rotork CK Series User manual

CK Range
Profibus Actuator Control
Profibus DP Option Card Installation Manual
Keeping the World Flowing
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Contents
Section Page Section Page
Table of figures 4
Glossary of Terms 6
Abbreviations 6
References 6
Notes for Rotork 6
1 Introduction 7
1.1 General 8
2 Profibus Dp Option Card Properties 9
2.1 Mechanical Properties 9
2.2 Electrical Properties 9
2.3 Operation and Storage 9
3 Fitting the Profibus DP Option Card 10
3.1 Inside a CKCor CKRC Actuator 10
3.2 Replacing or Fitting a Profibus DP
Option Card 11
4 Single and Dual Data Highway Configurations 12
4.1 Profibus Data Highway 12
4.2 Segmented Single Highway System 13
4.3 Redundant Systems – Simple Redundancy 14
4.3.1 Flying Redundancy Slave to
Master Connection 15
4.3.2 System Redundancy Slave to
Master Connection 16
4.4 Redundant Systems – RedCom Redundancy 17
4.4.1 Extended Diagnostic Messages
for RedCom 18
4.5 Cable Types 19
4.6 Termination Network 19
4.7 Connecting to the Highway and
Setting up the Profibus Card 20
4.7.1 Single Channel Highway 20
4.7.2 Dual Highway 21
4.7.3 Optional CK disconnect module 22
5 The Actuator Cyclic Data Signals 23
5.1 Control Outputs 24
5.1.1 Controls Priority 26
5.1.2 Profibus Control using the
ACTCON Register 27
5.1.3 Profibus Control using the
POS DV register 27
5.1.4 The Centronik ‘S’ contacts (Profibus DOs)
controlled by the O_STAT register 28
5.1.5 Profibus Network Control
Disable feature 29
5.2 Digital Input Status Feedback 29
5.2.1 Digital Inputs 30
5.2.2 Digital Inputs Reporting the
Profibus Card Condition 32
5.3 Actuator Analogue Input Feedback 33
5.4 Configuring the Registers to be
Exchanged in Cyclic Communication 33
6 Profibus DP Communication 34
6.1 Electrical Specification 34
6.2 Protocol 34
6.3 Single Highway, Single Channel 34
6.4 Dual Highway, Dual Channel – SR Mode 34
6.5 Single Highway Dual Channel – FR Mode 36
6.6 Dual Channel Indication LEDs 37
6.7 Basic Operation on Start up 38
6.8 Static Diagnostics 38
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7.2 Parameters viewed and set by
DP-V1 Communication 45
7.2.1 Actuator Tag Data (Parameter 20) 47
7.2.2 Software Versions
(Parameter 21 and 22) 47
7.2.3 Field Interface Type (Parameter 24) 47
7.2.4 Permit GSD Parameterisation
(Parameter 25) 47
7.2.5 Control Outputs (Parameter 26 to 29) 47
7.2.6 Configure Data Exchange
(Parameter 40) 47
7.2.7 Parameterisation Date (Parameter 68) 45
7.2.8 Function for indication Contacts
S1 – S8 (Parameters 78-81 and 86-89) 48
7.2.9 Position Trip for indication Contacts
S1 – S8 (Parameters 82-85 and 90-93) 49
7.2.10 ESD Parameters (Parameter 97 - 101) 49
7.2.11 Interlock enable (Parameter 102) 49
7.2.12 Open Limit position (Parameter 103) 49
7.2.13 Interrupter Timer parameters
(104 – 108) 49
7.2.14 Language used (Parameter 109) 49
7.2.15 IDs and notes (Parameters 111 - 120) 49
8 Setting Up And Maintaining the
Profibus Module 50
8.1 Using a Network Configuration Tool 50
8.1.1 FDT (Field Device Tool) 50
8.1.2 PDM (Process Device Manager) 50
8.2 Accent- Actuator Configuration Tool 51
8.3 Setting up the network address in the PFU 51
8.4 Setting up a Centronik with the Setting Tool 51
8.5 Setting up the remote source in a CK actuator
with the Setting Tool 53
8.6 Maintenance and Repair 53
8.7 Records 54
Contents
Section Page Section Page
7 Parameters 39
7.1 Parameters set by GSD and DP-V1
Communication 39
7.1.1 Limited Range Position Minimum
and Maximum (Parameter 1 and 2) 41
7.1.2 Deadband and Hysteresis
(Parameter 3 and 4) 41
7.1.3 Motion Inhibit Timer (Parameter 6) 42
7.1.4 Manual Movement Travel
(Parameter 7) 42
7.1.5 Valve Jammed Time (Parameter 8) 42
