3x2.2x2.1

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

PE x1.3

Redundanzeinheit Basiseinheit BasiseinheitRedundanzeinheit

Der Systembus wird von Station zu Stationjeweils von der Redundanzeinheit zurRedundanzeinheit und von Basiseinheit zuBasiseinheit mit Hilfe der vorhandenenDoppelklemmen verdrahtet. Am letztenKlemmenblock wird der Abschlusswiderstandmontiert.

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

Redundancy unit Base unit Redundancy unit Base unit

Fig. 9 Service bus in redundancy

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While the PC is searching for any connectedbus couplers, a bar graph display showsthe progress of the search in per cent (Fig.11). It searches for bus couplers fromaddress 1 to 10 (max. 255). After completionof the search, a list of stations found isdisplayed. Use the MOUSE to select thestation with which you wish to communicate.If you happen to know that the bus coupleryou are looking for has an address withinthe range 1 to 25, you can limit the search tothis range.

If connection to the station cannot be estab-lished, the picture Fig. 12 appears.

Make sure that no other applications onyour PC that could have access to the set

interface are active. This could, for example,be the case if you use the HART software ofother manufacturers and have not yetclosed the application when you call up theFB Remote I/O configuration.

Check that the connection cable is connect-ed correctly to the PC and the bus station.Check that the settings according to Section1.2 have been carried out.Close the other programmes that also usethe interface. During the communicationyellow luminious diodes flash in the windowof the bus coupler.

After selecting a station and pressing theOK button, you return to the main menu. Thebus coupler is now in the appropriate po-

Fig. 11 Status window during station search

Fig. 12

Fig. 13

sition of your setup drawing. Then load thecomplete station configuration. The order ofthe modules hereby is arbitrary.

The system recognizes the correct positionin relation to existing configurations, just as itis also able to recognize new configurations.The modules themselves do not require anypresetting of addresses and, for this reason,they do not feature switches or potentiome-ters.

If, when loading, you do not wish to carry outany immediate new setting of modules, pressthe Y key to take over the existing stand-ard setting during the loading process for allmodules.

The setup drawing shows the modules usedfor the station selected. The part number ofeach module is entered at the top of eachslot, the slot number is entered at the bottomand the TAG-No. is entered vertically be-tween them (see illustration Fig. 13).

You can now select the module data menu toconfigure stations or to transfer configurationdata to or from the station.

1.6 Options / Communication Set-upThe service bus is generally a MODBUS,even if the main bus works with other busstandards.

When a commercially available RS 232 -RS 485 converter is used, the RS 232 inter-face of your PC or LAPTOP is converted intoa true bus connection and can operate up to31 stations via a single bus line.

You can connect the service bus cable toany free serial interface of your LAPTOP orPC (COM 1 to COM 4). Enter the port num-ber in the window (Fig. 14).

The following PC-internal settings apply:

Port HEX Address Interrupt

COM 1 3F8 4COM 2 2F8 3COM 3 2A0 12COM 4 2A8 15

For this, normal commercially availableinterface converters should be used (seeaccessories).The interface converters require an auto-matic baud rate recognition and an auto-matic direction changeover in order to fulfilall requirements.

Fig. 14

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1.7 Configuring of Module Data

1.7.1 MaintenanceSelect the menu item MODULE DATA /EDIT MODULE DATA to change from theMain Menu to the Module Data Menu (Fig.15).With the Module Data Window you can con-figure the station and the individual I/O mod-ules or load and save data, either in the fieldstation or on the hard disk.

The configuring of module data could not besimpler. You can set or change the data of amodule after double-clicking the slot youwant to configure with the mouse. The settingof a module that has already been config-ured will then appear in a window that corre-sponds to the check sheet of the slot andshows all the set parameters.

If you wish to occupy a new slot, the proc-ess is similar. By double-clicking a blankposition you will receive the list of modulesavailable (Fig 16). Choose the I/O unit youwant and click the OK button or double-clickthe desired module directly. You will thensee the parameter window for this moduleand you can now configure the moduleaccording to your own requirements.

In this way you can place up to 48 I/O mod-ules. The mains units FB 92XX cannot beconfigured and, therefore, they cannot beselected. The settings are determinedautomatically by the programme. You canmerely enter the mains voltage being used.

A list of the available slots (Fig. 17) appearsin the menu window (Fig. 18) when the com-plete station is configured.

The basic position of any module type canbe saved in a Default File. This facilitates thesetting of many plugging positions of thesame form (see file Load Module Data,Save Module Data).

Fig. 15

Fig. 16 By double-clicking a free slot, you will obtain a list of available modules.

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

Fig. 18

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Each bus coupler features 2 galvanicallyisolated serial interfaces. One bus connec-tion is for the connection to the DCS or PLC.The second bus connection serves as aservice bus during commissioning andmaintenance activities, as well as for theHART communication.

Note: The system bus and service busshould be laid seperately.

The bus coupler features a dual port RAMwhich shows the complete status and datasituation of the I/O modules connected to thebus coupler at any one moment in time. Thisenables the DCS or PLC to access data atany time without delay. Data for as many as48 I/O modules in the dual port RAM is up-dated every 5ms. The PLC or DCS does nothave to wait for the analogue to digital con-version of the channels to be performed.The bus coupler also collects the statusinformation of each I/O module. In the eventof a fault in one of the I/O modules, thisinformation can be transmitted via the fieldbus.

The service bus enables you to analysefaults in detail. Knowing the position of theunit which has reported the fault, you canaddress the point and look at it on yourmonitor during operation. In this way it is, forexample, possible to find out if a line faulthas occurred on a pressure transmitter loop(0 mA < I < 1 mA), or if the transmitter isfaulty (1 mA < current < 3.6 mA), or the loophas been shorted (current > 21 mA).

2.1.1 System Speed - Cable Length

2.1.1.1 Fundamental PrinciplesThe different transmission rates arerecognized by the bus coupler automatically.The standardized interfaces determine thepossible cable types and bus lengths. Youshould use screened twisted cables for thebus. The installation requirements accordingto VDE 0165 must be taken into account forwiring in hazardous areas.

The bus connections are generally fitted withstandard RS 485 hardware. This guaranteesa reliable communication link. Commerciallyavailable components can be used to adaptthem for fibre optic links or other media (e.g.telephone modems).

The technical data (Fig.19) applies to type Acables for standard applications toDIN 19245 Part 3 or EN 50 170.

The FB Remote I/O modules can be posi-tioned on the backplane in any order de-siredfollowing the bus coupler on the left handside of the first segment. A mains unit isneeded for each segment of 24 I/O de-vicesto stabilize the internal supply voltages andmonitor the modules. All modules can beexchanged during operation. This alsoapplies for mains units and bus couplers.The enclosure connection terminals are onlyaccessible in a volt free state after removingthe perspex cover. The intrinsically safemodule terminals can also be plugged orscrewed in during operation if the condi-tions applicable for intrinsically safe circuitsare observed.

2.1 Bus CouplersVarious bus couplers are available toaccommodate the various PLC systems orcontrols.

1) MODBUS RTU, ASCII, MODICON2) PROFIBUS FMS, DP

Successful couplings are already in opera-tion with the following systems:

ABB AdvantABB MOD 300AEG MODICONALFA LAVALAllen BradleyBabel BoxBailey Fisher&Porter DCI SIXFisher Rosemount RS3 and PROVOXFOXBORO Eckardt Micro I/AFOXBORO Eckardt PLS 80GE FANUCHartmann&Braun Digimatik/FREELANCEHartmann&Braun SymphonyHilscherHIMAHitachiHMSHoneywellIntellution FIXDMACSMatsushitaSiemens S5, S7, Teleperm AS235SoftingTrebel&HimstedtWonderwareYokogawa

More bus couplings are in preparation.Changing the bus coupler does not effect theexplosion protection.

BUS Data transmission rate Cable length, max.

MODBUS 19.2 kBit/s, 38.4 kBit/s 1200 m

PROFIBUS FMS, DP 1.5 Mio bit/s 200 m

PROFIBUS FMS, DP 500 kBit/s 400 m

PROFIBUS FMS, DP 187.5 kBit/s 1000 m

PROFIBUS FMS, DP 93.75 kBit/s, 19.2 kBit/s, 9.6 kBit/s 1200 m

PROFIBUS PA, H1 31.25 kBit/s 1900 m

Service bus 9 600 bit/s 1200 m

Hardware

Fig. 19

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Off-the-shelf repeaters (amplifiers) allow youto increase the cable length even further(Fig. 20). Installation of repeaters in thehazardous area on request, e.g. usingflameproof enclosures.

2.1.1.2 PROFIBUS SpeedThe system reaction time for a PROFIBUSsystem is basically dependent on thefollowing factors:

the reaction time in which a participantcan respond,the selected transmission rate (Baud-rate),the Min_Slave_Interval,the net data length agreed on.

The following simplified example can beused as an estimate:1 master and 5 slaves are connected to theProfibus DP. 10 bytes output data and20 bytes input data are to be transmittedper slave. The transmission rate is, forexample,1.5 MBaud. Thus:1 bit at 1.5 MBaud = 1 / 1.5 Mio bits/s =0.67 ms = 670 ns1 symbol consists of 11 bits (1 start bit,1 stop bit, 1 parity bit, 8 data bits)Therefore 1 symbol requires 11 x 670 ns =7.33 ms

The basic requirement for an informationcycle results from the addition of the bustimes and the telegram header.TMC = 2 x length header (bytes) x 11 bit +TSDR + TSYN + Tidi(Fig. 21 and 22)

In the data exchange the header comprises9 bytes. The bus time-out times for thesynchronization are to be taken as beingTSYN = 33 bit and Tidi 36 bit (at 1.5 MBaud).The delay times of the signals at the bus arenegligible. A typical value for an ASIC isTSDR = 30 bit. Thus:TMC / bit = 2 x 9 x 11 + 30 +33 + 36 = 300or 300 x 670 ns = 201 ms.

Thus, the approximate time for an informa-tion cycle is:201 ms + quantity of net data (e.g. 10 outputbytes + 20 input bytes)201 ms + 30 x 7.33 ms = 420.9 ms perslave or ca. 2.1 ms with 5 slave stations.

2.1.1.3 MODBUS SpeedThe reaction time to Modbus telegrams isapproximately 3.5 Character Times + 2 ms.This results in the following reaction timesdepending on the baud rate:

baud rate 9600 => approx. 6 ms19200 => approx. 4 ms38400 => approx. 3 ms

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

MASTER Station 1 RepeaterStation30

Station 1 Station 2 Station31Station30

Linie 1

Linie 2

Abschlußwiderstand

Line 1

Line 2

Termination impedance

Fig. 20

Fig 21

Fig. 22

Bus cycle time of aPROFIBUS-DP Mono-Master System

Bus cycle time

Initial conditions: Each slave has 2 byte input and 2 byte output dataThe minimal slave-interval-time is 200 microsecondsTsdi=37 bit times, Tsdr=11 bit times

DP-Slaves

Closing-Info

Principle of informative data traffic

Call-up telegram

Closing Info Output data Heading-Info

Heading-Info Input data

Response telegram

SRD-Request, variable information field length

SRD-Response, variable Information field length

Telegram formats

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

2.1.2 RS 485 Bus

2.1.2.1 Fundamental PrinciplesThe bus connection to the DCS or PLCfeatures the same RS 485 hardwarestandard as the service bus. The followingproperties in accordance with the Europeanstandard EN 50170 must be taken intoconsideration:

Bus structure Lines to be terminated atboth ends with the cha-racteristic impedance.No branch lines.Branches toparticipants < 0.3 m.

Medium Screened, twisted pair.Characteristic impedance100-130 W.Cross section> 0.22 mm², ca. 60 pF/m.

Cable length 1200 m max., dependingon the data transmissionrate.

Bus participants 32 active or passive par-ticipants and repeaters.

The cable length can be increased using bi-directional amplifiers (repeaters). Amaximum of 3 repeaters may be insertedbetween 2 participants. The followinglimitations must be observed at < 93.75kBit/s with serially connected data lines:

0 Repeater 1.2 km one master plus31 participants with48 I/O modules each(1488 modules).

1 Repeater 2.4 km and 62 partici-pants (2928 modules).

The participants are connected to the busby means of a double terminal in the form ofa T-connection. The terminal assignment isas follows:

Terminal Function

X2.4 = RxD/TxD-P receive/transmit-data-P

X2.3 = DGND reference potential X2.6 = + 5 V only at cable end X2.5 = RxD/TxD-N receive/transmit-

data-N

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

2.1.2.2 Bus Interface Connection inZone 1The same regulations apply when wiring thebus cables as with the power cables. Inhazardous locations where there is a risk ofexplosion, the assembly regulations inaccordance with VDE 0165 are to beobserved.E.g. section

5.6.1.1: Cables must be chosen that meetthe mechanical, chemical and thermaldemands.

5.6.1.2: Any cables that are not being laid inthe ground or in sand filled channels or arenot otherwise protected against fire entrain-ment must have the fire characteristicsproven...

5.6.3.1: Duct openings for cables and wiringto non-hazardous locations must be suffi-ciently sealed e.g. by sand bags, mortarfilling.

5.6.3.3: Cables that lead through locationsthat are particularly subject to thermal,mechanical or chemical demands need tobe protected, e.g. by laying protectivepipes, plastic hosing, metal hosing with sideprotection (terminal sleeves) or by covers...

2.1.2.3 Earthing and ScreeningWiring and cable screens are, depending onthe application, to be earthed at one or bothends. Earthing at both ends is not permittedif earth loops could occur, or if the screen isbeing used as a return line. Large scaleearthing of the screens in the CEAG fieldstations is provided by means of the metalscrew fittings. The screen end of the input/output lines are thus connected via the metalcasing or metal-coated part of the plasticcasing to the earthing point X1.3 (refer tooperating instruction FB 92XX). This earthingconnection is to be connected with theequipotential bonding for applications inZONE 1.

Fig. 23

390 Ω

120 Ω

390 Ω

X 1 .4+ 5 V

X 1 .2

D a ten

X 1 .5D a ten

X 1 .3D G N D

B u sa b sc h lu ß K lem m e n b e le gu n g

390 Ω

120 Ω

390 Ω

X 1 .4+ 5 V

X 1 .2

D a ten

X 1 .5D a ten

X 1 .3D G N D

B u sab sc h lu ß K lem m e n b e le g u n g

X2.6+ 5 V

X2.5Data

X2.4Data

X2.3ISO_GND2

390 W

RD 220 W

390 W

X2.2B1

X2.1A1

RD 120 W

RS 485/2 RS 485/1

Service bus System bus

Terminal assignment for bus termination

14

There is no earthing of the screens on sepa-rate screen bars in the casings as electro-magnetic noise fields could gain entranceinto the inner casing this way. The screeningeffect must therefore be guaranteed and allwires and cables including the network andbus connections must be screened.For Profibus screening also see the literatureoffered by the Profibus User Group.

2.1.3 System ExpansionIn order to be able to set up additional busstations during operation, it is advisable to fitempty stations at the positions provided atthe initial installation stage. A station can thenbe connected there at a later point in time(Fig. 24).Substations can be extended during opera-tion if the necessary measures were takenduring initial commissioning.An extension of the bus line during opera-tional running would require the removal ofthe bus termination resistor. In this case,operational running can only be maintainedby means of redundant stations.

2.1.4 PROFIBUS PA and DPV1Ever increasing field device manufacturersare offering PROFIBUS PA devices that offerthe user additional advantages that werepreviously only offered by HART devices.PA devices allow parameters to be set viathe bus and to carry out diagnostic andrepair work. In the coming years thetechnologies of both HART and PA will

co-exist. CEAG already offers the HARTprotocol via the service bus. In the future,with the assistance of the PROFIBUS DPV1,it will be possible to allow HART communica-tions via the system bus and to carry out theconfiguration and parameterisation of thefield stations.PROFIBUS PA devices are fed via the busas intrinsically safe participants and theparameters can be remotely set just likeHART devices. They work at a data rate of31,25 kBaud that is much lower than thenormal bus speed used for the PROFIBUSwhich is 1500 kBaud. PA field devices arefed intrinsically safe via segment couplers.At the same time the segment couplers areused to increase the data rate to 93,75kBaud in order to make the connection witha PROFIBUS Master possible.Alternatively PA field devices can be coupleddirectly to the PROFIBUS DP via LINKs andExi-feed buffers. These LINKs allow shareduse of the bus for CEAG field stations andPA field devices of any manufacturer.Normal structural components are used inthe process (Fig. 25).

2.1.5 RedundancyRedundant bus couplers must beconnected together via Exi-lines on the frontpanel.Active redundant couplers have flashinggreen LEDs on the front panel. Passive re-dundant couplers can be detected by asteady green light on the front panel.

2.1.5.1 IntroductionRedundancy is used to make sure that theoperation of a bus station continues even if abus coupler is faulty. FB Remote I/Oprovides redundant buses and redundantbus couplers. If a bus line or a bus couplerfails, the higher ranking system switches tothe redundant bus line.

The redundant coupler has the same con-figuration as the primary coupler andcontinuously receives the same data that isalso processed in the primary coupler.Because of that a bumpless change-over ispossible when the bus line or bus couplerfails.

Bus couplers are SLAVES to the bus andwait for a data request from the digitalcontrol center (DCS) or from programmablelogic control system (PLC). The bus couplerinterfaces the field bus with the DCS or PLC(master). A maximum of 31 bus couplerscan be linked in parallel to the bus segment.If repeaters are used, a maximum of 126(when using PROFIBUS) or 247 (when usingMODBUS) FB-stations per master arepossible.

Every bus coupler has 2 serial interfaces,which are galvanically isolated: one bus linkis for communication with the higher rankingsystem, PLC or DCS, the other bus link canbe used as a service bus during commis-sioning, during maintenance or for transmit-ting the HART protocol.

PROFIBUS DP

1,5 Mbaud

LINK

PA

PA

PA

PAPA

PA

PA

Exi Exi

31,25 kbaud

PA

PA

PA

PAPA

PA

PA

31,25 kbaud

Exi Exi

31,25 kbaud

heute verfügbare Lösung

93,75 kbaud

ZONE 1

Possible solution

Fig. 25

Fig. 24

Station 1 Station 2 Station 3

withBus end

Free stationX

.

withBus termination

15

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

2.1.5.2 Redundancy ConceptDepending on the redundancy concept ofthe master, several options are possible:

Redundancy concept AThe simplest way of achieving redundancyenvisages 1 bus cable and 2 bus couplersper station in which different bus addressesneed to be used. That concept is not idealbecause in the event of a bus failure (e.g.cable, master, etc.) not only one completeslave fails, but the complete bus line, i.e. upto 15 x 48 analogue circuits or 15 x 144binary inputs or any combination of inputsand outputs (without repeater).

