Alstom GEM80 User manual

GEM80 Fieldbus Modules
Technical Manual
Publication No. T2035EN
Issue 002 (07/05)
ABCD

GEM80 1. Introduction
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1. Introduction........................................................................................................... 2
1.1 Preface ........................................................................................................................... 2
1.2 Introduction to Fieldbus ................................................................................................. 2
2. Common Technical Specification ........................................................................... 3
2.1 Electrical ........................................................................................................................ 3
2.2 Physical .......................................................................................................................... 3
2.3 Environmental................................................................................................................3
2.4 Standards....................................................................................................................... 3
3. Hardware Layout................................................................................................... 4
4. Installation ............................................................................................................ 5
4.1 Introduction ................................................................................................................... 5
4.2 Module Installation ........................................................................................................ 5
4.3 Module Identification ..................................................................................................... 6
5. Operation.............................................................................................................. 7
5.1 Introduction ................................................................................................................... 7
5.2 Module Configuration Parameters ................................................................................. 7
5.2.1 Validity Flag (Pn and Pn+12) ......................................................................................... 9
5.2.2 Device Type (Pn+1 to Pn+2 and Pn+17 to Pn+18) ......................................................10
5.2.3 Scan Rate (Pn+3 and Pn+19)....................................................................................... 10
5.2.4 Input Buffer (Pn+4 to Pn+6 and Pn+20 to Pn+22) ......................................................10
5.2.5 Output Buffer (Pn+7 to Pn+9 and Pn+23 to Pn+25).................................................... 10
5.2.6 Version Buffer (Pn+10 to Pn+12 and Pn+26 to Pn+28)............................................... 10
5.2.7 Reserved Parameters.................................................................................................... 10
5.3 System Configuration................................................................................................... 11
6. Maintenance and Fault Finding ........................................................................... 12
6.1 Fixed F-Table ............................................................................................................... 12
6.1.1 Error Code ................................................................................................................... 12
6.1.2 Exchange Mode............................................................................................................ 13
6.1.3 Exchange Counter........................................................................................................ 14
6.1.4 Presence Indication ...................................................................................................... 14
6.2 Version Buffer .............................................................................................................. 15
6.3 Fixed V-Table ............................................................................................................... 15
7. Hilscher System software (SyCon)........................................................................ 16
7.1 Preface ......................................................................................................................... 16
7.2 Introduction to the Hilscher System software................................................................ 16
7.3 Installation of the Hilscher System software ................................................................. 16
7.4 Hilscher Profibus System software (SyCon) Operation Guide .......................................18
7.4.1 Start to build a representation of your Fieldbus system................................................ 19
7.4.2 Inserting Slaves............................................................................................................ 22
7.5 Download Configuration.............................................................................................. 25
7.5.1 Common Error Message during Download – 170 – GEM80 RUNNING ........................ 27
7.6 Importing Slave Configuration Files (.GSD).................................................................. 28
8. Spares, Service and Support....................................................................................

GEM80 1. Introduction
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1. Introduction
1.1 Preface
This manual provides the information necessary to configure and install various
Fieldbus modules into GEM80 Controllers. The manual covers the modules’ technical
and physical specifications, installation, operation and general use. Examples and
application notes are also included.
1.2 Introduction to Fieldbus
Fieldbus is a generic term for communication between a GEM80 Controller and plant
input and output. The currently supported protocols are Profibus FMS/DP, CANopen
and DeviceNET. Master functionality is supported in each case.
The Fieldbus plug-in modules are peripherals of the GEMLAN-T compatible processor
module. Up to two modules in any combination are supported per controller. A power
converter module must also be fitted; this can power up to two Fieldbus modules
simultaneously.
Each Fieldbus module has a front panel to permit connection to the Fieldbus network
and to a diagnostic serial link. Ribbon cables connect the module and the panel. The
panel also has LED indicators, which mimic the Fieldbus module’s on-board indicators.
The GEM80-500 can support up to 5 plug-in modules; each Fieldbus module fitted
consumes one from this allowance.

