Aventics 580 PROFIBUS DP User manual

580 PROFIBUSTM DP
Technical Manual
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Conditions for use of this product
AVENTICSTM 580 Manifold ("the PRODUCT") SHALL NOT BE USED IN CONDITIONS where any problem, fault or failure
occurring in the PRODUCT may lead to any incident resulting in damage to property, serious injury or loss of life and where
the end user does not have appropriate external backups and fail-safe measures incorporated within the systems that the
PRODUCT is used.
The PRODUCT has been designed and manufactured for use in general industries. Therefore, the PRODUCT and related
document(s) are not for use in any nuclear and/or medical related applications.
For avoidance of doubt, AVENTICS and its affiliated companies shall have no responsibility or liability including but not
limited to any and all responsibility or liability based on contract, warranty, tort, product liability for any injury or death
to persons, loss or damage to property caused by the product that are operated or used in application not intended or
excluded by instructions, precautions or warnings contained in AVENTICS documentation including any Technical, User,
Instruction, Safety manuals or bulletins.
Safety Precautions
Before using this product, please read this manual and the relevant manuals carefully and pay attention to safety and
product application. The following symbols are used in the manual to identify important safety, installation, and application
information.
The CAUTION symbol indicates a possible hazard which may cause injury or equipment damage. Please review and take
appropriate action.
The NOTE symbol indicates important information regarding equipment installation and setup. Please review and take
appropriate action.
NOTE!
CAUTION
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Electrical Installation And Operational Guidelines
AVENTICS valve systems with integrated fieldbus communications must only be connected to a
Class 2 power source.
All AVENTICS communication nodes should be grounded during the installation process. Proper
grounding guidelines can be found in National Electrical code IEC 60204-1 or EN 60204-1.
All AVENTICS 580 Electronics Products must only be installed or wired in accordance with ASCO
AVENTICS published instructions and applicable electrical codes.
When using MULTIPLE CLASS 2 POWER SOURCES all sources shall be Listed and rated suitable
for parallel interconnection.
All field wiring shall be suitable for Class 1, Electric Light and Power, or if Class 2, 3 wirings, such
wirings shall be routed separately and secured to maintain electrical and physical separation
between Class 2 wiring and all other class wiring and limited energy circuit conductors from
unlimited energy circuit conductors.
When using Class 2 Device Wiring Only, you SHALL NOT Reclassify and Install as Class 1, 3 or
Power and Lighting Wiring.
When using molded connector power cables, DO NOT RELY ON WIRE COLORS FOR PIN-OUT;
Always use pin number references.
Wire connections shall be rated suitable for the wire size (lead and building wiring) utilized.
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Table of Contents
PAGE
1. About PROFIBUSTM DP .................................................................................................................................. 1-5
1.1 Overview ........................................................................................................................................... 1-5
1.2 580 PROFIBUSTM DP Node Features ...................................................................................................... 1-5
1.3 Cabling and Drop Line Lengths (as defined by PROFIBUSTM specification) .................................................. 1-5
2. 580 PROFIBUSTM DP Introduction .................................................................................................................. 2-6
2.1 Pneumatic Valve Manifold – 501 Series shown ....................................................................................... 2-7
2.2 Manifold Connectors ........................................................................................................................... 2-8
2.3 Z-Board™ Connectors ......................................................................................................................... 2-9
3. Zoned Power ............................................................................................................................................. 3-10
3.1 503 Series Zoned Power application .................................................................................................... 3-10
3.2 503 Series Zoned Power example ........................................................................................................ 3-11
4. Communication Module ............................................................................................................................... 4-12
4.1 580 PROFIBUSTM DP Node .................................................................................................................. 4-12
4.2 580 Node Description ........................................................................................................................ 4-13
4.3 Connector Pin-Outs ........................................................................................................................... 4-14
4.4 Electrical Connections ........................................................................................................................ 4-15
4.5 Chassis Ground ................................................................................................................................. 4-16
4.6 Power Consumption ........................................................................................................................... 4-17
4.7 Recommended External Fuses............................................................................................................. 4-18
4.8 Diagnostics – 580 PROFIBUSTM DP Node LED Functions .......................................................................... 4-19
5. Extended Coil Capability .............................................................................................................................. 5-20
5.1 Extended Coil Configuration ................................................................................................................ 5-20
5.2 Extended Coil Valve driver IO Mapping ................................................................................................. 5-21
5.3 501 Series, up to 64 solenoid coils ...................................................................................................... 5-22
