Kollmorgen AKT-PRB-000-000 User manual

I/O Terminal
Installation Manual
Revision 1.1, June 2011
AKT-PRB-000-000 PROFIBUS Coupler
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Copyright©Kollmorgen™2010–2011. All rights reserved. Kollmorgen holds the copyright to this manual. All rights are
reserved and no part of this publication may be reproduced or transmitted in any form or by any means without prior
written consent from Kollmorgen.
Disclaimer
The information in this manual was accurate and reliable at the time of its release. However, Kollmorgen. reserves
the right to change the specifications of the product described in this manual without notice at any time.
This document contains proprietary and confidential information of Kollmorgen. The contents of the document may
not be disclosed to third parties, translated, copied or duplicated in any form, in whole or in part, without the express
written permission of Kollmorgen.
Registered Trademarks
Kollmorgen is a registered trademark of Danaher Corp.
Technical changes which improve the performance of the device may be made without prior notice! Printed in the
Federal Republic of Germany. All rights reserved. No part of this work may be reproduced in any form (by printing,
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their respective owners.
June 2011
Revision Remarks
1.0 Preliminary edition
1.1 Added dimensions to technical data table and mechanical drawing to
Appendix B. For more information, see “Technical Data” page 8 and
“Appendix B” page 76.

I/O Terminal / CONTENTS
3
1Safety Precautions
1.1 Safety Rules............................................................................................6
1.2 State at Delivery......................................................................................6
1.3 Personnel Qualification...........................................................................6
1.4 Description of Notes and Warnings ........................................................6
2Overview
2.1 PROFIBUS Coupler (AKT-PRB-000-000) ..............................................7
2.1.1 Technical Data........................................................................................8
2.2 System Overview....................................................................................9
2.2.1 Bus Terminal System..............................................................................9
2.3 PROFIBUS DP......................................................................................11
2.4 PROFIBUS DPV1 .................................................................................12
3Mounting and Wiring
3.1 Dimensions ...........................................................................................13
3.2 Installation.............................................................................................14
3.3 Wiring....................................................................................................15
3.3.1 Potential Groups ...................................................................................15
3.3.2 Insulating Testing..................................................................................16
3.3.3 PE Power Contacts...............................................................................16
3.4 Power Supply........................................................................................17
3.4.1 Power Contacts Supply (Up).................................................................18
3.4.2 Power Contacts.....................................................................................18
3.4.3 Configuration and Programming Interface............................................18
3.4.4 Electrical Isolation.................................................................................19
3.5 PROFIBUS Connection ........................................................................19
3.5.1 M12 Circular Connector........................................................................19
3.5.2 Nine Pole D-Sub ...................................................................................20
3.5.3 PROFIBUS Conductor Colors...............................................................20
3.5.4 Connection of Fieldbus Box Modules ...................................................21
3.6 PROFIBUS Cabling...............................................................................21
3.6.1 Cable-Based Transmission...................................................................21
3.6.2 Cabling for Profibus DP and Profibus FMS ..........................................22
3.6.3 Distances ..............................................................................................23
3.6.4 Bus Segments.......................................................................................23
3.6.5 Installation Guidelines...........................................................................23
3.6.6 Checking the Profibus Wiring................................................................24
4Start-up Behavior of the Bus Coupler
4.1 Self-Test................................................................................................25
5Automatic Configuration
5.1 Scan Devices........................................................................................26

I/O Terminal / CONTENTS
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6Manual Configuration
6.1 The Bus Coupler’s UserPrmData..........................................................28
6.2 Configuration.........................................................................................31
6.2.1 Configuration: CfgData .........................................................................31
6.2.2 Configuration of the Coupler Modules ..................................................31
6.2.3 Configuration of Complex Modules.......................................................32
6.3 Cyclic Data Exchange...........................................................................33
6.3.1 Process Data and Image ......................................................................33
6.3.2 Standard-Bus Cycle..............................................................................35
6.4 DPV1 – Acyclic Data Transfer ..............................................................39
6.4.1 DPV1 Interface......................................................................................39
6.4.2 DPV1 at the Coupler.............................................................................41
7Extended Functions
7.1 2-byte PLC Interface.............................................................................47
7.2 Word Alignment.....................................................................................47
7.3 Deactivating the CfgData Check...........................................................48
7.4 Multi-Configuration Mode......................................................................49
7.4.1 Creating a DP Configuration for Various Implementation Levels.........49
7.4.2 Reserved Bus Terminals.......................................................................49
7.4.3 Assign Bus Terminals to Freely Choose Process Image Addresses ...49
7.4.4 Setting the Multi-configuration Mode ....................................................49
7.4.5 Rules for Multi-configuration Mode.......................................................49
7.4.6 Enabling/disabling Bus Terminals.........................................................50
7.5 Changing the Size of the Process Data................................................53
7.5.1 Exceeding the Input Data Length (InputData) ......................................53
7.5.2 Exceeding the Output Data Length (OutputData).................................53
7.5.3 Exceeding the Configuration Data Length (CfgData) ...........................53
8Error Handling and Diagnosis
8.1 Fieldbus LEDs.......................................................................................55
8.1.1 DIA-LED Blink Codes............................................................................56
8.1.2 Standard-Bus LEDs (Local Errors) .......................................................57
8.2 DP Diagnostic .......................................................................................58
8.2.1 DP Diagnostic Data (DiagData)............................................................58
8.2.2 Errors During DP Start-up.....................................................................62
8.2.3 Reaction to PROFIBUS Error ...............................................................64
8.3 Standard-Bus Diagnostic......................................................................64
8.3.1 Standard-Bus Interruption.....................................................................64
8.3.2 Terminal Diagnostics.............................................................................65
Appendix A
A.1 GSE File................................................................................................67

