rotork Profibus Modbus Module Mk2 User manual

Publication PUB088-005-00_1017
Profibus Actuator Control
Profibus DP Option Card
Installation Manual

Profibus DP Mk2 Option Card Installation Manual
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Note 1:
Throughout this manual the Profibus DP Module (Mk2) 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 software version PNIC 1.20 (single) and 1.40 (Simple
dual and RedCom dual), or newer.
Actuator Interface Card software version M207, IQ M304, CVA V1.08 ROMPAK V1.01, or
newer.
Note 3:
The Profibus DP Module (MK2) described in this manual is suitable for inclusion in Rotork IQ,
IQT, CVA, ROMPAK, Skil and Q actuators.
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 Controls Ltd.
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

Contents
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Contents
Glossary of Terms:............................................................................................................................5
Abbreviations: ...................................................................................................................................5
References:........................................................................................................................................6
1INTRODUCTION.................................................................................................7
1.1 General.....................................................................................................................................8
2PROFIBUS DP (MK2) OPTION CARD PROPERTIES.......................................9
2.1 Mechanical properties............................................................................................................9
2.2 Electrical Properties .............................................................................................................11
2.3 Operation and Storage .........................................................................................................11
3FITTING THE PROFIBUS DP (MK2) OPTION CARD......................................13
3.1 Inside an IQ or IQT actuator.................................................................................................13
3.2 Inside a Q actuator................................................................................................................14
3.3 Inside a CVA actuator...........................................................................................................15
3.4 Inside ROMPAK actuator......................................................................................................16
3.5 Inside a Skil or EH actuator .................................................................................................17
3.6 Replacing or Fitting a Profibus DP (Mk2) Option Card .....................................................18
4SINGLE AND DUAL DATA HIGHWAY CONFIGURATIONS ..........................19
4.1 Profibus Data Highway.........................................................................................................19
4.2 Segmented Single Highway System ...................................................................................20
4.3 Redundant Systems –Simple Redundancy.......................................................................21
4.3.1 Flying Redundancy Slave to Master Connection .............................................22
4.3.2 System Redundancy Slave to Master Connection...........................................23
4.4 Redundant Systems –RedCom Redundancy....................................................................24
4.4.1 Extended Diagnostic Messages for RedCom ..................................................25
4.5 Cable Types...........................................................................................................................26
4.6 Termination Network ............................................................................................................26
4.7 Connecting to the Highway and Setting up the Profibus Card ........................................27
4.7.1 Single Highway with Analogue Input................................................................27
4.7.2 Dual Highway ...................................................................................................29
4.7.2 Optional IQ and IQT disconnect module..........................................................31
5THE ACTUATOR CYCLIC DATA SIGNALS....................................................33
5.1 Control Outputs.....................................................................................................................34
5.1.1 Controls Priority................................................................................................37
5.1.2 Profibus Control using the ACTCON Register .................................................39
5.1.3 Profibus Control using the POS_DV register ...................................................39
5.1.4 The IQ ‘S’ contacts (Profibus DOs) controlled by the O_STAT register ..........40
5.1.5 Multiport Position Selection using the PORTCM register (Future)...................40

