SMAR DC303 Installation guide

DC303
D C 3 0 3 M E
FEV / 18
REMOTE I/O PROFIBUS - PA
VERSION 3
OPERATION & MAINTENANCE
INSTRUCTIONS MANUAL

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Introduction
III
INTRODUCTION
Until all types of devices are available with Profibus-PA systems will have to be of a hybrid nature
accepting both Profibus and conventional signals. A mixed traditional and Profibus environment is
inevitable during the transition to a Profibus technology. DC303 makes integration of Profibus and
conventional I/O easy. Discrete devices such as pressure switches, push buttons, on/off valves,
pumps and conveyors are integrated to the system over the Profibus-PA field-level network using
DC303. The DC303 remote I/O units can be distributed into the field where they are mounted close
to the conventional devices without the need to run the conventional wiring to the control room. The
DC303 is an integral part of SYSTEM302 but also it integrates into other systems supporting
Profibus.
The DC303 makes conventional analog and discrete inputs and outputs available using standard
Profibus-PA Function blocks making the system homogenous and control strategy configuration
easy as conventional I/O appears as if they were regular Profibus devices. Control loops are
implemented consistently regardless of I/O being conventional or Profibus based. Only a single
programming language has to be used.
The DC303 is a simple low-cost DIN-rail mounted unit. The DC303 is a single integrated easy to
use piece of equipment including power, control, networking and I/O under one compact device
requiring less panel space than other solutions.
Function block like Discrete Input and Discrete Output, as well FFB (Flexible Function Block)
enables the DC303 to perform logic and r control functions in the field integrating the control
strategy with other Profibus devices on the same network. Function blocks provide great flexibility in
control strategy. Conventional discrete I/O now works together with pure Profibus devices on the
same network and in the same loop. The DC303 is fully configured SYSTEM302 or any other
Profibus-PA configuration tool. Function blocks provide logic such as AND, OR, NAND etc. as well
as latches etc.
The DC303 may be installed close to the sensors and actuators, thereby eliminating long wire runs
and associated marshalling panels and cable trays for the conventional I/O, with subsequent
savings further reducing overall system cost. Use DC303 to make it possible to distribute I/O at
various locations in the field and connect them via Profibus-PA. DC303 is ideal to connect motor
control centers, variable speed drives, and electrical actuators and motor operated valves to
Profibus-PA.
Get the best result of the DC303 by carefully reading these instructions.
NOTE
In case of using Simatic PDM as the configuration and parameterization tool, Smar
recommends that the user does not apply the option "Download to Device". This function
can improperly configure the field device. Smar recommends that user make the use of the
option "Download to PG / PC" and then selecting the Device Menu, use the menus of the
transducer, function and display blocks acting specifically, according to each menu and
method for reading and writing.
WARNING
This manual applies to equipment with a serial number from 2000 onwards.
NOTE
For previous DC303 versions (with plastic cowling), pick up equivalent manual.

