ICP DAS USA ICP CON GW-7557 User manual

GW-7557 PROFIBUS/HART Gateway
User's Manual
GW-7557 PROFIBUS/HART Gateway User Manual (Version 1.00, Dec/2011) PAGE:1
High Quality, Industrial Data Acquisition, and Control Products

GW-7557 PROFIBUS/HART Gateway User Manual (Version 1.00, Dec/2011) PAGE:2
Warranty
All products manufactured by ICP DAS are under warranty regarding
defective materials for a period of one year from the date of delivery to the
original purchaser.
Warning
ICP DAS assumes no liability for damages resulting from the use of this
product. ICP DAS reserves the right to change this manual at any time
without notice. The information furnished by ICP DAS is believed to be
accurate and reliable. However, no responsibility is assumed by ICP DAS
for its use, or for any infringements of patents or other right of third parties
resulting from its use.
Copyright
Copyright 2011 by ICP DAS. All rights are reserved.
Trademark
The names used for identification only may be registered trademarks of
their respective companies.
List of Revision
Date Author Version Revision
2012/03/30 Ryan 1.10 Release

GW-7557 PROFIBUS/HART Gateway User Manual (Version 1.00, Dec/2011) PAGE:3
Table of Contents
1. Introduction 4
1.1 Features 5
1.2 Specification 5
2. Hardware 7
2.1 Block Diagram of GW-7557 7
2.2 Pin Assignment 7
2.3 Wiring 9
2.4 Setting the PROFIBUS Address 13
2.5 LED status indicator 15
2.6 Normal/Setting DIP switch 16
2.7 Jumper 17
3.1 PROFIBUS data exchange 18
3.2 HART data exchange 19
3.3 Communication protocol transfer 20
4. Communication 23
4.1 Field of application 23
4.2 GSD file 24
4.3 The Configuration of the common parameters 26
4.4 The Configuration of the modules 28
4.5 Diagnostic messages 30
4.6 I/O data exchange 32
4.7 Establish connection with GW-7557 34
4.8 Data exchange example — Transparent format 36
4.9 Data exchange example — Compact format 44
5. Application of Utility 55
5.1 Install Utility 55
5.2 Utility introduction 58
5.3 Establish connection with GW-7557 69
6. Troubleshooting 72
7. Dimensions 73
Appendix A. HART Command 75

1. Introduction
PROFIBUS and HART are two kinds of famous protocols and are wildly used in the
fields of factory and process automation. The GW-7557 is a PROFIBUS to HART
gateway. By using this module, users can easily put the HART slave devices into
PROFIBUS network. Figure 1 shows an application example for the GW-7557
module.
Figure 1 Application architecture of the GW-7557 module
The GW-7557 gateway is specially designed for the slave device of PROFIBUS DP
protocol. In the HART application, the GW-7557 can be a HART master device. The
HART slave devices can exchange data with the PROFIBUS master device via the
GW-7557 module.
The main features and specification of GW-7557 are described as below:
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1.1 Features
●16-bit Microprocessor inside with 80MHz
●Profichip VPC3+C PROFIBUS controller
●Support PROFIBUS DP-V0 slave
●PROFIBUS transmission rate detect automatically
● Max transmission speed up to 12 Mbps for PROFIBUS and 115.2 kbps for
COM Port
● COM Port driver has 1K bytes QUEUE input buffer & 512 bytes QUEUE
output buffer
● Allow two HART masters
● Working in point-to-point or multi-drop HART mode
● Support 4 HART channels
● Connecting up to 15 HART slave devices per HART channel
● Support HART Short/Long frame
●Support HART burst mode
●2500Vrms High Speed iCoupler Isolation Protection for PROFIBUS network
●3000VDC Isolation Protection on the PROFIBUS side
● Provide LED indicators
● Built-in Watchdog
●Mountable on DIN Rail
1.2 Specification
COM Port specs:
●Serial port - RS-232
●Serial port interface: screw terminal block
●Baud Rate：2400/4800/9600/19200/38400/57600/115200 bps
●Data Format: 7/8 data bits, None/Odd/Even parity bit, 1/2 stop bit
PROFIBUS specs:
●PROFIBUS interface connector: D-Sub 9-pin female
●Baud Rate: 9.6k/19.2k/45.45k/93.75k/187.5k/500k/1.5M/3M/6M/12Mbps
●Address Setting: 0~126 (set by DIP switch or EEPROM)
HART specs:
● 4 HART channels
● HART port interface: screw terminal block
● Working in point-to-point or multi-drop HART mode
● Connecting up to 15 HART slave devices per HART channel
● Support HART Short/Long frame
● Support HART burst mode