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5.1.6 Profibus Network Control Disable feature........................................................40
5.2 Digital Input Status Feedback..............................................................................................41
5.2.1 Digital Inputs.....................................................................................................42
5.2.4 Digital Inputs Reporting the Profibus Card Condition.......................................46
5.3 Actuator Analogue Input Feedback ....................................................................................48
5.4 Configuring the Registers to be Exchanged in Cyclic Communication..........................49
6PROFIBUS DP COMMUNICATION .................................................................51
6.1 Electrical Specification.........................................................................................................51
6.2 Protocol..................................................................................................................................51
6.3 Single Highway, Single Channel .........................................................................................51
6.4 Dual Highway, Dual Channel –SR Mode............................................................................52
6.5 Single Highway Dual Channel –FR Mode..........................................................................54
6.6 Dual Channel Indication LEDs.............................................................................................55
6.7 Basic Operation on Start up ................................................................................................56
6.8 Static Diagnostics.................................................................................................................57
7 PARAMETERS.................................................................................................59
7.1 Parameters set by GSD and DP-V1 Communication.........................................................59
7.1.1 Limited Range Position Minimum and Maximum (Parameter 1 and 2)............61
7.1.2 Deadband and Hysteresis (Parameter 3 and 4)...............................................61
7.1.3 Slow Mode Range (Parameter 5).....................................................................62
7.1.4 Motion Inhibit Timer (Parameter 6)...................................................................62
7.1.5 Manual Movement Travel (Parameter 7)..........................................................63
7.1.6 Valve Jammed Time (Parameter 8) .................................................................63
7.1.7 Watchdog Timeout (Parameter 9)....................................................................63
7.1.8 Action on Loss of Comms (Parameter 10).......................................................63
7.1.9 Comms Lost Position (Parameter 11)..............................................................63
7.1.10 Comms Fault Timer (Parameter 12).................................................................64
7.1.11 Auxiliary Input Mask (Parameter 13)................................................................64
7.1.12 ESD DI-4/Net Disable and Data Logger Disable (Parameter 14) ....................65
7.1.13 Redundancy FR/SR Mode and Simple/RedCom Mode (Parameter 15)..........66
7.1.14 Part Stroke Position (Parameter 16) ................................................................66
7.1.15 Part Stroke Limit and Timeout (Parameter 17) ................................................66
7.1.16 Actuator type (Parameter 18)...........................................................................66
7.2 Parameters viewed and set by DP-V1 Communication.....................................................67
7.2.1 Actuator Tag Data (Parameter 20)...................................................................70
7.2.2 Software Versions (Parameter 21 and 22).......................................................70
7.2.3 Field Interface Type (Parameter 24) ................................................................70
7.2.4 Permit GSD Parameterisation (Parameter 25).................................................70
7.2.6 Control Outputs (Parameter 26 to 29)..............................................................70
7.2.7 Actuator Feedback Data (parameter 30 to 36).................................................71
7.2.8 Multiport feedback and Setup (Parameter 37 to 39) .......................................71
7.2.9 Configure Data Exchange (Parameter 40).......................................................71
7.2.10 Data Logger Information (Parameter 42 to 67) ................................................72
7.2.11 Parameterisation Date (Parameter 68) ............................................................72
7.2.12 Function for indication Contacts S1 –S8 (Parameters 78-81 and 86-89) .......73
7.2.13 Position Trip for indication Contacts S1 –S8 (Parameters 82-85 and 90-93).73

Contents
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7.2.14 ESD Parameters (Parameter 97 - 101)............................................................74
7.2.15 Interlock enable (Parameter 102).....................................................................74
7.2.16 Open Limit position (Parameter 103) ...............................................................74
7.2.17 Interrupter Timer parameters (104 –108)........................................................74
7.2.28 Language used (Parameter 109) .....................................................................75
7.2.28 IDs and notes (Parameters 111 - 120).............................................................75
8 SETTING UP AND MAINTAINING THE PROFIBUS MODULE.......................77
8.1 Using a Network Configuration Tool...................................................................................77
8.1.1 FDT (Field Device Tool) ...................................................................................77
8.1.2 PDM (Process Device Manager)......................................................................78
8.2 Setting up the network address in the PFU .......................................................................79
8.3 Setting up an IQ or IQT with the Infra-red Setting Tool.....................................................79
8.3 Setting up a Skil or EH with the Infra-red Setting Tool .....................................................81
8.3 Maintenance and Repair.......................................................................................................81
8.4 Records..................................................................................................................................82
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

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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

Introduction
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Pakscan Modbus Data Base Information
1 INTRODUCTION
The Rotork Profibus DP Actuator Control option card (PFU) has been certified by 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
Supports Siemens PDM and FDT applications
Address changes by master class 2, IR link (IQ and IQT only), FDT or PDM
Zero internal stub length
Mounted within the double sealed actuator enclosure
All card settings are non-intrusive and can be made over the data highway
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 Profibus DP Module (Mk2) Option Card Actuator Compatibility

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1.1 General
The Profibus DP Module (Mk2) has three versions:
Single Channel Profibus DP plus one analogue input channel
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.
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
Fig 2: The Types of Profibus DP Module (Mk2) Option Card
Profibus DP
Highway
Analogue
Input
Single Profibus DP Highway + Analogue Input
Simple Dual Profibus DP Highway Connections
Profibus DP
Highway 1
Profibus DP
Highway 2
RedCom Dual Profibus DP Highway Connections
Profibus DP
Highway 1
Profibus DP
Highway 2

