Moeller CM4-505-GV1 User manual

Moeller GmbH
Industrial Automation
Hein-Moeller-Str. 7–11
D-53115 Bonn
E-Mail: in [e-mail]
Internet: www.moeller.net
© 2001 by Moeller GmbH
Subject to alteration
AWB2700-1409GB DMD MDS B+W 04 01
Printed in the Federal Republic of Germany (04 01)
Article No.: 231344
Hardware and Engineering
CM4-505-GV1
CM4-505-GV2
AS-i/PROFIBUS-Gateways
Think future. Switch to green. Think future. Switch to green.
SystemsIndustrial Automation Building Automation
AWB2700- 409GB 04/0
CM4-505-GV. AS-i/PROFIBUS-Gateways
AWB 2700-1409 GB (Bund 5mm) 18.05.2001 11:48 Uhr Seite 1

AS-i/PROFIBUS Gateway Table of Contents
issue date22.6.2001
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Table of Contents
1The Used Symbols ...................................................................................5
2Safety ........................................................................................................7
2.1 Intended Use ........................................................................................................... 7
2.2 General Safety Information .................................................................................... 7
3General Information .................................................................................9
4Connections, Displays and Operating Keys ........................................11
4.1 Power Supply Concepts and AS-i Connection Techniques ............................. 12
4.1.1 Single Masters in IP65 ............................................................................................ 12
4.1.2 Single Masters in IP20 with Power Supply A .......................................................... 12
4.2 The PROFIBUS Interface ...................................................................................... 13
4.2.1 Devices in IP20 ....................................................................................................... 13
4.2.2 Devices in IP65 ....................................................................................................... 14
4.3 Display and Operating Elements ......................................................................... 14
4.3.1 LEDs of the Single Masters ....................................................................................14
5Operating the AS-i/PROFIBUS Gateway ..............................................17
5.1 Master Start-Up ..................................................................................................... 17
5.2 Configuration Mode .............................................................................................. 17
5.3 Protected Operating Mode ................................................................................... 18
5.3.1 Switching to Protected Operating Mode ................................................................. 18
5.3.2 Configuration Errors in Protected Operating Mode .................................................18
5.4 Assigning an AS-i Address in Configuration Mode .......................................... 19
5.4.1 Assigning a Slave Address ..................................................................................... 19
5.4.2 Erasing the Slave Address ..................................................................................... 19
5.5 Programming the Address in Case of Configuration Errors ............................ 20
5.5.1 Automatic Address Assignment .............................................................................. 20
5.5.2 Manual Address Assignment .................................................................................. 20
5.6 Setting of the PROFIBUS Station Address ......................................................... 21
5.6.1 PROFIBUS Station Address ................................................................................... 21
5.7 Error Messages ..................................................................................................... 21
6Advanced Diagnostics for AS-i Masters ..............................................23
6.1 List of Corrupted AS-i Slaves (LCS) ................................................................... 23
6.2 Error Counters: Counters of corrupted data telegrams .................................... 23
6.3 Off-line Phase on Configuration Errors (LOS) ................................................... 24
7PROFIBUS-DP ........................................................................................25
7.1 DP Telegrams ........................................................................................................ 25
7.1.1 Diagnosis ................................................................................................................25
7.1.2 Configuration DP V0 (cyclic data) ........................................................................... 28
7.1.3 I/O-Data .................................................................................................................. 29
7.2 DP V1 ..................................................................................................................... 32

AS-i/PROFIBUS Gateway Table of Contents
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7.3 Mailbox ...................................................................................................................32
7.3.1 Construction ............................................................................................................32
7.3.2 Mailbox commands .................................................................................................35
7.3.3 Mailbox example .....................................................................................................60
8Commissioning Tools and Accessories .............................................. 63
8.1 Windows Software AS-i Control Tools ...............................................................63
8.2 PROFIBUS-DP master simulator .........................................................................66
8.3 Serial PROFIBUS Master ......................................................................................67
9Appendix: Displays of the Figure Display ........................................... 69
10 Appendix: The First Commissioning of AS-i ...................................... 71
11 Appendix: Putting PROFIBUS into Operation with a Siemens S5 .... 73
11.1 Putting into Operation in Easy Mode ..................................................................73

AS-i/PROFIBUS Gateway The Used Symbols
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1The Used Symbols
This symbol warns the user of possible danger. Failure to heed this
warning can lead to personal injury or death and/or damage to equip-
ment.
This symbol warns the user of a possible failure. Failure to heed this
warning can lead to total failure of the equipment or any other con-
nected equipment.
This symbol gives the user important hints.

