Proconx ESEPRO User manual

ESEPRO
Profibus gateway
for CANopen
genset controls
User manual
Edition 1
UMESEPRO-2201

ESEPRO
Profibus gateway for CANopen genset controls: User manual
Copyright © proconX Pty Ltd. All rights reserved.
No part of this material may be reproduced or transmitted in any form or by any means or used to make any derivative work without
express written consent from the copyright holders.
proconX is a trademark of proconX Pty Ltd. PROFIBUS and PROFIBUS-DP are trademarks of PROFIBUS & PROFINET International (PI).
CANopen is a registered trademark of CAN in Automation e.V. Easygen is a trademark of Woodward, Inc. All other product and brand
names mentioned in this document may be trademarks or registered trademarks of their respective owners.
Disclaimer
proconX Pty Ltd makes no warranty for the use of its products, other than those expressly contained in the Company’s standard warranty
which is detailed in the Terms and Conditions located on the Company’s Website. The Company assumes no responsibility for any errors
which may appear in this document, reserves the right to change devices or specifications detailed herein at any time without notice,
and does not make any commitment to update the information contained herein. No licenses to patents or other intellectual property
of proconX are granted by the Company in connection with the sale of proconX products, expressly or by implication. proconX products
are not authorized for use as critical components in life support devices or systems.
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We provide an electronic support and feedback system for our proconX products. It can be accessed through the following web link:
https://www.proconx.com/support
Your feedback and comments are always welcome. It helps improving this product.
Contact
For further information about the ESEPRO product please visit https://www.proconx.com/esepro

Contents
Important user information ....................................................................................... vii
Safety Precautions .............................................................................................. vii
Document conventions ...................................................................................... viii
1 Introduction ............................................................................................................. 1
Features ................................................................................................................ 2
Quick start checklist ............................................................................................. 2
2 Description ............................................................................................................... 3
LED indicators ...................................................................................................... 3
3 Installation ................................................................................................................ 5
Regulatory notes .................................................................................................. 5
Unpacking, handling and storage ........................................................................ 5
Before connecting anything ................................................................................. 5
DIN rail mounting and removal ........................................................................... 6
Mounting rules .................................................................................................... 6
Powering the ESEPRO .......................................................................................... 7
Wiring the Profibus interface ............................................................................... 7
Wiring the CAN interface ..................................................................................... 8
Connecting Ethernet ............................................................................................ 9
4 Profibus configuration ............................................................................................ 11
Mapping of Woodward devices into the process I/O ......................................... 12
Direct mapping ........................................................................................... 12
Indexed mapping ....................................................................................... 14
Generic Woodward device module ............................................................. 15
RPDO Profile ............................................................................................... 18
5 Profibus operation .................................................................................................. 21
Organisation of the data in Woodward CANopen devices ................................. 21
Addressing of Woodward CANopen devices ...................................................... 22
Methods of data transfer ................................................................................... 22
DP-V0 indexed data mapping ............................................................................ 23
Read Mux object ........................................................................................ 23
Read parameter .......................................................................................... 25
Write parameter ......................................................................................... 26
DP-V1 functions ................................................................................................. 27
Writing/reading data with STEP 7 .............................................................. 27
Read MUX objects ...................................................................................... 28
Read Remote Control word ........................................................................ 28
Write Remote Control word ....................................................................... 29
Remote Control Word IDs .......................................................................... 29
Remote Control Examples .......................................................................... 30
6 Configuration of connected Woodward controls ................................................... 33
Specific information for Easygen-3000 series controls ....................................... 35
CAN interface ............................................................................................. 35
Transmit PDOs ............................................................................................ 36
Specific information for LS-5 controls ................................................................ 37
CAN interface ............................................................................................. 37
Transmit PDOs ............................................................................................ 38
7 Decommissioning ................................................................................................... 39
Disconnecting ..................................................................................................... 39
UMESEPRO-2201 iii