DC303 –Operation and Maintenance Instruction Manual
IV
Waiver of responsibility
The contents of this manual abides by the hardware and software used on the current equipment
version. Eventually there may occur divergencies between this manual and the equipment. The
information from this document are periodically reviewed and the necessary or identified corrections
will be included in the following editions. Suggestions for their improvement are welcome.
Warning
For more objectivity and clarity, this manual does not contain all the detailed information on the
product and, in addition, it does not cover every possible mounting, operation or maintenance
cases.
Before installing and utilizing the equipment, check if the model of the acquired equipment complies
with the technical requirements for the application. This checking is the user’s responsibility.
If the user needs more information, or on the event of specific problems not specified or treated in
this manual, the information should be sought from Smar. Furthermore, the user recognizes that the
contents of this manual by no means modify past or present agreements, confirmation or judicial
relationship, in whole or in part.
All of Smar’s obligation result from the purchasing agreement signed between the parties, which
includes the complete and sole valid warranty term. Contractual clauses related to the warranty are
not limited nor extended by virtue of the technical information contained in this manual.
Only qualified personnel are allowed to participate in the activities of mounting, electrical connection,
startup and maintenance of the equipment. Qualified personnel are understood to be the persons
familiar with the mounting, electrical connection, startup and operation of the equipment or other
similar apparatus that are technically fit for their work. Smar provides specific training to instruct and
qualify such professionals. However, each country must comply with the local safety procedures,
legal provisions and regulations for the mounting and operation of electrical installations, as well as
with the laws and regulations on classified areas, such as intrinsic safety, explosion proof, increased
safety and instrumented safety systems, among others.
The user is responsible for the incorrect or inadequate handling of equipments run with pneumatic
or hydraulic pressure or, still, subject to corrosive, aggressive or combustible products, since their
utilization may cause severe bodily harm and/or material damages.
The field equipment referred to in this manual, when acquired for classified or hazardous areas, has
its certification void when having its parts replaced or interchanged without functional and approval
tests by Smar or any of Smar authorized dealers, which are the competent companies for certifying
that the equipment in its entirety meets the applicable standards and regulations. The same is true
when converting the equipment of a communication protocol to another. In this case, it is necessary
sending the equipment to Smar or any of its authorized dealer. Moreover, the certificates are
different and the user is responsible for their correct use.
Always respect the instructions provided in the Manual. Smar is not responsible for any losses
and/or damages resulting from the inadequate use of its equipments. It is the user’s responsibility to
know and apply the safety practices in his country.

Table of Contents
V
TABLE OF CONTENTS
SECTION 1 - INSTALLATION.................................................................................................................. 1.1
GENERAL.....................................................................................................................................................................1.1
MOUNTING..................................................................................................................................................................1.1
ELECTRIC WIRING .....................................................................................................................................................1.2
TOPOLOGY AND NETWORK CONFIGURATION......................................................................................................1.5
GENERAL SYSTEM.....................................................................................................................................................1.6
SECTION 2 - OPERATION....................................................................................................................... 2.1
FUNCTIONAL DESCRIPTION –ELECTRONICS .......................................................................................................2.1
(CPU) CENTRAL PROCESSING UNIT, FRAM.......................................................................................................................... 2.1
COMMUNICATION CONTROLLER ........................................................................................................................................... 2.1
POWER SUPPLY....................................................................................................................................................................... 2.1
FACTORY RESET...................................................................................................................................................................... 2.1
INPUT LATCHES ....................................................................................................................................................................... 2.1
OUTPUT LATCHES ................................................................................................................................................................... 2.1
OPTICAL ISOLATION................................................................................................................................................................ 2.1
SECTION 3 - CONFIGURATION.............................................................................................................. 3.1
CONNECTING PHYSICAL SIGNALS TO DIGITAL INPUT BLOCK...........................................................................3.1
CONNECTING PHYSICAL SIGNALS TO DIGITAL OUTPUT BLOCK.......................................................................3.1
EXAMPLES OF APPLICATIONS................................................................................................................................3.2
EXECUTING LOGIC WITH DC303.............................................................................................................................3.3
DESCRIPTION........................................................................................................................................................................... 3.3
STATUS ..................................................................................................................................................................................... 3.3
SUPPORTED MODES ............................................................................................................................................................... 3.3
SCHEMATIC............................................................................................................................................................................... 3.4
PARAMETERS........................................................................................................................................................................... 3.4
FUNCTIONS............................................................................................................................................................................. 3.10
TP TIMER PULSE.................................................................................................................................................................... 3.10
TON TIMER ON-DELAY........................................................................................................................................................... 3.10
TOF TIMER OFF-DELAY ......................................................................................................................................................... 3.11
CTD PULSE COUNTER DOWN .............................................................................................................................................. 3.12
CTU PULSE COUNTER UP..................................................................................................................................................... 3.12
RS FLIP-FLOP ......................................................................................................................................................................... 3.12
SR FLIP-FLOP ......................................................................................................................................................................... 3.12
ERROR CODE ..........................................................................................................................................................3.13
EXAMPLE OF APPLICATIONS.................................................................................................................................3.14
DC303 CYCLICAL CONFIGURATION......................................................................................................................3.17
CYCLICAL DIAGNOSIS............................................................................................................................................3.19
ADDRESSING THE DC303.......................................................................................................................................3.21
DOWNLOAD USING SIMATIC PDM ........................................................................................................................3.22
SECTION 4 - MAINTENANCE PROCEDURES........................................................................................ 4.1
GENERAL....................................................................................................................................................................4.1
DISASSEMBLY PROCEDURE ...................................................................................................................................4.1
REASSEMBLY PROCEDURE ....................................................................................................................................4.1
FIRMWARE UPDATE PROCEDURE .........................................................................................................................4.2
BOARDS INTERCHANGEABILITY.............................................................................................................................4.2
ACCESSORIES...........................................................................................................................................................4.2
EXPLODED VIEW.......................................................................................................................................................4.3
SPARE PARTS............................................................................................................................................................4.3
SECTION 5 - TECHNICAL SPECIFICATIONS......................................................................................... 5.1
GENERAL....................................................................................................................................................................5.1
DC303 INPUTS ...........................................................................................................................................................5.1
DESCRIPTION-INPUTS............................................................................................................................................................. 5.1
TECHNICAL SPECIFICATIONS................................................................................................................................................. 5.1
DC303 OPEN COLLECTOR OUTPUTS.....................................................................................................................5.2
DESCRIPTION –OUTPUTS...................................................................................................................................................... 5.2