Redundancy concept BThe best form of redundancy envisages 2bus cables and 2 bus couplers per station.That concept ensures that the function of thesystem is maintained even if a bus couplerfails.

2.1.5.3 Redundancy FunctionThe bus coupler controls the I/O modulesvia an internal bus. The 48 linkable I/Omodulesare addressed via the backplane segments.Redundant selectors are present for thispurpose, which switch the respectiveinternal bus through to the I/O modules. Theselectors are each responsible for operatinga segment of 12 I/O modules. The internalbuses for the two couplers are connected toone another via a resistor to enable theprimary coupler to use the redundantcoupler as an additional module and to alsoenable the redundant coupler to read thedata.

The primary coupler and the redundantcoupler have access to the I/O modules viathe selectors and the data line. Bothcouplers constantly read all the incomingdata. However, only one of the two couplerscan set activated outputs. Duringcommissioning, a fixed Timeout is used todecide between the two bus couplers withregard to who will be given access to theoutputs. Subsequently, the Masterdetermines which of the two couplers will belinked to the outputs.

The redundant coupler receives identicalfield information by reading the databetween the active coupler and the I/Omodules on the internal bus. As a result, abumpless change-over is made possible inthe event of the failure of a coupler.

The primary coupler continuously checksthe redundant coupler . For the master canconstantly obtain the status informationabout the state of both couplers. When themaster determines a communication faultcommunication, it changes over to theredundant bus within 200 ms and transmitsthe settings for the outputs.

In the event of an internal failure or if thecommunication with its master is inter-rupted, the active bus coupler is switched topassive status automatically. It does not tryto set outputs. In passive mode, the datafrom the I/O modules on the internal bus isonly monitored, the addressing lines are inhigh impedance mode (tristate outputs). Theredundant coupler then assumes the bump-free control via the internal bus. If neither theprimary coupler nor the redundancy couplerare connected to the Masters and the LB-/FB-station, then the output modules areswitched to a safe OFF status.

Faults can be caused by faulty selectors,faulty power supply units, faulty I/O modulesor faulty internal bus coupler components.All faults emit a collective alarm within thebus coupler. If the master detects such analarm or if it cannot establish a connectionwith the bus coupler, it then addresses theredundancy coupler. Unclear change-overstatus can be monitored by a plausibilitycheck in the master and can be verified bycomparing it with the redundancy coupler.

A malfunction in the redundancy coupler onthe internal bus is also signalled by thestatus register of the primary coupler (Error12, synchronisation fault). To check thecomplete functionality of both bus couplers,the functions of the primary and redundantcouplers can be switched around; e.g.every 24 hours. The master needs to sendthe 0xF5 command to the primary couplerto switch the redundancy around. In aPROFIBUS operation, the values of bothoutput bytes for the command/statuspseudo module need to be changed to 0x00and 0xF5.

2.1.5.4 HART Communication in theevent of redundancyDuring HART communication, no continuousredundancy change-over should take placebetween the primary coupler and theredundant coupler, because the field unitstransmit their HART telegrams independentof the data transmission during redundancy.If the primary coupler diverts the HARTtelegram to the redundant coupler in themiddle of a redundancy change-over, theprimary coupler, which has sent the HARTtelegram, remains in stand-by mode. Thistype of situation should be avoided bymaking sure no redundancy change-overtakes place during HART communication.

16

2.1.5.5 Power supply redundancyThe bus couplers get their power supplyfrom the FB 9204 or FB 9215 power supplymodules. During redundancy operation, the 2power supply modules are individually ableto supply the bus coupler and 24 I/Omodules. The necessary wiring is alreadycontained in the BACKPLANE segment.Should one of the power supplies fail, thenthe second power supply assumes theoperation without any interruption. An errorbit allows you to signal this fault in theprocess control room.

NOTE: Each comm unit is supplied by onepower supply. In case of redundancy thefailure of a power supply will shut down thecorresponding comm unit. The other one willmaintain full operation.

2.1.5.6 SegmentingThe 48 I/O modules in a station are parti-tioned into 4 segments containing 12modules each. Any 2 segments are suppliedby a separate power supply in the case ofredundancy and are independently linked tothe bus coupler.The failure of a segment does not influencethe other segments (Fig. 26).

2.1.5.7 Wiring in event of redundancyThe wiring of the redundant stations issimilar to that of the standard bus configura-tions. Both buses are treated equally. Youcould operate 31 bus couplers on one busline without a repeater (Fig. 27). Everystation is linked to the next station via a T-piece (installed double terminals). A busterminating resistor is mounted at the laststation. If you are pursuing redundancyconcept A with only one bus, pleaseremember that the 15 redundant stationshave already been equipped with 30 buscouplers.

2.1.5.8 Configuring redundancyThe task: bus couplers are to be configuredwith redundant service bus address N.Assumption: bus couplers (BK) are alreadyset to the service bus address N. All buscouplers are supplied with the address N = 1when they are shipped.

2.1.5.9 Initial configuration forredundancy operationProceed as follows for the initial configura-tion of a redundant station:The configuration of the field stations can becarried out under the following ambientconditions:- In the office with the help of configura-

tion kit FB 9250,- In Zone 1 via the service bus,- In Zone 1 with hot work permit.Plug the redundant bus coupler into its slot inthe redundancy rack if the primary coupler ismissing (Fig. 28) and start communication bythe communication interface.

Station 1 Station N Station 31

Master

Primärbus

Redundanzbusredundant bus

Primary bus

Fig. 27

12

Bus2Bus1

1 13-24

Daten

memory

comm 2

memory

comm 1

Selektor

1

Selektor

2

Segment 1

Segment 2

Segment 3-4

PROFIBUS Feldgeräte Ex-iMODBUS

Ex-i Modules

Data

Fig. 26 Partitioning into 4 segments which are individually linked to the bus couplers

Fig. 28

Redundant coupler Primary coupler

17

3

1

2

Fig. 29:(1 ) Set the service bus address N + 128

(e.g. 130 for N = 2) in the device datawindow.

(2 ) Select Save and confirm the optionSave data in module with OK. Aftertransmission, re- confirm with OK onceagain.

Fig. 30:(1 ) Add the second bus coupler (primary

coupler) to the appropriate slot.Establish communication with theprimary coupler with the address N(e.g. N = 2).

(2) Open the device data window for theprimary coupler by double clicking on it.Mark the checkbox include redundantcomm unit.The primary coupler and the redundantcoupler can now be accessed as a pairand can be parameterised at the sametime.Before to activating the redundancy thewarning shown in Fig. 31 will appear.

(3) Now you can also set other parameters,e.g. the bus address for communicatingwith the master, the type of protocol(MODBUS; PROFIBUS). Click the buttonParameters to access the para-meters of the redundant coupler.

(4 ) When finished, press the button Saveand send the station data to the buscouplers. Both bus couplers will receivetheir respective data.

The bus couplers now are passive and re-dundant at the internal bus of the station. Thecoupler with the service bus address Nbecomes active first. The second couplerwill only activated when the first couplerfails or if a change-over command is issuedvia a bus telegram. For this purpose, it isnecessary that the master transmit the 0xF5command. It is now possible to configure theI/O modules (see Chapter 3).Caution: Bus monitoring is automatically setto 200 ms by the system. This minimum timeis frequently exceeded by the Masterspolling cycle. It should therefore be set to arealistic value, so that it is longer than thepolling cycle duration which is needed by themaster to address the corresponding station(e. g. > 5 sec).

During configuration, you will come acrossthe following warning (Fig. 32).

2.1.5.10 Retrofitting of RedundancyThe configuration of the field stations can bemade under the following ambient conditions:

- In the office with the help of configura-tion kit FB 9250,

- In Zone 1 via the service bus,- In Zone 1 with the hot work permit.Procedure for refitting redundancy inpreviously configured stations (in thesystem, see Fig. 28):

Fig. 29 Configure the redundant coupler first.

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

4

2

1

Fig. 31

Fig. 32

18

1. Remove the previously used primarycoupler with the address N.

2. If there is no primary coupler, plug redundant bus coupler into the slot in theredundancy rack and establish communication with the communication interface.

3. Set the service bus address N + 128(e.g. 130 for N = 2) in the device datadialogue box.Select Save and confirm the optionSave data in module with OK. Aftertransmission, re-confirm with OK(see Chapter 2.1.5.9).

Steps 2 and 3 could be prepared using theconfiguration kit. In that case it is notnecessary to remove the primary coupler.4. Add the primary coupler to the basic

rack. Establish communication with theprimary coupler with the addressN (e.g. N = 2).

5. Load the existing configuration of thisstation from primary coupler (Fig. 33).The existing configuration is nowpresent in the main memory.

6. Open the device data window for theprimary coupler by double clicking on it.Mark the checkbox include redundantcomm unit. The primary coupler andthe redundant coupler can now beaccessed as a pair and can beparameterised at the same time.

7. Click the button Parameters to accessthe parameters of the redundant coupler.(e. g. the address of the redundantcoupler to be addressed by the master).

8. After completion, press the button OKand then select Save station in field inthe Device dialogue window. Thestation data is now stored in both buscouplers.

9. The bus coupler now are passive and re-dundant at the internal bus of the station.The coupler with the service bus ad-dress N becomes activated at first. Thesecond coupler will become activatedonce the first coupler fails or if achange-over command is given via a bustelegram. It now has a copy of all the I/Omodules in order to ensure a smoothchange-over possible at any time. Forthis purpose, the master must transmitthe 0xF5 command.

Caution: The bus monitoring is automaticallyset to 200 ms by the system. This minimumtime is frequently exceeded by the Masterspolling cycle. It should therefore be set to arealistic value, so that it is longer than thepolling cycle duration which is needed by themaster to address the corresponding station(e. g. > 5 sec).

During configuration, you will come acrossthe following warning (Fig. 32, previouspage).

2.1.6 Bus Change-overThe redundant bus couplers are intercon-nected to each other via an intrinsically safeline that supplies the secondary coupler withthe information from the primary coupler. If,the positive status signal of the primarycoupler is not available because it displays afault, an error signal is transmitted to thehigher-ranking system via the system bus.The higher-ranking system must thentransmit a change-over command.

2.1.7 Self-monitoring featuresThe I/O modules need no redundancy,because even with conventional technology,one assumes that modules with 1 to 4channels have a high availability. In addition,all modules are self-monitoring and theincoming wires are monitored for interrup-tions or short circuits. The outputs switchover to a safe OFF status in the event of afault. The time is set up in such a way, thatthe redundant coupler can take the control atthe right time. A failure criteria is a lack ofinternal communication with one or both ofthe bus couplers.

Every I/O module is equipped with self-monitoring. Light emitting diodes (LED) onthe front indicate the status of the module.The green LED lights up when the modulecorrectly supplies secondary power and themodule fuse is intact. The red LEDs displaythe monitoring status of the field circuits. Allinput and output circuits from the tempera-ture sensor, the transmitter power supplycircuits, binary inputs, valve outputs e.g. aremonitored for cable breakage or short-circuits. The yellow LEDs display the switchstatus of the binary inputs and outputs. TheLEDs are largely visible through a roundwindow on the front of every module.

The internal data transmission between themodules and the bus coupler is protected bythe Manchester code. In the case oferroneous data from an I/O module, 4subsequent polling cycles will be attemptedto obtain the correct information from thefaulty module. If all attempts are unsuccess-ful, this triggers an error message.

The selectors are equipped in such a waythat they separate any faulty I/O modulesfrom the bus, to avoid faults in neighbouringcircuits.

Malfunctions are stored as error codesin the bus coupler and could be readtogether with the measuring data by themainframe. Every fault triggers a collectivealarm in the bus coupler. The collective alarmand the red LED for the bus coupler are NOTautomatically reset. An acknowledgecommand has to be issued by the system orvia the service bus once all the alarmconditions have been rectified (see Chapter7).

Fig. 33

19

2.1.8 Collective alarmThe bus coupler generates a collective alarmif one of the following error conditionsexists:1. I/O module line break2. Incorrect or missing component device in

an I/O plug-in slot3. Defective I/O module4. 4 communication errors in succession

between the bus coupler and anI/O module.

5. Internal fault within the control processorof the internal bus.

6. Fault in the control processor of thePROFIBUS/MODBUS interface.

Detailed error codes are listed in Chapter6.1.5.1

2.1.9 Time OutThe Master and Slave are both able tomonitor the system bus data traffic. For thispurpose a response monitoring time in theSlave and/or Master is activated. Thesetimes often lead to conflicts if the pollingcycles are not adapted to the monitorperiods.If the response monitoring time is ZERO, thenboth CEAG outputs remain frozen if there isan interruption in the data traffic. In order toachieve smooth resumption of traffic,measures must be in place to ensure that theMaster does not set all the outputs to ZEROwhen it establishes a connection with theSlave.In the event of a failure in the internal datatraffic between the bus coupler and theoutput module, the output switches to ZEROafter approximately 0.5 seconds.The response monitoring period for themaster should be considerably longer thanthe longest polling cycle. If in doubt, deacti-vate the monitoring function.

2.1.10 SafetyApplications relevant to safety (e.g. Z-circuits or EZA) can be achieved with thehelp of the FB Remote I/O components with aseparate signal path. Details for this can beprovided upon request.

2.2 ConfigurationThe baud-rate and the bus address can beset via the service bus. Unless otherwiseagreed in advance, the bus couplers havean address of 1 and a baud-rate of 9600when they are delivered from the factory.During commissioning you can set theaddress to suit the system requirements. Ifall bus couplers have the same factorysetting, initially only one bus coupler shouldbe connected. Then all the other buscouplers are allocated an address one byone.

Fig. 34 MODBUS Parameter

Fig. 35 PROFIBUS Parameter

Fig. 36

one. Once the individual addresses havebeen set, the bus couplers can be con-nected to each other via the bus line.

Starting from the main menu, the sequenceof commands for establishing communica-tions via the service bus is as follows:

Headline Window Options Communication set-up

Set the communications port of your LAPTOPor PC (usually COM1). The baud- rate for theservice bus is set at 9600 ex works.

Bus couplers can also be configured byauthorized users via the service bus. It isalso possible to carry out the configuration inthe office using the FB 9250 configurator KIT..

Starting from the main menu, the sequenceof commands is as follows:

Headline Window Module data Process module data

Headline Window File Configure bus coupler

Process control systems or controls that arecapable of setting parameters via the systembus can exercise direct access to theappropriate memory cells in the bus coupler.

Should you have any questions, you canreach us via our HOTLINE (see READ ME fileon the disk / CD-Rom supplied).

Depending upon the desired system bus,further parameters can be set in the config-uration window for the bus parameters (Fig.34 and 35). Provided that the PLC and DCSsupport this high speed, a baud rate of38.4 kBaud can be set for the MODBUS. Atpresent transmission rates of up to 1.5miobit/s are available for the PROFIBUS (seewindow at Fig. 37 next page).

Further adaptations to the main system arepossible with the PROFIBUS. In each case itis necessary to refer to the manuals for theDCS and PLC systems, as they containdetails that are specific to the respectivemanufacturers and these allow optimumadaptation to the FB Remote I/O.

Here the settings available with theFB Remote I/O for marshalling (packing) data,scaling analogue values, etc. are particularlyuseful, as the standard for DCS and PLCsystems is used in various ways (see Fig.36 and Software Marshalling).

20

Fig. 38 Dialogue window in case of redundancy

Fig. 37

(1 ) The model number of the module isentered automatically. For updatesplease see the READ ME file on thedisk supplied.

(2) The number of the firmware version.(3) TAG-No. or device identification no. with

up to 20 characters.(4) Name of project or part of installation for

which the bus coupler is responsible.(5 ) Description of the device for which the

bus coupler is responsible.

8

1

3

2

4

5

7

6

9

X

9

X

14

15

16

17

18

10

11

12

13

(6 ) Unpacked data is transmitted followingthe module structure.

- Data of I/O circuits can be packed tocompress it into words.

- Data can be packed in a userdefined manner to group them intowords.

(7 ) Suppress consequences of alarm.(8 ) Temperature Class fixes values for

installable power consumption, e.g.number of I/O modules. Pay attention tothe user instruction of FB 92XX.

(9 ) Installation of redundant bus coupler.After marking a new button parameterappears (see little menu). Click para-meter to open menu for redundant buscoupler.Here you have the possibility to set onlythose values, which are marked by Xin the menu Fig. 38; TAG-No. and busaddress.

(10) The bus time-out defines the periodwhich will elapse before all outputs areset to ZERO following a total breakdownof communications on the bus. If thistime-out period is ZERO, the station canalso be operated without bus. Then afailure of the bus transmission is notused for disconnecting the outputs.

(11) The bus connections are activatedindividually.

(12) Bus addresses must range between1-255 for MODBUS and 1-126 for

PROFIBUS. The address 0 is blocked.(13) Open a window to configure furtherdata for authorized users.

Bus couplers can be configured forMODBUS and PROFIBUS applications.

(14) Press the OK button after completionof the coupler specification.

(15) Use CANCEL if you wish to abort allchanges and return to the original

setting.This button will return you to the mainmenu without carrying out any changes.

(16) After configuration save the setting inthe bus coupler.

(17) Call up the works setting.(18) Call up HELP.

MODBUS note:From software version 2.52/2.45 onwardsthere is an additional selection box underredundancy.

Transparent ModeIf this mode is activated then the passivelyswitched primary coupler acts as a relaypoint. Here, the bus telegrams are ex-changed via the intrinsically safe frontconnector of both bus couplers!

21

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

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

2.2.1 ON-LINEThe system can now be configured stationby station. You can do so ON-LINE or OFF-LINE. For ON-LINE configurations simplyplace the I/O modules on the backplane in thedesired order. Next use the command LOADALL FROM FIELD UNIT to load the hardwareconfiguration from the station to be proc-essed. Next double-click module position bymodule position and carry out the individual I/O settings with the aid of the menu. Startingwith the main menu, the sequence ofcommands is as follows:

Headline Window Module data Process data

Headline Window Module Load all from field unit

Caution!Check if the control system or the PLC willallow an ON-LINE configuration to be carriedout. With some Master functions the busstation will run down temporarily after achange has been made. CEAG bus stationscan be frozen for the time needed to re-connect, see 2.1.9. The Master must ensurethat not all data is set to ZERO on detectionof the new configuration.