Disposal .............................................................................................................. 39
A Specifications ......................................................................................................... 41
Dimensions ......................................................................................................... 42
References .................................................................................................................. 43
Glossary ..................................................................................................................... 45
Figures
2.1 Location of connectors .......................................................................................... 3
4.1 Commissioning the ESEPRO using Simatic Step 7’s HW Config tool .................... 11
4.2 Assigning station address using Step 7’s HW Config tool ................................... 11
4.3 Example configuration of direct mapping with 4 Easygens using 6 Mux objects
each ........................................................................................................................... 12
4.4 Data Protocols from Easygen-3500 manual ........................................................ 13
4.5 Example how the Easygen-3000 Mux object 1 maps into the PLC iput area ......... 13
4.6 Parameter assignment of a Mux object module .................................................. 14
4.7 Example configuration with 3 Easygens (Node-ID 1, 2 and 3) and 2 LS-5
(Node-ID 11 and 12) ................................................................................................. 15
4.8 Extract from Easygen manual with Data Protocol 4103 J1939 Standard
Visualization ............................................................................................................... 16
4.9 J1939 Data Protocol TPDO configuration with Woodward ToolKit ....................... 17
4.10 Parameter assignment for a Generic Woodward device module to access
Easygen’s J1939 Standard Visualization data protocol .............................................. 18
5.1 Organisation of data in Woodward controls ....................................................... 21
5.2 Message sequence chart for reading the three generator currents ...................... 24
5.3 Message sequence chart for reading parameter ID 1752 "Gen. rated active
power" ....................................................................................................................... 25
5.4 Layout of process I/O image for writing Parameters ............................................ 26
5.5 Message sequence chart for writing parameter ID 10402 "Password for CAN
Interface 1" ................................................................................................................ 26
5.6 Message sequence chart for writing parameter ID 1752 "Gen. rated active
power" ....................................................................................................................... 27
5.7 Message sequence chart for reading Remote Control Word 1 (Parameter ID
503) ........................................................................................................................... 28
5.8 Message sequence chart for setting Remote Control Bit 1 (Parameter ID
556) ........................................................................................................................... 29
6.1 "Configure interfaces" menu in Woodward Toolkit .............................................. 35
6.2 "Configure CAN interface 1" menu in Woodward Toolkit ..................................... 35
6.3 "Transmit PDOs" menu in Woodward Toolkit ....................................................... 36
6.4 "Interfaces config" menu in Woodward Toolkit .................................................... 37
6.5 "CAN interface 1 config" menu in Woodward Toolkit .......................................... 37
6.6 "Transmit PDOs" menu in Woodward Toolkit ....................................................... 38
A.1 Enclosure dimensions .......................................................................................... 42
Tables
2.1 LED diagnostic codes ............................................................................................ 4
3.1 Power supply connector pinout ............................................................................ 7
3.2 Profibus connector pinout ..................................................................................... 8
iv UMESEPRO-2201

3.3 CAN bus connector pinout .................................................................................... 9
3.4 Ethernet connector pinout .................................................................................. 10
5.1 CANopen Data Protocols ..................................................................................... 22
5.2 Relationship between Remote Control Word ID and DP-V1 Index ........................ 29
6.1 CANopen Node-ID & COB-ID relationship ............................................................ 33
6.2 Supported Data Protocols ................................................................................... 34
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vi UMESEPRO-2201

Important user information
Important user information
This manual explains how to install, operate and configure the ESEPRO. This device may
only be used for the applications described in this document.
These instructions are intended for use by trained specialists in electrical installation
and control and automation engineering, who are familiar with the applicable national
standards and safety procedures.
Safety Precautions
ELECTRICAL HAZARD
• This equipment must be installed and serviced only by qualified personnel. Such
work should be performed only after reading this entire set of instructions.
• Before performing visual inspections, tests, or maintenance on this equipment,
disconnect all sources of electric power. Assume that all circuits are live until they
have been completely de-energized, tested, and tagged. Pay particular attention
to the design of the power system. Consider all sources of power, including the
possibility of backfeeding.
• Apply appropriate personal protective equipment and follow safe electrical
practices.
• Turn off all power supplying the equipment in which the ESEPRO is to be installed
before installing, wiring or removing the ESEPRO.
• Always use a properly rated voltage sensing device to confirm that power is off.
• The successful operation of this equipment depends upon proper handling,
installation, and operation. Neglecting fundamental installation requirements
may lead to personal injury as well as damage to electrical equipment or other
property.
Failure to follow these instructions could result in death or serious injury!
UMESEPRO-2201 vii

Document conventions
Throughout this manual we use the following symbols and typefaces to make you aware
of safety or other important considerations:
Indicates a potentially hazardous situation that, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation that, if not
avoided, could result in damage to equipment.
Indicates information that is critical for successful applica-
tion and understanding of the product.
Provides other helpful user information that does not fall in
above categories.
Provides supplemental user information.
Acronym This typeface is used to introduce acronyms or product
names.
Command This typeface is used to represent commands, prompts, in-
put fields and filenames. In the context of programming
it is used for functions, variable names, constants or class
names.
Placeholder This typeface is used to represent replacable text. Replace-
able text is a placeholder for data you have to provide, like
filenames or command line arguments.
User input This typeface is used to represent data entered by the user
or buttons.
Screen output
Screen output or program listing
viii UMESEPRO-2201