7.1.6 Watchdog Timeout (Parameter 9) 42
7.1.7 Action on Loss of Comms
(Parameter 10) 42
7.1.8 Comms Lost Position (Parameter 11) 42
7.1.9 Comms Fault Timer (Parameter 12) 42
7.1.10 Auxiliary Input Mask (Parameter 13) 43
7.1.11 ESD DI-4/Net Disable (Parameter 14) 44
7.1.12 Redundancy FR/SR Mode and
Simple/RedCom Mode (Parameter 15) 44
7.1.13 Part Stroke Position (Parameter 16) 44
7.1.14 Part Stroke Limit and Timeout
(Parameter 17) 44
7.1.15 Actuator type (Parameter 18) 44
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1 The Centronik 7
2 The Types of Profibus DP Module Option Card 8
3 The Profibus single channel NIC, showing the
network connector 9
4 The Profibus option card located in a Centronik unit 10
5 Typical Profibus DP Data Highway 12
6 Profibus Single Channel Data Highway Topology 13
7 Profibus DP Simple Dual Redundant Option
Block Diagram 14
8 Profibus DP Flying Redundancy Connection 15
9 Profibus DP System Redundancy Connection 16
10 Profibus DP RedCom Dual Redundant Option
Block Diagram 17
11 Typical Profibus DP cable specifications 19
12 Single Highway 20
13 Dual Highway SR Mode Connections 21
14 Disconnect module showing normal powered
operation - connection though to the actuator 22
15 Disconnect module showing unpowered
operation - disconnected from the actuator 22
16 Disconnect module 22
17 Input and Output Data Direction 23
18 Centronik relay outputs DO-1 to DO-4 28
19 Single Channel Profibus card LED positions 34
20 System Redundancy – Two highway redundancy 35
21 Flying Redundancy – One highway redundancy 36
22 Dual Channel Profibus card LED positions 37
23 Profibus Start Up Sequence 38
24 Limited Range Position Control and Reporting 41
25 Deadband and Hysteresis settings 41
26 Rotork DTM running in the M&M FDT container 50
27 Rotork EDD running in the Siemens PDM application 50
28 Insight 2 Software; connected to a CK actuator
using Bluetooth, viewing the actuators settings 51
29 Setting tool menu structure and PFU settable
parameters 52
Table of figures
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Notes
Notes for Rotork:
There are two models of the CK actuator that can use the
Profibus Network; The CKCstandard duty actuator and
the CKRC modulating duty actuator. These two models are
interchangeable when talking about Profibus: this manual
refers to both. Centronik is the term applied to a Rotork
actuator that has an optional electronic control system in it.
This is required for Profibus use.
The CK Centronik can be fitted with either a DSM (Digital
Switching Mechanism) or a MSM (Mechanical Switching
Mechanism). The DSM can report analogue torque values
(0-120%) and position (0-100%). The MSM will only report
torque as minimum (0%) or maximum (tripped), it does not
report any intermediate values. It also only reports position as
fully closed, fully open or intermediate (mid-travel).
Therefore any functions that require use of analogue
position or torque will not function and as such should
not be used for units fitted with an MSM.
There is an optional potentiometer that can be fitted to the
MSM which allows it to report position (0-100%), which
means that the position features can be used, however, this
does not include the torque.
If there is any uncertainty about what the model is, please
consult the wiring diagram which will show which option
is fitted.
Note 1:
Throughout this manual the Profibus®DP Module may simply
be referred to as the module or the Profibus module.
Note 2:
The information in this manual relates to the following
firmware releases:
Profibus Network Interface Card V101.
Rotork Main Board software version V013.
The manual can be used with other versions, but be aware
that there may be differences.