GEM80 2. Common Technical Specification
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2. Common Technical Specification
2.1 Electrical
Power Consumption 650mA from host GEM80 +5v
LED Indication Green LED - Run
Yellow LED - Ready / Communication
Red LED - Error
2.2 Physical
Dimensions 90 x 96 x 23 (L x W x H)
2.3 Environmental
Operating
Temperature 0 to +55 deg. C
2.4 Standards
Noise Immunity EN50082 - 2

GEM80 3. Hardware Layout
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3. Hardware Layout
Fieldbus Front panel and Module (Profibus shown)
Power Converte
r
Fieldbus front panel
Module
Identification
Rotary Switch
Section 4.3

GEM80 4. Installation
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4. Installation
4.1 Introduction
The Fieldbus Modules contain electrostatic sensitive devices. Handling precautions must
be observed.
If it is necessary, in the case of repair, to return any PCBs, they must be enclosed in a
static shielding bag, e.g. 3M Type 2100, be suitably protected by foam plastic
wrapping, and packed in a box labelled 'Caution Static Sensitive PCBs
CAUTION
This equipment contains solid state devices, which may be affected by
electrostatic discharge. Observe static handling precautions.
4.2 Module Installation
The Fieldbus Modules are peripherals of the TCP/IP Ethernet module (9716-4020).
Prior to the installation of any Fieldbus modules, ensure that a TCP/IP Ethernet module
is correctly installed and configured. Refer to the GEM80-500 Series Controller
Technical Manual for installation instructions and the GEMLAN-T Technical Manual for
configuration instructions for the TCP/IP Ethernet module.
Before installation, the Fieldbus module must be hardware configured by setting the
Module Identification rotary switch. Refer to section 4.3.
With the controller powered down remove the front panel mains and watchdog
connector. Move the controller to a suitable location and proceed as follows, noting
that all references to left and right refer to the controller when viewed from the front.
(a) Release the upper right-hand side cover and power supply assembly. Lay the
controller down on its left-hand side and remove the four M3 Pozi-pan head
earthing/grounding screws. Retain for re-assembly.
(b) Lift the cover and slide the louvered side under the controller.
(c) The TCP/IP Ethernet module should now be visible. This is retained using four M3 x
6 mm screws and spring washers. Remove these screws and washers and retain for
re-assembly.
(d) Secure the TCP/IP Ethernet module in position by substituting 4 mounting pillars for
the M3 x 6mm screws.
(e) The site is now ready to receive a Fieldbus module.
(f) Check that the connector pins on the underside of the Fieldbus module are correctly
aligned. Orientate the module so that the matching connectors are in line. Gently
push the connector halves together until the module sits flat on the mounting
pillars.
(g) Insert the front panel mounted Fieldbus and diagnostic ribbon cables to their
associated headers.
(h) Secure the Fieldbus module in position using 4 more mounting pillars.
(i) If all required Fieldbus modules are now fitted proceed at instruction (j), otherwise
continue at instruction (e).
(j) The site is now ready to receive the power converter module.

GEM80 4. Installation
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(k) Check that the connector pins on the underside of the power converter module are
correctly aligned. Orientate the module so that the matching connectors are in line
and the mounting holes correspond with the two mounting pillars nearest to the
front of the controller. Gently push the connector halves together until the module
sits flat on the mounting pillars.
(l) Secure the power converter module in position with 2 of the screws and washers
removed at instruction (c). The unused screws and washers may be stored in the
other two mounting pillars.
(m) Remove a blanking panel from the front of the controller, to make space for each
of the Fieldbus module front panels. The blanking panels are secured with two M3
Pozi-pan screws, remove and retain the screws.
(n) Secure the Fieldbus front panel(s) in position using the screws removed at
instruction (m).
(o) Replace the upper right-hand side cover and power supply assembly. Secure in
position using the screws removed at instruction (a).
WARNING
Insertion or removal of modules with the equipment
energised will cause malfunction of the equipment.
4.3 Module Identification
A rotary switch located on the fieldbus module PCB achieves module identification. A
maximum of two fieldbus modules can be installed into a GEM80-500, each identified
in the system by reserved rotary switch position 2 or 3.
The GEM80-500 Fieldbus driver will find the module with the lowest switch position
and use the configuration parameters from Pn to configure this module, this is referred
to as Module #1. The next module if fitted will use parameters from Pn+16, this
referred to as Module #2 (see section 5.2).
If a single Fieldbus module is fitted, the rotary switch must be set to position 2 (Module
#1). If two modules are fitted, one rotary switch must be set to positions 2 (Module
#1) and the other to position 3 (Module #2).
If a module is removed, ensure that the remaining module’s rotary switch is set to
position 2 and that the configuration data starting at Pn are suitable for the application.
N.B. If two modules are fitted, setting the rotary switch to the same position will cause
malfunction of both modules. Selecting any position other than 2 or 3 will cause
malfunction of the host processor.

