Softing FG-200 HSE/FF Troubleshooting guide

FG-200 HSE/FF Modbus
Quick Startup Guide
Version: EN-012018-1.20
© Softing Industrial Automation GmbH

The information contained in these instructions corresponds to the technical status at the time of
printing of it and is passed on with the best of our knowledge. The information in these
instructions is in no event a basis for warranty claims or contractual agreements concerning the
described products, and may especially not be deemed as warranty concerning the quality and
durability pursuant to Sec. 443 German Civil Code. We reserve the right to make any alterations or
improvements to these instructions without prior notice. The actual design of products may
deviate from the information contained in the instructions if technical alterations and product
improvements so require.
It may not, in part or in its entirety, be reproduced, copied, or transferred into electronic media.
Disclaimer of liability
Softing Industrial Automation GmbH
Richard-Reitzner-Allee 6
85540 Haar / Germany
http://industrial.softing.com
+ 49 89 4 56 56-0
+ 49 89 4 56 56-488
[e-mail]
[e-mail]
The latest version of this manual is also available in the Softing download area at
http://industrial.softing.com/en/downloads.html

© Softing Industrial Automation GmbH 3
Table of Contents
Table of Contents
Chapter 1 ................................................................................... 6Introduction
................................................................................................................ 61.1 Intended use
................................................................................................................ 71.2 System requirements
................................................................................................................ 81.3 Scope of delivery
................................................................................................................ 81.4 Safety precautions
Chapter 2 ................................................................................... 9Hardware installation
................................................................................................................ 92.1 Installation in hazardous locations
.................................................................................................. 10
General requirements2.1.1
.................................................................................................. 13
European and International Approval2.1.2
.................................................................................................. 14
North American Approval2.1.3
................................................................................................................ 152.2 Mounting and dismounting
................................................................................................................ 172.3 Connection diagram
................................................................................................................ 182.4 Connecting the power supply
................................................................................................................ 192.5 Connecting to the network
................................................................................................................ 202.6 Modbus serial connection
................................................................................................................ 202.7 FG-200 redundancy
................................................................................................................ 222.8 FF-H1 interface connection
................................................................................................................ 242.9 Powering up the device
................................................................................................................ 252.10 Adding a second FG-200 for redundancy
Chapter 3 ................................................................................... 26Commissioning FG-200 HSE/FF Modbus
................................................................................................................ 263.1 Installing comConf
................................................................................................................ 263.2 Configuring IP address and Modbus parameters

Table of Contents
© Softing Industrial Automation GmbH4
................................................................................................................ 273.3 Setting up a comConf project
Chapter 4 ................................................................................... 28Status indicators - LEDs
................................................................................................................ 294.1 PWR - power supply
................................................................................................................ 294.2 Device LED statuses in stand-alone mode
................................................................................................................ 304.3 RUN/ERR/RDL - LED statuses in redundant mode
................................................................................................................ 344.4 H1 channel status indicators
Chapter 5 ................................................................................... 35Technical data
................................................................................................................ 355.1 Specifications
................................................................................................................ 365.2 Installation positions
Chapter 6 ................................................................................... 38ATEX Type Examination Certificate
Chapter 7 ................................................................................... 41UL Certificate of Compliance
Chapter 8 ................................................................................... 42Declarations of conformity

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FG-200 HSE/FF Modbus - Quick Startup Guide
6© Softing Industrial Automation GmbH
1Introduction
Read this manual before starting
For damages due to improper connection, implementation or operation Softing
refuses any liability according to our existing warranty obligations.
1.1 Intended use
The Softing FG-200 HSE/FF Modbus is designed to integrate up to four FF H1 links into
control systems supporting Modbus. The device can be used as a redundant link. It
provides fast access to process data, while making use of FOUNDATION Fieldbus
advantages such as reduced cabling, central field device parametrization, comprehensive
diagnostics or intrinsically safe device segments. It is compatible with the R. STAHL bus-
Carrier Series 9419 and Power Supply 9412 products for easy commissioning.
The FG-200 HSE/FF Modbus is a gateway from FOUNDATION fieldbus High Speed Ethernet
(HSE) to the FOUNDATION fieldbus H1 (FF-H1). It is also called FG-200 and used for process
automation. It provides a remote access of OEM Systems to FF-H1 field devices.
Use in hazardous areas
The FG-200 is an electrical equipment with degree of protection Ex nA, approved for use in
hazardous areas of Zone 2 or in the safe area. The four FF-H1 interfaces are designed
according to the protection method Ex ic. Only certified circuits with an according
protection method shall be connected to these FF-H1 interfaces.