AS-i/PROFIBUS Gateway The Used Symbols
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AS-i/PROFIBUS Gateway Safety
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2Safety
2.1 Intended Use
2.2 General Safety Information
The protection of operating personnel and the system against possible
danger is not guaranteed if the control interface unit is not operated in
accordance with its intended use.
The device may only be operated by appropriately qualified personnel
in accordance with this operating manual.
Safety and correct functioning of the device cannot be guaranteed if any
operation other than that described in this operation manual is per-
formed.
The connecting of the equipment and any maintenance work to be car-
ried out with voltage applied to the equipment must only be performed
by appropriately qualified electrotechnical personnel.
In the case that a failure cannot be repaired, the device must be taken
out of operation and kept from inadvertently put back into operation.
Repair work is to be carried out by the manufacturer only. Additions or
modifications to the equipment are not allowed and void the warranty.
The operator is responsible for the observance of local safety stan-
dards.

AS-i/PROFIBUS Gateway Safety
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AS-i/PROFIBUS Gateway General Information
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3General Information
This operating instruction is for use with the following devices of the Moeller GmbH:
•AS-i/PROFIBUS-DP gateway power supply A Article no. CM4-505-GV1
•AS-i/PROFIBUS-DP gateway IP65 power supply A Article no. CM4-505-GV2
The AS-i/PROFIBUS-Gateways serve to connect AS-Interface systems to the
PROFIBUS. They act as a Master for the AS-Interface and as a slave for the
PROFIBUS.
New AS-i Specification 2.1
The AS-i/PROFIBUS-DP Gateways already fulfil the new AS-i Specification 2.1. This
means:
•Up to 62 AS-Interface slaves can be connected per 1 AS-i network
•The transfer of analog signals via AS-i is integrated in the Masters
•All further functions of the new specification as e.g. the diagnosis of the AS-i pe-
ripheral fault are implemented.
All AS-i functions are provided cyclically via PROFIBUS-DPV0 and acyclically via
PROFIBUS-DPV1.
In the cyclic data transfer optionally up to 32bytes I/O data are transfered for the bi-
nary data of 1AS-i network. Furthermore analog signals and all further commands of
the new AS-i specification can be transferred in the management channel via
PROFIBUS.
The AS-i Control Tools can be used for the monitoring of the AS-i data online via the
PROFIBUS-DPV1.
Advanced Diagnostics
Diagnostics, which go far beyond the standard diagnostics facilitate the simple detec-
tion of the occassionally occuring configuration errors and further irritations towards
the AS-i communication. So in case of an error the down time of machines can be
minimized or you can initiate preventive maintenance.
Two Sorts of Housing
The AS-i PROFIBUS Gateways with one Master can be delivered in a housing for
cabinet mounting or in a field housing in IP65. The handling of the AS-i/PROFIBUS
Gateway in IP65 is identically with the AS-i/PROFIBUS-DP Gateway in IP20. The
high protection category IP65 makes the device suitable for applications in the ex-
treme industrial environments frequently encountered in the field. AS-Interface is con-
nected using the penetration technique of EMS (Electromechanical Interface).
PROFIBUS is connected with heavy gauge terminals and cage clamp terminal blocks.
Commissioning and monitoring
The AS-i/PROFIBUS Gateways can be commissioned respectively programmed with
the help of the software "AS-i Control Tools" in combination with the PROFIBUS-DP
Master Simulator. The GSD file are included in the package.

AS-i/PROFIBUS Gateway General Information
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Commissioning, debugging and setting up of the AS-i parameters without the soft-
ware can only be accomplished with the use of two push-buttons, the display and the
LEDs directly on the system.
Accessories
Software "AS-i Control Tools"
PROFIBUS-DP Master Simulator DP V1
D-Sub data transmission cord for AS-i masters in IP65

AS-i/PROFIBUS Gateway Connections, Displays and Operating Keys
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4Connections, Displays and Operating Keys
Devices in IP20:
On the front panel of the AS-i/PROFIBUS gateways in IP20 are:
•terminals to connect the power supply and the AS-i circuit
•a 9-pin SUB-D connector as PROFIBUS interface
•7 LEDs
•a two-digit seven-segment display
•2 push-buttons to configure the gateway
Devices in IP65:
The devices in IP65 have the terminals for PROFIBUS (cage clamp terminals) and
the push buttons under the top of the housing to prevent liquids from entering. The
AS-interface is connected with the electromechanical interface with penetration tech-
nique developed for AS-i at the bottom of the housing.