Profibus Card Properties
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2 PROFIBUS DP (MK2) OPTION CARD PROPERTIES
2.1 Mechanical properties
The PFU module consists of a network interface card, that either fits directly to the main actuator
printed circuit board (CVA and ROMPAK) or fits to an interface card; then the two board assembly is
fitted inside the actuator electrical housing (IQ range, Skil/EH and Q).
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.)
Fig 3: The Profibus single channel NIC, showing the network connector.
Network Connector

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Interface Card (IQ/Skil/EH/Q)
The CVA and ROMPAK do not require in additional interface card.
The interface card is profiled and assembled to fit an IQ, Skil or Q actuator. For the Skil/EH and
Q, it carries the processor for collecting the data from the actuator main board and passing this
data to the Network Interface card. For the IQ/IQT it is used simply for physical connection to
the main card.
The primary connection to the actuator circuits is by a multi-pin connector on the Interface Card
that, due to its physical shape may only be fitted in the correct polarisation. Internal wiring
harnesses connect to the Interface card for other signals and options within the actuator. The
Interface card is powered from within the actuator.
Fig 5: The Interface Card (IQ/IQT actuator)
Fig 4: The Interface Card (Q and Skil/EH actuators)

Profibus Card Properties
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2.2 Electrical Properties
The PFU connects directly to the Interface Card of the actuator. 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: -40oC to +70oC
Storage temperature: -50oC to +85oC
Relative Humidity: 5% to 95% (<50oC) non-condensing
Refer to actuator manuals for environmental range applicable for the particular actuator type.

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Fitting the Profibus card
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Pakscan Modbus Data Base Information
3 FITTING THE PROFIBUS DP (MK2) OPTION CARD
3.1 Inside an IQ or IQT actuator
The PFU is suitable for fitting into IQ Mk2 actuators with 3000 or 5000 series wiring diagrams and IQT
with 6000 or 7000 series wiring diagrams. The connections and fitting in an IQT is similar to that for an
IQ and the following information effectively relates to both actuator types. The PFU is normally located
in the first option board slot inside the IQ/IQT electrical housing using Main PCB connection SK1. In
addition the PFU can be fitted inside IQ Mk1 actuators in certain cases.
The Interface card must be correctly profiled and loaded with the appropriate connectors to match the
IQ/IQT actuator. The illustration below shows the IQ/IQT version of the PFU. The links for the bias
resistors are shown in the ‘not terminated’ position.
With the IQ/IQT actuator the remote inputs are always present (they are conditioned by the PFU) 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 IQ and IQT actuator.
PFU Socket
Wiring Harness
SK2
24V power supply input from actuator
SK3
Profibus Fieldbus connection
SK10
Analogue Input connection 
Note: –Only available on Single Channel module, 3000-900 or 6000-900
Fig 6: The Profibus Mk2 card profiled for the IQ or IQT actuator

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3.2 Inside a Q actuator
The PFU is fitted in the option board position in this actuator. Only one option board may be fitted at
any one time. The necessary internal components must also be present; in this case a potentiometer
and auxiliary limit switches at end of travel must be fitted to the actuator.
The illustration below shows the Q version of the circuit board. The links for the bias resistors are
shown in the ‘not terminated’ position.
Digital Outputs from relay contacts are not supported from the Q actuator, nor is the ability to report
the status of the remote control inputs as Digital Inputs. The following table shows the wiring
harnesses that must be fitted and the function of each loom for the Q range actuator.
PFU Socket
Wiring Harness
SK2
24V power supply input from actuator
SK3
Profibus Fieldbus connection
SK9
Limit switches
SK10
Analogue Input connection 
SK11
Potentiometer
Note: - Only available on Single Channel module
In a Q actuator there is a direct connection from PL2 on the Interface Card to SK5 of the actuator main
board.
To restore the interface card to its factory defaults and the associated default parameter settings, LK1
on the Interface card should be fitted and the actuator power cycled (see Fig. 11).
Fig 7: The Profibus Mk2 card profiled for the Q actuator
SK10
EPROM
SK9 SK11 SK2
LK1 SK3

