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Manual Part Number: MAN/E1556-0122 • Revision 8 • © Copyright May 2009

www.betalasermike.com

PROFIBOX PIB1000 & PIB1001

INSTRUCTION HANDBOOK - installation, setup, technical reference -

Beta LaserMike Inc. 8001 Technology Blvd. Dayton, OH 45424

USA

Beta LaserMike Limited Unit 3 First Avenue

Globe Park Marlow Buckinghamshire

SL7 1YA UK

Beta LaserMike Asia Unit 101, 102 & 201 XinAn Plaza, Building 13 No. 99 TianZhou Road

Shanghai, 200233 China

http://www.betalasermike.com/

Instruction handbook - Profibox

MAN/E1556-0122 of 52 Revision 8 (May 2009)

Contents

Proprietary Information .................................................................................................. 3

European Commission Requirements ........................................................................... 4

Declaration of Conformity .............................................................................................. 5

Safety Information .......................................................................................................... 6 Intended Use ............................................................................................................... 6

Introduction ..................................................................................................................... 6

Mechanical Installation ................................................................................................... 8 PIB1000 Mechanical Installation ................................................................................... 8 PIB1001 Mechanical Installation ..................................................................................13

Electrical Installation .....................................................................................................16 PIB1000 Connections and Gland termination ..............................................................16 PIB1001 Connections and Gland termination ..............................................................18 Earthing (PIB1000 / 1001) ...........................................................................................19 PIB1001 Wiring Diagrams ...........................................................................................20 Gauge Connectors (PIB1000 / PIB1001) .....................................................................22

GSD Software Installation..............................................................................................22

Configuration .................................................................................................................23 RS232 Configuration ...................................................................................................23 Configuration via DP Master ........................................................................................24

Common Status Codes ..................................................................................................25

General Profibus Communication .................................................................................26

General RS232 Communication with Gauges ...............................................................26

Data Format and Units ...................................................................................................27

Input Data .......................................................................................................................28

Output Data ....................................................................................................................28

Gauge Parameters .........................................................................................................30 CS Centerscan Gauges ..............................................................................................33 LD / MLD / AS3000 / AS5000 Diameter Gauges .........................................................35 LD Diameter Gauges in HELIX Mode ..........................................................................37 LN Fault Gauges .........................................................................................................40 LS LaserSpeed Gauges ..............................................................................................43 SI900 Sparktesters......................................................................................................45 Preheater MCS ...........................................................................................................46

Maintenance ...................................................................................................................47

Troubleshooting / LED Signals .....................................................................................48

Servicing and Returning your Equipment ....................................................................49

Disposal / Recycling ......................................................................................................50

Specification ..................................................................................................................51

Index ...............................................................................................................................52


Proprietary Information


Proprietary Information

Manufacturer/Distributor Beta LaserMike Inc.,8001 Technology Blvd., Dayton, OH 45424, USA.

Beta LaserMike Limited, Unit 3, First Avenue, Globe Park, Marlow, Buckinghamshire, SL7 1YA, U.K.

About This Manual

Comments or suggestions for possible improvements to the manual are appreciated. Please email

us at [email protected].

This manual contains descriptions, drawings, and specifications for a Beta LaserMike product. Equipment or

products made prior to or subsequent to the publication date of this manual may have parts, features,

options, or configurations that are not covered by this manual. Specifications contained herein are subject to

change by Beta LaserMike without prior notice. Beta LaserMike is not responsible for errors or omissions

that may be contained herein or for incidental or consequential damages in connection with the furnishing or

use of this information.

The information contained in this manual is the property of Beta LaserMike. The information disclosed in this

document is furnished in confidence and upon the condition that individual and corporate intellectual rights,

whether patented or not, will be respected. If this document is supplied on removable media (e.g. CD), an

electronic copy (stored on-site) and one printout is permitted. If this document is supplied in printed form, no

part of this document may be reproduced or scanned without the prior written consent of Beta LaserMike.

This document may not be distributed or circulated to third parties.

Limited Warranty Beta LaserMike will correct by repair, or at Beta LaserMike„s option, by replacement, F.O.B Beta

LaserMike‟s plant, any defect in workmanship or material in any equipment manufactured by Beta

LaserMike which appears under normal and proper use within twelve months from the date of shipment

(eighteen months for OEM‟s), provided Beta LaserMike is given reasonable opportunity to inspect the

alleged defective equipment at the place of its use and under conditions of its use.

EXCLUSIONS: This warranty does not cover products which have been modified, altered, or repaired by

any other party than Beta LaserMike or its authorized agents. Furthermore, any product which has been, or

is suspected of being damaged as a result of negligence, misuse, incorrect handling, servicing, or

maintenance; or has been damaged as a result of excessive current/voltage or temperature; or has had its

serial number(s), any other markings, or parts thereof altered, defaced, or removed will also be excluded

from this warranty.