AS-i/PROFIBUS Gateway Connections, Displays and Operating Keys
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4.1 Power Supply Concepts and AS-i Connection Techniques
An AS-i power supply has to be used which also supplies the AS-i master with power
and can be connected to the AS-i cable like all the other AS-i components at any
place.
4.1.1 Single Masters in IP65
Every AS-i master and all the AS-i gateways in IP65 come with power supply A. The
AS-i master is connected to AS-i using the penetration technique of the electrome-
chanical interface which is common with AS-i slaves as well.
4.1.2 Single Masters in IP20 with Power Supply A
The terminals have the following functions:
+"AS-i +", Actuator Sensor Interface, positive terminal
-"AS-i -", Actuator Sensor Interface, negative terminal
GND Ground terminal, used for better EMC.
Should be connected with a short wire to machine GND.
The AS-i masters do not need a voltage supply of their own. They can
be powered completely out of the AS-i line (the power consumption is
about 200 mA from AS-i). An additional 24 V voltage source is not nec-
essary. The AS-i master merely requires the connection to the AS-i line.
When the AS-i power supply is switched on, the master starts to oper-
ate.
AS-i Master
AS-i power
AS-i
Slave AS-i Slave AS-i Slave
AS-i power
supply
AS-i master
AS-ipower
GND
+
-
+ -

AS-i/PROFIBUS Gateway Connections, Displays and Operating Keys
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4.2 The PROFIBUS Interface
4.2.1 Devices in IP20
The PROFIBUS interface is realized as a 9-pin SUB-D connector, in accordance to
the standard for PROFIBUS DIN 19245. It is placed on the right hand side of the front
panel.
The AS-i/PROFIBUS gateway sends and receives on pins 3 and 8 of the SUB-D sock-
et. The PROFIBUS signal “RxD/TxD-N (data line A)1” lies on pin 8, the signal “RxD/
TxD-P (data line B)1” lies on pin 3.
The pins 5 (0V) and 6 (5V) supply 5VDC for the bus termination.
Connection samples for the AS-i power supply:
In the wiring schemes above the current through the AS-i master
must not exceed 5 A.
1. If you measure the DC voltage between RxD/TxD-P (data line B) and RxD/TxD-N (data line A), RxD/TxD-P (data line B) is the positive pole
when the bus is silent.
AS-i Master
max. 5 A
PELV according to EN
60950 (Protective
extra low voltage)
AS-i
power
supply
-
+
AS-i Slave
-
+
AS-i Slave
-
+
GND
AS-i Master
max. 8 A
PELV according to EN 60950
(Protective extra low voltage)
AS-i
power
supply
-
+
AS-i Slave
-
+
AS-i Slave
-
+
GND
5
4
3
2
1
9
8
7
6
RxD/TxD-P
(data line B)
RxD/TxD-N
(data line A)
PROFIBUS

AS-i/PROFIBUS Gateway Connections, Displays and Operating Keys
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4.2.2 Devices in IP65
The AS-i/PROFIBUS gateway in IP65 can be connected to PROFIBUS with cage
clamp terminals inside of the device. For that purpose the top of the housing has to
be screwed off.
You can use a SUB-D data cable as an accessory part forAS-i masters in IP65 which
is led through the heavy gauge terminals and is connected after the following colour
scheme:
3 - green, 4 - yellow, 5 - blue, 10 - red
The device in IP65 is powered out of theAS-i line to which it is connected by the elec-
tromechanical interface (penetration technique as it is used with AS-i slaves).
Bus Termination
IftheAS-i/PROFIBUS gateway is attheendofthe PROFIBUS line, bothDIP-switches
have to be switched on to terminate the bus with the built-in termination resistors.
If the gateway is not at the end of the line, swith off both DIP switches.
4.3 Display and Operating Elements
On the front panel of the AS-i/PROFIBUS gateway are seven light-emitting diodes, a
two-digit display and two push buttons.
With the devices in IP65 the push buttons are situated inside of the housing to avoid
liquids from entering. The top of the housing has to be screwed off to operate these
push buttons.
4.3.1 LEDs of the Single Masters
power The master's power supply is sufficient.
bus active LED on: Gateway is allocated to a PROFIBUS master.
LED off: Gateway is not allocated to a PROFIBUS master.
config err Configuration error
At least one configured slave is missing, or at least one detected
slave is not projected or for at least one projected and detected
slave the actual configuration data does not match the nominal
configuration data.
Connection of PROFI-
BUS
interface on cage clamp
terminal block and
arrangement on circuit
board:
1RxD/TxD-N (data line A)
2RxD/TxD-P (data line B)
3RxD/TxD-N (data line A)
4RxD/TxD-P (data line B)
50 V
6Shield
7FG function ground
8FG function ground
9Shield
10 +5 V
10 6789
12354
clamp terminal block
buttons DIP switches
off