2.2.2 OFF-LINEYou can engineer a system using OFF-LINEconfigurations without actually having thehardware in your possession. You can storethe configuration of each station on disk. Thefiles can be loaded on to the hardware later.During this storage process the system willautomatically check that the arrangement ofthe I/O modules with regard to type andsequence coincides with the configurationchosen during engineering. This gives theuser complete support during the commis-sioning stages as mounting errors are auto-matically detected and indicated.For OFF-LINE configurations use thefollowing commands starting with the mainmenu:

Headline Window Module data Edit module data

Headline Window File Edit

A window (Fig. 39) will now display the first6 I/O slots. By double-clicking the slot to beconfigured you will receive the list ofstandard modules available. Choose the typeof module required from the list of standardmodules. The exact type of module can bedetermined in the adjacent window (Fig. 40).Once you have double-clicked the module ofyour choice, the associated data spec sheetopens auto-matically for you to configure it.Once this task has been completed, theservice programme returns to the selectionwindow to choose additional I/O modules.Use the COPY button to make identicalcopies of the last I/O module you configuredin any slot. After switching off the COPYmode you can proceed as initially described.

22

Fig. 41

1

2

9 10

11

3

7654

8

2.3 Self-DocumentingAs soon as you leave the configuration win-dow the I/O modules will appear on thescreen in the order which you have chosenon the BACKPLANE. This gives you animmediate document of the work you havecarried out. You can also use this tool toestablish your wiring diagrams.Use the following commands starting withthe main menu:

Headline Window Module data Edit module data

Headline Window Services Set additional parameters

Fig. 41 appears:(1 ) Name of station or project using 20

alphanumeric characters.(2 ) Choose the desired field or main cable.(3 ) Selected I/O module. Define all slots

one by one.(4) (5) (6) (7) Enter the target terminals Mx:y

adding a description if necessary(8 ) Click a line in section 4-7 to make your

entries. Enter the data in the columns ofline 8.Again click the desired line in columns4-7 to accept the data.

(9 ) Continue to next window.(10) Abort session without accepting any

changes.(11) Call up HELP.

All the parameter settings carried out withthe bus coupler are registered automaticallyand can be printed out. To do so use thefollowing commands starting with the mainmenu:

Display Headline Window Options Print preview

Print Headline Window Options Print

First of all you will see the window with thestation set-up. Click CONTINUE to display awindow in which the target designations ofcable connections are listed.

You can now create your cable wiring plansmodule by module. In addition to this, this filecan be exported and can be used as anASCII file in other software tools, e.g.AUTOCAD. The reverse is also possible,thus enabling you to import data from otherprogrammes employing ASCII files.

To do this use the following commandsstarting with the main menu:

Headline WindowModule data Edit module data

Headline WindowFile Import

The resulting documentation will print astation layout which the field engineer canuse to assemble the station hardware. It alsodocuments the configuration of eachindividual module so that you can check onthe measuring ranges and additionalparameters.

These settings, including the additional textsper measuring point, can be stored in a file(FILENAME.Ibu).Any notes and device specific commentscan be stored on file. However theinformation will not be stored in the communit. It can be reassigned to the substationat a later stage when loading data from thecomm unit. During that process you will beasked whether data should be added froman existing file.

23

2.3.1 Station LayoutThe automatic documentation provides ageneral plan showing all the modules thathave been configured (Fig. 42). With this

plan the field engineer can install the moduleson the backplane segments in the correctorder. An error signal is given if a module isnot in the correct position.

Fig. 42 Automatic documentation

FB Remote I/O Unit

24

2.3.2 Printing TAG NumbersThe configuration software allows you toprint device identification labels (TAG num-bers).

Starting with the main menu select OPTIONS.Next activate PRINT TAG LABELS. Fig. 43appears. Print on blank paper first beforeusing the sheet of blank labels provided.Adjust the settings suggested in the windowto the millimetre to match your printer. Thesetting is stored.Print a test page with the offset setting at 0.Insert the difference between the measuredoffsets to the set point offsets in the corre-sponding parameter box. The set pointoffsets in diagram 44 are to be taken intoaccount.

Fig. 44 Test page (dimensions in mm)

32 .0 23.0

10.0

1 3 .5

Fig. 43

Fig. 45 I/O modules

TAG TAG

Fig. 46 TAG numbers for backplane

The labels are also suited for labelling thecarrier plates of the backplane segments.The labels should be affixed after printing(see 2.4 Station Set-up).

TAG numbers or measuring point designa-tions can comprise up to 20 characters. Thisdoes, however, influence the size of thelettering, as the lettering space for narrowmodules is only small. With multi-channelmodules it is advisable to limit the number ofcharacters per channel to 4,e.g. PTIC 1234 3781 5783 (3-channel).Please print out the labels in duplicate. Affixthe labels as shown in Fig. 45 and 46.

Platz fürTAG Nr.

Space for

TAG No

25

2.3.3 Terminal PlansThe software draws up the terminal plansfor each station from the configuration data

2.3.4 Configuration DataThe software draws up plans according toslots based on the module related data for

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

Fig. 47

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

Fig. 48

26

2.3.5 Data StructureWhen the software marshalling mode for theI/O modules is activated, the documentationsoftware draws up a list of the marshallingaddresses of each station (Fig. 49).To insert your own logo replace theLocalbus.wmf file or .emf at 32 Bit compu-

ters with one of your own that has the sameformat. To do this open the file with a suitablegraphics program and replace the CEAGlogo. The file must be stored under the nameLocalbus.wmf or Localbus.emf.

Fig. 49

27

FB 1202:Line monitoring channel 1 (on/off);Line monitoring channel 2 (on/off);Line monitoring channel 3 (on/off);6* terminal data:

Cable from (14 characters);Terminal specification (20 charac-ters);Wire-No. (5 characters);Cable name (15 characters);

FB 1203:Line monitoring channel 1 (on/off);Burn-out drive (-20% = 0, 0% = 1,100% = 2, freeze = 3),Break delay (1 - 255 * cycle time);Measurement mode;Counting direction for pulse measure-ment (no significance);Action triggering for pulse measurement(no significance);Beginning of range (frequencymeasurement);End of range (frequency measurement);Prescaler (pulse measurement);Counter limit (pulse measurement);Input filter (0-4),4 * terminal data:

Cable from (14 characters);Terminal specification (20 characters);Wire-No. (5 characters);Cable name (15 characters);

FB 2201 - FB 2213:Line monitoring channel 1 (on/off);Line monitoring channel 2 (on/off);Line monitoring valve (on/off);Local connection (LC) (inactive = 0,active = 1);Type of LC (digital = 0, analogue = 1);Type of LC (normal = 0, inverse = 1);LC with module at slot (1-48);and with channel (1-3);Limit value (0-100%);Hysteresis (0.0-10.0% = 0-100);6 * terminal data:

Cable from (14 characters);Terminal specification (20 characters);Wire-No. (5 characters);Cable name (15 characters);

FB 3201-FB 3203:Line monitoring channel 1 (on/off);Burn-out drive;Limit for wire break (0.00-25.99);Limit for short circuit (limit FB-26.00);3 * terminal data:

Cable from (14 characters);Terminal specification (20 characters);Wire-No. (5 characters);Cable name (15 characters);

FB 4201 - FB 4203:Line monitoring channel 1 (on/off);Local connection (inactive=0, active=1);LC with module at slot (1-48);2 * terminal data:

Cable from (14 characters);Terminal specification (20 characters);Wire-No. (5 characters);Cable name (15 characters);

Minimum current;

2.3.6 Importing - Exporting of DataHaving created your cable wiring plansmodule by module, you can export this fileand use it as an ASCII file in other engineeringprogrammes, e.g. AUTOCAD. The reverse isalso possible, thus enabling you to importdata from other programmes employingASCII files. To do this use the followingcommands starting with the main menu.

Headline WindowModule data Edit module data

Headline WindowFile Import

The data in this file is arranged in the orderof the modules. The configuration of theindividual modules is stored in the file as inthe following text described. This way, theconfiguration drawn up in the PLS can betransferred correctly to the hardware of thefield stations.

2.3.6.1 Format of the Import / Export FileThe character lengths stated are maximumcharacter lengths

Line 1, 1st character:The first character in the first line of the filecontains the separator for the data (e.g.semicolon). Further characters up to the firstnew line are arbitrary.

2nd to last line:One line corresponds to one module. Theformat of the line is specific to each module.

General: Applies for all modulesType (e.g. 8201/8202, 1201,1202,...,5201);Type extension, currently not in use (allinformation included in type code);Slot number;Communication status (active = 1,passive = 0);TAG-No. (20 characters);Software marshalling parameters (perchannel, analogue modules = 1 channel):

Marshalling active (inactive = 0,active = 1, not in 82XX);Normal / inverted (0/1);Register address,Bit address (of no significance foranalogue modules, !! however, theposition must, for example, beassigned with BLANK as otherwisethe data structure would bedestroyed !!);

FB 1201:Line monitoring channel 1 (on/off);Line monitoring channel 2 (on/off);4* terminal data:

Cable from (14 characters);Terminal specification(20 characters);Wire-No. (5 characters);Cable name (15 characters);

28

FB 5201 - FB 5202:Line monitoring channel 1 (on/off);Burn-out drive (-20% = 0, 0% = 1,100% = 2, freeze = 3);Break delay (1-255 * cycle time);Cycle time in ms;Mains filter (50 Hz = 0, 60 Hz = 1);Temperature unit (°C = 0, °F = 1);Measurement mode;Measurement sensor;Start of measurement;End of measurement;Reference junction value;Input filter (0-4);

4 * terminal data:Cable from (14 characters);Terminal specification (20 characters);Wire-No. (5 characters);Cable name (15 characters);

for FB 5202 only:Duty cycle of PT 100: TC sensor forinternal VST (1-255);

FB 820X:Name of project (20 characters);Field bus connection 1 (inact.=0, act.=1);Field bus connection 2 (inact.=0, act.=1);Bus address (1-255);Address FBA 1;Address FBA 2;Data format;Type of cable (22 characters);Description of measuring point(25 characters);Baud rate PC, (of no significance:setting = 9600);Baud rate FBA 1, (of no signif. forPROFIBUS);Baud rate FBA 2, (of no signif. forPROFIBUS);Parity PC, (of no signif., no settings);Parity FBA1, (of no signif. forPROFIBUS);Parity FBA2, (of no signif: forPROFIBUS);Bus time-out time (in s);Bus type (Modbus-Modbus (0),Modbus redundant (1), Profibus-Modbus (2), Profibus redundant (3)),Profibus type (DP (0), FMS (1), DP/FMS(2), PA (3));Profibus-DP parameters:

Modus,Meanings of bits (0 = no, 1 = yes)Bit0: Module status rangeBit1: Status/command wordBit2: Outputs scaled separatelyBit3: Inputs/outputs scaledBit4: packed (data from

Xchange range)Bit5: Block / modularBit6 = 1 (reserved)Bit7 = 1 (reserved)

Factor for input scaling, (0.002...1.999)Offset for input scaling, (0.002...1.999)Factor for overall output scaling,(0.002...1.999)Offset for overall output scaling,(0.002...1.999)Redundancy (master = 1, slave = 2 (is2nd coupler));Deactivate alarm (0 = no, 1 = yes);

Temperature class ( 0 =T4, 1 = T6)additionaly activate bus monitoring(0 = no, 1 = yes);Offset for datas of local access (0-38);

2.3.6.2 Example for Importing/Exportingof DataA redundant system consisting of tworedundant bus couplers is exported (not aI/O module). Similar to this example are thedata of the other I/O modules.

First bus coupler:;; semicolon8202; type0; extension0; slot1; activeFB 820X-m; TAG-No.0; no marshalling

parameterred; name of project1; FBA1 active0;1; PC-address2; address FBA10; address FBA21;; format of data

unpackedBus coupler;4; baud rate4; FBA10; FBA20;0;0; parity0; bus time-out1;0;224; DP-parameter1.1;1;0.9;2;1; redundant (master

= 1st coupler)1;1;1;0;0;0;0; PLC-parameter

2nd bus coupler:8202;0;0;1;FB-820X-s;0;red;1;0;1;1;0;1;;bus coupler;4;4;0;0;0;0;0;1;0;224;1.1;1;0.9;2;2;1;1;1;0;0;0;0; slave when redundancy (is2nd coupler)

Notes to the example:baud rate 1 = 1200

2 = 24003 = 48004 = 96005 = 192006 = 38400

parity 0 = non1 = even3 = uneven

DP-parameter247 = 11110111 (bit7 ... bit0)The possible settings in the menu buscoupler FB 8201/2 and redundant buscoupler FB 8201/2 are written in chapter 2.2.

2.3.7 Power Failure ProtectionAn EEPROM secures all data in the event ofa power failure. However, it is advisable tosave a BACKUP file on disk or hard disk asthis data can be used to produce duplicatecopies of the bus coupler. The memory isdesigned for 10 000 write cycles.

29

2.4 Station Set-upEach bus station consists of a bus couplerand various I/O modules. The stations areprefabricated ex works and feature slots for24 or 48 modules and terminals for the busconnection and power supply (Fig.50).

You may also use two separate redundantpower supplies (e.g. battery back-up) asthese are decoupled by diodes at the supplypoint.

The bus coupler occupies the first slot on theleft (Fig. 51). It is the link between the DCS orPLC and the I/O modules that are plugged intothe BACKPLANE segments. EachBACKPLANE segment features 12

slots for I/O modules. A supply modulesFB 92XX is required for every 24 slots. Anadditional BACKPLANE segment is providedwhen a redundancy coupler is used. This isaccommodated in a redundancy enclosure(see catalogue). Unused slots can be leftempty for future extensions.

Bus

kop

ple

r

Net

ztei

l

bus

coup

ler /

pow

er s

uppl

y /

Fig. 50

Bus

kopp

ler

Net

ztei

l

Net

ztei

lN

etzt

eil

Bus

kopp

ler

Net

ztei

l

pow

er s

uppl

y/

pow

er s

uppl

y/

bus

coup

ler/

pow

er s

uppl

y/

bus

coup

ler/

pow

er s

uppl

y/

Fig. 51 Redundancy station with 48 slots FB 9249

Fig. 52

Fig. 53 Screw plug-in connectorsPHOENIX COMBICON MC 1.5/6-STF-3.81 withfixing screws of the type FB 9107(recommended type)

Fig. 54 Example of an I/O module

Multi-core cable

Plug-in screw connector Plug-in Plug-inwith enclosure for FIELD BUSon request only

Enclosure screw connector screw connector

654321

FB remote I/O

TAG Nr.

Kodierfahne654321

coding piece

The TAG-No. ormeasuring point numbercan be printed using theconfiguration software.

Example of a codingpiece and pin assign-ment.

coding piece

2.4.1 Field Wiring - Mechanical CodingField wires are connected to the I/O mod-ules via front screw terminals using the plug-in PHOENIX COMBICON system (Fig. 52).

The connectors are designed for wires up to1.5 mm² in diameter. However, it is advisablenot to use wires of more than 0.75 mm² (Fig.53).

Plugs can be mechanically coded to avoidany confusion regarding connections. To dothis you can remove one or more of the 6plastic pins provided on the plugs. Accord-ingly, small plastic inserts are placed in thefront sockets of the I/O modules in thecorresponding positions. This gives you26 = 64 combination possibilities (see Fig. 54).A COMBICON plug with housing and integralPt100 sensor is provided for cold junctioncompensation in thermocouple measure-ments (see Fig. 55, next page).

2.4.2 Power ConsumptionThe power consumption and the powerdissipation of the FB Remote I/O modules arewritten in the operating instructionsFB 9225 to FB 9249.

2.5 Local ConnectionsAnalogue and digital I/O modules can beinterconnected locally. In addition to thetransmission of data to the DCS or PLCsystem, input signals are then also used todrive outputs. This feature opens up theapplications Fig. 56, next page.

An output used locally is not accessible tothe DCS or PLC system. Should the bus linkfail, a locally driven output does not drivedown to ZERO, but continues to follow theinstructions given by the input to which it isconnected.

In addition to the local connection, there is asoftware tool available that opens up thepossibility of mathematical functions,conditional transfers, control algorithms,logical configurations and many otherfunctions that relieve the bus and provide thebus station with even more intelligence(Disk available on request).

30

that have just been entered. This com-mand returns you to the main menuwithout registering any changes.

(11) You can load any I/O configurations thatalready exist from disks or from thehardware.

(12) You can save the entries made on disksor in the hardware.

(13) You can recall the original setting status,but remain in the current configurationwindow.

(14) Set input and status values for testingpurposes during service and com-missioning.

(15) Call up HELP.

2.6 Commissioning - MaintenanceDuring commissioning it is possible to testeach field circuit via the service bus withouthaving to use the DCS or PLC system. Themounting position of each module can betaken from the documentation which isautomatically generated while you configureyour station. When you commission asystem, you simply transfer the configu-ration from file to the bus coupler. An auto-matic check is carried out comparing theconfiguration of the station with the hard-ware installed by your members of staff.Any discrepancies will be displayed on yourLAPTOP so that you can take correctiveaction immediately. Either you replace thewrongly placed I/O module or you changethe configuration.

During servicing it is possible to replacefaulty modules on-line while the rest of thesystem continues to operate. Modules takenfrom stock need not be reconfigured. Cali-bration is not necessary. Once you plug thecorrect module into position to replace itsidentical predecessor, it will automaticallyreceive the same parameter settings as thispredecessor - from measuring range toburn-out drive.

In order to transfer a station configuration toa bus coupler use the following commandsstarting from the main menu.

Headline WindowModule data Edit module data

Headline WindowFile Open file

The station data has now been transferredfrom the file to LAPTOP memory.

Headline WindowDevice Store all in field

The configuration is now transferred to thestation. Then, as explained above, an auto-matic check of the configuration against thehardware is carried out.

Example of a local connection (Fig. 57)(1 ) The module type is entered

automatically.(2 ) TAG-No. or measuring point number

with up to 20 characters.(3 ) Number of the slot currently being

processed.(4 ) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the query.The actual state of the module is shown.In the above example the simulationmode is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5 ) Line monitoring (LFD) On/Off.(6 ) Here you activate the local connection.(7 ) Local connection with slot 1 (example).(8 ) Space for notes.(9 ) Click OK after completing the descrip-

tion of the measuring point.(10) Press CANCEL if you want to restore

the original setting ignoring the changes

COMBICON Stecker

Pt100Vergleichstellenmodul

für ThermoelementmessungenFB 9112

COMBICON plug

Cold junction module for measurement withthermocouple

Fig. 55

Output Connected to Application

Field displayAnalogue output Transmitter supply Signal duplication

Temperature input Discrete controllersConnection to second DCS

Temperature input Trip amplifierTransmitter supply Trip amplifierDigital input Switch amplifierFB 1203 Dosing system

Solenoid valvedriver Temperature input 2 point controller

Transmitter supply Acoustic soundersDigital input Lamp driverFB 1203 Dosing system

Fig. 56

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

1

2 3

4

5

8

6

7

9

10

11

12

13

14

15

31

From version 2.52/2.45 onwards there is anadditional menu with the following choices: Device Store station in display

with restart of the bus coupler without restart of the bus coupler

Caution! A restart will temporarily set alloutputs to ZERO.A restart is necessary when addresssections are being shifted in the packedmode.A restart is not necessary when working inthe packed mode if things are only beingdeleted or if adding information into emptylocations.Caution! Carrying out several changes atvarious times may make it necessary toperform a restart.A restart is not necessary if reconfiguring inthe unpacked mode.

