murdoch university engineering thesis appendix xii...make sure gsd file si028131.gsd is installed in...
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Murdoch University Engineering Thesis
585 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Appendix XII
Profibus PA System
Configuration Instructions
Author: Hao Xu
Page: p585 - p602
Last modified: 10/11/2013
This is part of the Engineering Thesis “WinCC SCADA System via Profibus & OPC” by Hao Xu.
Murdoch University Engineering Thesis
586 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Preface This configuration instruction provides a comprehensive description about the operations and configurations
of DP/PA coupler, Levelflex M FMP40 and Deltabar S PMD70. The contents are summarized as follows:
DP/PA coupler operation instruction
DP/PA coupler slave module description
DP/PA coupler telegram structure
DP/PA coupler communication diagnostic
DP/PA coupler slave module data exchange sample code
Levelflex M FMP40 operation instruction
Levelflex M FMP40 slave module description
Levelflex M FMP40 telegram structure
Levelflex M FMP40 communication diagnostic
Levelflex M FMP40 slave module data exchange sample code
Deltabar S PMD70 operation instruction
Deltabar S PMD70 slave module description
Deltabar S PMD70 telegram structure
Deltabar S PMD70 communication diagnostic
Deltabar S PMD70 slave module data exchange sample code
TIA Portal communication configuration
Prerequisite Background knowledge of PLC operations
Background knowledge of ladder logic diagram
Background knowledge of basic electric circuit
Background knowledge of Profibus communication
Completion of Appendix V “S7-300 PLC & RS485 Repeater configuration instructions”
Resources Levelflex M FMP40 level transmitter
Deltabar S PMD70 pressure transmitter
Tank with appropriate height
Tank with bottom outlet
DP/PA coupler
S7-300 PLC with DP interface
CP5611 Profibus interface PCI card
TIA Portal configuration software
Profibus cable
Profibus DP connector
Profibus PA M12 connector (Optional)
MPI adaptor (Optional)
Murdoch University Engineering Thesis
587 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
DP/PA Coupler (Refer to DP/PA Coupler section in the thesis report for an overview of the functions and some background
information)
The specifications of DP/PA coupler are shown in Table 356.
Specification Transmission speed over DP 45.45 kBaud Transmission speed over PA 31.5 kBaud Bus protocol Profibus DP Rated supply voltage 24V DC (20.4 – 28.8V) Output voltage for PA section 19V DC Output current for PA section 400mA
Table 356: Specification of DP/PA coupler [79]
DP/PA coupler has an internal bus termination switch. It must be turned on to prevent the signal reflection on
its end. If this internal termination is not used, an external termination must be wired up.
DIP Switches The assignments of the DIP switches are shown in Table 357. The Ring redundancy DIP switch needs to be
switched on while using ring redundancy. Otherwise set it to coupler redundancy.
DIP switch Ring 1 2 4 8 16 32 64 Address value Ring/coupler redundancy +1 +2 +4 +8 +16 +32 +64
Table 357: DIP switch assignments of DP/PA coupler [79]
The Profibus address is determined by the DIP switch setting and the new Profibus address will take effect
after restart.
Murdoch University Engineering Thesis
588 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Profibus Communication First of all, connect PLC and DP/PA coupler with a Profibus connector and also make sure the Profibus signal is
terminated properly on each end of the network.
Make sure GSD file SI028131.gsd is installed in TIA Portal, then locate the DP/PA coupler station in TIA Portal
Hardware Catalog (Figure 496).
Figure 496: DP/PA coupler station in Hardware Catalog in TIA Portal
If the master Profibus network has been established earlier, drag the DP/PA coupler station into the Network
view and join it into the Profibus subnet (Figure 497).
Figure 497: Assign DP/PA coupler to the master PLC in TIA Portal
Double click the Profibus master connection, under Properties tab, in the PROFIBUS section, change the
Transmission speed to 45.45 (31.25) kbps as shown in Figure 498.