AS-i/PROFIBUS Gateway Connections, Displays and Operating Keys
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This LED blinks if there is at least one periphery fault at one AS-i
slaveinthe AS-i network.Ifthereareconfigurationerrors as well
as periphery faults, only configuration error is displayed.
U ASI The AS-i circuit is sufficiently powered.
ASI active Normal operation active.
(Blinks, if an B slave is displayed)
prg enable Automatic address programming enabled.
Exactly one slave is missing in protected operating mode. The
slave can be replaced by another slave of the same type with ad-
dress zero. The master addresses the new slave to the faulty ad-
dress and thus eliminates the configuration error.
prj mode The AS-i master is in configuration mode.

AS-i/PROFIBUS Gateway Connections, Displays and Operating Keys
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AS-i/PROFIBUS Gateway Operating the AS-i/PROFIBUS Gateway
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5Operating the AS-i/PROFIBUS Gateway
5.1 Master Start-Up
After powering on, all segments of the figure display and all LEDs light up for approx-
imately one second (self-test). Afterwards, the LEDs display the condition of their re-
spective flags. The figure display shows the condition of the master:
40 Off-line Phase
The AS-i master initializes - there is no data communication on the AS-i.
In configuration mode or when an AS-i Control program is started auto-
matically the device can leave the off-line phase.
In protected mode, if the PROFIBUS communication is interrupted, the
AS-i master switches to the off-line phase after the watchdog time of the
PROFIBUS has expired unless an AS-i Control program is running and
was started automatically.
41 Detection Phase
Start of the start-up phase, where the system looks for slaves located on
the AS-i. The master remains in the detection phase until it finds at least
one slave.
42 Activation Phase
Condition at the end of the start-up operation where the parameters are
transmitted to all connected and recognized slaves. This enables access
to the AS-i slaves’ data connections.
431Start of Normal Operation
In normal operation the AS-i master can exchange data with all active
slaves. It transmits management messages and looks for and activates
newly connected slaves. During normal operation, the system keeps the
maximum cycle time of 5 milliseconds.
5.2 Configuration Mode
The configuration mode serves to configure the AS-i circuit.
If the AS-i circuit is insufficiently powered (“U AS-i”
does not light up) or there is no communication relation-
ship between the PROFIBUS master and the AS-i/PROFI-
BUS gateway, the master remains in the off-line phase.
1. Activation phase and the start of normal operation maybe so short that the numbers can not be seen in the display.
In the configuration mode, all recognized slaves are activated even
when the desired and actual configurations do not match.

AS-i/PROFIBUS Gateway Operating the AS-i/PROFIBUS Gateway
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Pressing the “mode” button for at least five seconds switches the master to configu-
ration mode. While in configuration mode, the yellow “prj mode” LED lights up.
The system then displays one after the other all detected slaves at a speed of two per
second. First all "A" slaves and afterwards all "B" slaves. If the display is empty, no
slaves were detached on the AS-i circuit.
In configuration mode, all recognized slaves are activated except of slave zero. The
AS-i master is in normal operation. There is data exchange between the AS-i master
and all AS-i slaves detected by the master regardless of whether the detected AS-i
slaves were projected before.
5.3 Protected Operating Mode
5.3.1 Switching to Protected Operating Mode
The configuration mode can be left by pressing the “mode” button.
Pressing the button shortly:
Exits the configuration mode without projecting the current AS-i configuration.
Pressing the button for more than five seconds:
Exits the configuration mode and projects the actual AS-i configuration. Simul-
taneously the actualAS-i configuration is stored as nominal configuration in the
EEPROM.
In the protected operating mode, only AS-islaves that are projected andwhoseactual
configurations match the nominal configurations will be activated.
5.3.2 Configuration Errors in Protected Operating Mode
As long as there is no configuration error, the numeric display is turned off while in
protected operating mode. Otherwise, the address with a faulty assignment is dis-
played. A faulty assignment occurs when a slave has been recognized or projected
but cannot be activated.
If there are more than one faulty assignments the one that was first detected is dis-
played. Pressing the “” button shortly displays the next higher faulty address.
When delivered the device is in configuration mode.
In contrast with the configuration mode in the protected mode there is
only data exchange between the AS-i master and the projected AS-i
slaves.
If the system detects anAS-i slave with address zero on theAS-i, it can
not leave the configuration mode.