Once the data transfer has been completed,you can check the system loop by loop. Anexplanation of how to handle each I/O isgiven in the description of the individualmodules.

2.6.1 Commissioning InformationIt is only possible for us to give limited im-portant information regarding the use of thebus interfaces here. Additional informationon various system couplings is available onthe CD ROM. Detailed information on theMODBUS and PROFIBUS can be found in thespecialized literature, e.g. MODBUS ProtocolReference Guide (from: AEG SchneiderAutomation Essen), PROFIBUS DPSchnelleinstieg or the TechnischeDruckschrift PROFIBUS (from: PROFIBUSNutzerorganisation Karlsruhe). GSD (basicdevice data) files that allow a high speedlinkage of the SLAVES from various manu-facturers with the PLC or DCS are suppliedfor the FB Remote I/O BUS and can be calledup via Internet from the PROFIBUS UserOrganisation.

Address: Http://www.PROFIBUS.com

For Siemens systems we also supply aTYPE file. That file should be deleted forPCS 7, because the GSD file will be morecomfortable for the operator.Bus protocols define the structure of thedata packets that, independent of the busparticipants, are recognized by the transferpaths being used. They describe the way inwhich processors request data from otherdevices how they react to these requests,and how errors are detected and reported.MASTER / SLAVE techniques are used here.The MASTER is the only bus partici-pant thatcan request data from others or issuecommands. The bus protocol deter-mines theset-up of the command struc-tures. The set-up of the data packets for MODBUS andPROFIBUS data protocols are described inthe annex to this manual. Please note that theMODBUS has 2 addressing modes, namelythe MODBUS and the MODICON addressingmodes. TheI/O addresses of the FB Remote I/O BUSmodules described in the chapter MODBUSAddressing must be called up according to

the PLC or DCS being used (see 6.3FB 8202 MODBUS Data Interface).

With the PROFIBUS a GSD (basic devicedata) file allows a high speed connection toyour system. The identification number of theFB Remote I/O BUS file that was issued toCEAG by the PROFIBUS User Organisation toallow the unmistakable identification ofSLAVES from several manufacturers duringoperation is: 0710 HEX (file CEAG0710.GSD).The PROFIBUS knows 3 protocols. ThePROFIBUS DP is designed for the high speeddata exchange from the sensor / actuatorlevel to MASTER / SLAVEoperation. A multi-master operation is onlypossible if they form independent subsys-tems that are allocated to a DPM1 master.The PROFIBUS FMS (field message specifi-cation) allows the intercommunication ofautomation devices, as well as the communi-cation of automation devices with intelligentfield devices. Multi-master operation ispossible here. The multi-master capacityrequires a protocol structure that is consid-erably more extensive than that of thePROFIBUS DP and, therefore, with the sametiming-pulse rate on the bus, it results inlonger cycle times. PROFIBUS PA withintrinsically safe field bus devices requiresan appropriate intrinsically safe supply unit.However, due to the explosion protection,the transmission rate for the Exi field busand the number of participants is extremelylow.

During commissioning it is advisable not tocommission all the SLAVES at one time, butto connect the participants with the masterone after the other. A commercially availablebus monitor that can listen in on the bustelegrams as a passive participant isrecommended for error analysis. FB RemoteI/O BUS stations receive their addresses viathe service bus (works setting Address 1).The I/O modules are to be determined relativeto the station address in accordance withthe annex. LEDs on the front of the buscoupler indicate data transmission. If, whena SLAVE is called up, no yellow LED of thebus coupler lights up (blinks), the transmis-sion line of the master is interrupted (inter-face fault in the master or cable fault). Ifcommunication cannot be established, it ispossible that the wrong station address wasgiven. It is also possible that the terminatingresistor of the bus is not connected, or thatnon-approved branch lines were installedinstead of short T-junctions.

When installing the bus, take care that thereis no confusion of the transmitting and thereceiving lines RTD-P and RTD-N (see 2.1.2RS 485 Bus). The result of this could be thatthis SLAVE cannot be reached, but all others.If confusion occurs during the looping ofterminals, all the subsequent participantsalso cannot be reached. Pay attention to thefact that the parameters or configuration ofthe MASTER and SLAVE match and that thecorrect identification number has beenselected. In the case of PROFIBUS applica-

32

tions, the FB Remote I/O helps you to set thecorrect configuration if you call up the DPconfiguration string in the menu (Fig. 58).The definitions listed in the annex apply here,e.g. 10 = digital input, 51 = count input, 60 =analogue input, etc. Set the station con-figuration with your master configurationsoft-ware with the aid of the GSD (basicdevice data) file. With Siemens systems youcan use the TYPE file supplied together withthe FB Remote I/O Manual. That file should bedeleted for PCS7, because the GSD file ismore comfortable for the operator.

A common cause of faults is the absence ofterminating resistors at the start and the endof the bus (accessories: terminating resis-tors). It is also important that the polling cycleof the master and the time-out (watch-dog)of the slave match. (Set time-out of PLC orDCS).

The various process control and program-mable control systems have their own datastructures that can be adapted in an optimumway to the FB Remote I/O slaves with the aidof software marshalling (see Section 5Software Marshalling).

Siemens TELEPERM systems can, forexample, process only 32 bytes input dataand 32 bytes output data per SLAVE.

However, the accuracy of analogue circuitsrequires the transfer of 2 bytes per channel,i.e. in this case only 16 analogue inputs canbe used in a FB Remote I/O station. Mixedinstallations can be planned with the aid ofthe data in the annex. The data volumerequired per module is described in Section 5Software Marshalling.

For communication via serial interfacesFisher Rosemount forms 31 data blocks thatcan be adapted to the station set-up. The FBRemote I/O software marshalling can beused to utilize these 31 blocks to the full, asthis makes it possible to combine analogueand digital circuits. Without this softwaremarshalling it would be necessary to form 4groups made up of analogue inputs, ana-logue outputs, digital inputs and digitaloutputs within the hardware of a bus station.The sequence of the modules of a stationwould then no longer be arbitrary in the waythat is actually made possible by the FBRemote I/O.

NOTE: If you use the software marshalling,you should assign free spaces for laterextensions. Otherwise, when new modulesare added, the marshalling addresses shiftand make it necessary to change theparameter settings of the PLC or DCS.

Fig. 58

33

How to Configure I/OModules

3.01 IntroductionBelow, the adaptation of the module andoutput signals is described in detail with thehelp of standard bus systems which havealready been successfully coupled in manyinstalla-tions with different systems viaPROFIBUS DP and MODBUS.In the case of digital inputs which arelocated in the same station with digitaloutputs you can use the economicallypriced combimodule FB21XX which offersinputs and outputs at one plug position.On request, both a double bus coupler anda double power supply for the bus couplerare available. This is a special advantage ofthe CEAG concept.All I/O modules have the monitoring connec-tions for lead breakages and short circuitsstated in the data leaflet. Disturbances of thetransmitter which can be recognised byleaving the measuring range, are also rec-orded. The status information can be calledup via the bus.The terminals for the input/output circuitshave been developed as screw-plug con-nectors of the PHOENIX COMBICON sys-tems. On request, terminals with cage clampconnectors are available.All types as per norm DIN 19245 are suitableas bus cables.

3.02 Module ReplacementAll modules can be replaced during opera-tion. Status information on binary inputs andoutputs is recognisable by front LEDs on themodules.The components are to a major extent main-tenance free. Replacement devices arepluggable and self configurating. Alignmentand address setting are not necessary. Thesoftware supports the maintenance per-

3

sonnel by means of assistance informationon the nature of a defect.The modularity of the system allows simpleextendibility even in small units.An extension of the installation is possibleduring operation if this function is supportedby the master system or by the memoryprogrammed control system. Furthertechnical data are contained in thehandbook and the catalogue.All I/O modules can be adapted to specifictasks. When a module is replaced, the set-ting of the predecessor is automaticallytransferred to the new unit. Therefore adjust-ments or recalibration have become a thingof the past (no address settings required).Therefore modules cannot be mounted inthe wrong position.Additional information can be entered foreach module. This data can only be storedon file, not in the bus coupler or theI/O module. However, when the station isbeing loaded from the field, it can bereallocated to the original configuration perfile access.

3.03 Signal ProcessingThe measured values are kept available witha high data rate in a memory for delay freecall up by the master system. The refreshingof the data is carried out with a station fullyequipped with 48 plug positions accordingto figure 59.Details can be seen in the descriptions ofthe individual modules.The signal processing is carried out more orless simultaneously for all modules, howevernot synchronised. Monitoring for wire break-age and short circuits can be activated perinput and output.

Input / output Signal Form of signal Typical conversion

Binary input Switching position, valve position, etc. NAMUR, contact < 5ms

Binary output Solenoid valve, detector, etc active, V, mA < 5 ms

Analogue input Pressure, head mounted transmitters, 4-20mA < 20 msThroughflow, analysis, etc.

Analogue output I/P converter, position regulator 4-20mA < 20 ms

Temperature Pt100, thermocouples W, mV < 100 ms

Fig. 59

34

3.04 Functional SafetyIf required, bus couplers are supplied withredundant auxiliary energy. For each I/O mod-ule a feed component is available. In this waya high availability is ensured.The structural components can be assem-bled horizontally or vertically.The failure of one bus station does not impedeother bus stations. After return of the auxil-iary energy of a bus station this is auto-

Fig. 61

Fig. 60

matically reset and restarted.All structural components are earth free.There is a secure galvanic separation to thefield side and to the mains. The I/O circuitsare decoupled against earth and againstEMC effects by suppressor capacitors. Thedevices bear the CE identification. A doublepower supply is possible (Figs. 60 and 61).

Field station with 48 slotswith redundancy

2 x 24 VDCextention stationcommon zero line

mai

ns s

uppl

y

24 VDCbasis stationcommon zero line

bus

coup

ler

mai

ns s

uppl

y

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

PE x1.3

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

24 VDCredundancycommon zero line

busc

oupl

er

mai

ns s

uppl

y

mai

ns s

uppl

y

+ -+ -+ -

Field station with 48 slotswith redundancy

2 x 230 Vextention station

230 Vbasis station

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

PE x1.3

230 Vredundancy

mai

ns s

uppl

y

bus

coup

ler

mai

ns s

uppl

y

busc

oupl

er

mai

ns s

uppl

y

mai

ns s

uppl

y

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

35

3.1 FB 1201 Digital InputThe digital input module FB 1201 interfacesthe process signals of mechanical contacts,NAMUR initiators, or opto-couplers with theDCS or PLC. The device features 2 channelsthat are independent of the bus and gal-vanically isolated from each other.

Each channel is individually fitted with a linemonitoring feature to test for open or shortcircuits. This monitoring function can be de-activated with the software. With mechanicalcontacts either the line monitoring is de-activated or the switch must be wired to aresistor combination to emulate a NAMURinitiator. Only then is it possible for the elec-tronics to distinguish between a closed con-tact and a short circuit (see figure 62). Theresistor network is available as an acces-sory.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.Red LEDs indicate the state of the field ca-bles. They light up in the event of a short oropen circuit. Yellow LEDs indicate theswitching status of digital inputs. The greenLED, the red LED of channel 1 and, if appli-cable, the yellow LED of channel 1 arevisible in the front window of the modules.For explosion protection reasons it is notpossible to display more LEDs.The maximum input frequency is 100 Hz perchannel if supported by the master. Forfrequency measurements see FB 1203.

3.1.1 How to Configure Digital InputsWhen you select the input module FB 1201you will see the following device spec sheet(Fig. 63). The module can now beconfigured.

2.2kW

10kW

FB Remote I/O

Fig. 62

Notes for menu Switch Amplifier FB 1201(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physi-cally or it is not to be included in thedata acquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) in channel 1indicating the status of the field wiring(OK or fault).

(6) Line monitoring (LFD) in channel 2indicating the status of the field wiring(OK or fault).

(7) Here you can activate or deactivate theline monitoring (LFD) feature.

(8) Space for notes and remarks concer-ning the respective measuring point.

(9) Number of the slot which is currentlybeing configured.

(10) Press OK to store the parametersetting.

(11) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. Thiscommand returns you to the mainmenu without registering any changes.

(12) LOAD allows you to load existingconfigurations from the disk or thehardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore theoriginal parameter settings whilestaying with the present configurationwindow.

(15) Call up HELP.(16) Interpretation of the input contact as

logical 0 or 1.(17) Set input and status values for test

purposes during service and commis-sioning.

(18) TAG no. per channel.

10

11

12

13

14

17

1

2

3

4

5

6

7 16

15

Fig. 63

918

8

36

3.2 FB 1202 Digital InputThe digital input module FB 1202 interfacesthe process signals of mechanical contacts,NAMUR initiators, or opto-couplers with theDCS or PLC. The device features 3 channelsthat are independent of the bus and are gal-vanically isolated. The field circuits have acommon negative potential.

Each channel is individually fitted with a linemonitoring feature to test for open or shortcircuits. This monitoring function can be de-activated with the software. With mechanicalcontacts either the line monitoring is de-activated or the switch must be wired to aresistor combination to emulate a NAMURinitiator. Only then is it possible for the elec-tronics to distinguish between a closedcontact and a short circuit (see figure 64).The resistor network is available as anaccessory.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.Red LEDs indicate the state of the field ca-bles. They light up in the event of a short oropen circuit.Yellow LEDs indicate the switching status ofdigital inputs. The green LED, the red LED ofchannel 1 and, if applicable, the yellow LEDof channel 1 are visible in the front window ofthe modules. For explosion protection rea-sons it is not possible to display more LEDs.

The maximum input frequency is 100 Hz perchannel if supported by the master. Forfrequency measurements see FB 1203.

Fig. 64

10kW 2.2kW

FB Remote I/O

3.2.1 How to Configure Digital InputsWhen you select the input module FB 1202you will see the following device spec sheet(Fig. 65). The module can now be configured.

Notes for Switch Amplifier FB 1202(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) in channel 1indicating the status of the field wiring(OK or fault).

(6) Line monitoring (LFD) in channel 2indicating the status of the field wiring(OK or fault).

(7) Line monitoring (LFD) in channel 3 in-dicating the status of the field wiring (OKor fault).

(8) Here you can activate or deactivate theline monitoring (LFD) feature for channel1, 2 or 3.

(9) Space for notes and remarks concer-ning the respective measuring point.

(10) Number of the slot which is currentlybeing configured.

(11) Press OK to store the parametersetting.

(12) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(13) LOAD allows you to load existingconfigurations from the disk or thehardware.

(14) SAVE allows you to store configurationson a disk or in the hardware.

(15) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(16) Call up HELP.(17) Interpretation of the input contact as

logical 0 or 1.(18) Set input and status values for test

purposes during service and commis-sioning.

(19) TAG no. per channel.

1

2

3 19 10

11

12

13

14

15

18

4

56

7

17

8

916

Fig. 65

37

Frequency MeasurementsFrequencies from 1mHz to 15 kHz are mea-sured. The result of the frequency measure-ment is transferred as an integer value with0.1 % accuracy to the bus coupler. De-pending on the frequency measured, newresults are registered here from every 5 ms(200 Hz) to every 1000 ms (1 Hz). The frequen-cy is measured using the internal 16 MHzquartz crystal to measure the time thatelapses between 2 pulses. The shortestpulse duration is 20 ms.

Direction of Rotation (Up / down counter)The second digital input allows you to detectdirection of rotation by registering the phaseshift between the 2 pulses. The result istransferred to the bus coupler as a statusbit. In this respect the maximum countingfrequency is 1000 Hz. In figure 67 function 5is explained when two sensors transmit aphase displaced signal to the module.If the channel 1 impuls input is logical 1 andat the same time the direction of rotationinput is logical 0, than counting goesforward. If the channel 1 impuls input islogical 1 and the direction of rotation input islogical 1, than counting goes backward.

Pulse CounterThe counting direction is determined by theswitch position of input 2:Contact closed = upwards,Contact open = downwards.When configured as a pulse counter themodule has a 4 byte counter to count up to109 with pulse rates up to 15000 pulses persecond. You can pre-set the counter at agiven value using the system bus. When theSTART bit is set, the counter starts to work,starting from 0.A status bit will tell you when the presetvalue has been reached. The status bit isnot reset until the counter is restarted viathe bus. This allows you to build dosingsystems (FB 220X).The frequency can be measured at thesame time and transmitted as measuredvalue.

Remark:In redundant systems both comm units willregister the pulse count. However if youremove or power down one of them thememory contents of the counter in thatcomm unit will be lost.

3.3 FB1203 Digital InputThe digital input module FB 1203 interfacesthe process signals of mechanical contacts,NAMUR initiators, or opto-couplers with theDCS or PLC. The device features 2 chan-nels. One channel is designed to determinethe direction of rotation or the direction ofcounting - up or down.

The device can be used to perform thefollowing tasks:1) Frequency measurements up to 15 kHz.2) Frequency measurements with pulse

counting to 50 Hz.3) Frequency measurements with deter-

mining direction of rotation to 15 kHz.4) Frequency measurements with deter-

mining direction of rotation and pulsecounting to 50 Hz.

5) Pulse counting to 15 kHz (109).6) Pulse counting with determining direction

of rotation ( counter forward andbackward to 15 kHz).

The module features a line monitoring featureto test for open or short circuits. This optioncan be deactivated in the software. Withmechanical contacts either the line monito-ring is deactivated or the switch must bewired to a resistor combination to emulate aNAMUR initiator. Only then is it possible forthe electronics to distinguish between aclosed contact and a short circuit (see figure66).

The input is interrupt-controlled so that nopulse is lost.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.Red LEDs indicate the state of the field ca-bles. They light up in the event of a short oropen circuit.

NOTE: In the frequency mode themeasured value will be zero until the first twopulses have been registered. In live zerosystems (ranges 10 000 - 50 000) this willlead to a negative result.

Fig. 67

Fig. 66

-

CH 1 Richtung

-1 2 3 4 5 6

Local Bus

Direction

10kW

2.2kW

FB Remote I/O

Direction of rotation

Binary input LB / FB 1X03

ch1

Rtg.backward

ch1

Rtg.

1

0 forward

direction

2.2 kW10 kW

38

3.3.1 How to Configure Digital InputsWhen you select the input module FB 1203you will see the following device spec sheet(Fig. 68). The module can now be configured.