Performance Box Controllers / INTRODUCTION
5
Appendix B
B.1 AKT-PRB-000-000 Mechanical Drawing...............................................76

I/O Terminal / SAFETY PRECAUTIONS
6
1 SAFETY PRECAUTIONS
This chapter provides safety information for the I/O terminal.
1.1 Safety Rules
The appropriate staff must ensure that the application or use of the products described satisfy all
the requirements for safety, including all the relevant laws, regulations, guidelines and standards.
1.2 State at Delivery
All the components are supplied in particular hardware and software configurations appropriate
for the application. Modifications to hardware or software configurations other than those
described in the documentation are not permitted, and nullify any liability from Kollmorgen.
1.3 Personnel Qualification
This description is only intended for the use of trained specialists in control and automation
engineering who are familiar with the applicable national standards.
1.4 Description of Notes and Warnings
The following notes and warnings are used in this manual. They are intended to alert the reader
to the associated safety instructions.
Danger —This note is intended to highlight risks for the life or health of personnel.
Warning — This note is intended to highlight risks for equipment, materials or the environment.
Note — Indicates information that contributes to better understanding.

I/O Terminal / OVERVIEW
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2 OVERVIEW
This section provides an overview of the PROFIBUS Coupler.
Note: For information about configuring the PROFIBUS Coupler, see the Kollmorgen Automation
Suite™ IDE software and online help system.
2.1 PROFIBUS Coupler (AKT-PRB-000-000)
The Bus Coupler connects the PROFIBUS system to the electronic terminal blocks, which can be
extended in modular fashion. One unit consists of the Bus Coupler, any number of up to 64
terminals and one end terminal. Up to 64 digital input/output terminals can be connected.
The Bus Coupler recognizes the connected terminals and automatically generates the affiliations
of the inputs/outputs to the bytes of the process image. The first input/output signal is inserted in
the first bit of one byte (LSB), beginning from the left. The Bus Coupler inserts further signals in
this byte. Inputs and outputs are clearly separated. The Bus Coupler automatically begins a
further byte if the number of inputs or outputs exceeds 8 bits.
The Bus Coupler supports the operation of all Bus Terminals. As far as the user is concerned,
handling of the analog inputs/outputs is not different to other series. The information is available
in the process image of the controller for processing in the form of a byte array.
The Bus Terminals can be controlled by the control system. Via function blocks (FBs), the
programmable logic controller (PLC) or the handles configuration of the complete periphery
during the start up phase. If required, the controller can upload the de-centrally created
configuration data in order to centrally manage and store this data. Therefore, new adjustments
are not necessary in the event of replacement of a Bus Terminal. The controller automatically
sets the required setting on power up.
Figure 2.1 PROFIBUS Coupler (Front View)

I/O Terminal / OVERVIEW
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2.1.1 Technical Data
This section provides the technical details for the ETHERCAT Coupler.
Parameters (AKT-PRB-000-000)
Number of Bus Terminals 64
Digital peripheral signals 512 inputs/outputs
Analog peripheral signals 128 inputs/outputs
Configuration possibility IDE software or controller
Maximum number of bytes 64 bytes (DP and FMS operation)
128 bytes (DP operation only)
Baud rate (automatic detection) Up to max. 12 MBaud
Bus connection 1 x D-sub plug, 9-pin with shielding
Power supply 24 VDC (-15 % /+20 %)
Input current 70 mA + (total Standard-Bus current)/4, max. 500 mA
Starting current 2.5 x continuous current
Standard-Bus current up to 1750 mA (BK3x00)
Power contact voltage (Up) Maximum 24 VDC
Power contact current load (Up) Maximum 10 A
Recommended fuse (Up) Maximum 10 A
Electrical isolation Power contact / supply / fieldbus
Dielectric strength 500 Vrms (power contact / supply / fieldbus)
Dimensions (H × W ) 100 × 51 mm
Weight ~150 g
Permissible ambient temperature
(operation) 0 °C … +55 °C
Permissible ambient temperature
(storage) -25 °C … +85 °C
Permissible relative humidity 95 % (no condensation)
Vibration / shock resistance According to EN 60068-2-6 / EN 60068-2-27,
EN 60068-2-29
EMC resistance Burst / ESD According to EN 61000-6-2 (EN 50082) /
EN 61000-6-4 (EN 50081)
Protection class IP 20
Installation position Variable