Chapter 1 - Introduction
© Softing Industrial Automation GmbH 7
Special hints for safe use
Before setting the FG-200 into operation, the corresponding marking field has
to be signed (e.g. if the device is used in ic environment, the upper marking
field on the type label has to be signed).
Use an appropriate permanent pen for signing, e.g. an etching pen.
More than one marking is not allowed. If you need a second marking, you must
replace the existing equipment with a new one.
An equipment which has been operated under non-intrinsically safe
conditions is no longer permitted to be used under intrinsically safe
conditions.
The FG-200 HSE/FF Modbus is only approved for intended and appropriate use. In case of
noncompliance, the warranty and manufacturer’s liability do no longer apply!
1.2 System requirements
Communication Configuration tool comConf
PC with operating system Windows 7 or Windows 8.1 (both 32 bit or 64 bit
supported)
Supported browsers
Microsoft Internet Explorer version 8.0 or higher
Mozilla Firefox version version 35 or higher

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1.3 Scope of delivery
The FG-200 HSE/FF Modbus is delivered with the following:
FG-200 HSE/FF Modbus device
CD-ROM including firmware and manuals
Quick Startup Guide
Note
The FG-200 is available in two variants. They have identical technical
specifications. Their only differentiating characteristic is their mount direction
that is mirrored, i.e. rotated by 180°.
1.4 Safety precautions
CAUTION
During operation, the device's surface will be heated up. Avoid direct contact.
When servicing, turn off the power supply and wait until surface has cooled
down.
Note
Do not open the housing of the FG-200. It does not contain any parts that need
to be maintained or repaired. In the event of a fault or defect, remove the device
and return it to the vendor. Opening the device will void the warranty!

Chapter 2 - Hardware installation
© Softing Industrial Automation GmbH 9
2Hardware installation
2.1 Installation in hazardous locations
The FG-200 HSE/FF Modbus can be used in hazardous locations and is certified according
to ATEX, IEC and North America Approval cULus.
WARNING
Use only according to operating conditions from instructions!
Use the FG-200 in accordance with its designated use only! Otherwise, the
manufacturer’s liability and warranty will expire. The device is only to be used
according to the operating conditions described in these instructions.
WARNING
Do not connect or disconnect energized conductors!
Be aware that energized conductors are not to be connected or
disconnected! This can lead to danger of life if potentially explosive
atmosphere is present there at that time!

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2.1.1 General requirements
Following general requirements must be observed while installing FG-200 on hazardous
locations:
The details of this document must be observed along with the conditions for use and
the applicable details stated on the marking and type labels of each.
Any selection and operation of the device must be done as per the technical rules.
Adequate precautions must be taken to prevent unintended actuation or impairment
of the device.
Connectors must not be connected or disconnected when area is known to be
hazardous. This can be life threatening in a potentially explosive atmosphere. Open
or not securely closed sockets shall not be energized in the Ex-atmosphere!
Ensure the installed equipment comply with the types of protection applicable to the
corresponding zones.
All connected electrical equipment must be suitable for the respective intended use.
The operator must ensure protection against lightning in compliance with the locally
applicable regulations.
Electrostatic aspects must be considered when mounting the bus-modules.
Electrostatic charges have to be prevented.
In explosion group IIC and Zone 2 no protected plastic surfaces > 20 cm2are allowed;
in IIB or dust-Ex, 100 cm2may be reached.
The hazard of any objects falling onto the bus-module must be prevented.