Note 3:
The Profibus DP Module described in this manual is suitable
for inclusion in the following Rotork Centronik Actuators: CKC
(Isolating Duty) and CKRC (Modulating Duty) Actuators.
Note 4:
This manual is to be used in conjunction with, and makes
reference to, the CK technical manual (PUB111-005/6) and
assumes a pre-existing level of knowledge of using the CK
range of actuators.
It is advised that the CK technical manual is read before
attempting to set-up Profibus with the actuator.
As we are continually developing our products their design is
subject to change without notice.
© The contents of this document are copyright and must not
be reproduced without the written permission of Rotork.
The name Rotork is a registered trademark.
Windows™is a registered trademark by Microsoft
Corporation.
Profibus®is a registered trademark by PROFIBUS
Nutzerorganisation e.V., Germany.
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Glossary
Glossary of Terms:
Address
The unique address for a node on the fieldbus,
range 0-126.
Fieldbus
The digital, two-way, multi-drop Profibus DP
communication link.
Field Unit
The Profibus option card fitted to the actuator.
Interoperability
The capability for a device from one manufacturer to interact
with that of another manufacturer, on a fieldbus network,
without loss of functionality.
Master/Slave
The method of communication used by the Profibus DP
Module. The fieldbus requires a Profibus master to control the
data exchange on the highway.
Profibus DP
The communication protocol used on the highway.
Profibus DP-V0 and DP-V1
The cyclic (V0) and acyclic (V1) versions of the protocol
supported by the Rotork module.
PNO
Profibus Nutzerorganisation – Profibus User Group, Germany.
RedCom
Dual redundant system as defined in PNO 2.212.
Node
A single device on the fieldbus.
RS485
The electrical properties of the data highway as defined
by the IEC 61158 standard, copper conductors, 2-wire
twisted pair.
Segment
A section of an RS485 fieldbus that is correctly terminated in
its characteristic impedance. Each Segment can include up to
32 devices.
Abbreviations:
Comms Communications
PFU Profibus Field Unit
DTM Device Type Manager
RAM Random Access Memory
EDD Electronic Device Description
ROM Read Only Memory
FDT Field Device Tool
RTU Remote Terminal Unit
GSD Generic Station Description
SW Software
PDM Process Device Manager
References:
Profibus Guideline 2.112 Installation Guideline for
Profibus DP/FMS
Profibus Guideline 2.212 Specification Slave Redundancy
Profibus Guideline 2.152 Specification for Profibus
Device Description and Device
Integration – EDD
Profibus Guideline 2.162 Specification for Profibus
Device Description and Device
Integration – FDT
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Introduction
1 Introduction
The Rotork Profibus DP Actuator Control option card (PFU)
conforms to the PNO as compliant with specifications
IEC61158 and EN50170. The card supports both Profibus
DP-V0 cyclic and Profibus DP-V1 acyclic messages. Three
versions are available - single channel, simple dual channel
and RedCom dual channel. The simple dual channel card
does not include the Redstate diagnostics whilst the RedCom
dual channel card fully supports RedCom (Redundant
Communication) extensions to the V1 protocol as specified
by PNO for systems using either FR (Flying redundancy) or SR
(System redundancy) configurations. The inclusion of acyclic
message capability (V1) allows for system maintenance and
asset management tools to be used. Electronic data sheets
are available in GSD, EDD and DTM formats.
• Profibus DP-V0 and DP-V1 compliant
• RedCom redundancy included, both FR and SR modes
• GSD, EDD, DTM device description files available
• Address changes by master class 2, IR/Bluetooth®,
FDT or PDM
• Zero internal stub length
• Mounted within an IP68 enclosure, 8 meters for 96 hours.
• All card settings are non-intrusive and can be made over
the data highway or with Bluetooth or the setting tool.
The Profibus DP Module circuits do not impinge on the
actuator control electronics; the actuator itself remains fully
self-protecting. The module performs the tasks of network
interface, actuator data collection and the issuing of actuator
commands to open, stop, close, perform an ESD operation or
move to a set position.
Fig. 1: The Centronik.