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● Allow two HART masters
Power requirement:
●Unregulated +10 ~ +30 VDC
●Power reverse protection, Over-Voltage brown-out protection
●Power consumption 2.0W
Module specs:
●Dimensions: 119mm x 72mm x 33mm
●Operating temperature: -25 ~ 75 ºC
●Storage temperature: -30 ~ 85 ºC
● Humidity：5 ~ 95% RH, non-condensing
● LED Status Indicators(Table 1)
Table 1: LED status indicator
PWR LED Show the power state
Show data state
ERR LED Show error state
RUN LED Show communication state of PROFIBUS

2. Hardware
2.1 Block Diagram of GW-7557
Figure 2 Block diagram of GW-7557
2.2 Pin Assignment
Figure 3 Pin assignment of GW-7557
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Table 2 14-pin screw terminal block
Pin Name Description
1 HART 0+ Positive of HART channel 0
2 HART 0- Negative of HART channel 0
3 HART 1+ Positive of HART channel 1
4 HART 1- Negative of HART channel 1
5 HART 2+ Positive of HART channel 2
6 HART 2- Negative of HART channel 2
7 HART 3+ Positive of HART channel 3
8 HART 3- Negative of HART channel 3
9 RX Receive Data of RS-232
10 TX Transmit Data of RS-232
11 GND GND of RS-232
12 INIT* Initial Pin
13 +VS V+ of Power Supply(+10 ~ +30 VDC)
14 GND GND of Power Supply
Table 3 PROFIBUS DB9 Female Connector
Pin Name Description
1 - N/A
2 - N/A
3 B Non-inverting Bus Line
4 ISODE Isolated DE output for use in PROFIBUS
applications where the state of the isolated drive
enable node needs to be monitored.
5 GND Power supply ground for the first node and the last
node
6 VP +5V Power Supply for the first node and the last
node
7 - N/A
8 A Inverting Bus Line
9 - N/A
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2.3 Wiring
GW-7557 supports PROFIBUS to HART communication. The following section
describes the connection interface of GW-7557.
2.3.1 RS-232 connection
The RS-232 port of the GW-7557 has got three pins. The wiring of the RS-232
device with the RS-232 port of the GW-7557 is shown in Figure 4.
RS-232 device
GW-7557
RS-232
p
or
t
Figure 4 RS-232 wiring diagram
2.3.2 PROFIBUS connection
The PROFIBUS interface of the GW-7557 is a DB9 female connector. The
connector uses the standard PROFIBUS 9 pin assignment. It is recommended to
use a standard PROFIBUS cable and connector (DB9 male). As with every
serial bus the rate of safe data transmission in a PROFIBUS network decreases
with increasing distance between Master and Slave. Table 4 shows the
transmission rate and range for a cable with the following properties:
1. Impedance :135~165 Ω
2. Capacity : lower than 30 pF/m
3. Loop resistance : lower than 110 Ω/km
4. Wire diameter : greater than 0.65 mm
5. Core cross-section : greater than 0.34 mm2
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Table 4 Transmission rate decreasing with increasing transmission distance
Transmission Rate(kbps) Transmission Distance per Segment (meter)
9.6, 19.2, 45.45,93.75 1200
187.5 1000
500 400
1500 200
3000, 6000, 12000 100
In order to minimize the reflection effect of signal transmission, both ends (first
node and last node) of a PROFIBUS segment needs to be equipped with an
active terminal resistor as shown in Figure 5. A standard PROFIBUS connector
is usually already equipped with a terminal resistor. The user therefore only has
to switch on the resistor of the devices stationed at the ends of a segment as
shown in Figure 6.
Figure 5 PROFIBUS connection
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Terminator Switch
Terminator OFF
Terminator ON
Figure 6 PROFIBUS connector
The number of stations in a PROFIBUS network is restricted to 126. According
to the PROFIBUS specification up to 32 stations are allowed per segment. A
repeater has to be used to link the bus segments.
2.3.3 HART connection
The HART connection is divided into two types: “Loop Power Source” and
“External Power Source”, as shown in the below:
Figure 7 Loop Power Source (1)
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Figure 8 Loop Power Source (2)
Figure 9 Loop Power Source (3)
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Figure 10 External Power Source
2.4 Setting the PROFIBUS Address
The station address of GW-7557 can be set by using the DIP switch or by writing
it directly to the EEPROM. The DIP switch covers a range from 0 to 255. The
valid address range of a PROFIBUS station spans from 0 to 126. Table 5 shows
three examples of setting the station address by using the DIP switch. The DIP
switches are accessed by opening the modules housing (Figure 11). Table 6
explains which address will be used by the module after power on, if the DIP
switch address setting differs from the address stored in the EEPROM.
Table 5 DIP switch setting example
DIP switch (SW1)
Station address
1 2 3 4 5 6 7 8
1 1 0 0 0 0 0 0 0
10 0 1 0 1 0 0 0 0
126 0 1 1 1 1 1 1 0
Note: 1=>ON, 0=>OFF
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Table 6 The Address setting of the GW-7557
DIP switch Setting Description
0~125
1. The address setting of the EEPROM is ignored.
2. The address can not be set by the PROFIBUS configuration
tool.
126-254
1. The address setting of the DIP switch is ignored.
2. If the address in the EEPROM is 126, the PROFIBUS
configuration tool can set a new address and save it to the
EEPROM.
255 1. Slave address in the EEPROM is set to 126.
Figure 11 DIP switch
Each Slave must have a unique valid address (1 to 125) in order to be able to
communicate with the master. To change the address by using the configuration
tool it is necessary to first set the address that stored in the EEPROM to 126. This
is done by setting the DIP switch to 255 in the power off state. Switching the
module on is forcing the module to change its address that stored in the EEROM
to 126. In the next step switch the module off and change the DIP switch setting
to any value from 126 to 254. This step is necessary in order to prevent the
module to change its address that stored in the EEPROM to 126 every time. The
configuration tool can assign a new address to slave now.
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2.5 LED status indicator
The GW-7557 provides three LEDs to indicate the statuses of the GW-7557
module. The position of LEDs and descriptions are shown in Table 7 and Figure
12.
Table 7 LED status description
LED Name Status Description
flash Power supply is ok.
HART port is transmitting or receiving HART frame.
on Power supply is ok.
The firmware has loaded.
PWR
off Power supply has failed.
flash
When the GW-7557 connects with the utility tool, it
will flash fast (flash once about 55ms).
When the GW-7557 has diagnostic message, it will
flash slowly (flash once about 220ms).
on
Connection error between PROFIBUS Master and
Slave or
PROFIBUS system has not been configured
correctly.
ERR
off Normal operation
PROFIBUS system has been configured correctly
on Data exchange mode
Normal operation.
RUN
off GW-7557 module is not in a data exchange mode.