5.4 501 Series, up to 128 solenoid coils ..................................................................................................... 5-23
5.5 502 and 503 Series, up to 80 coils ...................................................................................................... 5-24
6. 580 PROFIBUSTM DP Node Graphic Display .................................................................................................... 6-25
6.1 Network Address Sub-Menu ................................................................................................................ 6-26
6.2 Set Slave Address Lock Sub-Menu ....................................................................................................... 6-27
6.3 500 Series Extended Coil Capability ..................................................................................................... 6-28
6.4 Advanced Settings – Flip Display ......................................................................................................... 6-29
6.5 Advanced Settings - Parameters ......................................................................................................... 6-30
6.6 Factory Defaults ................................................................................................................................ 6-31
6.8 Diagnostics ....................................................................................................................................... 6-32
6.9 Diagnostics - Self Test Mode ............................................................................................................... 6-33
6.10 Error Messages ................................................................................................................................. 6-34
7. PROFIBUSTM DP Configuration and Mapping ................................................................................................... 7-35
7.1 GSD File ........................................................................................................................................... 7-35
7.2 User Configurable Device Parameters .................................................................................................. 7-35
7.3 Fail Safe Mode Parameter ................................................................................................................... 7-36
7.4 Commissioning 580 ProfibusTM with Siemens TIA Portal Software ............................................................ 7-37
8. PROFIBUSTM DP Mapping ............................................................................................................................. 8-41
8.1 I/O Sizes .......................................................................................................................................... 8-41
8.2 Bit Mapping Rules .............................................................................................................................. 8-41
8.3 Mapping Example No.1 ...................................................................................................................... 8-42
8.4 Mapping Example No.2 ...................................................................................................................... 8-43
9. Appendix................................................................................................................................................... 9-44
9.1 System Specifications ........................................................................................................................ 9-44
9.2 Factory Default Settings ..................................................................................................................... 9-44
9.3 Troubleshooting ................................................................................................................................ 9-44
9.4 Glossary of Terms ............................................................................................................................. 9-45
9.5 Technical Support.............................................................................................................................. 9-45
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1. About PROFIBUSTM DP
1.1 Overview
PROFIBUSTM DP is a communication protocol used to network industrial devices to eliminate labor intensive and
expensive point to point wiring schemes. Siemens originally developed PROFIBUSTM DP, but it is now supported by
a multitude of manufacturers and the protocol standard governed by the PROFIBUSTM Trade Organization (PTO).
The 580 PROFIBUSTM DP Node is designed to conform to the PROFIBUSTM standard EN50170 and is certified by
PROFIBUS Interface Center (PIC) according to the guidelines determined by the PROFIBUSTM Trade Organization
(PTO). The certification process ensures interoperability for all PROFIBUSTM DP devices.
PROFIBUSTM DP uses a 2-wire (plus shield) network and can have up to 126 nodes. The protocol can transfer a
maximum of 244 bytes of data per node cycle with nine selectable communication (baud) rates of 9.6 Kbps, 19.2
Kbps, 45.45 Kbps, 93.75 Kbps, 187.5 Kbps, 500 Kbps, 1.5 Mbps, 3 Mbps, 6 Mbps and 12 Mbps. Maximum distance
is depended upon baud rate and cable media type. Refer to the section below for details.
More information about PROFIBUSTM can be obtained from the PROFIBUSTM web site www.PROFIBUS.com
1.2 580 PROFIBUSTM DP Node Features
Features Description
Bus Topology Linear bus, active bus termination on both ends. Stub lines permitted
only for <= 1.5Mbit/sec baud rates.
Baud Rates Supported 9.6 Kbps, 19.2 Kbps, 45.45 Kbps, 93.75 Kbps, 187.5 Kbps, 500 Kbps,
1.5Mbps, 3 Mbps, 6 Mbps and 12 Mbps
Duplicate address detection Node address must match address in Master configuration software,
before node will enter the data exchange mode
Address Setting options Via Software (with Profibus-DP Class 2 Master) or graphic display
Supported Versions DP-V0 and DP-V1
1.3 Cabling and Drop Line Lengths (as defined by PROFIBUSTM specification)
Maximum Cable Length
Baud
Rate 9.6Kbps 19.2Kbps
93.75Kbps 187.5Kbps 500Kbps 1.5Mbps 12Mbps
Range/
Segment
1200M 1200M 1200M 1000M 400M 200M 100M
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2. 580 PROFIBUSTM DP Introduction
The 580 PROFIBUSTM DP Node is an electronic interface that features an integrated graphic display for simple
commissioning and displaying of diagnostic information. The 580 PROFIBUSTM DP Node mates to a variety of valve
series including, the 501, 502, and 503. The 580 PROFIBUSTM DP Node is capable of addressing a total of (128) coil
outputs, with diagnostic functionality built in. With proper assembly and termination the 580 PROFIBUSTM DP Node has
an IP65 rating.