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General
1.1 General
The Profibus DP Module has three versions:
• Single Channel Profibus DP
• Simple Dual Channel, independent isolated Profibus DP
highways for redundant systems that do not support full
RedCom
• RedCom Dual Channel, independent isolated Profibus DP
highways for RedCom compliant systems
The two dual channel versions have the same physical
assembly, but are configurable to include the necessary extra
messages for RedCom systems. PLCs that cannot accept the
extended diagnostic messages from RedCom slaves should
use the Simple Dual channel card. The reporting of RedCom
extended diagnostics can be selected from the GSD file.
Probus DP
Highway 1
Single Profibus DP Highway
Probus DP
Highway 1
Probus DP
Highway 2
Simple Dual Profibus DP Highway Connections
Probus DP
Highway 1
Probus DP
Highway 2
RedCom Dual Profibus DP Highway Connections
Fig. 2: The Types of Profibus DP Module Option Card
Communication Media RS485 2-wire highway (single or
dual), half duplex
Protocol Profibus DP-V0 and DP-V1
Mode Master/Slave, module is a slave,
cyclic and acyclic messaging
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Profibus DP option card properties
2 PROFIBUS DP OPTION CARD PROPERTIES
2.1 Mechanical Properties
The PFU module consists of a network interface card, which
fits directly to the main actuator printed circuit board.
All the connectors are polarised to prevent incorrect insertion.
• Network Interface Card (NIC)
This small printed circuit board carries the Profibus DP, RS485
highway connections and protection circuits.
There are two versions of the Network Interface Card, one
for a single highway and a second for two highways, Simple
or RedCom Dual (RedCom has two highway configurations,
two highways for SR mode or one highway with two network
interface connections for FR use).
Network connector
Fig. 3 : The Profibus single channel NIC, showing the network
connector
2.2 Electrical Properties
The PFU does not sit in the main control path for the actuator
and does not affect the actuator control integrity.
The Profibus DP fieldbus data highway connections are fully
isolated from the actuator electronics.
2.3 Operation and Storage
The PFU is designed to be stored in the actuator and operated
within the same environment as the actuator.
The constraints are:
• Operating temperature: -40 to +70°C
• Storage temperature: -50 to +85°C
• Relative Humidity: 5 to 95% (<50°C)
non-condensing
Refer to actuator manuals for environmental range
applicable for the particular actuator type.
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Fitting the Profibus card
3 FITTING THE PROFIBUS DP OPTION CARD
3.1 Inside a CKCor CKRC Actuator
The PFU is suitable for fitting into CKCactuators with
P000.0000 and K000.0000 series wiring diagrams
and CKRC with P000.1000 and K000.1000 series wiring
diagrams. The connections and fitting in a CKRC are the
same as the CKC so the following information effectively
relates to both actuator types. The PFU is normally located
in the first option board slot inside the electrical housing,
using Main PCB connection SK2.
The Interface card must be correctly profiled and loaded
with the appropriate connectors to match the actuator. The
illustration below shows the location of the cards in the
Centronik unit.
POWER ELECRONICS ASSY
2OPTION CARDS
2
4
11
13
15
10
17
18
19
511
510
508
NA NA
1OPTION CARD NO OPTION CARD
514
12
9
14
NA
502
503
504
505
507
23
513
30
506
23
524
A
A
SECTION A-A
25
26
21
24
513
48
44
43
40
41
POWER PIN WITH RING
46
56
ABB CONTACTOR OPTION
512
3
514
31
529
516
29
47
555
POWER SOCKET & GRUB ASSY
EARTH SOCKET & RING
42
527
526
52
527
CONTROL SOCKET ASSY CUST.
525 524 41 527
45
521
521520
553
554
528
32
Fig. 4: The Profibus option card located in a Centronik unit.
Within the actuator the remote inputs are always present and
are conditioned by the auxiliary mask setting and there is an
option to include Digital Outputs from relay contacts. If
the PFU is required to operate the 4 digital outputs that can
be controlled from the card, then the Extra Relay Indication
card associated with these outputs must be fitted into the
actuator. The following table describes the wiring harnesses
and their function in the Rotork actuator.
PFU Socket Socket Function
SK1 Power and CANbus to option 2 card.