Figure 498: Profibus network transmission speed in TIA Portal
Assign a Profibus address to DP/PA coupler station based on the DIP switches. (Refer to Table 357 for setting
Profibus address for DP/PA coupler)
Murdoch University Engineering Thesis
589 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
The current slave module is on the module rack by default and cannot be removed as shown in Figure 499.
Figure 499: Current slave module in the module rack in TIA Portal
The DP/PA coupler cannot perform standalone operation, therefore, one or more PA instruments need to be
connected to the DP/PA coupler and also configured in TIA Portal.
(Refer to Levelflex M FMP40 or Deltabar S PMD70 section for PA instruments configuration)
Murdoch University Engineering Thesis
590 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Slave Modules (Refer to Slave Modules section in the thesis report for some background)
Current The current slave module shows the current on the equipotential bonding line.
(Refer to Sample Code section for some data exchange examples)
Voltage The voltage slave module displays the voltage value on the equipotential bonding line. This module is not
deliverable on the DP/PA coupler standalone mode. [80] (Refer to Sample Code section for some data exchange
examples)
Data Structure There is a fixed structure for all the slave modules to represent data. The first 4 bytes (Table 358 & Table 359)
are the data bytes and the 5th byte is the status byte (Table 360).
Data Byte Byte 1 Byte 2
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
VZ 27 26 25 24 23 22 21 20 2-1 2-2 2-3 2-4 2-5 2-6 2-7 Exponent Fraction
Table 358: DP/PA coupler slave module data structure part 1 [80]
Byte 3 Byte 4 Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 Fraction
Table 359: DP/PA coupler slave module data structure part 2 [80]
The equation to obtain the actual measured value is:
𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑉𝑎𝑙𝑢𝑒 = (−1)𝑉𝑍 × 2(𝐸𝑥𝑝𝑜𝑛𝑒𝑛𝑡 − 127) × (1 + 𝐹𝑟𝑎𝑐𝑡𝑖𝑜𝑛)
Equation 3: DP/PA coupler slave module actual value conversion equation [80]
Status Byte Status code Device status Description
00 Bad Bad (non-specific). 23 Uncertain Uncertain (initial value). 24 Bad Short circuit/wire brake/bad signal level. 25 Bad Lower limit violated (maintainence alarm). 26 Bad Upper limit violated (maintenance alarm). 68 Uncertain Parameter error. 69 Uncertain Lower limit violated (maintenance demanded). 6A Uncertain Upper limit violated (maintenance demanded). 80 Good OK. 81 Good Lower limit violated. 82 Good Upper limit violated.
Table 360: DP/PA coupler slave module status code description [80]
Murdoch University Engineering Thesis
591 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Diagnostic SF (red): Batch error.
BF (red): Bus fault.
DP (yellow): Profibus DP monitoring.
PA (yellow): Profibus PA monitoring.
ACT (yellow): DP/PA coupler activated in PA redundancy mode.
ON (green): 24V power supply.
SF BF DP PA ACT ON Description – – – – On DP/PA coupler is ready. Off Off – – Off On DP/PA couple without diagnositc message. – – – – Off On DP/PA coupler without diag nostic message.
– – – – Off Off No voltage is applied to the DP/PA coupler or error in DP/PA coupler.
– – – – – Flashes Profibus PA overloaded. – Flashes – – – On DP/PA coupler not correctly configured. – On Off Off – Flashes No Profibus DP data is received. Off Off On Flashes On On Profibus PA data received. On Off On Off On On No Profibus PA data is received.
Off On – – – On No Profibus master available. Diagnostic not available. Illegal Profibus address.
– – – – On – DP/PA coupler is the active energizing coupler. Table 361: Diagnostic LED behaviour of DP/PA coupler [79]
Murdoch University Engineering Thesis
592 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Levelflex M FMP40 (Refer to Levelflex M FMP40 section in the thesis report for an overview of the functions and some background
information)
DIP Switches Switch HW/SW DIP switch on to set the Profibus address in the Endress+Hauser configuration software called
ToF Tool. When HW/SW DIP switch is at off position, the Profibus address is determined by the DIP switch
setting according to Table 362. The new Profibus address will become valid 10 seconds after switching.