Introduction
Chapter 1.Introduction
ESEPRO is a Profibus gateway specifically designed to interface Woodward’s Easygen
series genset controls with Profibus-DP networks. It interfaces via the CAN bus with the
Woodward controls and is easy to configure using standard Profibus configuration tools
like Simatic Manager.
A single ESEPRO added to the CAN network will make all Visualisation Data of connected
Woodward CANopen controls available without adding additional load to the CAN
bus communication. The Visualisation Data is buffered in the ESEPRO gateway which
decouples Profibus' cyclic process I/O from the CANopen cyclic TPDO transfers.
The ESEPRO appears as a modular I/O module in the Profibus configuration tool.
The ESEPRO offers three different methods to map data into the PLC’s process I/O image
to suit different application requirements and programming styles. Visualisation Data
of connected Easygen and LS-5 devices can be mapped directly into the PLC’s process
image. For larger data tables which exceed the Profibus I/O space, an indexed mapping
similar to the Profidrive standard can be used. Alternatively access to larger data blocks
via acyclic DP-V1 transfers is also possible. In addition, read and write access to the
Easygen’s device Parameter IDs is possible which are internally translated to CANopen
SDO transfers.
Common applications include:
• PLC connection
• Operator panel interfacing
• HMIs
UMESEPRO-2201 1

• SCADA integration
• Power station automation
• Gen set control
• Remote control & monitoring
• Data logging
Features
The ESEPRO gateway provides the following key features:
• Supports Easygen-3000 Series (3500, 3400, 3200, 3100)
• Supports Easygen-2000 Series
• Supports Easygen-1000 Series
• Supports LS-5
• Supports DTSC-200
• Addresses up to 8 Woodward controls
• Easy configuration using Simatic Manager
• Direct mapping of data into process I/O
• Fast indexed access to Basic Visualisation Data table
• Acyclic DP-V1 functions to read and write Remote Control words
• Acyclic DP-V1 access to larger data blocks
• Reading and Writing of device parameters
• Internal buffer for Visualisation Data
• Transparent handling of data guarantees future compatibility
• Firmware upgradable via Ethernet bootloader
Quick start checklist
• Read this set of instructions properly and in its entirety.
• Mount the unit.
• Wire Profibus plug.
• Wire CAN bus plug.
• Connect the power.
• Configure the device with a Profibus configuration tool.
2UMESEPRO-2201

Description
Chapter 2.Description
The power terminals and CAN bus connector are placed on the top side of the unit. The
Profibus connector and Ethernet jack are placed on the bottom side of the unit as shown
in the following illustration:
TOP VIEW
BOTTOM VIEW
FRONT VIEW
Figure2.1:Location of connectors
 Clear front cover
 Profibus connector
 Ethernet jack
 DIN rail clip
 Power LED
 Ethernet link LED
 Device status LED
 Communication status LED
 Power terminals
 CAN bus connector
LED indicators
Four LEDs located at the front panel indicate the status of the ESEPRO. The LEDs assist
maintenance personnel in quickly identifying wiring or communication errors.
A LED test is exercised at power-up, cycling each LED off, green and then red for
approximately 0.25 seconds. At the same time the power-on self test of the device is
performed.
UMESEPRO-2201 3

The following table outlines the indicator condition and the corresponding status after
the power-on self-test has been completed:
LED Function Condition Indication
Power Power Off No power applied to the device.
Green Power supply OK
Link Ethernet link Off No Ethernet link
Green Ethernet link OK
Status1 Device status Off The device has an unrecoverable fault; may need replacing.
Flashing green at 1 s
rate
Device operational but needs commissioning due to configuration
missing, incomplete or incorrect.
Green The device is operating in normal condition.
Flashing red at 1 s rate Device operational but has a fault listed which requires acknowledg-
ment.
Red The device has an unrecoverable fault; may need replacing. Flashing
sequence and rate of Status2 LED indicates fault class.
Status2 Network status Flashing red at 1 s rate No CAN comms and not in DP Data_Exch state
Off CAN comms OK, but not in DP Data_Exch state
Flashing red/green at 1
s rate
No CAN comms but in DP Data_Exch state
Green CAN comms OK and in DP Data_Exch state
Table 2.1: LED diagnostic codes
4UMESEPRO-2201