Figure 12 LED position
2.6 Normal/Setting DIP switch
There is a DIP switch on the back of the GW-7557 module, as shown in Figure 13.
The DIP switch is used to set the communication settings of COM port. In the normal
situation, it needs to set the DIP switch to the “Normal” position. If the user forgets
the communication settings of COM port. The user can sets the DIP switch to the
“Setting” position, the communication settings of COM port will be started at default
settings.
PS:
About default settings are shown in the below:
Baudrate：115200 bps
Data bit：8 bits
Stop bit：1 bit
Parity：None
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Figure 13 DIP switch of the GW-7557
2.7 Jumper
There are four Jumpers (JP5~JP8) at the GW-7557 module, as shown in Figure 14.
These jumper can provide HART channel with 250 Ω(1/4 W) resistor. When the pin
1&2 of JP5 is closed, the resistor will connect to HART channel 0. When the pin 2&3
of JP5 is closed, it will disconnect the resistor from HART channel 0. By default, the
pin1&2 of JP5 is closed. Please refer to section 2.3.3 HART connection for detail.
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PS:
The relation between jumpers and
HART channels is shown in below:
JP5 => Channel 0
JP6 => Channel 1
JP7 => Channel 2
JP8 => Channel 3
Figure 14 Jumpers of GW-7557

3. Communication protocol transfer theorem
3.1 PROFIBUS data exchange
The GW-7557 is a PROFIBUS DP slave device. The GW-7557 is first
parameterized then configured and finally it goes into the data exchange mode
(Figure 15).
Figure 15 State machine of PROFIBUS DP Slave device
The GW-7557 exchanges data cyclically between internal Output Queue、Input
Queue and PROFIBUS Master device in data exchange mode, as shown in Figure
16.
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Figure 16 Data exchange between PROFIBUS master device and GW-7557
The GW-7557 downloads the parameter and configuration from PROFIBUS
master device to be the module parameters. The GW-7557 and PROFIBUS master
device have different data type and data address, the GW-7557 can transfer
different data format to PROFIBUS master device through module parameters.
3.2 HART data exchange
HART protocol belongs to Master-Slave communication and it uses query and
response message to arrive at data exchange and device control, as shown in
Figure 17.
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Figure 17 Data exchange between the HART slave devices and the GW-7557
3.3 Communication protocol transfer
In section 3.1 and 3.2, we can understand that data exchange is through Output
Queue、Input Queue of the GW-7557 between PROFIBUS Master、HART slave
devices and the GW-7557. The data exchange runs continuously between
PROFIBUS master、HART slave device and the GW-7557, as shown in Figure
18 and Figure 19
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