This manual details specific information for configuring and commissioning the Aventics 580 PROFIBUSTM DP Node. For
more information relating to pneumatic valving and valve manifold assemblies, please refer to the Aventics 501, 502
and 503 Series catalogs at www.asco.com.
580 PROFIBUS DP Node Valve Side
Drives up to 128 coils
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2.1 Pneumatic Valve Manifold – 501 Series shown
The pneumatic valve manifold with internal circuit board technology is modular. The valve solenoid coil connections
are automatically made using Z-Board™ technology (plug together PC boards, which allow internal connection from
solenoid coils to output drivers without the use of wires). This allows easy assembly and field changes.
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2.2 Manifold Connectors
Solenoid Coil Connections using Z-BoardTM Technology for 501/502/503 valve series
Z-Board™ plug together technology connects all valve solenoids to the valve coil output drivers, located in the 580
Node. There is a maximum of 128 coil outputs available on the complete manifold assemblies. The 128 available
outputs are accessed on the 501 series valves utilizing 3 and 4 station manifolds and on the 502 and 503 series
utilizing 2 station manifolds.
A single solenoid valve’s coil is always on the “14” end.
NOTE!
14 Solenoid,
Pin No. 1
Common,
Pin No. 4
12 Solenoid,
Pin No. 2
Not Used,
Pin No. 3
Pin out of integral plug is the same for 501, 502,
and 503 Series valves manifolds
Manifold Z-Boards
TM
580 Node Connection to Z-Boards
TM
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2.3 Z-Board™ Connectors
The 501/502/503 valve series utilize 2 different Z-Board™ designs to achieve the single and double solenoid
output functions. This yields the possible 32 single, 16 double, or various combinations of valve coil output
capabilities. The 501 Z-Board™ is either (3) stations or (4) stations, the 502 and 503 Z-Board™ is minimum (2)
stations.
501 Series 502 Series
503 Series
Each series Z-Board
TM
can be selected in either SINGLE or DOUBLE output (coil) versions.
The SINGLE and DOUBLE output function cannot be mixed on the
Z
-
Boards
TM
NOTE!
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3. Zoned Power
3.1 503 Series Zoned Power application
The Zoned Power Manifold blocks can be incorporated into a 503 manifold assembly
to isolate Power to a number of valve stations, independent from the main power of
the manifold. This is achieved by the integral 4 Pin M12 connector along with the
modified manifold board. The total number of Zoned Power Manifold blocks is
determined by the maximum solenoid outputs as defined by the type of interface
(e.g. G3 Electronics, Terminal Strip, D-Sub). For user flexibility, the Zoned Power
Manifold blocks are available in both "proprietary" and "ISO" versions and can be
ordered with the M12 connector starting at the first or second station.
Technical Data:
Electrical Data
:
Voltage:
24 VDC (0 VDC must be common with main power)
Connection:
4 Pin M12 Single Key Male
Environmental:
IP65 (with proper connection)
V
W V Wiring Option
W Wiring Option
W & V Connector Pin Out
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3.2 503 Series Zoned Power example
In the example shown below there are two Zoned Power Manifold blocks used. One is a "W" wiring option
and the other is a "V" wiring option. The first (5) stations of the manifold assembly get their power from
the M12 4 Pin connector at station one. The next (5) stations get their power from the M12 4 Pin
connector at station six. Each of these "Zones" can be individually switched of if the machine or process
requires. This example is considered a manifold with (2) Power Zones. The Main Power (7/8" MINI) cannot
be considered or used as a Power Zone; Switched Power (Solenoid/Output Power) MUST be present for
control to the solenoids
24 VDC
V Wiring Option W Wiring Option
V
a
l
v
e
&
O
u
t
p
u
t
The 0 VDC reference for the +24 VDC applied to Pin 4 of the M12 connector MUST be the same
as the one used on G3/580/Terminal Strip/25 or 37 Pin Sub-D/19 or 26 Pin Round Connector.