WARRANTY SERVICE AT CUSTOMER SITE: Warranty service performed at the customer‟s facility will be

free of charge for parts and labor; however, the customer will be liable for transportation and living expenses

of personnel dispatched to effect such repair. A purchase order or other written confirmation of the

acceptance of these charges, signed by an authorized individual, will be required prior to commencement of

repairs. Additional charges may be assessed the customer if: 1) The equipment is not made available on a

timely basis, 2) The equipment is found to be without fault, and/or 3) It is determined the equipment is not

under warranty, whether by expiration of the warranty or any act which voids the warranty.

OTHER THAN AS SET FORTH HEREIN, BETA LASERMIKE MAKES NO WARRANTIES, EXPRESSED

OR IMPLIED, OF MERCHANTABILITY AS TO THE EQUIPMENT MANUFACTURED BY IT, AND THERE

ARE NO EXPRESSED OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON

THE FACE THEREOF. Beta LaserMike‟s obligation to correct defects in such equipment by repair or

replacement in accordance with the foregoing provisions is in lieu of any other warranties, expressed or

implied, and in no event shall Beta LaserMike be liable for incidental or consequential damages. No service

of Beta LaserMike‟s equipment is permitted during the warranty period without the specific written consent

of Beta LaserMike.

Note: For Unpacking/

Returns and Servicing – see section

“Servicing and Returning your Equipment”

at the back of

this manual.

mailto:[email protected]


European Commission Requirements


European Commission Requirements

This equipment is intended for use in a heavy industrial environment. The

equipment generates, uses and can radiate radio frequency energy and, if not

installed and used in accordance with the instructions, may cause harmful

interference to other equipment. There is no guarantee that interference will not

occur in a particular installation. If this equipment does cause harmful interference

to other equipment the user is encouraged to try to correct the interference by one

or more of the following measures:

Re-orientate or relocate the equipment.

Increase the separation between the pieces of equipment.

Connect the pieces of equipment on separate mains circuits.

Ensure that the relevant items of equipment are properly and securely earthed/grounded to a common earth point using adequately sized cable or other means of connection.

Where supplied or specified, shielded interconnection cables must be employed

with this equipment to ensure compliance with the pertinent RF limits. Changes or

modifications not expressly approved by the company could void the user‟s

authority to operate the equipment.

This product has been rigorously tested to comply with the European EMC

Directive (Electromagnetic Compatibility). With regard to this, Beta LaserMike

recommends that any non-Beta LaserMike peripheral equipment is CE marked for

the Heavy Industrial environment (EN50082-2). Beta LaserMike also recommends

that any cables not supplied by Beta LaserMike, but used for powering Beta

LaserMike equipment, be built using good EMC practices (i.e. cables with braided

shield, and connectors with 360 termination of the braid to a metal/metalised shell

connector at both ends). If you have any questions regarding this, contact the Beta

LaserMike Service Department.


Declaration of Conformity


Declaration of Conformity


Safety Information


Safety Information

Electrical Installation must be carried out by a person suitably qualified for the country of installation.

This equipment must be earthed

Relays and associated wiring are rated for SELV levels i.e. 60 Vdc and 30 vac rms. These levels must not be exceeded.

Intended Use

This equipment is intended for use on a production line for communication

between an individual Beta LaserMike (BLM) gauge and the industry Profibus

network, and thereafter to a master production control computer system or plc.

If the equipment is not used in a manner specified by the manufacturer, the

protection provided by the equipment may be impaired.

Introduction

Profibus is a Process Field Bus industry standard communications network. The

Profiboxes (described in this manual) are modular interface devices for

communication between an individual Beta LaserMike (BLM) gauge and the

standard Profibus network, and thereafter to a master production control

computer system or plc.

The Profibox continuously monitors and controls the connected gauge for which

it has been configured. The most recent data from the gauge is instantaneously

made available to other computers on the Profibus network using the DP

protocol. This protocol allows a clean interface between gauge and computer,

and removes the overhead and complexity of gauge management from

computers requesting data or making setpoint changes. In this way the Profibox

forms a compact and modular front-end processor for BLM gauges.

The precise nature of the data transferred through the Profibox will vary

according to the type of gauge and customer requirements.

All Profiboxes are shipped with the network address 126 to allow for

configuration via the network.

The type of the BLM gauge to be connected to the Profibox is defined at time of

ordering. Prior to delivery the Profibox is tested with the relevant BLM Gauge

Series.


Introduction


A BLM Gauge Series is defined according to commonality in function. More than one gauge type may exist within a particular series:

BLM Gauge types Profibus Part No. Description

Serial communications (PIB1000)

LD, CS and LN GA1556-0050-1/A LD Diameter gauges, Centerscan and Lump and Neck gauges

SI900RC GA1556-0050-2/A Sparktester indicator

LaserSpeed GA1556-0050-5/A LaserSpeed Gauge

Analog (PIB1001)

MCS120/190/280 (C580) GA1556-0058-1/A Preheater

S 1525/2550/25100/40100/50150 -I GA1556-0058-2/A Intelligent Gaugehead Sparktester series

HFS GA1556-0058-3/A High Frequency Sparktester

Profibox Features

Integration of Profibus network to BLM range of instruments. Connects to serial communications gauges (PIB1000) or analog gauges (PIB1001). BLM Digital Interface PIB1001 option. Configurable serial ports (PIB1000). Automatic reconfiguration on serial gauge change (between gauges of same series). Modular design for cost effectiveness and future expansion. Well-defined interface language for speedy inclusion of new gauges and configurations. Operable in harsh industrial environments - having extended temperature range capability. High speed data transfer rate of up to 12 Mbits/sec across the network. Autodetect network data rate. Remote address change capability.