SK2 Power and CANbus from actuator.
SK3 Profibus Fieldbus connection.
For layout please see Fig. 19 in section 6.3.
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Fitting the Profibus card
3.2 Replacing or Fitting a Profibus DP
Option Card
The PFU should be replaced or fitted only in a suitable
environment. The actuator must be made electrically safe
before opening any covers.
!
Warning: Removal of certain covers will void
warranty, it is advised that a Rotork
approved engineer perform this function.
Suitable anti-static precautions should be taken, as the
actuator circuitry contains static-sensitive components.
The electrical housing cover should be removed and the
existing PFU carefully unplugged from its main connector.
The Interface card will be attached to the Main PCB mounting
ring by four screws, which are T20 (or T15 if two cards are
present). Once removed from the main connector the wiring
loom connectors should be removed. The replacement board
is fitted in the reverse order to removal. The wiring harnesses
are polarised so that only the correct one will fit its mating
part on the circuit board.
If the operation is to fit a PFU for the first time then the
necessary wiring looms must be added to the internal wiring
harness of the actuator. The actuator wiring diagram shows
the connectors and harnesses used. The wiring harnesses are
fitted inside the actuator before attempting to fit the PFU.
Once the looms are in place connect them to the PFU, then fit
the PFU to the actuator main board connector.
Once the module is fitted the actuator should be re-
assembled and the battery reconnected (if applicable). If an
option card is fitted into a Rotork after it has left the factory
then the actuator needs to be set-up to use this card in the
software, the card will not do anything until this has been
done. This can be done using the HMI or Accent but needs
to be done by a Rotork service engineer. This is not necessary
if a card is being replaced with the same type of card, e.g.
replacing Profibus with Profibus.
It is advisable to check the software version numbers are the
same between the new and old card to ensure consistence
operation.
For more information please contact Rotork.
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4 Single and Dual Data Highway Configurations
4.1 Profibus Data Highway
The rules governing the installation and connection of a
Profibus DP highway should be observed at all times to
produce a successful installation. The highway does not allow
power to be transferred and the Profibus module is powered
from the actuator itself. The module can only report data
when the actuator is powered up.
PLC
+5V
0V Probus DP Highway Screened cable
+5V
0V
Terminator
T
T
Fig. 5: Typical Profibus DP Data Highway
The data highway must be terminated with a proper active
termination network at each end of a segment. To ensure
successful operation the highway itself should not use tapped
spur or stub connections. The connection should be made
in and out of each actuator in a daisy chain arrangement
on separate terminals to eliminate any internal cabling stubs
inside the actuator. The length of the highway and number
of devices connected will vary from project to project. The
standard permits up to 32 devices to be connected on a
section, though one of these will be the PLC. If more devices
are needed (up to the maximum addressable of 126) then
repeaters may be added as required. Up to 9 repeaters can
be used on a single highway provided no more than 4 are
between any two devices.
Data Rate (Baud) 9600 19200 45.45k 93.75k 187.5k 500k 1.5M
Maximum Segment Length 1.2 km 1.2 km 1.2 km 1.2 km 1000m 400m 200m
Maximum Highway Length 10 km 10 km 10 km 10 km 10 km 4 km 2 km
Max number of actuators/
segment
311311311311311311311
Note¹ – The PLC or Repeater module will be one device. Max 32 devices/segment
Since the data passes over a single 2-wire cable there are
periods between messages when no devices are actively
driving the lines. In order to ensure that data continues to
flow correctly after these periods it is advisable to ensure the
lines are biased to suitable voltage levels during the time the
line is idle. The PFU contains active termination circuits that
ensure suitable levels are maintained on the line even with no
device transmitting.
Single and Dual Data Highway Configurations
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Single and Dual Data Highway Configurations
4.2 Segmented Single Highway System
Powered
Active
Terminator
Repeater
Repeater
Segment 1
Segment 2
Segment 3
Bus Master
Fig. 6: Profibus Single Channel Data Highway Topology
The data highway may be connected as several segments
coupled by repeaters. The repeaters or actuator slaves will
require termination components if they are on the end of the
segment. Alternatively, separately powered active termination
devices can be used so that when the actuator is switched off
the bus performance is not affected.