Installation
Chapter 3.Installation
Regulatory notes
1. The ESEPRO is suitable for use in non-hazardous locations only.
2. The ESEPRO is not authorized for use in life support devices or systems.
3. Wiring and installation must be in accordance with applicable electrical codes in
accordance with the authority having jurisdiction.
4. This is a Class A device and intended for commercial or industrial use. This
equipment may cause radio interference if used in a residential area; in this case it
is the operator’s responsibility to take appropriate measures.
5. The precondition for compliance with EMC limit values is strict adherence to the
guidelines specified in this set of instructions. This applies in particular to the area
of grounding and shielding of cables.
FCC Notice (USA only)
This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.
Industry Canada Notice (Canada only)
This Class A digital apparatus complies with Canadian ICES-003.
Unpacking, handling and storage
1. Please read this set of instructions. carefully before fitting it into your system.
2. Keep all original packaging material for future storage or warranty shipments of
the unit.
3. Do not exceed the specified temperatures.
Before connecting anything
1. Before installing or removing the unit or any connector, ensure that the system
power and external supplies have been turned off.
UMESEPRO-2201 5

2. Check the system supply voltage with a multimeter for correct voltage range and
polarity.
3. Connect the power supply cable and switch on the system power. Check if the
Power LED is lit.
4. Turn off system power.
5. Connect all I/O cables.
6. Once you are certain that all connections have been made properly, restore the
power.
DIN rail mounting and removal
The ESEPRO gateway is designed to be mounted on a 35 mm DIN rail according to DIN/
EN 50022. The enclosure features a 35 mm profile at the back which snaps into the DIN
rail. No tools are required for mounting. Please observe the rules outlined in the section
called “Mounting rules”.
2
1
Click
To mount the unit on a DIN rail, slot the top part of the
ESEPRO into the upper guide of the rail and lower the
enclosure until the bottom of the red hook clicks into
place.
2
1
To remove the ESEPRO from the DIN rail, use a screw
driver as a lever by inserting it in the small slot of the red
hook and push the red hook downwards. Then remove
the unit from the rail by raising the bottom front edge of
the enclosure.
Mounting rules
The enclosure provides protection against solid objects according to IP20 / NEMAType1
protection rating. When mounting the unit observe the following rules:
• No water splash and water drops
6UMESEPRO-2201

Installation
• No aggressive gas, steam or liquids
• Avoid dusty environments.
• Avoid shock or vibration
• Do not exceed the specified operational temperatures and humidity range.
• Mount inside an electrical switchboard or control cabinet.
• Make sure there is sufficient air ventilation and clearance to other devices mounted
next to the unit.
• Observe applicable local regulations like EN60204 / VDE0113.
Powering the ESEPRO
Before connecting power please follow the rules in the section called “Safety Precau-
tions” and the section called “Before connecting anything”.
Power is supplied via a 3.81 mm 2-pin pluggable terminal block located at the top side
of the mounted unit (refer to Figure2.1, “Location of connectors”). The following table
and picture shows the power terminal socket pinout:
V+
V-
Pin Signal Function
1 V+ Positive voltage supply (10 - 30 V DC)
2 V- Negative voltage supply, DC power return
Table 3.1: Power supply connector pinout
Make sure that the polarity of the supply voltage is correct before connecting any
device to the CAN port! A wrong polarity can cause high currents on the ground
plane between the V- power supply pin and the ground pins of the non-isolated
CAN port, which can cause damage to the device.
Wiring the Profibus interface
The Profibus interface connects the ESEPRO to a Profibus-DP master station.
UMESEPRO-2201 7

The Profibus connector is a female 9-pin D-sub type, located at the bottom side of the
mounted unit. It has Profibus standard IEC 61158-2 pinout as shown in the following
table and picture:
Pin Signal Function
1 NC
2 NC
3 RxD/TxD-P Non-inverting transceiver terminal, line B (red)
4 CNTR-P Control of repeater direction
5 DGND Signal ground (isolated)
6 VP Power supply +5 V (for bus termination)
7 NC
8 RxD/TxD-N Inverting transceiver terminal, line A (green)
9 NC
SHIELD Shield
Table 3.2: Profibus connector pinout
Wiring and installation must be carried out as specified in "Installation Guideline for
PROFIBUS-DP/FMS", Order No 2.112 published by PROFIBUS & PROFINET International
(PI) [PIG98].
• Use an appropriate shielded twisted pair cable which conforms with Profibus Type A
classification as per EN 50170.
• Use a Profibus connector plug to connect to the RS-485 segment.
• Line termination at both ends of the RS-485 bus segment is required and is best
accomplished using a Profibus connector plug with activated integrated termination.
• Maximum number of RS-485 nodes in one bus segment is 32. Bus segments can be
interconnected using RS-485 repeaters.
• In order for the cable shield to be effective at high frequencies the shield must be
connected to chassis ground at both ends low inductively. In cases were there is a
concern of ground currents passing along the cable shield, capacative grounding at
one of the ends may be an option or an additional potential equalisation cable may
be required.
Wiring the CAN interface
The CAN interface connects the ESEPRO to the Woodward CANopen based controls.
8UMESEPRO-2201