DC303 –Operation and Maintenance Instruction Manual
VI
TECHNICAL SPECIFICATIONS................................................................................................................................................. 5.2
ORDERING CODE......................................................................................................................................................5.2
APPENDIX A –SRF –SERVICE REQUEST FORM ................................................................................A.1
RETURNING MATERIALS..........................................................................................................................................A.2

Installation Flowchart
VII
Installation Flowchart
START
ATTENTION
Get the best results of the DC303
by carefully reading all instructions manual.
Install the DC303 using DIN
rail in panel mounting.
Check the area classification and
respective practices. For explosion-proof
installations use certified enclosure
to put the DC303.
Power the DC303 outputs and inputs
according to the connection diagram.
(Section 1, Figures 1.5 and 1.6)
Are the inputs
OK? NO
YES
*More information in Section 1 from DC303. Operation, Maintenance and Instructions Manual.
Check the power, input, output and
communication LEDs when
establishing the communication.
●
●
Check power;
Check cabling and connections.
Are the outputs
OK?
●
●
●
●
Check power;
Check cabling and connections;
Check if the outputs are open collector;
Check the load limits.
NO
Before powering up the DC303, please
read Section 3:Addressing the DC303. Before powering up the DC303, please
read Section 3: Addressing the DC303.
Check the load limits.
(Section 5)
YES
ATTENTION
*More information in Section 1 of DC303. Operation, Maintenance and Instructions Manual.

DC303 –Operation and Maintenance Instruction Manual
VIII

Section 1
1.1
INSTALLATION
General
ATTENTION
Before powering up the DC303, please, read Section 3: Addressing the DC303.
The overall accuracy of measurement and control depends on several variables. Although the
Profibus Remote I/O has an outstanding performance, proper installation is essential, in order to
maximize its performance.
Among all factors, which may affect the accuracy, environmental conditions are the most difficult to
control. There are, however, ways of reducing the effects of temperature, humidity and vibration.
Locating the Profibus Remote I/O in areas protected from extreme environmental changes can
improve its performance.
In warm environments, the Profibus Remote I/O should be installed to avoid, as much as possible,
direct exposure to the sun. Installation close to lines and vessels subjected to high temperatures
should also be avoided.
Use of sunshades or heat shields to protect the Profibus Remote I/O from external heat sources
should be considered, if necessary.
Humidity is fatal to electronic circuits. In areas subjected to high relative humidity, the protection
cover must be provided.
For details of mounting, please, refer to Figure 1.1 and Figure 1.2
Mounting
Use DIN rail (TS35-DIN EN 50022 or TS32-DIN EN50035 or TS15 DIN EN50045), as shown in
Figure 1.1 –Mechanical Mounting. The DC303 can optionally be supplied preinstalled in an
enclosure ready for field mounting.
LOCK
DIN
RAIL
Figure 1.1- Mechanical Mounting