DIP switch 1 2 3 4 5 6 7 8 Address value +1 +2 +4 +8 +16 +32 +64 HW/SW
Table 362: DIP switch assignments of Levelflex M FMP40 [81]
Murdoch University Engineering Thesis
593 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Profibus Communication First of all, connect DP/PA coupler and Levelflex M FMP40 with a Profibus cable and also make sure the
Profibus PA signal is terminated properly on each end of the network.
Make sure GSD file EH3_152D.gsd is installed in TIA Portal, then locate the Levelflex M FMP40 station in TIA
Portal Hardware Catalog (Figure 500).
Figure 500: Levelflex M FMP40 station in Hardware Catalog in TIA Portal
If the master Profibus network with DP/PA coupler has been established earlier, drag the Levelflex M FMP40
station into the Network view and join it into the Profibus subnet (Figure 501).
Figure 501: Assign DP/PA coupler and Levelflex M FMP40 to the master PLC in TIA Portal
Assign a Profibus address to Levelflex M FMP40 based on the DIP switches. (Refer to Table 362 for setting
Profibus address for Levelflex M FMP40)
Place slave modules onto the module rack from Catalog. At least one of the slave module needs to be placed on
the rack as shown in Figure 502.
Figure 502: Slave modules in the module rack in TIA Portal
Murdoch University Engineering Thesis
594 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Perform a download to the PLC and the communication will be established as shown in Figure 503.
Figure 503: Online network view of DP/PA coupler and Levelflex M FMP40 in TIA Portal
Slave Modules (Refer to Slave Modules section in the thesis report for some background)
Main Process Value Display the scaled actual value of the measurement. [81]
(Refer to Sample Code section for some data exchange examples)
2nd Cyclic Value Display the distance between the sensor membrane and the measuring surface. [81]
(Refer to Sample Code section for some data exchange examples)
Display Value Value sent from PLC to the transmitter to be displayed on the on-site LCD module. [81]
Free Place This module must be placed on the module rack if there is an empty slot. [81]
Murdoch University Engineering Thesis
595 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Data Structure There is a fixed structure for all the slave modules to represent data. The first 4 bytes are the data bytes (Table
363 & Table 364) and the 5th byte is the status byte (Table 365).
Data Byte Byte 1 Byte 2
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
VZ 27 26 25 24 23 22 21 20 2-1 2-2 2-3 2-4 2-5 2-6 2-7 Exponent Fraction
Table 363: Levelflex M FMP40 slave module data structure part 1 [83]
Byte 3 Byte 4 Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 Fraction
Table 364: Levelflex M FMP40 slave module data structure part 2 [83]
The equation to obtain the actual measured value is:
𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑉𝑎𝑙𝑢𝑒 = (−1)𝑉𝑍 × 2(𝐸𝑥𝑝𝑜𝑛𝑒𝑛𝑡 − 127) × (1 + 𝐹𝑟𝑎𝑐𝑡𝑖𝑜𝑛)
Equation 4: Levelflex M FMP40 slave module actual value conversion equation [83]
Status Byte Status code Device status Main process Value 2nd Cyclic Value
0C Bad N/A Device error 0F Bad Device error. N/A 1F Bad Out of service (target mode). N/A 40 Uncertain N/A Non-specific 47 Uncertain Last usable value. N/A 4B Uncertain Substitute set. N/A 4F Uncertain Initial value. N/A 5C Uncertain Configuration error. N/A 80 Good OK. OK 84 Good Active block alarm. N/A 89 Good Low alarm. N/A 8A Good High alarm. N/A 8D Good Low low alarm. N/A 8E Good High high alarm. N/A Table 365: Levelflex M FMP40 slave module status code description [83]
Murdoch University Engineering Thesis
596 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Deltabar S PMD70 (Refer to Deltabar S PMD70 section in the thesis report for an overview of the functions and some background
information)
DIP Switches Switch HW/SW DIP switch on to set the Profibus address in the Endress+Hauser configuration software called
FieldCare. When HW/SW DIP switch is at off position, the Profibus address is determined by the DIP switch
setting according to Table 366. The new Profibus address will become valid 10 seconds after switching.