Installation
The CAN bus connector is a male 9-pin D-sub type located at the top side of the mounted
unit (refer to Figure2.1, “Location of connectors”). It has industry standard CiA DS-102
pinout as shown in the following table and picture:
CAN_L
GND
CAN_H
GND
1
6
Pin Signal Function
1 NC
2 CAN_L CAN_L bus line
3 CAN_GND CAN ground
4 NC
5 NC
6 CAN_GND CAN ground
7 CAN_H CAN_H bus line
8 NC
9 NC
Table 3.3: CAN bus connector pinout
• The network must be terminated at both ends with its characteristic impedance,
typically a 120 Ohm 1/4 W resistor.
• Maximum number of electrically connected CAN nodes is 64 1.
• Maximum CAN bus cable length is 250 m (820 ft) and is derated depending on bit
rates and cable type.
• Stub connections off the main line should be avoided if possible or at least be kept as
short as possible. Stub connections must not have terminating resistors.
• To ensure a high degree of electromagnetic compatibility and surge protection the
cable should be twisted pairs and shielded. An additional cable conductor or pair may
be used for the CAN_GND reference.
Do not connect the cable shield to the CAN_GND pins or the connector shell! Use
an external chassis ground connection to terminate the shield.
Connecting Ethernet
The ESEPRO is equipped with an Ethernet interface for diagnostic and maintenance
purposes. The Ethernet interface is not used in normal operation. The default IP address
is 169.254.0.10.
1The number of logically adressable units may be less.
UMESEPRO-2201 9

The following table describes the 10BASE-T Ethernet RJ-45 connector pinout:
TX+
TX-
RX- RX+
1
Pin Signal Function
1 TX+ Non-inverting transmit signal
2 TX- Inverting transmit signal
3 RX+ Non-inverting receive signal
4 Internal termination network
5 Internal termination network
6 RX- Inverting receive signal
7 Internal termination network
8 Internal termination network
Table 3.4: Ethernet connector pinout
• We recommend to use Category 5 UTP network cable.
• Maximum cable length is 100 m (3000 ft).
10 UMESEPRO-2201

Profibus configuration
Chapter 4.Profibus configuration
The ESEPRO gateway is configured using a Profibus configuration tool like Simatic Step
7’s HW Config. The required GSD file PROX0EAB.GSD can be downloaded from https://
www.proconx.com/esepro/gsd
Install the GSD file according to the requirements of your Profibus configuration tool.
After successful installation the ESEPRO is listed under the device family Gateway/
CANopen and can be added as a node into the master’s Profibus network as shown
below:
Figure4.1:Commissioning the ESEPRO using Simatic Step 7’s HW Config tool
The Profibus station address of the ESEPRO is configured via Profibus using your
Profibus configuration tool. For example in Simatic Step 7 it is assigned from the menu
PLC→PROFIBUS→Assign PROFIBUS Address… using the following dialog:
Figure4.2:Assigning station address using Step 7’s HW Config tool
The default Profibus station address of an uncommissioned ESEPRO device is 126. Once
configured, the Profibus station address is stored in non-volatile memory. The station
address can be checked using the Ethernet diagnostic interface.
UMESEPRO-2201 11

There is no baud rate setting, the baud rate is detected automatically and matched to
the baud rate of the master station.
Mapping of Woodward devices into the process I/O
The ESEPRO gateway is a modular Profibus slave device which is organised into virtual
modules. Different type of virtual modules can be configured. Each of the types facilitate
different methods of data transport.
Direct mapping
The ESEPRO does support direct mapping of Data Protocol Mux objects into the process
I/O. Mux objects in a Woodward device are organised in word triplets (3 × 16-bit)
which are identified by a Mux number (refer to chapter Interfaces And Protocols, section
CANopen Protocols of your Woodward device manual). All Woodward CANopen devices
do list the available Mux numbers in the Data Protocols section of their respective
manual.
To map data directly into the process I/O space of the Profibus master, a Mux Object
module has to be inserted into a slot. The GSD file defines a selection of Mux object
modules with different data lengths to allow insertion of a single Mux object or multiple
consequtive Mux objects. A Mux object consumes 6 input bytes.
Figure4.3:Example configuration of direct mapping with 4 Easygens using 6 Mux objects each
The following example shows how to identify the object with Mux number 1 which
contains the 16-bit value "Gen. Power Factor" and the 32-bit value "Av. Gen. Wye-Voltage".
12 UMESEPRO-2201