DC303 –Operation and Maintenance Instruction Manual
1.2
174
1,6
(6.85)
63,5
(2.5)
(0.06)
25
(0.98)
77,3
(3.04)
NOTE
The measurements are in mm.
Electric Wiring Access the wiring block by the front View with label for inputs, outputs power supply and bus
connection. The connections are made using the screws.
SCREWS
LABEL
Figure 1.3 - Terminal Block Connections

Installation
1.3
Figure 1.4 –Label DC303
The following table describes the terminal numbers for DC303.
Upper (U)
Lower (U)
Remark
VIN (1A)
GNDIN (2A)
Auxiliary power for inputs
IN1 (1B)
IN9 (2B)
Digital Inputs
IN2 (1C)
IN10 (2C)
IN3 (1D)
IN11 (2D)
IN4 (1E)
IN12 (2E)
IN5 (1F)
IN13 (2F)
IN6 (1G)
IN14 (2G)
IN7 (1H)
IN15 (2H)
IN8 (1I)
IN16 (2I)
VOUT (3A)
GNDOUT (4A)
Auxiliary power to drive outputs
OUT1 (3B)
OUT5 (4B)
Digital Outputs
OUT2 (3C)
OUT6 (4C)
OUT3 (3D)
OUT7 (4D)
OUT4 (3E)
OUT8 (4E)
VDC (5A)
Main power
GND (5B)
COMM+ (6A)
Profibus PA communication signal.
COMM- (6B)
Table 1.1 - Terminal Block Connections
The used connections should be plugged accordingly. For examples, please see the Figure 1.5 and
Figure 1.6.
Figure 1.5 –Example of Input Connections

DC303 –Operation and Maintenance Instruction Manual
1.4
Figure 1.6 –Example of Output Connections
The DC303 is a non bus-powered device. The DC303 uses a 31.25 Kbit/s voltage mode option for
the physical signaling. Various types of Profibus-PA devices may be connected on the same bus,
being bus-powered or non-bus-powered. When bus-powered, the devices must use the same
signaling.
The total of equipment on a Profibus-PA network depends on the area classification, total
consumption each device on the bus, distances used, etc.
The DC303 is a non bus-powered device.
In hazardous area, the number of devices may be limited by intrinsically safe restrictions.
The DC303 is protected against reverse polarity, and can withstand ±35 VDC without damage.
NOTE
Please refer to the General Installation, Operation and Maintenance Manual for more details.

Installation
1.5
WARNING
HAZARDOUS AREAS
In hazardous zones with intrinsically safe or non-incendive requirements, the circuit entity parameters and
applicable installation procedures must be observed.
Cable access to wiring connections is obtained by the two conduit outlets. Conduit threads should be sealed
by means of code-approved sealing methods.
Topology and Network Configuration
Bus topology (See Figure 1.7 - Bus Topology) and tree topology (See Figure 1.8 - Tree Topology)
are supported. Both types have a trunk cable with two terminations. The devices are connected to
the trunk via spurs. The spurs may be integrated in the device giving zero spur length.
A spur may connect more than one device, depending on the length. Active couplers may be used
to extend spur length.
Active repeaters may be used to extend the trunk length.
The total cable length, including spurs, between any two devices in the Profibus-PA should not
exceed 1900 m.
WARNING
POWER SUPPLIES
If there are requirements for power supply isolation between inputs and outputs, it is recommended to use at
least two power supplies, one for inputs and another one for outputs and Vdc.
If the application does not require isolation between inputs and outputs, only one power supply could be used
for inputs, outputs and Vdc.
Inputs and outputs are optically isolated from each other.
Terminator
Spur
SpurSpur
Shield
Junction
Box
+
+
+
Coupler
DP/PA
Figure 1.7 - Bus Topology

DC303 –Operation and Maintenance Instruction Manual
1.6
+ +
Junction
box
Terminator
Coupler
DP/PA
Figure 1.8 - Tree Topology
General System
According to the figure below, we can see a general network topology where the DC303 is
integrated in a simple Profibus network.
DT303FY303TT303LD303
DC303
Master
Profibus DP
Coupler DP/PA
Figure 1.9 –DC303 and a general Profibus System