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The FG-200 does not meet the requirements of impact protection and IP54 (according
to IEC 60529). It must be installed in a protective enclosure which meets the
requirements for resistance to impact and IP as stated in section 26.4 of IEC/EN
60079-0. This enclosure must be fully mounted and intact. If the enclosure is
damaged, the operation is not permitted.
The FG-200 is defined as instruments and apparatus of low energy according to
clause 23 of IEC/EN 60079-15; thus the requirement stated in sub-clause C, limiting
the transient characteristic to 40% above the rated voltage, has to be adhered to when
erecting the equipment.
When removing the packaging ensure that no dirt can enter the enclosure or the
plugs.
If any vibration during the operation may cause parts of the plugs to loosen, then the
plugs have to be provided with a light firm varnish used for securing screws. An
extraction force of 0.5 Nm has to be achieved at an equivalent thread.
To circuits of Zone 2 only such equipment may be connected that is suitable for
operation in this zone and has been certified accordingly.
Components may only be replaced by original spare parts which are also approved
for the use in Ex-atmospheres. Spare parts are ordered as complete units giving the
material number stated on the device (marking, type label).
Only such auxiliary components may be used in potentially explosive atmospheres
which meet all requirements of European and national directives and legislation.
The environmental conditions specified in the manual have to be followed strictly.
The FG-200 is not to be used in systems where cathodic systems for corrosion
protection are in place. Although special precautions may allow the use in such
systems (additional earthing bridges), the manufacturer has to be consulted in each
case.

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The operator has to provide measures for protection against lightning.
According to the local conditions and in compliance with the environmental rules, the
operator is responsible to visually inspect the system and to remove dust settlements
in a regularly interval (every 6 months).
The company installing the device has to ensure that the transient characteristic is
limited to 40% above the service voltage.
Additional precautions have to be taken, if the presence of hydrosulfide, ethylene
oxide and/or carbon monoxide is to be expected: those substances are of a vary low
ignition energy.
Icing is not permitted.
Pair of values for fieldbus voltage and current for Intrinsic Safety Fieldbus (ic):
Pair 1
Pair 2
Pair 3
Fieldbus Voltage
Ui = 14 Volt DC
Ui = 17.5 Volt DC
Ui = 32 Volt DC
Fieldbus Current
li = 570 mA
li = 319 mA
li = 100 mA
CAUTION
Make sure that the sum of power supply voltage and fieldbus supply voltage
does not exceed 60 VDC!
Explosion hazard
Do not disconnect equipment unless power has been removed or the area is
known to be non-hazardous.

Chapter 2 - Hardware installation
© Softing Industrial Automation GmbH 13
Observe national regulations, standards and directives
This manual does not supersede the relevant national regulations, standards
and directives. These must be observed and have to be applied according to the
national conditions!
2.1.2 European and International Approval
The equipment has been a based on the following standards and editions:
a) IEC 60079-0:2011 Ed. 6, modified Cor. 2012 + Cor. 2013 / EN 60079-0:2012 + A11:2013
b) IEC 60079-11:2011 Ed. 6 + Corr. 2012 / EN 60079-11:2012
c) IEC 60079-15:2010 Ed. 4 / EN 60079-15:2010
Wh indicated on the device label or in the technical documentation, the FG-200 is suitable
for use in gas-Ex atmospheres of Zone 2 in the explosion groups IIA, IIB and IIC in
temperature class T4, if accommodated in a tested enclosure.
IECEx marking for explosion protection: Ex nA [ic] IIC T4 Gc.
ATEX marking for explosion protection: II 3G nA [ic] IIC T4 Gc.
The Ex protection method [ic] corresponds only to the FF-H1 fieldbus interfaces.
The FG-200 HSE/FF Modbus complies with the applicable standards and regulations and
meets the requirements of European Directive 94/9/EC. The requirements for erecting the
device as part of the system in potentially explosive atmospheres (e.g. IEC / EN 60079-14)
must be strictly adhered.