DIP switch 1 2 3 4 5 6 7 8 Address value +1 +2 +4 +8 +16 +32 +64 HW/SW
Table 366: DIP switch assignments of Deltabar S PMD70 [83]
Murdoch University Engineering Thesis
597 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Profibus Communication First of all, connect DP/PA coupler and Deltabar S PMD70 with a Profibus cable and also make sure the Profibus
PA signal is terminated properly on each end of the network.
Make sure GSD file EH3X1542.gsd is installed in TIA Portal, then locate the Deltabar S PMD 70 station in TIA
Portal Hardware Catalog (Figure 504).
Figure 504: Deltabar S PMD70 station in Hardware Catalog in TIA Portal
If the Master Profibus network with DP/PA coupler has been established earlier, drag the Deltabar S PMD70
station into the Network view and join it into the Profibus subnet (Figure 505).
Figure 505: Assign DP/PA coupler and Deltabar S PMD70 to the master PLC in TIA Portal
Assign a Profibus address to Deltabar S PMD70 based on the DIP switches. (Refer to Table 366 for setting
Profibus address for Deltabar S PMD70)
Place slave modules onto the module rack from Catalog. At least one of the slave module needs to be placed on
the rack as shown in Figure 506.
Figure 506: Slave modules in the module rack in TIA Portal
Murdoch University Engineering Thesis
598 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Perform a download to the PLC and the communication will be established as shown in Figure 507.
Figure 507: Online network view of DP/PA coupler and Deltabar S PMD70 in TIA Portal
Slave Modules (Refer to Slave Modules section in the thesis report for some background)
Main Process Value This modules displays the scaled actual value of the measurement. 3 types of measurements, pressure, level
and flow could be chosen in either on-site LCD module or FieldCare. [83]
(Refer to Sample Code section for some data exchange examples)
2nd Cyclic Value Display the value of the measurement depending on the option selected in either on-site LCD module or
FieldCare. Four available options are as follows:
Temperature: Corresponds to the temperature parameter (factory setting)
Sensor value: Corresponds to the sensor pressure parameter.
Trimmed value: Corresponds to the corrected pressure parameter.
Secondary value: Corresponds to the pressure parameter. [83]
(Refer to Sample Code section for some data exchange examples)
3rd Cyclic Value Display the value of the measurement depending on the option selected in either on-site LCD module or
FieldCare. Two available options are as follows:
Totalizer 1 (factory setting)
Totalizer 2 [83]
Display Value Value sent from PLC to the transmitter to be displayed on the on-site LCD module. [83]
Free Place This module must be placed on the module rack if there is an empty slot. [83]
Murdoch University Engineering Thesis
599 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Data Structure There is a fixed structure for all the slave modules to represent data. The first 4 bytes are the data bytes (Table
367 & Table 368) and the 5th byte is the status byte (Table 369).