Section 2
2.1
OPERATION
The DC303 accepts up to 16 optically isolated inputs and up to 8 open collector outputs. It is
therefore ideal for interfacing existing discrete points to a Fieldbus system.
Function Blocks provide great flexibility to control strategies. The DC303 has 16 DIs and 8 DOs.
The conventional discrete I/Os work together with Fieldbus devices integrated in the same network
and in the same control loop.
Output function blocks include standard Profibus-PA safety mechanism in case of failures.
Inputs and Outputs are isolated from each other and are accessed via communication network
through the function blocks channel. The leds are used to indicates the I/Os status. The use of
Functional Blocks make the system homogeneous in a way that the device with conventional
discrete and analog I/Os can be available in order to make the control strategies configuration
easy.
Functional Description - Electronics
Refer to the block diagram (See Figure 2.1 –DC303 Block Diagram). The function of each block is
described below.
(CPU) Central Processing Unit, FRAM
The CPU is the intelligent part of the DC303, being responsible for the management and operation
of the execution block, self-diagnosis and communication. The program and the temporary data are
stored in a FRAM memory. In the absence of energy, the data stored in the FRAM is not lost. The
FRAM memory also stores the non-volatile data that will be used later. Examples of such data are:
calibration, configuration and identification data.
Communication Controller
It monitors line activity, modulates and demodulates the signal from network line.
Power Supply
Takes power of the loop-line to power the Discrete Controller circuitry.
Factory Reset
The factory reset inscription can be found on the superior left side of the DC303 housing. In order
to accomplish this operation, simply short-circuit the contacts on the circuit board, turn-on the
DC303 in this short-circuit condition, and keep the key until the saving led goes to on state.
They are two mechanical contacts to perform the factory reset.
Input Latches
They are latches to hold the condition of inputs.
Output Latches
They are latches to hold the condition of outputs.
Optical Isolation
Optical isolation for inputs and outputs.

DC303 –Operation and Maintenance Instruction Manual
2.2
SIGNAL
SHAPING
POWER
SUPPLY
FIRMWARE
DOWNLOAD
INTERFACE
FRAM
MODEM
CPU
FACTORY
RESET
INPUT
LATCHES OPTICAL ISOLATION
OUTPUT
LATCHES OPTICAL ISOLATION
POWER
ISOLATION POWER SUPPLY
I
N
P
U
T
S
O
U
T
P
U
T
S
VDC
Vin
1
16
Vout
1
8
MAIN CIRCUIT BOARD INPUT - OUTPUT CIRCUIT BOARD
Figure 2.1 –DC303 Block Diagram

Section 3
3.1
CONFIGURATION
The DC303 may be configured using SYSTEM302 from Smar or a third party configuration tool
based on EDDL or FDT/DTM.
The DC303 has DO (Discrete Output Block) and DI (Discrete Input Block). In addition, there is a
built-in flexible function block to execute logics with Boolean resources, timers, counters, etc.
Function Blocks are not covered in this manual. For explanation and details of function blocks, see
the Function Blocks Manual.
Connecting physical signals to Digital Input Block
The DI block takes the discrete input data, selected by channel number, and makes it available to
other function blocks at its output.
For details, please see the Function Block Manual.
Figure 3.1 - DC303 and DI Block connections
Connecting physical signals to Digital Output Block
The DO block converts the value in SP_D to something useful for the hardware through the
CHANNEL selection.
For details, please see the Function Blocks Manual.
Figure 3.2 - DC303 and DO Block connections

DC303 –Operation and Maintenance, Instruction Manual
3.2
Examples of Applications
Application 1: From the computer the input and output can be manipulated.
Figure 3.3 - DC303 –Appplication 1
Application 2: Distributed control (Level limit will start a motor, a pump, or open/close an on/off
valve).
DT303FY303TT303LD303
DC303
Master
Profibus DP
Coupler DP/PA
Figure 3.4- DC303 –Appplication 2