If multiple 24 VDC power supplies are used the 0 VDC references of each supply MUST be
common.
NOTE!
N
o
d
e
&
I
n
p
u
t
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4. Communication Module
4.1 580 PROFIBUSTM DP Node
This module is the communication interface to the manifold. It contains communication electronics and internal short
circuit protection for power. It can be configured via the graphic display or via software (Class 2 Master required).
The Aventics 580 PROFIBUSTM DP node is tested by the ProfibusTM Interface Center to ensure compatibility and
interoperability.
Communication Interface Part Number
580 PROFIBUSTM DP Node P580AEPT1010A00
580 PROFIBUSTM DP Node w/DIN Rail P580AEPT1010DRM
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4.2 580 Node Description
Detail No. Description
1 5 Pin M12 Male Communication Connector per PTO specification
2 5 Pin M12 Female Communication Connector per PTO specification
3 Mounting Hole
4 5 Pin M12 Male Power Connector
5 Module Status LED
6 Network Status LED
7 SET Button – used to navigate through user menus and to set parameters
8 Graphic Display – used to display parameter information
9 NEXT Button – used to navigate through user menus and to set parameters
1
2
3
4
5
6
7
8
9
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4.3 Connector Pin-Outs
Industry standard connectors are used for communication and power. The PROFIBUSTM DP communication connectors
are a M12 reverse key 5 pin male connector and a M12 reverse key 5 pin female connector. The Power connector is an
M12 5 pin male connector.
PROFIBUSTM Communication Connector Pin-Out
Power Connector Pin-Out
Pin No. Function Description (FEMALE)
BUS OUT
Description (MALE)
BUS IN
1 +5 VDC
+5 V output from node, used for
termination of network or auxiliary
devices.
Not Connected
2 Data Line A RxD/TxD-N A-Line (Green) RxD/TxD-N A-Line (Green)
3 0VDC Common Data Ground Not Connected
4 Data Line B RxD/TxD-P B-Line (Red) RxD/TxD-P B-Line (Red)
5 N/C Not Connected Not Connected
Shell Shield Internally connected to Data
Ground
Internally connected to Data
Ground
Pin No. Function Description
1 +24 VDC
(Node) Voltage used to power node electronics UNSW
2 0 VDC Common
(Valves) 0 VDC Voltage used to power outputs (Valves) SW
3 0 VDC Common
(Node) 0 VDC Voltage used to power node electronics UNSW
4 +24 VDC
(Valves) Voltage used to outputs (Valves) SW
5 FE Functional Earth
!
Power common (0 VDC) pins 2 and 3 are isolated from each other to allow separate
(isolated) power supply connection if required. However, they can be tied together if a single
common, non-isolated, application is preferred.
The draw of the +24VDC Valves (Pin 4) and +24VDC Node (Pin 1), pins cannot exceed 4
Amps, at any given moment in time.
The Node pins supplies power to the node electronics. These pins must be powered at all
times for communication node to be functional.
To be connected to Class 2 power source only
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4.4 Electrical Connections
Standard Power Connector Wiring Diagram Examples
Single Power Supply Example (Non-isolated commons)
Separate Power Supply Example (Isolated commons)
Please see page 4-18 for external fuse sizing guide.
When using molded connector power cables, Do Not rely on wire colors for
Pin-Out. Always use pin number references.
To be connected to a Class 2 power source only
Class 2 Device Wiring Only – Do Not Reclassify and Install as Class 1, 3 or
Power and Lighting Wiring.
Wire connections shall be rated suitable for the wire size (lead and building
wiring) employed.
CLASS 2 WIRING: All filed wiring shall be suitable for class 1, Electric Light
and Power, or Class 2, Class 3 wirings are routed separately and secured to
maintain separation between 1) Class 2 wiring and all other class wiring, and
2) limited energy circuit conductors from unlimited energy circuit
conductors.
MULTIPLE CLASS 2 POWER SOURCES: when interconnects, Class 2 sources
shall be listed and rated suitable for parallel interconnection.
!
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4.5 Chassis Ground
All Aventics manifolds should be grounded for safety. Grounding guidelines can be found in National Electrical code IEC
60204-1 or EN 60204-1.
CHASSIS GROUND CONNECTION POINT,
501 VALVES
When grounding to a machine frame, please ensure that the machine frame itself is
already properly grounded.
Better grounding can be achieved when larger diameter (lower gauge) wire is used.