AS-i/PROFIBUS Gateway Operating the AS-i/PROFIBUS Gateway
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Shortly appearing configuration errors are stored in the device (advanced AS-i diag-
nosis). The last error that occurred can be displayed by pressing the set button. If a
short AS-i power failure is responsible for the configuration error the display shows a
“39”.
5.4 Assigning an AS-i Address in Configuration Mode
AS-i can be put into operation in a very comfortable manner by using the Windows
software AS-i Control Tools (see chapter 8.1)(addressing directly or with the AS-i ad-
dress assistant).
Furthermore you can use a hand held addressing device.
If you don’t have neither a PC nor a hand held addressing device, address assigning
of the AS-i slaves is also possible with the AS-i/PROFIBUS gateway using the push
buttons. How it works is described as follows.
5.4.1 Assigning a Slave Address
(assigning an available address to a slave with address zero)
In configuration mode, the addresses of all detected slaves are displayed one after
the other. To display the next higher available operating address, press the “set” but-
ton shortly. Each time you press the “set” button, the next available address is dis-
played.
Choose the displayed address as your target address by pressing the button for more
than five seconds. The address display blinks. The master is ready for programming;
pressing the “set” button again addresses the connected slave with address zero to
the target (blinking address).
Any errors will be displayed by their error codes according to chapter 9. Otherwise,
the detected slaves are displayed again as described in chapter 5.2..
5.4.2 Erasing the Slave Address
(assigning address zero to a detected slave)
In configuration mode, the addresses of all recognized slaves are displayed one after
the other. By pressing and releasing the “set” button, the master displays the next
available address. If you press the button for more than five seconds while the ad-
dress of a detected slave is displayed, this slave will get the address zero and the dis-
play shows “00”.
When you release the button, the display continues to display the detected slaves.
Only slaves with address 0 can get a new address by the master.
There must not be two AS-i slaves with the same adrress on the AS-i
circuit.

AS-i/PROFIBUS Gateway Operating the AS-i/PROFIBUS Gateway
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5.5 Programming the Address in Case of Configuration Errors
5.5.1 Automatic Address Assignment
For automatic programming to work, some requirements must be met:
1.The AS-i master must be in the protected operating mode.
2.The “Auto_Address_Assign” release flag must be set.
3.Only one of the projected slaves may not be detected.
If these requirements are met, the AS-i master’s “prg enable” LED lights up and a
slave with address zero will be automatically assigned to the operating address of the
missing slave. The "Automatic Address Assignment" can be activated and deactivat-
ed via the software "AS-i Control Tools".
5.5.2 Manual Address Assignment
Inprotectedoperating mode, wrongassignmentsaredisplayed as errors (seechapter
5.3). By pressing the “set” button, you can display all faulty assignments one after the
other. By pressing the “set” button for more than five seconds, you can select the cur-
rently displayed address as a potential target address, and the display starts to blink.
If the faulty slave was previously replaced by a slave with address zero, the new slave
can now be programmed for the blinking address by pressing the “set” key again. As
a requirement, the new slave’s configuration data must match the configuration data
for the blinking address.
After the address has been successfully set, the next faulty assignment is displayed
and the address assignment can begin from the start. Otherwise, the system displays
an error code (chapter 9). When all faulty assignments are eliminated the display is
empty.
One of AS-i’s great advantages is the automatic address assignment. If
a slave fails, it can be replaced by one of the same type with address
zero. The master will detect the replacement and automatically
addresses the new slave with the address of the faulty one.
If the two slaves have different configuration data, i.e. are not of the
same type as far as AS-i is concerned, the automatic address assign-
ment will not be carried out.
If several slaves fail, they cannot be replaced automatically by the AS-i
master. Then these addresses have to be set manually. If this should
not be done via the host interface(using the AS-i Control Tools) or with a
hand held addressing device, the slave addresses can also be changed
with the help of the push buttons and the figure display of the device.