FG-200 HSE/FF Modbus - Quick Startup Guide
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Certificates
ATEX The EC type examination number for ATEX is: BVS 15 ATEX E 063 X
A copy of the certificate is available in section ATEX Type Examination
Certificate .
IECEx The type examination number for IECEx is: IECEx BVS 15.0055X
The certificate can be downloaded from http://iecex.iec.ch
2.1.3 North American Approval
If indicated on the device label, the FG-200 is suitable for use in Class 1, Division 2,
Groups A, B, C and D hazardous or non-hazardous locations.
The device must be installed in a protective enclosure which meets the requirements for
resistance to impact and IP54 according to IEC 60529.
Marking for explosion protection: Class I Div.2 Groups A,B,C,D.
Certificate
cULus The cULus Certificate of Compliance number is: 20151215-E356500
A copy of the certificate is available in section UL Certificate of Compliance
.
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Chapter 2 - Hardware installation
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2.2 Mounting and dismounting
Note
Make sure the FG-200 is mounted in a manner that the power supply
disconnecting device or interrupt facility can always be reached easily.
Note
Depending on the installation position, the maximum ambient operating
temperature may differ. Refer to Technical Data for detailed information.
Installation and inspection
Installation and inspection tasks must be carried out by qualified personnel
only, according to TRBS 1203 or similar! The definition of terms can be found in
IEC 60079-17.
Mounting
1. Hook the two upper notches to the rail to mount the FG-200 on a DIN rail (35 mm).
2. Press the device down towards the rail until it locks into place.
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FG-200 HSE/FF Modbus - Quick Startup Guide
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Note
Do not put stress on the system by bending or torsion.
Dismounting
To dismount the FG-200 from the DIN rail, slide a screw driver horizontally underneath the
housing into the locking bar, slide the bar downwards – without tilting the screw driver -
and fold the device upwards.

Chapter 2 - Hardware installation
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2.3 Connection diagram
The following connection diagram gives an overview about the different plugs and
interfaces:
Note
If ambient temperatures exceed 55 °C at the place of installation, it may occur
that the temperatures of connecting cables strongly rise if those cables have
been put in place in an unfavorable condition. In such cases, either perform
measurements to confirm that the service temperature of the cables is not
exceeded (i.e. 80 °C), or use such variants that withstand temperatures of
minimum 90 °C.

FG-200 HSE/FF Modbus - Quick Startup Guide
18 © Softing Industrial Automation GmbH
2.4 Connecting the power supply
1. Connect the FG-200 to a 24 V DC power supply.
2. Use different or redundant power supplies for redundant FG-200s.
3. Turn on the power supply. The boot process takes approx. 50 seconds. For indication
of proper operation of a FG-200 acting in non-redundant mode or as primary device
in redundant mode refer to Status indicators - LEDs .
The supply voltage (18 VDC .... 32 VDC) is connected by a 3-pole terminal block. The power
supply is connected to the plug connector via flexible wires with a cross section of 0.75 to
1.5 mm². The ground connection wire must have a cross section of 1.5 mm².
Pin
Signal
Description
1
GND
Ground
2
Functional earth
3
L+
Positive supply voltage
CAUTION
The Functional Earth (FE) connection of the device has to be connected at low
inductance with the Protective Earth (PE) of the system.
Note
As indicated in the connection diagram, the power can be applied alternatively
by a special DIN rail connector (Rail Power Supply). For further information
contact Softing Industrial Automation.
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Chapter 2 - Hardware installation
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2.5 Connecting to the network
The FG-200 provides the following network connections:
EtherNet/IP and
PROFINET
Note
We strongly recommend connecting the two Ethernet interfaces to different
physical LAN networks (EtherNet/IP communication system and PROFINET
communication system).

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2.6 Modbus serial connection
When connecting the FG-200 via serial connection use the connector from your delivery
with the following pin assignment:
Pin No.
Signal
Connector symbol
6
RX
+
5
TX
S
4
GND
-
Note
If you are working with two FG-200 in redundant mode, the serial connection
cannot be used, refer to Section FG-200 redundancy .
2.7 FG-200 redundancy
When using two FG-200s as a redundant set, the redundancy link interfaces (RDL) of both
FG-200s (primary and secondary) must be connected by a cable, thus forming a
redundancy link. If the redundancy link is not installed during start-up (power-on), the FG-
200 will operate in non-redundant mode.
Note
The interface is not galvanically isolated. Thus make sure that there is no
potential difference between the two connected devices.
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