!
CHASSIS GROUND CONNECTION POINT,
502 & 503 VALVES
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4.6 Power Consumption
Power Connection
Pin No. Function Description
1 +24 VDC (Node) Voltage used to power node electronics UNSW
2 0 VDC Common (Valves) 0 VDC Voltage used to power outputs (Valves) SW
3 0 VDC Common (Node) 0 VDC Voltage used to power node electronics UNSW
4 +24 VDC (Valves) Voltage used to outputs (Valves) SW
5 FE Functional Earth
Power Rating
 The maximum system current capability is 4 Amps. Care should be taken not to exceed 4 Amp draw through
the power connector pins.
Component Voltage Tolerance
+24VDC
(Valve)
Pins 2 and 4
+24VDC
(Node)
Pins 1 and 3
Current Power Current Power
Solenoid Valve Coil 501 (Each) 24 VDC +10%/-15% 0.03 Amps 0.8 Watts NA NA
Solenoid Valve Coil 502 (Each) 24 VDC +10%/-15% 0.054 Amps 1.0 Watts NA NA
Solenoid Valve Coil 503 (Each) 24 VDC +10%/-15% 0.07 Amps 1.7 Watts NA NA
580 PROFIBUS
TM
DP Node 24 VDC +/- 10% NA NA 0.080 Amps 1.92 Watts
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4.7 Recommended External Fuses
External fuses should be chosen based upon the physical manifold configuration. Please refer to table below for
the fuse sizing chart.
External Fuse Sizing Chart
Power Consumption - Power Connector Pin for VALVES
Description Current
Number of Solenoid Valve Coils Energized Simultaneously
___ X 0.03 A (501 Series) = __________Amps
___ X 0.054 A (502 Series) = __________Amps
___ X 0.07 A (503 Series) = __________Amps
Total: __________Amps
Surge Compensation: X 1.25
Suggested External +24 VDC (Valves) Fuse Value: __________Amps
Power Consumption – Power Connector Pin for NODE
Description Current
Communication Node Power Consumption = 0.080 Amps
Surge Compensation: X 1.25
Suggested External Pin +24 VDC (Node) Fuse Value: 0.10 Amps
The Node Power pins supply power to the node electronics. These pins must be powered at all
times for the communication node to be functional. See page 4-14 for reference.
Reverse polarity protection is provided.
NOTE!
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4.8 Diagnostics – 580 PROFIBUSTM DP Node LED Functions
Upon power up, the Module and Network Status LEDs indicate the state of the unit. There are two LEDs on the 580
PROFIBUSTM DP node. The LEDs functions are described in the table below.
LED Name Color Status Description
NETWORK
STATUS
Red
ON Bus Error. Bus Connection failed or off-line; Invalid
parameterization, configuration, or bus address
FLASHING The module configuration in the user application is different
than the physical configuration of the manifold.
Green ON
Normal operation. The bus link is OK. Baud rate, detected
parameterization and configuration OK. Unit is in data
exchange mode.
MODULE
STATUS
Red ON Critical hardware fault. The microprocessor is not running.
Green ON Normal operation. Node hardware is OK.
Green Red FLASHING Module is in self-
test mode. Cycle power to end self-test mode.
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5. Extended Coil Capability
The Extended Coil manifolds must be connected to a 580 Electronics Node to operate. Not all 580
supported protocols will support the Extended Coil Manifolds. Below is a list of the hardware and
minimum firmware levels that support the Extended Coil Manifolds.
Module firmware revision levels can be confirmed in the integrated graphic display. See pg. 6-32
for more information.
5.1 Extended Coil Configuration
The Extended Coil Manifold can be configured to control 3 additional extended coil valve driver
assemblies; unless already configured from the factory. Modify the configuration with the graphic
display interface as shown on page 6-28.
Extended Solenoid Coil Capability requirements:
Module Part Number Firmware
Communication Module P580AEPT1010A00 Rev 2.0 Build 43053
Communication Module P580AEPT1010DRM Rev 2.0 Build 43053
Valve Series Number of Extended
Coil Valve Drivers Total number of coils Configuration Selection
Allocated number of I/O
Bytes designated for
valves
501
0 3-32 32 coils 4
1 33-64 64 coils 8
2 65-96 96 coils 12
3 97-128 128 coils 16
502/503
0 1-32 32 coils 4
1 33-48 64 coils 8
2 49-64 64 coils 8
3 65-80 96 coils 12
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