Notes for menu Counter / FrequencyConverter FB 1203(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE config.).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) The number of the slot being configured.(7) Here you can activate or deactivate the

line monitoring (LFD) feature.

18

(8) Set the delay to elapse until a line faulthas been accepted as rectified.Determination of the measured value(burn-out drive).

(9) Selection of the operating mode(frequency measurement, determinationof direction of rotation, pulse counter)

(10) Start and end of measurement forfrequency measurement. Counter valuefor setting the status bit (dosing).

(11) Activates the time filter.(12) Press OK to store the parameter setting.(13) LOAD allows you to load existing confi-

gurations from the disk or the hard-ware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(16) SAVE allows you to store configurationson a disk or in the hardware.

(17) Call up HELP.(18) Space for notes and remarks concer-

ning the measuring point.(19) Set input and status values for test pur-

poses during service and commissio-ning.

Fig. 68

1

2

34

5

6

7

9

8

10

11

12

13

14

15

16

17

19

39

3.4 FB 220X Digital OutputThe digital output FB 220X interfaces theDCS and PLC systems with solenoid valves,acoustic sounders or optical alarms (LEDs).The module features 1 output channel and 2status inputs which respond in the sameway as those of the digital input moduleFB 1202.

The module can be used for the followingpurposes:

- Solenoid valve driver- Lamps and acoustic alarms- Processing digital inputs

for NAMUR or mechanicalcontacts independent of thevalve circuit.

The valve driver and the digital inputs fea-ture a line monitoring mode for indicatingopen or short circuits. The option can be de-activated in the software. With mechanicalcontacts you can either deactivate the linemonitoring mode or the contact can be con-nected to a resistor combination to emulatea NAMUR initiator. This is to enable the elec-tronics to distinguish between a closed con-tact and a short (Fig. 69). The valve circuit ismonitored by means of a current pulse thatis so short that a connected valve does notrespond.

The monitoring of the valve circuit is notpossible in all cases if booster valves areused since these valves have a storagecapacitor which constitutes a short circuitwhen switched off. In such cases de-pending on the valve, a parallel resistance of10 kW can open line monitoring even forbooster valves. Should the line monitorcontinue to indicate a fault it must bedeactivated. Dedicated digital outputs areavailable to drive LED displays (see ordercode).

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.A red LED indicates the monitoring status ofthe field cables. It lights up in the event offaults in the field cables.Yellow LEDs indicate the status of the digitalinputs. For explosion protection reasons theyellow LEDs cannot be displayed in everycase.

There are 14 device options for operatingintrinsically safe solenoid valves. Thesecover more than 100 different commerciallyavailable valves from various manufacturersincluding: SAMSON, HERION, SEITZ,BÜRKERT, TELEKTRON, HONEYWELL,ASCO, RGS etc.

The digital output can be assigned locally toanalogue or digital inputs for the following

10kW

2.2kW

FB Remote I/O

applications:- Local connection to a temperature input

or converter /supply circuit, e.g. for two-position control.

- Local connection to a binary input forsignal amplification.

- Local connection to the pulse counterFB 1203 for creating a dosing system.

You determine which slot the digital output isto be connected to locally and what kind ofconnection you want it to be, analogue ordigital. Analogue connections allow you toset a switching point. Digital connectionsallow you to activate the line monitoring fea-ture of an input, the live ZERO monitor orother status bits.

A local connection has priority over controlsfrom the DCS or PLC system. With activelocal connections a setting of the out-put forservice purposes is also blocked.

3.4.1 Calculation of a Valve CircuitWhen connecting the valve control module tothe solenoid valve from one of the manu-facturers named above, it is necessary tocarry out calculations based on both meas-urement technique and safety factors.

Example 1: HERION 2035:

The internal resistance of the valve at anambient temperature of 65 °C is 458 W.A minimum of 13.8 V are necessary foractivation. In accordance with PTB No.Ex-95.D.2178 the safety ratings are 28 Vand 120 mA .The valve control module FB 2112 has a no-load voltage during operation of 25.3 V andan internal resistance of 329 W. In accor-dance with PTB No. Ex-95.D.2163 the safetyratings are 27.8 V and 110 mA.

Therefore, the safety data allow an intercon-nection.

The basic circuit layout is shown in figure 70.

The operating current isI = 25.3 V / (329 + 458) W = 32 mA

The voltage drop at the internal resistor ofthe valve control module allows a controlvoltage of

U = 32 x 458 mV = 14.7 V

Therefore, with regard to measurementtechnique factors, interconnection ispossible as a minimum voltage of 13.8 V isrequired.These considerations can be repeated forother valves.

Fig. 69

Fig. 70

458 Ω

329 Ω = Ra

25,3 V= Uo

40

(8) Space for notes and remarks con-cerning the measuring point.

(9) With a local connection you can deter-mine whether an analogue value ora digital input is to be responsible foractivating the valve control output andwhether it is normal or inverse.

(10) For connections with an analogue valueset the switching point here.

(11) The number of the slot being configured.(12) Press OK to store the parameter setting.(13) LOAD allows you to load existing config-

urations from the disk or the hardware.(14) RESET allows you to restore the original

parameter settings while staying with thepresent configuration window.

(15) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. This com-mand returns you to the main menuwithout registering any changes.

(16) SAVE allows you to store configurationson a disk or in the hardware.

(17) Call up HELP.(18) Set input and status values for testing

purposes during servicing and commis-sioning.

(19) Interpretation of the input contact as lo-gical 0 or 1.

(20) TAG no. per channel.

3.4.2 How to Configure Digital OutputsWhen you select the output module FB 220Xyou will see the following device spec sheet(Fig. 71). The module can now be configured.

Notes for Solenoid Valve Driver FB 2212(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (digital inputs/outputs OK or faulty).

(6) Here you can activate or deactivate theline monitoring (LFD) feature.

(7) Here you can activate a localconnection to an input module.

19

113

2

1

4

5

6 7

8

9

10

12

13

14

18

15

16

17

Fig. 71

41

3.4.4 Interconnection with an LEDsignal lampThe LED indicators GHG 418 2101 R 0001are passive, intrinsically safe components toEN 50020. Components of this naturerequire no special official admission if theintrinsic safety of the circuit is guaranteed.The interconnection with our binary outputmodules FB 2204 and FB 2213, whichcontain module LB 2101 and LB 2104certified to Ex-95.D.2163 is admissible. Inthe Instruction Manual FB 92. of the field busdevices you will find the ratings for theintrinsic safety. In accordance with ECdesign examination certificate PTB 97 ATEX1074 U, the structural components are setout and certified.The following calculations figure 73 apply.

The resistance incorporated in the signallamps restricts the operating current to safevalues.For the length of the leads, ratings of thebinary output can be used since thepassive IS LED component does notintroduce any additional currents or voltagesand no inductances and capacities into thecircuit.The control components FB 2204 or FB 2213are suitable for application withGHG 417 2101 R 0001 (Fig. 74).

Note: valve control components send out atest impulse in second cycles for monitoringthe lead. The switched off LED thereforeflashes on briefly every second. This alsoapplies if the lead monitoring is switched off.For this application use the component withthe corresponding order number withoutlead monitoring. Here, the test impulse isswitched off ex-works.

3.4.3 Dosing System using ValvesWhen using the valve control output forbuilding dosing system, the following timesequence results:1) Set the START bit and reset the counter

using the bus in module FB 1203.2) Release of the valve after recognition of

the status bit in FB 1203 by the valvemodule.

3) Integration of the counter pulses inmodule FB 1203.

4) The preset counter value has beenreached and the status bit set.

5) Cutting-off of the valve after recognitionof the status bit in FB 1203 by the valvecontrol module.

When fitted with 48 I/O modules and in theworst case condition, the valve controlmodule cuts off the valve with a maximumtime delay of 14 ms (Fig. 72). This results in anoverlap of 3 pulses at 200 Hz. In the case ofa station that is only fitted with 24 modules, thetime delay is reduced to (1+2x2+3)ms=8ms.The time delay is based on: a response timeof 1 ms for module FB 1103, plus 2 buscycles at 5 ms each with 48 participants,plus a reaction time of 3 ms for the valvecontrol module.

The counter of the input module FB 1103has a counting range up to109 that can beread by the valve control module. The buscoupler itself can only count up to 216. If thedosing is not local but controlled via thesystem bus, the bus coupler must beinterrogated by the master often enough.The response time and, therefore, theaccuracy of the dosing is clearly better witha local connection.

Fig. 72

3

(1+2x5+3)ms

1

2

(1+2x5+3)ms

4

5

LB1103

LB2101

FB 1203

FB 2201

Digital output LED signal lamps FB 2XXX GHG 417 XXXX R XXXX

Fig. 74

RiUo

Operating data 19 V 25 mAInner resistance 1 kW

Maximum values of the binary output FB 2204 24.2 V 146 mAOperating values 22 V 220 WOperating current with LED signal I = Uo / (Ri + R)

I = 22 / (220 + 1000) = 18.03 mAU = 18.03 V

Maximum values of the binary output FB 2213 28.7 V 70 mAOperating values 26.7 V 509 WOperating current with LED signals I = Uo / (Ri + R)

I = 26.7 / (509 + 1000) = 17.69 mAU = 17.7 V

Fig. 73

42

Fig. 76

FB Remote I/O

Fig. 75

The device has a built-in line monitoringfeature for the detection of open and shortcircuits. The feature can be activated or de-activated in the software. You can set theswitch points at < 1 mA or > 21 mA.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.Red LEDs light up in the event of faults in thefield cables.A yellow LEDs lights up when the inputsignal goes below the LIVE ZERO level. Dueto explosion protection reasons the yellowLED cannot be displayed in every case.

3.5.1 How to Configure Analogue InputsWhen you select the input module FB 3201you will see the following device spec sheet(Fig. 76). The module can now be configured.

Notes for Transmitter Power SupplyFB 3201(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) Status of the live zero signal (OK orfaulty).

(7) Here you can activate or deactivate theline monitoring (LFD) feature.

(8) Space for notes and remarks con-cerning the measuring point.

(9) The number of the slot being configured.(10) Press OK to store the parameter

setting.(11) Press CANCEL if you want to restore

the original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(12) LOAD allows you to load existing confi-gurations from the disk or the hardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) Call up HELP.(16) Set input and status values for test

purposes during servicing andcommissioning.

3.5 FB 3201 Analogue Input,Transmitter Power Supply, InputIsolatorThe analogue input FB 3201 interfaces thePLC and DCS with the processing signalsfrom pressure and differential pressuretransmitters, sensor transmitters and re-motely powered analysers, flow and levelgauges etc.

For transmitter supply applications useterminals 2 or 3(+) and 4 or 5(-).

For transmitter supply applications involving3-wire transmitters use terminals 2/3(+)(supply), 4/5(+) (return), 6(-).

Applications as input isolators for remotelypowered devices use terminals 4/5(+) and6(-) (Fig. 75). The input resistance is 15 W.

HART hand control units with a Certificate ofConformity use terminals 3(+) and 4(-).Communication via the bus is also possiblewith the aid of the HART supply isolatorstypes FB 3202 and FB 3203.

Features:Supply voltage 14.5 VOpen circuit voltage 24 V (Ex i)Short-circuit current 90 mA (Ex i)

The unit offers a minimum supply voltage of14.5 V at 20 mA. Up to this maximum valuethe voltage adapts itself to suit the requirements of the field device.

Input signals of 0-25 mA are converted witha 12 Bit resolution. This results in an 11 Bitresolution for a signal range of 4-20 mA or0-100 % (better 0.1 %). The conversion timefor the suppression of ripple voltages is ca.20 ms.

1

2

3

45

6

9

7

8

10

11

12

13

14

16

15

43

3.6 FB 3202 Analogue Input, HARTTransmitter Power Supply, InputIsolatorThe analogue input FB 3202 interfaces thePLC and DCS with the processing signalsfrom pressure and differential pressuretransmitters, sensor transmitters andremotely powered analysers, flow and levelgauges etc.

Fig. 77:(1) For transmitter supply applications use

terminals 2 or 3(+) and 4 or 5(-).

(2) For transmitter supply applicationsinvolving 3-wire transmitters useterminals 2/3(+) (supply), 4/5(+) (return),6(-).

(3) For applications as input isolators foractive signals from the field useterminals 4/5(+) and 6(-). The inputresistance is 15 W.

HART hand control units with aCertificate of Conformity can beconnected at terminals 3(+) and 4(-).Communication is also possible usingthe service bus. The 250 W communica-tion resistance is built in.

(4) HART field devices which are externallypowered and produce active 20 mA,have to be connected to the terminals1(+) and 6(-). The 250 W communicationresistance is built in. Input resistance265 W.

Features:Supply voltage 16.5 VOpen circuit voltage 27.1 V (Ex i)Short-circuit current 93 mA (Ex i)

The unit offers a supply voltage of 16.5 V at20 mA. The voltage adapts itself to suit therequirements of the field device. When theload is reduced to 4 mA, the supply voltageincreases to about 22 V.

Input signals of 0 - 25 mA are converted witha 12 Bit resolution. This results in an 11 Bitresolution for a signal range from 4 - 20 mAor 0 - 100 % (better 0.1 %). The conversiontime for the suppression of ripple voltages isca. 20 ms.The device has a built-in line monitoringfeature for the detection of open and shortcircuits. The feature can be activated ordeactivated in the software. You can set theswitch points at < 1mA or > 21mA.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.Red LEDs light up in the event of faults in thefield cables.A yellow LEDs lights up when the input signalgoes below the LIVE ZERO level. Due toexplosion protection reasons the yellow LEDcannot be displayed in every case.

3.6.1 HART Communication for FB3 2 0 2Field devices that can be remotely activatedwith the HART protocol can be addressedvia the service bus. The software interfaceseasily with the software supplied by theHART transmitter manufacturer. All thefeatures available there are accessible withthe HART protocol via the service bus.HART communication is also possible on thedevice terminals with the help of approvedmanual operation devices of the field devicemanufacturers (HHC). The250 W communication resistance is built in.(Some Krohne transmitters use an inverseparity bit, this is not HART conform. Theycan only be set via Krohne manual operationdevices. Following completion, a brief resetof the Krohne apparatus is necessary byinter-rupting the feed circuit.)

Fig. 77

1

2

3

4

FB Remote I/O

HART

FB Remote I/O

44

(6) Status of the live zero signal (OK orfaulty).

(7) Here you can activate or deactivate theline monitoring (LFD) feature.

(8) Space for notes and remarks concer-ning the measuring point.

(9) The number of the slot beingconfigured.

(10) Press OK to store the parametersetting.

(11) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(12) LOAD allows you to load existing confi-gurations from the disk or the hardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) Call up HELP.(16) Set input and status values for testing

purposes during servicing and com-missioning.

3.6.2 How to Configure Analogue InputsWhen you select the input module FB 3202you will see the following device spec sheet(Fig. 78). The module can now be configured.

Notes for Transmitter Power SupplyFB 3202(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATION-MODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

Fig. 78

1

2

3

45

6

7

10

911

12

13

14

16

15

8

45

Input signals of 0 - 25 mA are converted witha 12 Bit resolution. This results in an 11 Bitresolution for a signal range of 4 - 20 mA or0 - 100 % (better 0.1 %). The conversiontime for the suppression of ripple voltages isca. 20 ms.

The device has a built-in line monitoring fea-ture for the detection of open or short circuits.The feature can be activated or deactivatedin the software. You can set the switch pointsat < 1 mA or > 21 mA.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.Red LEDs light up in the event of faults in thefield cables.A yellow LEDs lights up when the inputsignal goes below the LIVE ZERO level. Dueto explosion protection reasons the yellowLED cannot be displayed in every case.

3.7.1 HART Communication for FB3 2 0 3Field devices that can be remotely activatedwith the HART protocol can be addressedvia the service bus. The software interfaceseasily with the software supplied by theHART transmitter manufacturer. All thefeatures available there are accessible withthe HART protocol via the service bus.HART communication is also possible on thedevice terminals with the help of approvedmanual operation devices of the field devicemanufacturers (HHC). The 250 Wcommunication resistance is built in. (SomeKrohne transmitters use an inverse paritybit, this is not HART conform. They can onlybe set via Krohne manual operation devices.Following completion, a brief reset of theKrohne apparatus is necessary byinterrupting the feed circuit.)

3.7 FB 3203 Analogue Input, HARTTransmitter Power Supply, InputIsolatorThe analogue input FB 3203 interfaces thePLC and DCS with the processing signalsfrom pressure and differential pressuretransmitters, sensor transmitters andremotely powered analysers, flow and levelgauges etc.

Fig. 79:(1) For transmitter supply applications use

terminals 2 or 3(+) and 4 or 5(-).

(2) For transmitter supply applicationsinvolving 3-wire transmitters useterminals 2/3(+) (supply), 4/5(+) (return),6(-).

(3) Applications as input isolators for activesignals from the field use terminals 4/5(+) and 6(-). The input resistance is15 W.

HART hand control units withCertificate of Conformity can beconnected at terminals 3(+) and 4(-).Communication is also possible via thebus. The 250 W communicationresistance is built in.

(4) HART field devices which are externallypowered and produce active 20 mA,have to be connected to the terminals1(+) and 6(-). The 250 W communicationresistance is built in. Input resistance265 W.

Features:Supply voltage 14.5 VOpen circuit voltage 24 V (Ex i)Short circuit current 74 mA (Ex i)

The unit offers a minimum supply voltage of14.5 V at 20 mA. The voltage adapts itself tosuit the requirements of the field device.

Fig. 79

1

2

3

4

FB Remote I/O

HART

FB Remote I/O

46

3.7.2 How to Configure Analogue InputsWhen you select the input module FB 3203you will see the following device spec sheet(Fig. 80). The module can now be configured.

Notes on Analogue Inputs FB 3203(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) Status of the live zero signal (OK orfaulty).

(7) Here you can activate or deactivatethe line monitoring (LFD) feature.

(8) Space for notes and remarks concer-ning the measuring point.

(9) The number of the slot beingconfigured.

(10) Press OK to store the parametersetting.

(11) Press CANCEL if you want to restorethe original setting ignoring thechanges that have just been entered.This command returns you to the mainmenu without registering any changes.

(12) LOAD allows you to load existing confi-gurations from the disk or the hard-ware.

(13) SAVE allows you to store configura-tions on a disk or in the hardware.

(14) RESET allows you to restore theoriginal parameter settings whilestaying with the present configurationwindow.

(15) Call up HELP.(16) Set input and status values for testing

purposes during servicing and com-missioning.