Fitting the Profibus card
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3.3 Inside a CVA actuator
The PFU is suitable for fitting into CVA actuators, wiring diagrams CXX-90 (where X can be any value)
details the option card connections to the terminal bung. The PFU module is fitted in the only option
board slot inside the CVA electrical housing –on the underside of the Main PCB assembly.
SK3 is the connection to the Profibus Fieldbus Data Highway.
The PFU in the CVA must be enabled. This would usually be done during factory test, but may be
required to be completed on site for spares. To enable, the Rotork PDA software Enlight
(downloadable from the Rotork web site) is utilised to change parameter 34. It must be read then
2048decimal added to it.
Fig 8: The Profibus Mk2 card located in a CVA actuator

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3.4 Inside ROMPAK actuator
The PFU is suitable for fitting into ROMPAK actuators, wiring diagram RX0X-6X0 (where X can be any
value) details the option card connections on the terminal strip. The PFU module is fitted in the only
option board slot inside the ROMPAK electrical housing.
SK3 is the connection to the Profibus Data Highway; this is connected to SK23 on the main PCB
assembly via an internal loom. The user wires the Profibus connections to the main PCB assembly at
the terminal block SK18 as per the wiring diagram.
On the ROMPAK, termination is achieved by setting L1 and L2 on the profibus card as per section 4.7;
this fits the ‘biasing resistors’. To connect the main termination resistor, attach a jumper to LK1 and
LK2 between pins 1 & 2. Pin 1 is labelled on the printed circuit board, next to LK1 and LK2.
Fig 9: The Profibus Mk2 card located in a ROMPAK actuator

Fitting the Profibus card
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3.5 Inside a Skil or EH actuator
The PFU is suitable for fitting into Skil and EH actuators, wiring diagram SWM SI-001 and WD18460.
The PFU is normally located in the first option board slot inside the electrical housing using connection
SK1.
The Interface card must be correctly profiled and loaded with the appropriate connectors to match the
actuator. The illustration below shows the Skil and EH version of the PFU. The links for the bias
resistors are shown in the ‘not terminated’ position.
With the Skil/EH actuator the remote inputs are always present (they are conditioned by the PFU) and
there is an option to include Digital Outputs from relay contacts. The following table describes the
wiring harnesses and their function in the Skil/EH actuator.
PFU Socket
Wiring Harness
SK2
24V power supply input from actuator
SK3
Profibus Fieldbus connection
SK5
Main Board connections
SK7
Not used
SK8
Not used
SK10
Analogue Input connection 
Note: –Only available on Single Channel module.
To restore the interface card to its factory defaults and the associated default parameter settings, LK1
on the Interface card should be fitted and the power cycled (see Fig. 11).
Fig 10: The Profibus Mk2 card profiled for the Skil and EH actuators

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3.6 Replacing or Fitting a Profibus DP (Mk2) 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 and in the case of an IQ or IQT it is advisable to
disconnect the internal battery.
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 two screws,
which may be T20. 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, in the case of the IQ or IQT, the
battery replaced.
The PFU must not be split between its Network Interface Card and the Interface card. Only complete
assemblies should be fitted or exchanged.
If at any time it is necessary to reset the interface card used for the Q and the Skil / EH to its supplied
default values, the Network Interface card should be removed and a shorting link applied to LK1. The
Interface card must then be put back in the actuator and the mains power cycled. The Network
Interface card must then be re-assembled onto the interface board and the pair refitted into the
actuator. LK1 is usually used as a mechanical connection link between the top and bottom boards.
SK5 SK7 SK10
EPROM
SK1
SK2
SK8
LK1
Fig 11: The Profibus Mk2 Interface card showing the position of LK1 (NIC removed)
LK1

Single and Dual Data Highway Configurations
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Foundation Fieldbus FF-01 Installation manual
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.
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
31
31
31
31
31
31
31
Note: –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. To select these termination components the appropriate
internal links must be fitted. A simple termination resistor is also included and can be connected by
linking the appropriate actuator terminals (refer to the actuator wiring diagram).
Fig 12: Typical Profibus DP Data Highway
Terminator
T
Profibus DP highway Screened cable
PLC
T
+5V
0V
+5V
0V

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4.2 Segmented Single Highway System
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.
Fig 13: Profibus Single Channel Data Highway Topology
Terminator
Bus Master
Segment 2
Segment 1
Segment 3
Repeater
Repeater
Powered
Active
Terminator