Maximum number of devices participating in the exchange of data 127 (addresses from 0 to 126, 0 is usually the PLC)
Maximum number of devices per segment including repeaters 32
Maximum number of segments in series EN50170 specifies a maximum of 4 repeaters
between any two devices. Some manufacturers of
repeaters allow more than this number.
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Single and Dual Data Highway Configurations
4.3 Redundant Systems – Simple Redundancy
The Simple Dual Channel Profibus DP Option Card version has
two redundant communications channels. Like the RedCom
version, this card supports two types of redundant operation.
• SR – System Redundancy
(One common slave address)
• FR – Flying Redundancy
(Two slave addresses offset by 64)
The Simple Dual Channel card is suitable for all
PLCs where redundant highways are being used.
This option does not report the extended
diagnostic bytes relating to the card’s
redundant status.
These two connection options allow for redundancy
protection against either a failure of the highway (SR mode)
or failure of the card interface channel (FR mode). Most dual
channel systems use two highways and one connection to
each, so the most common use for this card is in SR mode.
The functionality and provisions of the card are identical to
the RedCom version except in the way the card reports its
status on the highway.
There are a number of PLC systems, including older PLCs,
that do not have the ability to use the RedCom system
and as a consequence they are likely to report errors when
connect to a RedCom compliant card. If the PLC does not
support the RedCom standard then the Simple Redundant
card must be used.
Control System Master
Redundant Slave
Interface Card
Actuator
Probus
Primary Slave Backup Slave
Probus
Fig. 7: Profibus DP Simple Dual Redundant Option Block Diagram
The Profibus DP Simple Dual Channel card includes:
• Two Profibus Connections, Channel 1 and Channel 2
• Selectable FR/SR mode
• No Extended Diagnostics
A Simple Dual Channel card can be altered to a RedCom Dual
Channel card, or vice versa, by entering the appropriate value
in parameter 15 in the GSD file.
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4.3.1 Flying Redundancy Slave to Master Connection
Primary Master Backup Master
FR
First Master Second Master
Primary
n
64+n Slave
Backup
Primary
Slave
Backup
Primary
Slave
Backup
Primary
Slave
Backup
SR
n n
m m
Fig. 8: Profibus DP Flying Redundancy Connection
With FR (Flying Redundancy) the aim is to protect against
a failure of the Profibus Interface. The data highway is
considered to be more reliable than the connection interface.
There is a single data highway and both the Profibus card
inputs are connected to it. The card must be set to FR mode
and it then adopts a fixed offset of 64 between the set
address (used for primary communication) and the backup
communication address.
When the card is powered ‘on’, Channel 1 will be the Primary
channel. If the card does not enter Configuration Mode
within 1 second (because there is no Master present) then
Channel 2 will take over as Primary. Once again, if there is
no communication within 2 seconds, then it will revert to
Channel 1 and now it will wait 4 seconds before Channel 2
assumes Primary status. The switch over time will increase
by a factor of 2 each time until it reaches its maximum of 32
seconds. It will continue to switch channels using a 32 second
switch over time until one channel receives PLC messages.
In the event of a failure of the Primary channel, the Backup
automatically changes to use the Primary address. Hence for
all control purposes the Master only uses the Primary address.
The Backup address can be used for exchanging data but
any commands to move the actuator directed to the backup
address will be ignored. If a configuration message is sent
to the Backup address that is different to the one sent to
the Primary address it will be accepted, but not actioned.
The data exchanged between the Master and the Primary
includes information on the status of the device and hence
the availability of a Backup should the Primary fail.