Fig. 80

1

2

3

4

56

9

7

8

15

16

14

13

12

11

10

48

3.8.3 How to Configure AnalogueOutputsWhen you select the output module FB 4201you will see the following device spec sheet(Fig. 83). The module can now be configured.

Notes on Output Isolator FB 4201(1) The model number of the module is

entered automatically. Even though theinactive module is described, it does notexist physically or it is not to be includedin the query.

(2) TAG-No. or measuring point numberwith up to 20 characters.

(3) With a non-active module it is possiblefor the complete station to functionwhile the inactive module is pre-configured but not physically present.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) Status of the live zero signal (OK orfaulty).

(7) Here you can activate or deactivate theline monitoring (LFD) feature.

(8) Space for notes and remarks con-cerning the measuring point.

(9) The number of the slot beingconfigured.

(10) Press OK to store the parametersetting.

(11) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(12) LOAD allows you to load existing confi-gurations from the disk or the hardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) You can set input and status valuesfor servicing and commissioning pur-poses.

(16) Call up HELP.

7

1

2

3

4

5

9

6

8

10

11

12

13

14

15

16

Fig. 83

49

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.Red LEDs light up in the event of opencircuits in the field cables or as long as theoutput current is < 0.1 mA.

3.9.1 HART Communication for FB4 2 0 2You can address field devices which usethe HART protocol via the service bus. Thesoftware interfaces easily with the softwaresupplied by the HART transmitter manufac-turer. All the features available there becomeaccessible via the service bus with theHART protocol.

3.9.2 Local Connections for FB4 2 0 2Analogue outputs can be used to establishlocal connections:

with a temperature input or a transmittersupply circuit,to indicate measured values locally orduplicate signals,to accommodate discrete controllers, orconnect a second PLC.

You decide which slot the analogue output isto be connected to locally. A local connectionhas priority over controls from the DCS orPLC system. With active local con-nectionsa setting of the output for service purposesis also blocked.

3.9 FB 4202 Analogue Output,HART Output IsolatorThe analogue output FB 4202 interfaces PLCor DCS systems with process control out-puts for positioners, I/P converters, propor-tional valves, and local indicators (Fig. 84).

Output isolators use terminals 2 or 3(+) and4 or 5(-).

HART hand control units with Certificate ofConformity can be connected at terminals3(+) and 4(-). Communication is alsopossible via the service bus.

Features:Output load 800 WOpen circuit voltage 27.3 V (Ex i)Short-circuit current 87 mA (Ex i)

The unit offers a minimum output voltage of16 V at 20 mA. The voltage adapts itself tosuit the requirements of the field device.

Output signals of 0 - 25 mA are convertedwith a 12 Bit resolution. This results in an11 Bit resolution for a 4 - 20 mA signalcorresponding to 0 - 100 % (better 0.1 %).Minimum current is 1 mA. The device offersa built-in line monitoring feature for thedetection of open circuits. The feature canbe activated or de-activated in the software.Currents < 0.1 mA will be interpreted asopen circuits. A lead short circuit cannot berecorded due to the non-linear behaviour ofthe voltage requirement of modern HARTpositioners.

FB Remote I/O

Fig. 84

50

3.9.3 How to Configure AnalogueOutputsWhen you select the output module FB 4202you will see the following device spec sheet(Fig. 85). The module can now be configured.

Notes for Output Isolator FB 4202(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) Here you can activate or deactivate theline monitoring (LFD) feature.

(7) You can logic link the analog output withthe analog input.

(8) Space for notes and remarks con-cerning the measuring point.

(9) The number of the slot being configured.(10) Press OK to store the parameter

setting.(11) Press CANCEL if you want to restore

the original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(12) LOAD allows you to load existingconfigurations from the disk or thehardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) You can set input and status valuesfor servicing and commissioning pur-poses.

(16) Call up HELP.

1

2

3

4

5

9

76

8

10

11

12

13

14

15

16

Fig. 85

51

3.10 FB 4203 Analogue OutputThe analogue output FB 4203 interfaces PLCor DCS systems with process control out-puts for positioners, I/P converters, propor-tional valves, and local indicators (Fig. 86).

Output isolators use terminals 2 or 3(+) and4 or 5(-).

HART hand control units can be connectedat terminals 3(+) and 4(-).

To realize HART communication via servicebus please use FB 4202.

Features:Output load 400 WOpen circuit voltage 12.6 V (Ex i)Short circuit current 80 mA (Ex i)

The unit offers a drive voltage of 8 V at20 mA which is self regulating to the remotedevice´s requirements.

Output signals of 0 - 25 mA are convertedwith a 12 Bit resolution. This results in an11 Bit resolution for a 4 - 20 mA signalcorresponding to 0 - 100 % (better 0.1 %).The minimum current for LFD is 1 mA.

The device offers a built-in line monitoringfeature to detect open circuits. The featurecan be activated or deactivated in software.Currents < 0.1 mA are interpreted as opencircuits. Short circuits cannot be recordeddue to the non-linear behaviour of the voltagerequirement of modern HART positioners.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.A red LED lights up in the event of a fault inthe field cables or as long as the outputcurrent is < 0.1 mA.

3.10.1Local Connections for FB4 2 0 3Analogue outputs can be used to establishlocal connections:

to repeat a temperature input or atransmitter supply circuit,to indicate measured values locally orduplicate signals,to accommodate discrete controllers, orconnect a second PLC.

You decide which slot the analogue output isto be connected to locally.

A local connection has priority over controlsfrom the DCS or PLC system. With activelocal connections a setting of the output forservice purposes is also blocked.

3.10.2 How to Configure AnalogueOutputsWhen you select the output module FB 4203you will see the following device spec sheet(Fig. 87). You can now choose the devicespecification.

Notes for menu Output Isolator FB 42031) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) Here you can activate or deactivate theline monitoring (LFD) feature.

(7) You can logic link the analog output withthe analog input.

(8) Space for notes and remarks concer-ning the measuring point.

(9) The number of the slot beingconfigured.

(10) Press OK to store the parametersetting.

(11) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(12) LOAD allows you to load existingconfigurations from the disk or thehardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) You can set the input and status valuesat a given value for servicing andcommissioning purposes.

(16) Call up HELP.

FB Remote I/O

Fig. 86

3

2

1

4

5

6

8

7

9

10

11

12

13

14

15

16

Fig. 87

52

3.11 FB 5201 Temperature ConverterThe Pt 100 transmitter FB 5201 interfacesRTD signals of 2(-), 3(-), and 4-wire sensorswith the PLC or DCS system (Fig. 88).

In 2-wire configuration use terminals 5 and 6.

In 3-wire configuration use terminals 1, 5and 6.

In 4-wire configuration use terminals 1 and 2as well as 5 and 6.

Measuring range 0-400 W (0-600 W whenline resistance is 0 W).Smallest span 20 W.Maximum cable resistance 100 W.Non linearity 0.1 %Sensor current 200 µA.

Temperatures between -200 °C and +850 °Care measured with a resolution of 16 Bit.This leaves an 11 Bit resolution for thesmallest span of 20 W for 0 - 100 % (better0.1 %).

Conversion rate, Cycle time:20 ms without line monitor.125 ms with line monitor.

Measured values are sent to the bus cou-pler once every 5ms independent of theconversion rate. Input signals can be filteredusing a digital PT1 filter adjustable in stepsof:- Without line monitoring (LFD):

40 ms, 80 ms, 160 ms, 320 ms.- With line monitoring (LFD):

250 ms, 500 ms, 1000 ms, 2000 ms.

The device has a line monitoring feature toindicate short or open circuits. The cableresistance does not lead to false measuringresults. The line monitoring option can bedeactivated in the software. Line faults canlead to the following values:0 %, 20 % (4 mA), 100 % (20 mA).A burn-out (LFD) delay can be used to delaythe acceptance of correct results after aburn-out in order to avoid continued changesbetween fault and normal conditions in caseof loose contacts (1 - 250 cycles).

The conversion method can be adjusted to

suppress 50 Hz or 60 Hz noise.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.A red LED lights up in the event of faults inthe field cables.

NO adjustments need be made when repla-cing a module.

3.11.1 Line ResistanceWith 2-wire switching arrangements you canmeasure the line resistance by changingover to resistance measurement andshorting the PT100 sensor. To measure theresistance, call up the measured valuedisplay for the respective measuring point.Using the mouse click on to the input mod-ule. When the right mouse button is double-clicked, the measured value display isactive. Enter the line resistance measured inthis way after the changeover to 2-wiremeasurement for PT100 into the parameterspaces for the line resistance. The maximumpermissible line resistance is 100 W.

As an alternative to the line balancing meth-od described above, it is also possible touse the conventional method. Use a bal-ancing terminal with built-in balancing resis-tor in the feed line to the converter. Set themeasurement input FB 5201 for 2-wirePt100 measurement. With the menu set theline resistance at 20 W. Now replace thePt100 sensor at the location of measurementby a 100 W precision resistor.

Measure the value by calling up the meas-ured value display for the respective meas-uring point. Using the mouse click on to theinput module. When the right mouse buttonis double-clicked, the measured value dis-play is active.Now balance out the value shown to 0° Cusing the balancing potentiometer. Havingdone this, reconnect the Pt100 sensor.

Line balancing is not necessary for 3-wireand 4-wire measurement.

1 2 3 4 5 6

mV

Local Bus

2 Ltr.

3 Ltr.

4 Ltr.

FB Remote I/O

Fig. 88

53

fault condition.(8) Select the sensor, the measuring

method with 2-, 3-, or 4-wire configu-ration and the measuring range.

(9) The number of the slot beingconfigured.

(10) Press OK to store the parametersetting.

(11) Press CANCEL if you want to restorethe original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(12) LOAD allows you to load existingconfigurations from the disk or thehardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) Call up HELP.(16) Suppression of line noise.(17) Temperature scale (°F or °C).(18) Space for notes and remarks concern-

ing the measuring point.(19) Set input and status values for testing

purposes during servicing and com-missioning.

3.11.2 How to Configure TemperatureInputsWhen you select the temperature moduleFB 5201 you will see the following devicespec sheet (fig. 89). The module can now beconfigured.

Notes for Converter FB 5201(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) Here you can activate or deactivate theline monitoring (LFD) feature.

(7) Here you can set the output drive in a

1

32

45

6

8

7

9

10 11

12 13

14

15

19

16

17

18

Fig. 89

54

A burn-out delay can be used to delay theacceptance of correct results for a giventime after a burn-out in order to avoid acontinuous change-over between fault andnormal conditions in the event of a loosecontact (1 - 250 cycles).

The conversion method can be adjusted tosuppress 50 Hz or 60 Hz noise.

Front LEDs indicate the module status.A green LED indicates that the unit is prop-erly connected to the power supply and thatthe fuse of the module is intact.A red LED issues an alarm in case of faultsin the field cables. It lights up in the event ofa short or open circuits.

No adjustments need be made when repla-cing a module.

3.12.1 How to Configure TemperatureInputsWhen you select the temperature moduleFB 5202 you will see the device spec sheetbelow (Fig. 91). You can now choose thedevice specification.

Notes for Converter FB 5202(1) The model number of the module is

entered automatically.(2) TAG-No. or measuring point number

with up to 20 characters.(3) With a non-active module it is possible

for the complete station to functionwhile, even though the inactive moduleis described, it does not exist physicallyor it is not to be included in the dataacquisition cycle.

(4) Indicates the actual module status. Inthe above example the SIMULATIONMODE is active allowing a simulation ofthe I/O function. This enables you tolook at the function of the I/O modulewhen there is still no connection to thehardware (OFF-LINE configuration).

(5) Line monitoring (LFD) indicating thestatus of the field wiring (OK or faulty).

(6) Here you can activate or deactivate theline monitoring (LFD) feature.

(7) Here you can set the output drive in afault condition.

(8) Select the sensor, the type of thermo-couple and the measuring range.

(9) The number of the slot being configured.(10) Press OK to store the parameter

setting.(11) Press CANCEL if you want to restore

the original setting ignoring the changesthat have just been entered. Thiscommand returns you to the main menuwithout registering any changes.

(12) LOAD allows you to load existingconfigurations from the disk or thehardware.

(13) SAVE allows you to store configurationson a disk or in the hardware.

(14) RESET allows you to restore the originalparameter settings while staying with thepresent configuration window.

(15) Call up HELP.(16) Suppression of line noise.(17) Temperature scale (°F or °C)

3.12 FB 5202 Temperature ConverterThe thermocouple transmitter FB 5202 inter-faces all kinds of thermocouples and millivoltsignals with the PLC or DCS system (Fig.90).

Connect thermocouples at terminals 5 and 6.

For Pt100 cold junction compensation (CJC):use terminals 1 and 2.

Measuring range -75 ... + 75 mV.Smallest span 5 mV.Maximum line resistance 1000 W.Non-linearity 0.1%.Sensor current of CJC sensor 200 µA.

Temperatures between -200 °C and +1850 °Care measured with a 16 Bit resolution. Thisleaves an 11 Bit resolution for the smallestrange of 5 mV or 0-100 % (better 0.1 %).All the thermocouple characteristics arelinearized.

Conversion rate, Cycle timeFor external CJC:20 ms without line monitoring,80 ms with line monitoring.For internal CJC external mounting:120 ms with line monitoring,+ 120 ms for CJC.

Measured values are sent to the COM unitonce every 5 ms independent of the con-version rate. Input signals can be filteredusing a digital PT1 filter adjustable in stepsof:- Without line monitoring (LFD):

40 ms, 80 ms, 160 ms, 320 ms.- With line monitoring (LFD):

250 ms, 500 ms, 1000 ms, 2000 ms.

The device has its own line monitoringfeature to indicate shorts or open circuits. Aline fault is indicated when the line resistanceexceeds 1000 W. The option can bedeactivated in the software. Line faults canlead to the following values:0 %, 20 % (4 mA), 100 % (20 mA).

Fig. 90

1 2 3 4 5 6

m V

Local B us

C JC

+ -

FB Remote I/O

Fig. 91

9

1

2

34

5

6

8

7

18

10 11

12 13

14

19

15

16

17

55

(18) Space for notes and remarks concer-ning the measuring point.

(19) Set input and status values for testingpurposes during servicing and com-missioning.

3.12.2 Cold Junction CompensationWith measurements using thermocouples itis necessary that extension wires from thesensor are wired up to the measuring deviceor the cold junction in order to avoid meas-urement errors, because new thermocouplesare formed at the junction between theextension wires and the copper cable. Thus,the thermocouple measurement is then de-pendent on the ambient temperature at theterminal point. This temperature dependencecan be compensated in various ways.

Cold Junction ThermostatA thermostat is usually used with externalcold junctions. This keeps the transitionpoint between the extension wires and thecopper cable at a constant temperature of50 °C. In this case the external cold junctionmust be selected in the menu for the FB 5202.The cold junction value entered is a fixedvalue. This method allows exact measure-ments, but it is rather complicated. Thealternative is temperature measurement atthe cold junction.

Cold JunctionCold junction measurement provides a goodcompromise between the rather complicated

method described above and accuracy. Forthis the temperature measuring transmittertype 520X is set to Internal VST. Thesensor is assembled externally in order toachieve the best possible level of accuracy.With FB Remote I/O BUS modules a PT100sensor is used for the temperature meas-urement at the transition point between thecopper cable and the extension wires. Thetemperature registered by this sensor at theterminal point is used by the FB 5202 for thecompensation of ambient temperature influ-ences. The COMBICON terminal FB 9112with built-in Pt100 sensor was designed toachieve a good temperature constancy.

When activating the internal cold junction, anadditional parameter becomes accessible inthe measuring point window of the device(see 3.12.1). You can set the pulse-dutyfactor for the measurement of the coldjunction temperature for the measurement ofthe process tempe rature to between 1 and255. With a pulse-duty factor of 1 : 1 a coldjunction temperature is calculated on eachmeasurement. The overall time for ameasurement will double to approx. 250 ms.With a pulse-duty factor of 1 : 100 a newcold point temperature is only calculated onevery 100th measurement (every 10 sec.).Thus the normal measuring cycle remainsshort (approx. 120 ms).To balance out the lead resistances in themeasuring circle of the externally assembledinternal cold junction a lead resistance canbe entered.

56

HART Communication

Analogue inputs and outputs (FB 3202,FB 3203, FB 4202) are available for commu-nication with intelligent field devices ac-cording to the HART protocol. These subas-semblies receive the HART telegrams via theservice bus from a bus coupler (FB 820X)that is also designed for HART communica-tion. The bus coupler recognizes automaticallywhether service information or HART proto-cols are to be exchanged. This is made pos-sible by the various transmission frequen-cies. The configuration and service functionsoperate with the MODBUS protocol at 9600Baud. HART communication operates to theBell standard by sending out frequencypackets (1200 Hz = 1, 2200 Hz = 0). Theseare superimposed by the I/O modules in theFSK (frequency shift keying) mode on to the20 mA signals.When using an interface converter whichadapts the RS 232 interface of your PC orLAPTOP to the RS 485 bus, it must be ob-served that this interface requires an auto-matic Baud rate recognition (9600 Baud forconfiguring, 1200 Baud for the HART com-munication).

Figure 92:(1) Communication with certified hand control

units at the terminal of the I/O module.The 250 W communication resistor isincluded in all analogue I/O modules.

(2) Communication via the bus coupler andI/O modules without additional devices.

(3) Principle of HART / SMART communica-tion by the susperimposing of currentswith frequency packets.

Communication via the service bus is possi-ble with the software of any field device thatis HART compatible. Thus, you work withuser instruments you are already familiarwith. Leave the service programme of theFB Remote I/O BUS and call up the HARTprogramme of your field device manufac-turer. This ensures that both programmesdo not try to gain access to the serial inter-face at the same time.

Transmitters supplied by manufacturers withthe address ZERO must not all be con-nected at one time as this leads to addressconflicts.

Connect the first transmitter and establishconnection with the field device with the usersoftware of the transmitter manufacturer

4

(e.g. SMARTVISION). Give the field device aso-called long address (e.g. ad-dressingusing the TAG-No.). Then put the seconddevice into operation, etc. When all thetransmitters have been allocated a longaddress, they can all be connected to thesystem simultaneously.

On request modern automation managementsystems can be fitted with a driver thatallows the scanning of the connected HARTdevices. In this case it is not necessary toconnect the field devices sequentially whenputting into service for the first time. HARTcommunication has been tested with varioussystems. These include IBIS, AMS,KSMART, SMARTVISION, SIMATIC PDMand Krohne.

With all systems it is necessary to ensurethat the field devices are allocated withaddresses that are unmistakable, as theHART communication addresses all the fielddevices at once via the FB Remote I/O BUS,whereby the transmitter with the correctaddress answers.