Configuration
3.3
Application 3: General Application for Level and MCC control.
Figure 3.5 - DC303 –Appplication 3
Executing Logic with DC303
Description
The DC303 is designed to execute logic. In this case the discrete outputs blocks (DOs) will not act
physically on the hardware. The transducer block has a flexible built-in function block (FFB) that can
work with up to 8 discrete inputs coming from the Profibus network via parameters SP_D from DOs
blocks. On the transducer block these parameters are reference as IN_D1 to IN_D8. The transducer
block can also provide 8 discrete outputs to the Profibus network, through the OUT_D8 OUT_D1
parameters that are available via OUT_D from the DI blocks (DI1 to DI8). The FFB can receive up to
16 discrete inputs via hardware and also provides 8 discrete outputs via hardware. In this situation
the blocks DOs and DIs should be in automatic mode (block mode). When the FFB is enable in the
transducer block (via parameter TRD_FFB_ENABLED), the blocks DI9 to DI16 are configured to
"Out of Service".
When the FFB is disabled, the DC303 works with 16 DI blocks and 8 DO blocks, reading its 16
discrete inputs and writing on their 8 hardware outputs, respectively.
Status indication for the inputs depends on the I/O subsystem.
The FFB block provides logic such as AND, OR, XOR and NOT and functions such as Timer On-
Delay, Timer Off-Delay, Timer Pulse, Pulse Counter Down (CTD), Pulse Counter Up (CTU), RS Flip-
Flop and SR Flip-Flop. The logic is done using the discrete inputs (IN_Dx) variables from Profibus
network via DOs (SP_D), the output parameters for the Profibus network (OUT_Dx via DIs), the
input discrete variables from hardware, the output discrete variables from hardware, the failsafe
(FSx) values and the auxiliary bit variables (AUX’s).
Status
The outputs status OUT_Dx will be according to:
•Input failure –Bad: Device Failure;
•Power up –Bad: Device Failure.
In the logic, a status that is greater or equal to 0x80 is considered to be true and a status that is
less than 0x80 is considered to be false.
Supported Modes
O/S, and AUTO.
The changes on the Logic Lines and its parameters depend on the selection of CHANGE_OPTION

DC303 –Operation and Maintenance, Instruction Manual
3.4
Schematic
Figure 3.6 - Schematic
Parameters
Idx
Parameter
Data Type/
(Length)
Valid Range/
Options
Default
Value
Units
Store/
Mode
Description
16
TRD_FFB_ENABLE
Unsigned8
0- Disabled ;
1- Enabled
0- Disabled
S
Allows the execution of FFB
17
IN_D1
DS-34
D
Discrete Input 1 for FFB. It comes from
SP_D (DO1).
18
IN_D2
DS-34
D
Discrete Input 2 for FFB. It comes from
SP_D (DO2).
19
IN_D3
DS-34
D
Discrete Input 3 for FFB. It comes from
SP_D (DO3).
20
IN_D4
DS-34
D
Discrete Input 4 for FFB. It comes from
SP_D (DO4).
21
IN_D5
DS-34
D
Discrete Input 5 for FFB. It comes from
SP_D (DO5).
22
IN_D6
DS-34
D
Discrete Input 6 for FFB. It comes from
SP_D (DO6).
23
IN_D7
DS-34
D
Discrete Input 7 for FFB. It comes from
SP_D (DO7).
24
IN_D8
DS-34
D
Discrete Input 8 for FFB. It comes from
SP_D (DO8).
25
FSTATE_VAL_D1
Unsigned8
0
S
The preset discrete value to use in failure for
hardware output 1.
26
FSTATE_VAL_D2
Unsigned8
0
S
The preset discrete value to use in failure for
hardware output 2.
27
FSTATE_VAL_D3
Unsigned8
0
S
The preset discrete value to use in failure for
hardware output 3.
28
FSTATE_VAL_D4
Unsigned8
0
S
The preset discrete value to use in failure for
hardware output 4.
29
FSTATE_VAL_D5
Unsigned8
0
S
The preset discrete value to use in failure for
hardware output 5.
30
FSTATE_VAL_D6
Unsigned8
0
S
The preset discrete value to use in failure for
hardware output 6
31
FSTATE_VAL_D7
Unsigned8
0
S
The preset discrete value to use in failure for
hardware output 7.