• Single Data Highway, two communication ports
• Channel 1 is Primary on power up
• Default method is SR mode; to achieve FR parameter
15 must be altered
• Fixed offset of 64 between Primary and Backup addresses
• Backup automatically adopts Primary address if
Primary fails
• V0 cyclic Commands to Backup ignored
• Reports the status of Primary and Backup to the Master
• Configuration and Parameterisation changes only over the
Primary address
Single and Dual Data Highway Configurations
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4.3.2 System Redundancy Slave to Master Connection
Primary Master Backup Master
FR
First Master Second Master
Primary
n
64+n Slave
Backup
Primary
Slave
Backup
Primary
Slave
Backup
Primary
Slave
Backup
SR
n n
m m
Fig. 9: Profibus DP System Redundancy Connection
With SR (System Redundancy) there are two data highways
and the aim of the redundancy is to secure communication
with the actuator even if one of the highways fails. Although
two masters are shown they will normally be a Primary and
Backup pair and communication will occur directly between
them. SR mode is the default for all dual Profibus cards.
The Profibus card has two communication channels and both
have the same slave address. As with the FR mode, when the
card is powered ‘on’, Channel 1 will be the Primary channel. If
the card does not enter Configuration Mode within 1 second
(because there is no Master present) then Channel 2 will take
over as Primary. Once again, if there is no communication
within 2 seconds, then it will revert to Channel 1 and now it
will wait 4 seconds before Channel 2 assumes Primary status.
The switch over time will increase by a factor of 2 each time
until it reaches its maximum of 32 seconds. It will continue to
switch channels using a 32 second switch over time until one
channel receives PLC messages.
In the event of a failure of the Primary channel the
Backup automatically changes to become Primary and
communication will be established with the Second master
on the second highway. The Backup channel can be used
for exchanging data but any commands to move the
actuator directed to the backup channel will be ignored. If
a configuration message is sent to the Backup channel that
is different to the one sent to the Primary it will be ignored.
The data exchanged between the Master and the Primary
includes information on the status of the device and hence
the availability of a Backup should the Primary fail.
Two Data Highways, two communication ports
• Channel 1 is Primary on power up
• Default communication method is SR mode
• Both channels have the same address
• V0 cyclic Commands to Backup channel are ignored
• Reports the status of Primary and Backup to the Master
• Configuration and Parameterisation changes only over the
Primary channel
Single and Dual Data Highway Configurations
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4.4 Redundant Systems – RedCom Redundancy
The RedCom Dual Channel Profibus DP Option Card version
has two redundant communications channels. Like the Simple
card, the RedCom card supports two types of redundant
operation and the details are as described in Profibus
Guideline 2.212 ‘Specification Slave redundancy’. The two
modes are:
• SR – System Redundancy
(One common slave address)
• FR – Flying Redundancy
(Two slave addresses offset by 64)
The Rotork Profibus DP RedCom Dual Channel
Option Card obeys the Profibus REDCOM
Specification for Redundant Communications.
This includes 3 bytes of Extended Diagnostics for
RedState. Not all PLC systems can accept these
diagnostic messages.
As with the Simple Redundant card, there are two basic
considerations when looking at redundant systems;
protection against the failure of the connecting cable and
protection against failure of the device. Most systems
consider cable protection to be the most important and this
is termed ‘SR’ or System Redundancy. The alternative setup,
using only a single cable, but with two Profibus connections
is termed ‘FR’ or Flying Redundancy. With FR systems there
are two Profibus interfaces on the slave, but only one slave,
so protection against failure of the Profibus interface is
included. SR and FR are described in more detail in the
previous section.
Control System Master
Probus Probus
Redundant Slave
Interface Card
Actuator
Primary Slave Backup Slave
Red Extensions Red Extensions
Fig. 10: Profibus DP RedCom Dual Redundant Option
Block Diagram
The Profibus DP RedCom Dual Channel card includes:
• Two Profibus Connections, Channel 1 and Channel 2
• RedCom link between the two connections
• Redundancy extensions to the V1 protocol
• No loss of data during switching
• Selectable FR/SR mode
• Status reported in Extended Diagnostics data
Single and Dual Data Highway Configurations
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4.4.1 Extended Diagnostic Messages for RedCom
The Redundancy Extensions to the standard V1 protocol
allow the two channels to communicate between themselves
to establish correct operation of the highway if there is a
failure, both the Simple and RedCom versions of the card do
this. In addition to these, there are extra Extended Diagnostic
messages that are reported to the PLC as part of the RedCom
system that the Dual RedCom card reports. Not all PLCs
are RedCom compliant, so some are unable to understand
these messages and, as a consequence, will mark the device
as having an error. If this is the case, either reconfigure the
Profibus card to be ‘Simple’ or disable the PLC’s diagnostics
package that is looking at the extended diagnostics.