Our software package BUS-Tools can be avaluable aid when commissioning SMARTdevices, as it is capable of determining thedevice codes of the connected devices andlisting them for entering SMARTVISION, forexample, regardless of the capabilities ofthe HART software of the field devicemanufacturers.

The tests revealed the following limitations:HART communication is possible with thetransmitters for an operating range of4 - 20 mA. When there is no input signal(open circuit), some transmitters go intooverdrive (22 mA). In this state HARTcommunication with this transmitter is oftennot possible. This also applies for handcontrol units.

Krohne uses its own protocol, which doesnot correspond to the HART standard.Therefore, some Krohne transmitters cannotbe remotely operated with the Krohne pro-gramme via the FB Remote I/O BUS. In thecase of intrinsically safe hand control unitsfrom Krohne, communication is possible atthe terminals of the FB Remote I/O BUSsupply unit. After this, the Krohne devicehas to be RESET by briefly unplugging theplug-in connection to FB 320X.

Fig. 92

(1)

(2)

(3)

logisch 12200 Hz

logisch 01200 Hz

Amplitude+/- 0,5 mA

mA

ms

logical 0 logical 1

57

5 Software Marshalling

5.1 Automatic MarshallingThe structure of the data of a substation canbe adapted to suit the requirements of theDCS or PLC. This allows the processingspeed and the exploitation of the data for-mats offered by the systems to be supportedin an optimum way. Even when the I/O mod-ules are arranged on the backplane seg-ments in any mixed order, with the softwaremarshalling they can be sorted according toanalogue and digital data currents.

To do this switch from unpacked to packed

in the bus coupler window Transfer DataFormat (Fig. 93).The resulting address occupation can beread out and printed via the menu pointOptions/Documentation.

In the packed mode it is not possible to setanalogue and digital signals to test values viathe service bus. If you wish to use thisoperation mode, switch from the packedmode to the unpacked mode for theduration of the service tasks. However, thestation is then not connected to the mainsystem that expects packed data. Aftercompletion of the servicing tasks, switchback to the packed mode to reestablishthe connection to the system (see read mefile).

NOTE: When using the software marshalling,you should occupy unused slots for laterextensions. Otherwise, when you add newmodules, the marshalling addresses shiftand make it necessary to change the para-meters in the DCS or PLC.

Close the window of the bus coupler andselect as shown in figure 94: Services \I-/O-Data Marshalling

Fig. 93

Fig. 94

58

Select Auto Marshalling and the pro-gramme automatically optimizes the registerassignment (Fig. 96).You can pre-configure modules for laterextensions and then deactivate them. Thestorage areas are then reserved, even if nomodule is available. The advantage of this isthat, when extensions are made, it is notnecessary to reset the parameters of thecomplete DCS /PLC, but merely to activatethe section added.

5.2 Manual MarshallingIf you wish to carry out marshalling manually,you must proceed as shown in figure 97.Select the device in the top left window anddouble-click the register in the lower field orpress the Enter-key. Continue in this wayuntil all the registers or devices have beenmarshalled.

Please make a very careful record of themanual marshalling as the storage areasmust match the parameters set in the DCS /PLC. It is easier for our specialized staff toassist you over the phone with automaticmarshalling rather than with manual mar-shalling.

In the case of digital signals, please fill in thebit positions in the registers accordingly.When you have marshalled all the inputs /outputs, select Save station (see figure 97).Marshalling is then completed.

After you choose I-/O-Data Marshallingthe window in figure 95 appears.The configuration programme works out theoptimum register assignments. If you wish toreserve empty spaces in the registers forlater extensions, you must adapt the num-ber of registers accordingly.

Fig. 95

Fig. 96

Fig. 97

59

5.3 Software Marshalling by means ofTable ImportsIn the event of extensive marshalling activ-ities, it might make sense to prepare a tablewith the marshalling data in advance andthen import it into the configuration pro-gramme. There are various possible waysfor preparing the table. By way of examplethe Microsoft Excel method is to be de-scribed below.The table must feature the format as shownin figure 98.

5.3.1 Description of FormatThe first two lines are ignored by the importfilter to the FB, the next line must begin withan E for Eingänge or an I for Inputs.Further characters in this line are ignored(see also 2.3.6.1).

This is followed by the input-marshallingdata. Start with the marshalling of theanalogue devices (values in word structure)and then add the digital devices (values inbyte structure).

The column structure shown in the examplemust be kept to. The first column shows theregister, the second the bit to be assignedduring marshalling, the columns 4 and 5 arefor user information (in the example shownfor byte and bit in the Siemens S5 assign-ment). The existence of these columns isnecessary, although their content is merely acomment and is ignored otherwise.

Column 5 shows the slot (starting from 1)and column 6 the channel.Column 7 indicates the operation mode,0 = normal, 1 = inverse.

B e l e g u n g d e r E i n - u n d A u s g ä n g e z w i s c h e n S i e m e n s S 5 u n d L BL B - R e g i s t e r B i t S 5 B y t e B i t L B - S t e c k p l a t z K a n a l N o r m a l = 0 A k t i v = 0E i n g ä n g e : I n v e r s = 1 D e a k t i v = 1

0 8 6 4 0 1 2 0 00 9 6 4 1 1 3 0 00 1 0 6 4 2 3 1 0 00 1 1 6 4 3 1 1 0 00 1 2 6 4 4 2 3 0 00 1 3 6 4 5 3 2 0 00 1 4 6 4 6 0 00 1 5 6 4 7 0 00 0 6 5 0 6 3 0 00 1 6 5 1 6 1 0 00 2 6 5 2 6 2 0 00 3 6 5 3 5 3 0 00 4 6 5 4 5 1 0 00 5 6 5 5 5 2 0 00 6 6 5 6 0 00 7 6 5 7 0 01 8 6 6 0 3 3 0 01 9 6 6 1 4 1 0 01 1 0 6 6 2 4 3 0 01 1 1 6 6 3 2 2 0 01 1 2 6 6 4 2 1 0 01 1 3 6 6 5 4 2 0 01 1 4 6 6 6 0 01 1 5 6 6 7 0 0

A u s g ä n g e : 0 05 8 6 4 0 3 8 1 0 05 9 6 4 1 3 9 1 0 05 1 0 6 4 2 4 0 1 0 05 1 1 6 4 3 0 05 1 2 6 4 4 0 05 1 3 6 4 5 0 05 1 4 6 4 6 0 05 1 5 6 4 7 0 05 0 6 5 0 1 1 2 0 05 1 6 5 1 1 0 2 0 05 2 6 5 2 1 1 1 0 05 3 6 5 3 1 0 1 0 05 4 6 5 4 9 1 0 05 5 6 5 5 9 2 0 05 6 6 5 6 0 05 7 6 5 7 0 06 8 6 6 0 1 2 2 0 06 9 6 6 1 1 4 2 0 06 1 0 6 6 2 1 4 1 0 06 1 1 6 6 3 1 3 2 0 06 1 2 6 6 4 1 6 2 0 06 1 3 6 6 5 1 5 1 0 0

Fig. 98

Inputs:

Outputs:

Connecting Inputs and Outputs between Siemens S5 and FBFB - Slots channelF

cc

60

Column 8 shows whether the modules areactivated = 0 or deactivated = 1.The columns 7 and 8 are not absolutelynecessary. If the information in these 2columns is missing, the modules are setpermanently at 0 (operating mode normaland active).

Once all the inputs have been marshalled,the outputs can follow. Once again you startwith the analogue data and then add thedigital data. The column structure is the sameas that of the inputs.The output field starts with a line with the textoutputs in the first column, whereby the im-port programme merely wants to see an Afor Ausgänge or an O for outputs. Anyother information in this line is ignored.

The example on the previous page alsoshows that the arrangement of the bits in theregisters must also be taken into conside-ration. For example, the bits 8-15 of theFB Remote I/O BUS inputs belong to the bits0-7 of the register 64 for the Siemens S5.The bits 0-7 of the FB Remote I/O BUSinputs then belong to the bit 0-7 of theregister 65 of the Siemens S5.

5.3.2 Conversion of TablesFor operations using the FB Remote I/O BUSmenu it is necessary to convert the EXCELfile into an ASCII format.

Save your marshalling table in a file on yourdisk /hard disk using the Excel commandFile / Save. Mark one line in the table, callup Data / Text in columns. The textassistant will then appear on your screen.Click on Divided in the upper third (Fig. 99).

Then enter the division mark in the nextwindow (Fig. 100). By first clicking on theSemicolon and then End. You are nowback in the table.

Now under File /Save as call up the Filetype CSV (separator divided) and thenpress OK (Fig. 101).

Excel now generates the actual import file forthe FB Remote I/O BUS project.If you use other table calculation pro-grammes, you must prepare the table inexactly the same way as described at thebeginning. However, you must adapt theconversion into the import file according tothe software being used. You must bear inmind that a semicolon is being used as theseparator.

Fig. 99

Fig. 100

Fig. 101

(Samples in german language.)

61

Once the import file has been completed,you can import it by clicking Import data inthe Software-Marshalling window.

Having imported the marshalling data youcan then check the marshalling in thewindow (Fig. 102). If this is correct, save itby clicking Save station. Marshalling hasnow been completed.

5.3.3 Explanations for Importing /Exporting of DataThe separator is the first character of the file.Any character desired can be used for theseparator. Further characters in the first linecan be used as a comment.

Second line: first character E or I (Eingän-ge / Inputs) or A or O (Aus-gänge / Outputs), if you donot wish to marshall anyinputs.

This is then followed by the data for themarshalling of the inputs, whereby the orderfor the analogue and digital data is optional.However, the data area for analogue dataalways comes before that of digital data.

The range for the outputs begins with the linein which A/O is the first character. Thefollowing data applies for the outputs.

Order of data:1. FB register2. Bit for digital data (otherwise free)3. Of no significance (e.g. byte of

connected S5)4. Of no significance (e.g. bit of the

selected bytes of the connected S5)5. Slot-No. of module6. Channel to be marshalled (for multi-

channel digital modules, otherwise free)7. Significance (normal = 0 or free/in-

verse = 1)8. Active = 0 or free/inactive = 1

Example:;;;;;; Semicolon acts as separatorInputs;;;;;0;8;64;1;1;2;;10;9;64;2;1;3;1;0;10;64;3;3;1;;10;11;64;4;1;1;1;0;12;64;5;2;3;;0;13;64;6;3;2;1;10;14;;;1;0;15;;;;10;0;65;0;6;3;1;0;1;65;1;6;1;1;10;2;65;2;6;2;;0;3;65;3;5;3;;1Outputs;;;;;5;8;68;1;38;1;1;15;9;68;2;39;1;;5;10;68;3;40;1;;15;11;;;;5;12;;;;5;13;;;;5;14;;;;5;15;;;;5;0;69;0;11;2;;5;1;69;1;10;2;1;5;2;69;2;11;1;1;15;10;68;3;40;1;;1

Fig. 102

62

6 How to Address from thePLC or DCS

6.1 PROFIBUS DP

6.1.1 GSD FileThe certified firmware version P 1.45 for FBRemote I/O CEAG has been allocated theProfibus ID 0710 (Hex) by the PNO. Thepreviously used ID was 8101h. In order tonow avoid problems in mixed applicationswith older installations and for the event ofservice (replacement), the ident number hasbeen determined as an ajustable parameterwhich is accessible.

There are two ways of adapting the ID viathe configuration software.

1. Via the LBU file with an ASCII Editor:This is the only possibility for oldersoftware packages of carrying outconversions (on version 2.44 (16Bit) andsmaller or 2.50 and 2.51).In this respect the desired ID (8101 or0710) is allocated to the entryPB DP-ID=.

2. Upwards of the operating software vesion2.45 (16Bit) /2.52 (32Bit) the alteration canbe made from the programme.For this purpose the desired ID can beset under the menu pointServices\Alter Profibus-ID\ .Subsequently the station data in the fileand in the bus coupler must be saved, inorder to realise the alteration in aninterconnected manner. You can checkthe set ID by changing into the dialogue ofthe DP parameters of the bus coupler.

Replacement devicesNew bus couplers with the firmware P 1.45can be used very easily even as replace-ment for existing stations. For this yousimply have to build up the connection to thebus coupler, subsequently load the stationdata from the previously used configurationfile for which the bus coupler is to be usedas replacement and load these data downinto the coupler. The Profibus-ID will thenautomatically be set to that of the old station.This does not require any alteration in theMaster.

New installationsIf you design new stations attention must bepaid to the following:- operating software version 2.44 andsmaller, 2.50 and 2.51 create stations withthe ID 8101h.- as from version 2.45 / 2.52 stations withthe ID 0710h are created.Should you already have determined astandard for the bus coupler (default filecreated with BK\save\in default file) buscouplers with the ID set there (8101) willcontinue to be generated. You shouldtherefore now prepare a new standard bygenerating a new bus coupler with theexisting default settings, altering the identnumber (ID) as described above and thensaving as default.

In dependence on the selected ID the GSDfiles (Fig. 103) must be used for para-meterising the master. The addressoccupation can be read out and printed viathe menu point Options/Documentation.

Status Operating software ID file used

new as from 2.45, 2.52 0710 CEAG0710.GSD previously 2.44 and older, 2.50, 2.51 8101 CEAG8101.GSD

Fig. 103

63

Fig. 104

Fig. 105

Fig. 107

Fig. 106

Fig. 108

Fig. 109

6.1.2 PROFIBUS DP Configuration

6.1.2.1 Bus Coupler Configuration- Connect the configuration computer at

the service bus,- run the configuration program,- login acc. figure 104,- establish Sevice bus connection (Fig.

105),- edit module data (Fig. 106).- After FB selection the COM unit

configuration should appear. The COMunit configuration screen can alwaysbeen opened by double-clicking theCOM unit in the window (see 1.3).

- The screen in figure 107 will appear,- select Profibus (1),- define node address,- click configure, figure 108 will appear,- select DP (2),- click DP-Parameter, figure 109 will

appear,

1

2

3

- If hardware status information orcommands (like freeze, start/stopcounter,...) should be available, clickcheckbox status/command (3).

- If module status information should beavailable, click checkbox modulestatus area.

- First dont work with packed data.- Save the configuration (COM unit).

6.1.2.2 Control System Configuration- Load the GSD-file (see 6.1.1).- Attach I/O to bus system- I/O configuration:

Status/command and Modulestatus area act as virtual modules. Ifthey have been activated in the FBsystem; they have to be called first!e.g.: slot 0: Status/command

slot 1: Module status areaslot 2: FB I/O module 1slot 3: FB I/O module 2...

DCS/PLC FB Remote- For startup, set timeouts as high as

possible (or switch off).- Save configuration.

64

String Decimal Type Length Meaning00 00 No assignment10 16 N 1 Byte Digital input15 21 N 6 Bytes Module status (1 bit per module = 48 Bit = 6 Byte)20 32 OUT 1 Byte Digital output30 48 IN/OUT 1 Byte IN Digital input/output (valve with back indication)

1 Byte OUT31 49 IN/OUT 2 Bytes IN Global status and command

2 Bytes OUT50 80 IN 1 Word Analogue input (2 Byte)51 81 IN 2 Words52 82 IN 3 Words Frequency measurer and counter (6 Byte)60 96 OUT 1 Word Analogue output (2 Byte)

Warning! Depending on the configuration,the module FB1203 may have 2,4,6 Bytelength.Module status (Fig. 113).

The modul status range sets 6 bytes for acollective alarm per module. The 6 bytesinput data follow the input data of thecommando/status range, if that is active(see 6.1.5).

The module status bit is 1 if the moduleconcerned is active and in order. Otherwisethe bit is = 0.With Siemens systems the hexadecimalnumbers must be converted to decimalnumbers in order to be able to set theparameters of the DCS with, for example,the aid of the ET200. When using softwaremarshalling, the following can, for example,result:

Ident. No.Comment I-Addr O-Addr1 065OE 065 P0641 0641E 001 P0682 1282A 064 P066

Whereby the identification number iscalculated from the DP string data byconverting the hexadecimal numbers intodecimal numbers. The input and outputaddresses of the Siemens DCS can begenerated automatically.

6.1.2.3 PROFIBUS Configuration StringThe FB Remote I/O BUS helps you set theright configuration for PROFIBUS applicationif you call up the DP configuration string (Fig.110).The following configuration string results (Fig.111).This corresponds to the sequence of themodules placed above, including thepreceding status registers 31 and 15.

The following applies here (Fig.112).

Fig. 110

Fig. 111

Fig. 112

Modul status: byte 1 2 3 4 bit 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 module 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 ...

...

Fig. 113

65

Example read/write

Plug-in location 1 2 3 4 5 6 Typ 1X0X 2XXX 5X0X 4X0X 6X0X 3X0X Dp-config 10 30 50 60 20 50 Significance 1Byte In 1Byte In 1 Word In 1 Word In

1 Byte Out 1 Word Out 1 Byte Out Inputs in Byte 1 1 2 2 Outputs in Byte 1 2 1

Write outputs

Byte 0 1 2 3 4 5 Typ (Slot) 1X0X(1) 2XXX(2) 5X0X(3) 3X0X(6)

Read inputs

Byte 0 1 2 3 4 5 Typ (Slot) 2XXX(2) 4XXX(4) 6XXX(5) n. b. n. b.

Example of DP ScalingThe transmission of analogue data from the FB Remote I/O BUS is carried out usingunsigned integer values. The following applies when the scaling is activated: 0% = 10000,100% = 50000. Some systems can be optimized by scaling the data. If the scaling isactivated, the scaling data applies for all inputs or all outputs.

Input: DP Value = ( Factor x (FB Value + Offset) )Whereby: FACT = round(Factor x 32768)DP Value = ( FACT x (FB Value + Offset) ) / 32768

Output signals can also be scaled:

Output: FB Value = DP Value / Factor - OffsetFB Value = (32768 x DP Value) / FACT - Offset

The DP Value is the value that is transmitted via the Profibus DP to the PLC / DCS.The FB Value is the value that is used in the bus coupler for the internal data transfer.

Example: Siemens PROFIBUS DPCalculation of the Offset:Measured value 0 mA measured FB Value = 0

desired DP Value = 0Calculation: DP Value = (Factor x (FB Value + Offset)

0 = Factor x (0 + Offset)thus: Offset = 0

6.1.2.4 Data StructureThe configuring string gives information aboutthe sequence of the data words relative tothe bus coupler.

Example:PROFIBUS DP configuring string10 30 50 60 20 50

That means the arrangement of the followingdevices:1X0X, 2XXX, 5X0X, 4X0X, 6X0X, 3X0X

Look for the tables to see the sequence ofinput and output bits.1 Byte Inputs, 1 Byte Inputs + 1 ByteOutputs, 1 Word Inputs, 1 Word Outputs, 1Byte Outputs, 1 Word Inputs.