GEM80 5. Operation
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5. Operation
5.1 Introduction
CAUTION
The inclusion and configuration of one or more FIELDBUS modules grants read
and write access to GEM80 data tables. It is the user’s responsibility to ensure
that adequate safeguards are used to prevent dangerous situations arising.
5.2 Module Configuration Parameters
An Advanced GEM80 Programmer (or equivalent) must be used to supply the module
configuration parameters. These parameters must be entered into the P-table of the
host GEM80 Controller by the user before the module can be used. The GEMLAN-T
Module accesses these parameters on behalf of the Fieldbus module(s) after
completion of its boot procedure. The GEMLAN-T Module takes approximately one
minute to complete its boot procedure.
Note:
If the parameters are subsequently altered, they will be recognised and
validated by the GEMLAN-T Module following a recompilation. During
the validation, Fieldbus communication is halted. If the validation
should fail, the communication remains halted.
Remember that P-table entries above P149 will only exist if specifically
declared in the user program.
For the GEMLAN-T module to access the configuration data successfully, a value must
be written into P74. This value acts as a pointer to the P-table location containing the
configuration parameters for Fieldbus module #1. Fieldbus module #2 parameters
follow those of module #1 in the P-table.
E.G. if P74 contains a value of 300, the configuration parameters start at P300.
Inserting a value of 0 into P74 renders inactive all Fieldbus modules of the host
controller.
A detailed description of each configuration parameter is provided in the following
paragraphs. Table 5-1 provides a reference table. Table 5-2 is an example of the use
of the P-tables.

GEM80 5. Operation
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Table 5-1 P Table Configuration Parameters
Table Function Comment
P74 Pointer to configuration data. e.g. 300 = parameters start at P300
MODULE #1 parameters
Pn Validity flag @4801 ( Must be this value )
Pn+1 Device type (HIGH)
Pn+2 Device type (LOW)
Safety Check
Pn+3 Scan Rate Rate in ms, 0 = free running
Pn+4 Input table letter In LS byte, MS byte =0.
Pn+5 Input table offset
Pn+6 Input table quantity
Pn+7 Output table letter In LS byte, MS byte =0.
Pn+8 Output table offset
Pn+9 Output table quantity
Pn+10 Version table letter In LS byte, MS byte =0.
Pn+11 Version table offset
Pn+12 Version table quantity
Pn+13 Reserved (Must be 0)
Pn+14 Reserved (Must be 0)
Pn+15 Reserved (Must be 0)
MODULE #2 parameters
Pn+16 Validity flag @4802 ( Must be this value )
Pn+17 Device type (HIGH)
Pn+18 Device type (LOW)
Safety Check
Pn+19 Scan Rate Rate in ms, 0 = free running
Pn+20 Input table letter In LS byte, MS byte =0.
Pn+21 Input table offset
Pn+22 Input table quantity
Pn+23 Output table letter In LS byte, MS byte =0.
Pn+24 Output table offset
Pn+25 Output table quantity
Pn+26 Version table letter In LS byte, MS byte =0.
Pn+27 Version table offset
Pn+28 Version table quantity
Pn+29 Reserved (Must be 0)
Pn+30 Reserved (Must be 0)
Pn+31 Reserved (Must be 0)

GEM80 5. Operation
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Table 5-2 P-Table Example
P74 300 Pointer to P300
P300 @4801 Module #1
P301 @7910
P302 @9040
Profibus Master
P303 100 100 ms scan
P304 @0047
P305 1000
P306 100
P307 @0048
P308 2000
P309 50
P310 @0046
P311 500
P312 25
P313 0
P314 0
P315 0
G Table
G1000
Length 100 entries, 200 bytes.
H table
H2000
Length 50 entries, 100 bytes
F Table
F500
Length 25 entries, 50 bytes.
P316 @4802 Module #2
P317 @7910
P318 @9051
DeviceNet Master
P319 0Free running
P320 @0047
P321 1100
P322 50
P323 @0048
P324 2050
P325 100
P326 @0046
P327 F525
P328 25
P329 0
P330 0
P331 0
G Table
G1100
Length 50 entries, 100 bytes.
H table
H2050
Length 100 entries, 200 bytes
F Table
F525
Length 25 entries, 50 bytes
@ Denotes a Hexadecimal Value, .i.e. all other values are decimal
5.2.1 Validity Flag (Pn and Pn+12)
The first P-table entry of each module’s configuration data contains a validity flag. Its
function is to prevent an uninitialised ‘P’-table from being used as configuration
parameters. The user must insert the hexadecimal value @4801 (module #1) or
@4802 (module #2) into the relevant table entry to signify that the module
configuration data is valid.
The insertion of any other value into the table entry renders inactive the associated
Fieldbus module.