I/O Terminal / OVERVIEW
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2.2 System Overview
This section provides a system overview for the PROFIBUS Coupler.
2.2.1 Bus Terminal System
Up to 64 Bus Terminals each having 2 I/O Channels for each Signal Form
The Bus Terminal system is the universal interface between a fieldbus system and the
sensor / actuator level. A unit consists of a Bus Coupler as the head station, and up to 64
electronic series terminals, the last one being an end terminal. For each technical signal form,
terminals are available each having two I/O channels, and these can be mixed in any order. All
the terminal types have the same mechanical construction, so that difficulties of planning and
design are minimized. The height and depth match the dimensions of compact terminal boxes.
Decentralized Wiring of Each I/O Level
Fieldbus technology allows more compact forms of controller to be used. The I/O level does not
have to be brought to the controller. The sensors and actuators can be wired de-centrally, using
minimum cable lengths. The controller can be installed at any location within the plant.
Programmable Automation Controllers (PAC)
The use of a PAC as the controller means that the operating and observing element can be
implemented in the controller’s hardware. The controller can therefore be located at an operating
panel, in a control room, or at some similar place. The Bus Terminals form the decentralized
input/output level of the controller in the control cabinet and the subsidiary terminal boxes. The
power sector of the plant is also controlled over the bus system in addition to the sensor/actuator
level. The Bus Terminal replaces the conventional series terminal as the wiring level in the control
cabinet. The control cabinet can have smaller dimensions.
Bus Couplers for all Usual Bus Systems
The Bus Terminal system unites the advantages of a bus system with the possibilities of the
compact series terminal. Bus Terminals can be driven within all the usual bus systems, thus
reducing the controller parts count. The Bus Terminals then behave like conventional connections
for that bus system. All the performance features of the particular bus system are supported.
Assembly on Standardized C Mounting Rails
The easy, space-saving, assembly on a standardized C-rail, and the direct wiring of actuators and
sensors, without cross-connections between the terminals, standardizes the installation. The
consistent labeling scheme also contributes.
The small physical size and the great flexibility of the Bus Terminal system allow it to be used
wherever a series terminal is also used. Every type of connection, such as analog, digital, serial
or the direct connection of sensors can be implemented.

I/O Terminal / OVERVIEW
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Modularity
The modular assembly of the terminal strip with Bus Terminals of various functions limits the
number of unused channels to a maximum of one per function. The presence of two channels in
one terminal is the optimum compromise of unused channels and the cost of each channel. The
possibility of electrical isolation through potential feed terminals also helps to keep the number of
unused channels low.
Display of the Channel State
The integrated LEDs show the state of the channel at a location close to the sensors and
actuators.
Standard-Bus
The Standard-Bus is the data path within a terminal strip. The Standard--Bus is led through from
the Bus Coupler through all the terminals via six contacts on the terminals’ side walls. The end
terminal terminates the Standard-Bus. The user does not have to learn anything about the
function of the Standard-Bus or about the internal workings of the terminals and the Bus Coupler.
Many software tools that can be supplied make project planning, configuration and operation
easy.
Potential Feed Terminals for Isolated Groups
The operating voltage is passed on to following terminals via three power contacts. You can
divide the terminal strip into arbitrary isolated groups by means of potential feed terminals. The
potential feed terminals play no part in the control of the terminals, and can be inserted at any
locations within the terminal strip.
Up to 64 terminals can be used within one terminal strip. This count does include potential feed
terminals, but not the end terminal.
Bus Couplers for Various Fieldbus Systems
Various Bus Couplers can be used to couple the electronic terminal strip quickly and easily to
different fieldbus systems. It is also possible to convert to another fieldbus system at a later time.
The bus coupler performs all the monitoring and control tasks that are necessary for operation of
the connected Bus Terminals. The operation and configuration of the Bus Terminals is carried out
exclusively by the Bus Coupler. Nevertheless, the parameters that have been set are stored in
each Bus Terminal, and are retained in the event of voltage drop-out. Fieldbus, Standard--Bus
and I/O level are electrically isolated.
If the exchange of data over the fieldbus is prone to errors or fails for a period of time, register
contents (such as counter states) are retained, digital outputs are cleared, and analog outputs
take a value that can be configured for each output when commissioning. The default setting for
analog outputs is 0 V or 0 mA. Digital outputs return in the inactive state. The timeout periods for
the Bus Couplers correspond to the usual settings for the fieldbus system. When converting to a
different bus system it is necessary to bear in mind the need to change the timeout periods if the
bus cycle time is longer.
The Interfaces
A Bus Coupler has six different methods of connection. These interfaces are designed as plug
connectors and as spring-loaded terminals.