Module arrangement 1X0X 2XXX 5X0X 4X0X 6X0X 3X0X

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

Input bytes Output bytes

Example with module status area:

PROFIBUS DP configuration string

15 10 30 50 60 20 50

Arrangement of the device data as above.The module status area is however placedbefore the entrance area with a length of 6Byte.

Example with commando area and globalstatus:

PROFIBUS configuration string

31 10 30 50 60 20 50

Arrangement of the device data as above.The global status is placed before theentrance area with 2 Byte, the commandoarea is placed before the exit area with 2Byte.

Example Read/Write, write exits and readentrances see following tables:

66

Calculation of the Factor:Measured value 20 mA measured FB Value = 50000

desired DP Value = 8 x 2560 = 20480Calculation: DP Value = (Factor x (FB Value + Offset)

20480 = Factor x (50000 + Offset)thus: Factor = 0.4096

Thus the integral factor used in the bus coupler is:FACT = round(Factor x 32768), i.e. FACT = round(0.4096 x 32768) = 13422

Error AnalysisInput 4 mA measured FB Value = 10000

desired DP Value = 8 x 512 = 4096DP Value = (FACT x (FB_Value + Offset)) / 32768DP Value = (13422 x (10000 + 0)) / 32768 = 4096

thus: Error = 0

Input 20 mA measured FB Value = 50000desired DP Value = 8 x 2560 = 20480DP Value = (FACT x (FB Value + Offset)) / 32768DP Value = (13422 x (50000 + 0)) / 32768 = 20480

thus: Error = 0

Output 4 mA transmitted DP Value = 8 x 512 = 4096desired FB Value =10000FB Value = DP Value / Factor - OffsetFB Value = (32768 x 4096) / 13422 - 0 = 9999

thus: Error = 0,02 %

Output 20 mA transmitted DP Value = 8 x 2560 = 20480desired FB Value =50000FB Value = DP Value / Factor - OffsetFB Value = (32768 x 20480) / 13422 - 0 = 49999

thus: Error = 0,02 %

6.1.3 Modul Status and Command RegisterStructure of the modul status (2 bytes)

Those 2 bytes are transmitted with the following syntax:

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 fault code extension

see table single fault internal advicemultiple fault number of faults

local calculation: 1=activ0=not used

number of faults:0 means 1 fault1 means multiple fault

type of fault: 0=general fault1=modul fault

fault: 0=no fault1=fault

freeze: 0=no modules freezed 1=1 modul freezed at minimum

bus coupler: 0=passive 1=active

67

1 =

fau

lt

0 =

not

fre

ezed

1 =

fau

lt

0 =

gen

eral

fau

lt

6.1.3.1 Error Codes

13 12 118 Device Status Error Extension Module StatusRegister Register

0 x x No error Active power No errorsupplies *)

1 0 0 No error Active power No errorsupplies *)

1 0 1 Memory error RAM adress Time-outPIC (RAM) (= not installed)

1 0 2 Memory error Register adress Answer too longPIC (Register)

1 0 3 Memory error FLASH page Answer too shortPIC (FLASH) (incomplete)

1 0 4 PIC internal error Error sub-code Answer withparity error

1 0 5 Command error (PIC) Answer withwrong address

1 0 6 Module related error Module number Error telegramreceived

1 0 7 Power supply*) Active power Reservedsupplies *)

1 0 8 Memory error RAM page ReservedCPU32 (RAM)

1 0 9 Memory error FLASH page Wrong type installedCPU32 (FLASH)

1 0 A CPU32 internal error (Watchdog) Local link (LFD)

1 0 B CPU32 internal error (Arithmetic) Device error

1 0 C Redundancy error Error sub-code Reserved(synch.)

1 0 D Redundancy error (Not activable) Reserved

1 0 E Redundancy error (Inconsistent Reserved param.)

1 0 F Internal error Reserved Reserved

1 1 n Field bus see 1.1.1communication error

Bit 13: 0 = No error; 1 = ErrorBit 12: 0 = General error; 1 = Module specific errorBit811: Error code

CPU32 = main CPU for data processing and fieldbus controlPIC = second CPU for internal bus control

*) only FB

Example:By double clicking on the plug position of the bus coupler with the right hand mouse keyyou will receive the contents of the global status register e. g. A607

1 5 1 4 1 3 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 0 1 0 1 0 0 1 1 0 0 0 0 0 0 1 1 1

A 6 07device related error in Module 7

68

Command HEX Description Parameters

0X15 BUS TOOLS Command* 0=init, 1=done, 2=step, 3=run,4=stop, 5=reset

0XDA Activate HART communication slot no. 0XDB Switch off HART communication slot no. 0XF5 Redundancy switch-over (passive) - 0XF8 Cold start 0XF9 Warm start

One command can be transferred for each cycle.*BUS TOOLS is a CEAG Software Product that offers you comprehensive additional usesfor local signal processing. You can use the processor for a wide range of tasks frommathematical operations through to conditional branching (data leaflet available on request).

Example: To reset the collective alarm send

Byte 1 Byte 2 HEX 0 5

6.1.4 Data FormatTo transmit data by PROFIBUS DP see the following data format.This applies for LB Remote /FB Remote and in the same way for non-intrinsically safemodules.

6.1.4.1 Analogue DataAnalogue data are transmitted as Integer numbers without sign:

Meaning engineering unitValue Percent 3X0X, 4X0X 1X03, 5X0X 0 - 25 % 0 mA

Beginning of range 10000 0 % 4 mA as Full scale value 50000 100 % 20 mA parameterised

62500 131 % 25 mA

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

6.1.3.2 Module Related Error Codes FB 520X

Bit 11 Bit 10 Bit 9 Bit 8 Description1 x x x Faulty parameter set (CRC)x 1 x x Faulty calibration data (CRC)x x 1 x Calibration data outside tolerance band (> ±5%)x x x 1 Busy (Power up)

6.1.3.3 Command RegisterBit assignment of the command register.

Bit15Bit8 Bit7Bit0 Parameter, e.g. plug position no. Command

6.1.3.4 Commands

Code Command register parameter1 Deactivate module module slot no.2 Activate module module slot no.3 Freeze module module slot no.4 Unfreeze all modules module slot no. (0 = all module)5 Delete collective alarm 0 = delete, otherwise set6 Refresh marshalling7 Stop counter module slot no.8 Start counter module slot no.

69

Bit 1X01 1X02 2XXX7 empty empty empty6 empty empty empty5 empty LFD chan.3 LFD chan.24 empty channel 3 channel 23 LFD chan.2 LFD chan.2 LFD chan.12 channel 2 channel 2 channel 11 LFD chan.1 LFD chan.1 LFD valve0 channel 1 channel 1 empty

LFD = 0 no cable faultLFD = 1 cable breakage / short circuit

channel = 0 if open contact depending on thechannel = 1 if closed contact phase reversal mode

The solenoid valve driver has binary inputs and outputs. The input byte has binary inputs.

Option: phase reversal (see 3.1.1 and 3.2.1)

6.1.4.3 Binary OutputsBinary Outputs are transmitted as 8 Bit values:

7 6 5 4 3 2 1 0

Bit 2XXX 6X017 empty empty6 empty empty5 empty empty4 empty empty3 empty empty2 empty empty1 empty Relay 20 Valve Relay 1

The solenoid valve driver has binary inputs and outputs. The output byte only has onevalve driving bit:

valve = 0 output voltage = 0valve = 1 valve on.

Relay 1/20 = deenergized1 = energized

6.1.4.2 Binary InputsBinary inputs are transmitted as 8 Bit values.

7 6 5 4 3 2 1 0

Bit 0 to 3 contains the following information:

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

In the counter mode 1X03 counts from 0...65535 as far as the overflow (16 Bit unsignedinteger). When counting backwards the overflow occurs from 0 to 65535.

In the extended counting mode 1X03 counts from 0...429967295 as far as the overflow (32Bit unsigned integer). When counting backwards the overflow occurs from 0 to4294967295.During parametization the Low Byte is transmitted first and then the High Byte.

7 6 5 4 3 2 1 0

15 14 13 12 11 10 9 8

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

70

6.2 PROFIBUS FMSObject Dictionary

Index Type Dim Name Remark see also 0 - - - OD-header EN 50170 1..14 - - - standard data types EN 50170 15 - - - data structure definition for

slot parameter (see) config.doc 50 S U16 1 Status0 global status 6.3.1 51 S U16 1 Cmd command 6.3.7 60 A U8 48 Din binary input values;

channel 1=Bit0,...; bit wise coded 6.1.11.2 61 A U8 48 Dout binary output values;

channel 1=Bit0,... bit wise coded 6.1.11.3 62 A U16 48 Ain analog input value 6.11.1 63 A U16 48 Aout analog output value 6.11.1 64 A U16 48 Status module status 6.3.1 65 A S16 50 sData PLC integers 66 A U16 48 ID module Identification 6.3.4 70 A U16 50 xChng1 data exchange region part 1:

xChange 1 xChng[ 1..50] 6.3 71 A U16 50 xChng2 data exchange region part 2:

xChange 2 xChng[51..100] 6.3 72 A U32 25 xData1 data exchange region part 3:

counters 1 xData[ 1..25] 6.3 73 A U32 25 xData2 data exchange region part 4:

counters 2 xData[26..50] 6.3 74 A F 25 fData1 data exchange region part 5:

PLC floats 1 fData[ 1..25] 6.3 75 A F 25 fData2 data exchange region part 6:

PLC floats 2 fData[26..50] 6.3 80 A U8 1) Dpln DP data exchange input buffer 6.1.2 81 A U8 1) DpOut DP data exchange output buffer 6.1.2 101 R DS15 Para parameter for slot 1 config.doc ... ... ... ... ... 148 R DS15 Para parameter for slot 48 config.doc

S = simple variableA = arrayR = record (data structure)DSnn = data structure nn (record)U8 = unsigned8U16 = unsigned16U32 = unsigned32S16 = signed16F = floating point (Gleitkommastelle)1) variable (length of DP data_exchange in/out data), depends on configuration

71

6.3 FB 8202 MODBUS InterfaceThe different manufacturers (PLC or DCS) use two different possibilities of MODBUSadressing (MODBUS RTU and MODICON). Both possibilities can be used byFB Remote I/O. The address occupation can be read out and printed via the menu pointOptions/Documentation.The following table shows the two modes.

Name Length Type MODBUS Address MODICON Reference RemarksDin 384 Bit 8x(Modul1) + 10000 + 8x(Module 1) Channel 1 = Bit0,..; can

Channel -1 + Channel be addressed bit by bitDout 384 Bit 8x(Module1) + 8x(Module1) + Channel Channel 1 = Bit0,..; can

Channel -1 be addressed bit by bitAin 48 Word Module-1 30000 + Module Analogue input value

Status0 1 Word 99 30100 Device status (s.6.3.1) Status 48 Word 100+ Module - 1 30100 + Module Module status (s. 6.3.1) ID 48 Word 200 + Module - 1 30200 + Module Module identification

(s.6.3.4) Aout 48 Word Module - 1 40000 + Module Analogue output

value Cmd0 1 Word 49 40050 Global command

(s. 6.3.5) SData 50 Word 50 + Module - 1 40050 + Module Integer for PLC

Para 49 *) 100xModule 40001 + 100xModule Parameters toFB 8202

Xchng 100 Word 5000 45000 + index Data exchangeindex (1-100) range (packed)

XData 96 Word 5100 + 2x (Modul-1) 45101 + 2x (Module -1) Long Integer 32 bitsfor counter

fData 900 Word 5200 + 2x (index -1) 45201 + 2x (index - 1) 32bit float for localindex (1 - 450) calculation

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

Data type Type of FC FC FC MODBUS MODICONsignal read write write Address range Reference range

Input bit digital 2 0...65535 10000...19999Output bit digital 1 5 15 0...65535 0...9999Input register analogue 4 0...65535 30000...39999Output register

Xchng,Xdata,fdata analogue 3 6 16 0...65535 40000...49999single multiple with FC-code without FC-code

FC = function code

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

6.3.1 Status RegisterBit distribution of the status register:

Bit15 Bit14 Bit 138 Bit 7/6 Bit 5/4 Bit 3/2 Bit 1/0active frozen error code chan. 4 *) chan. 3 *) chan. 2 *) chan. 1 *)

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

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

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6.3.2 MODBUS System AddressesThe different system manufacturers use different methods for Modbus addressing.

6.3.2.1 Elsag Bailey (H+B)

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

6.3.2.2 Fisher Rosemount RS3

AddressDigital input 1000 + 8 x (Slot - 1) + ChannelDigital output 8 x (Slot - 1) + ChannelAnalogue input 30000 + SlotAnalogue output 40000 + Slot

6.3.2.3 HIMA

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

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

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7.3 Faulty ModulesIn the event of faults with a module pleasecheck whether

the green LED of the module is on (ifNOT, either there is no contact to thebackplane, or the fuse is defect, or if the24 modules of one segment fail, there isa fault in the voltage supply),the module can be activated via theservice bus (if NOT, see 7.1),the display shows that the module is OK,i.e. in operation (if NOT, check whetherthe module in this slot is the correctmodule),the display shows that the module isactive (if NOT, the module has been pre-configured for later extensions, but is notaddressed by the DCS or PLC),the modules selected by clicking themouse can indicate its measured value(if NOT, the reason could be a short oropen circuit),an output module has a local connection(if this is the case, the module cannot beaddressed by the DCS or PLC as thelocal connection has priority). In thiscase manual settings are also blocked.

7.4 Red LEDsIf the red LED of a module lights up, there isa fault in the field wiring. The red LED of amodule lights up if there are problems withan I/O module of the station. The red LED ofthe bus coupler cannot be switched off bythe system or via the service bus until allI/O modules function correctly.The collective alarm can be reset in the mainmenu of the configuration software with themenu item SERVICE in the headline. Themenu item DP-RAM Flash Viewer, that isalso accessible there, is reserved for theservicing engineer of the manufacturer.

Troubleshooting

7.1 CommunicationIf there is a fault in the communication withthe DCS or PLC please check whether

the cable connections are intact,the address selected matches thedesired station address,the baud rate and the start and stop bitsmatch,the bus terminating resistor is activated,the bus stations were accidentally star-connected to a branch point(inadmissible) andthe address strings of master and slave match. In the caseof packed dataparticular attention must be paid tocareful addressing. During trouble-shooting the FB Remote I/O BUSpro vides help via the service bus, as ineach case it indicates the first differencebetween the master string and the slave.

If there is a fault in the communication via theservice bus please check whether

the cable connections are intact,the address selected matches thedesired station address,the baud rate and the start and stop bitsmatch,the bus terminating resistor is activatedand the bus stations were accidentallystar-connected to a branch point(inadmissible).

7.2 Faulty Power Supply UnitsIn the event of faults with the power supplyFB 92XX please check whether

the green LED of the module is on (ifNOT, either there is no contact to thebackplane, or the fuse is defect, or thesupply is interrupted).

7

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7.5 Searching for Errors

Error Corrective measures

Green LEDs of the modules do not light up. Check mains connection and mains part.

24V power supply fault. Check if it has been operated on the correctmains.

Yellow LEDs of the bus couplers do not Check the connection of the configuration flash during data transmission. cable and of the adapter.

Software cannot find bus coupler when Check if the yellow LEDs flash when the connecting. connection is made. Check if the service bus

address is in the selected area (if necessaryextend the search area). Check if the buscoupler is correctly plugged in.

Bus coupler cannot be configurated. Check password. Bring bus coupler contentin to the PC with the menu point deviceLoad station from the field.

When reading out the bus coupler the The desired configuration has not been saved desired configuration is not recognisable. in the bus coupler. See menu point Device

Save station in the field.

Bus coupler advises module error when Possibly no error. May be no modules are reading back the saved data from confi- plugged in the configuration kit. The bus guration kit. coupler has checked if the configured

modules are present.

Communication disturbance after the Check the galvanic separation of the service successful establishment of the connection. bus. Operate the LAPTOP with a battery.

Use a normal commercially available interfaceconverter RS 232-RS 485 with automaticrecognization of the baud rate and linedirection changeover.

No HART communication Check if HART input/output separators arepresent. Use interface converter with auto-matic Baud rate and direction recognition.Ensure that HART field devices are notoverdriven (working range up to 20mA).Check if the correct address of the HARTdevice was used. Check if the HART softwarehas a driver for the field device used.

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7.6 Check list in the Event of Failure of Signals

Question Answer How many stations are affected? Are all output signals of a station affected? Are the stations equipped with a mixture of inputs and outputs?

Are analogue and binary outputs affected? Which module types are affected? In which plug positions are modules affected? Is it always the same plug position? On which plug rows are the modules situated?

Can the outputs be switched back on by software? Do the modules have to be replaced?

Is the address monitoring of the bus coupler active? How long is the programmed time? At which time intervals does a master communication take place? Are the stations structured redundant?

Is the lead monitoring of the modules active? How does the master react to breakage of the lead? Which lunimous diodes of the disturbed modules are switched on? Are red, yellow or red and yellow LEDs switched on?

Which master system is being used? Which bus protocol is being used?

Are the bus leads earth free? (bus couplers are separated galvanically) Are the earth connections linked with equipotential bonding? Are the screen connections of the field leads linked to the housing via the metal glands? Does the wiring between the basis unit and the extension unit correspond to the connection plan?

Which supply voltage do the stations receive? (at least 20 V DC incl. drops in voltage required. If necessary oscillograph) Is it possible to connect a bus monitor to the service bus? For this a PC with Windows 3.11 or Windows 95 with hard disk would be suitable.

Please fill out and send to us.

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Literary References

PROFIBUS PROFIBUS User organizationArt. No. 4.001 Haid-und-Neu-Straße 7

D-76131 KarlsruhePROFIBUS DP Rapid induction Tel ++ 721 9658 590Art. No. 4.071 FAX ++ 721 9658 589

Modbus Protocol AEG Schneider AutomationReference Guide Steinheimer Str. 117PI-MBUS-300 D-63500 Seligenstadt

Tel ++ 6182 810FAX ++ 6182 813 306

Internet www.profibus.comwww.CEAG.de

8

9 Index of Keywords

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

GH

G 2

10 7

003

P00

41(B

)/50

0/03

.200

0/W

E

CEAG Apparatebau Hundsbach GmbH & Co. KG

Bußmatten 10 - 1277815 Bühl/BadenTelefon07223 9909-117Fax 07223 9909-140Internet http://www.ceag.deE-mail: Info@apparatebau-hundsbach.de

P.O. Box 4999Wolfs & 7th North StreetsUSA Syracuse, NY 1321Phone + 1 315/477-7000Fax + 1 315/477-5717Internet http://www.crouse-hinds.com/worlwide/