Data Byte Byte 1 Byte 2
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
VZ 27 26 25 24 23 22 21 20 2-1 2-2 2-3 2-4 2-5 2-6 2-7 Exponent Fraction
Table 367: Deltabar S PMD70 slave module data structure part 1 [83]
Byte 3 Byte 4 Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 Fraction
Table 368: Deltabar S PMP70 slave module data structure part 2 [83]
The equation to obtain the actual measured value is:
𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑉𝑎𝑙𝑢𝑒 = (−1)𝑉𝑍 × 2(𝐸𝑥𝑝𝑜𝑛𝑒𝑛𝑡 − 127) × (1 + 𝐹𝑟𝑎𝑐𝑡𝑖𝑜𝑛)
Equation 5: Deltabar S PMD70 slave module actual value conversion equation [83]
Status Byte Status code Device status Main process value 2nd cyclic value 3rd cyclic value
00 Bad Not specific. 04 Bad Calibration configuration error. 0C Bad Device error. 10 Bad Sensor error. 1F Bad Out of service (target mode). N/A N/A 40 Uncertain Not specific. 44 Uncertain Last valid value. N/A N/A 48 Uncertain Substitute value. N/A N/A 4C Uncertain Initial value. N/A N/A 5C Uncertain Linearization configuration error. 60 Uncertain Simulation in progress. 80 Good OK. 84 Good Active block alarm. N/A N/A 89 Good Low alarm. N/A N/A 8A Good High alarm. N/A N/A 8D Good Low low alarm. N/A N/A 8E Good High high alarm. N/A N/A
Table 369: Deltabar S PMD70 status code description [83]
Murdoch University Engineering Thesis
600 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Sample Code
Read from DP/PA Coupler
Figure 508: Online sample code read current of current slave module of DP/PA coupler data exchange
Read 4130hex from Main Process Value low word 4130hex = 0100_0001_0011_0000bin, which indicates that VZ = 0, exponent = 130, the first part of the fraction gives 0.25 and 0.125. Ignore Main
Process Value high word because the value is too small. Therefore, the actual pressure read from the
level transmitter is (-1)0 × 2(130-127) × (1 + 0.25 + 0.125) = 11mA.
Read 80hex from Main Process Value status Current is ok.
Read from Levelflex M FMP40
Figure 509: Online sample code read level and distance of main process value and 2nd cyclic value slave module of
level transmitter data exchange
Read 4206hex from Main Process Value low word 4206hex = 0100_0010_0000_0110bin, which indicates that VZ = 0, exponent = 132, the first part of the fraction gives 0.03125 and 0.015625. Ignore
Main Process Value high word because the value is too small. Therefore, the actual level read from the
level transmitter is (-1)0 × 2(132-127) × (1 + 0.03125 + 0.015625) = 33.5.
Read 80hex from Main Process Value status Level is ok.
Read 444Fhex from 2nd Cyclic Value low word 0100_0100_0100_1111bin, which shows that VZ = 0, exponent = 136, the first part of the fraction gives 0.5, 0.0625, 0.03125, 0.015625 and 0.0078125.
Ignore 2nd Cyclic Value high word because the value is too small. Therefore, the actual distance read
from the level transmitter is (-1)0 × 2(136-127) × (1+ 0.5 + 0.0625 + 0.03125 + 0.015625 + 0.0078125) =
828.
Read 80hex from 2nd Cyclic Value status Distance is ok.
Murdoch University Engineering Thesis
601 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
Read from Deltabar S PMD70
Figure 510: Online sample code read pressure and temperature of main value and 2nd cyclic value slave module of
pressure transmitter data exchange
Read C168hex from Main Process Value low word C168hex = 1100_0001_0110_1000bin, which indicates that VZ = 1, exponent = 130, the first part of the fraction gives 0.5, 0.25 and 0.0625. Ignore
Main Process Value high word because the value is too small. Therefore, the actual pressure read from
the level transmitter is (-1)1 × 2(130-127) × (1 + 0.5 + 0.25 + 0.0625) = -14.5mbar.
Read 80hex from Main Process Value status Pressure is ok.
Read 41B6hex from 2nd Cyclic Value low word 0100_0001_1011_0110bin, which shows that VZ = 0,
exponent = 131, the first part of the fraction gives 0.25, 0.125, 0.03125, and 0.015625. Ignore 2nd Cyclic
Value high word because the value is too small. Therefore, the actual temperature read from the level
transmitter is (-1)0 × 2(131-127) × (1+ 0.25 + 0.125 + 0.03125 + 0.015625) = 22.75℃.
Read 80hex from 2nd Cyclic Value status Temperature is ok.
Murdoch University Engineering Thesis
602 | P a g e WinCC SCADA System via Profibus & OPC by Hao Xu
This is the end of Appendix XII.
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