A RedCom Dual Channel card can be altered to a Simple Dual
Channel card, or vice versa, by entering the appropriate value
in parameter 15 in the GSD file.
The extended diagnostics is contained in 3 bytes in the
diagnostic message and is reported by the Primary slave only:
Description Comment
Headerbyte = 8 hex
Status_Type = 9Fhex
Slot_Number = 0 hex
Specifier
Function
Red_State_1 State of Primary slave
Red_State_2 State of Back Up slave
Red_State_3 Not used
The information in the Red_State bytes is as below:
Description if set
This slave is the Backup
This slave is the Primary
There is a Hardware
Defect
This slave is in Data
Exchange Mode
Master State Clear
Baud rate not found
Toh started (hold timer
active - set if a change
of channel is imminent
Reserved
Bit No: 76543210
Single and Dual Data Highway Configurations
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4.5 Cable Types
The network must be connected using a suitable cable for
Profibus DP applications. Two conductors plus a shield are
required and there is a Profibus specification for the cable.
Amongst the cable manufacturers Belden have PVC
jacketed single pair 2 core cable, which meets the minimum
requirement. Information on Belden cable may be found on
the Belden website (www.belden.com).
PVC sheath, usually
coloured purple
Tinned
copper
screen
Signal wires
Red is positive, ‘B
Green is negative, ‘A’
Typical Profibus DP Cable Specification
Impedance 135 up to 165 ohm at a frequency
of 3 to 20 MHz
Cable capacitance <30 pF per metre
Core diameter >0.34 mm2(corresponds to AWG 22)
Cable type Twisted pair cable, 1x2 or 2x2 or
1x4 lines
Resistance <110 ohm per km
Signal attenuation Max 9 dB over total length of
line section
Shielding Copper shielding braid or shielding
braid and shielding foil
Fig. 11: Typical Profibus DP cable specifications
The terminals to which the wires connect in each actuator
type will be different and the actuator wiring diagrams must
be consulted to establish the connections.
4.6 Termination Network
In order to operate correctly all Profibus segments must be
terminated at each end in an active network termination
circuit.
The Profibus DP card includes the necessary components to
allow an active termination to be connected. The termination
can be set using the HMI or Accent software. It is advised
that internal termination is only used during the testing/
commissioning phase, because upon removal of power to the
unit or removal of the unit itself, the termination will be lost,
affecting communications of the entire network.
It is therefore advised that external termination is used during
full operation.
Active termination resistors are included on the Profibus card.
These can be switch on or off using the menu. Please see the
CK manual for details.
Profibus
cable
screening
+5V (VP)
390Ω
390Ω
220Ω
(RxD/TxD-P)
(RxD/TxD-N)
(DGND)
green A conductor
red B conductor
Single and Dual Data Highway Configurations
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4.7 Connecting to the Highway and Setting up the
Profibus Card
The Rotork Profibus variants allow for different highway
connections. The ‘single channel’ can be used for simple
highways. The ‘dual channel’ (both Simple and RedCom
compliant) is used for redundant highway applications where
the highway integrity (SR mode) or the physical connection is
important (FR mode).
4.7.1 Single Channel Highway
With the single channel option the actuator is connected
to only one highway. The connection of the actuator to the
highway uses terminals A and B (in and out terminals) and
are indicated on the actuator wiring diagram. The highway
should be arranged so as to eliminate any stub connections.
Take care to ensure that the correct polarity is observed on
the data highway connection, all the A terminals must be
used on one data line and all the B terminals on the other.
• Data line B is positive with respect to data line A when
the PFU is transmitting a ‘1’.
• Data line A is also called TxD/RxD-N
• Data line B is also called TxD/RxD-P
Actuator
InB
A
Out
In
Out
Actuator
InB
Txd/ Rxd. N Txd/ Rxd. P
A
Out
In
Out
PLC /Host
Data
Highway
Fit L1 and L2 on
the last actuator
Fig. 12: Single Highway
Single and Dual Data Highway Configurations
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