Mechanical Installation



PIB1000 Mechanical Installation

PIB1000 Dimensions - mm (inches)

160 (6.29)

100 (3.93)

22 (0.86)

22 (0.86)

60 (2.36)

160 (6.29)




Preparing the PIB1000 for Installation

Remove the PIB1000 lid to expose fixing holes:

Fixing hole centres are 145 x 63mm (5.7 x 2.48in)

If the Profibox is the last one on the line, the OUT cable will not be needed. Hole blanking plugs should then be fitted to ensure IP rating.




Securing PIB1000 next to an LD or LN

As the above gauges commonly use a mechanical height stand (light duty or

standard), it is recommended that the PIB1000 is secured to the stem of this stand.

1. See heading Preparing PIB1000 for Installation above. 2. Feed 4 M4x20mm (0.79in long) bolts through Profibus fixing holes and

through adapter plate (see illustration below).

Clamping Handle Fixing Clamp Height stand column Adapter plate

3. Determine optimal position of Profibox on height stand column, taking into account cable length to gauge and tighten bolts.

4. Attach interface plate to fixing bracket and tighten with clamping handle. 5. Secure Profibus lid tightly with the 4 screws -this will ensure specified IP rating.

100 (

3.9

4)

143 (

5.6

3)

184 (

7.2

4)

+ 1

0

160 (6.30)




Securing PIB1000 next to the Centerscan (CS)

The PIB1000 should be secured to the Centerscan height stand using the L-

shaped fixing bracket as illustrated. See heading "Preparing PIB1000 for

Installation" above. Use 4 M4 (Hank Bush) bolts. Dimensions are in mm (in).

Height stand

L-shaped Fixing

Bracket

Side View

Top View

Height stand interface plate

Centerscan

Profibox

149 (5.87) 156 (6.14)

126 (

4.9

6)

148 (5.83)

8 (0.31)




Securing PIB1000 next to a SI900RC (Sparktester) or LaserSpeed

The PIB1000 can be fixed to any secure metalwork next to gauge using the 4

fixing holes provided.

1. See heading Preparing the PIB1000 for installation. 2. Locate secure metalwork for securing gauge. 3. Use schematic drawing below to determine drilling points on metalwork. 4. Drill 4 holes (for 4 M4 CapHeads with M4 plain washer and M4 Nylock screw) 5. Secure Profibox to well-earthed metalwork (it is recommended that the 3 cable

glands face downwards to reduce strain on the cables). Note: the PIB1000 should not be located too close to the sparktester as this may result in interference.

6. Before refitting the Profibus lid refer to Electrical Installation.

Bottom view of Profibox

Fixing hole centres: 63mm (2.48 in)

Fixing hole centres: 145 mm (5.7 in)




PIB1001 Mechanical Installation

PIB1001 Dimensions - mm (inches)

22 (0.86) 160(6.29) 90 (3.54) 260 (10.23)




Securing PIB1001 to the Preheater (C580)

1. Remove 4 hole blanking plugs from the predrilled holes in side of Preheater. 2. Remove the PIB1001 lid to expose fixing holes which are located similarly to

the PIB1000 (for picture please refer to Preparing the PIB1000 for installation). The fixing centres are 240 x 110 mm (9.44 x 43.3in); O.D = 7 mm (0.27in).

3. Use the 4 mounting bolts to secure the Profibox onto the side of the Preheater. 4. Remove dome plug and connect the analog cable as shown. 5. Before refitting Profibox lid refer to Electrical Installation.

Profibox

Mounting bolt

(4 in total)

Preheater side

Position of access hole and orientation of

Profiboxes varies on different Preheater

models. Remove dome plug prior to fitting cable

gland.

4 holes (blind fasteners)

Cable gland

Analog Cable (refer also to Electrical

Installation)




Securing PIB1001 to the Sparktester

The following applies to the Sparktester intelligent gaugehead and to the HFS series sparktesters. For SI900 Sparktesters see relevant heading above.

1. Remove the 4 hole blanking plugs from the predrilled holes on Sparktester rear panel.

2. Remove the PIB1001 lid to expose fixing holes which are located similarly to the PIB1000 (for picture please refer to Preparing the PIB1000 for installation). The fixing centres are 240 x 110 mm (9.44 x 43.3in); O.D = 7 mm (0.27in).

3. Use the 4 mounting bolts to secure the Profibox onto the rear panel of the Sparktester.

4. Before refitting Profibox lid refer to Electrical Installation.

Sparktester rear access panel

Mounting bolt (4 in total)

4 holes

(blind fasteners) Profibox

Cable gland (for connection see

Electrical installation)


Electrical Installation



Electrical installations must be carried out by a suitable technician for the country of installation.

This equipment must be earthed.

Relays and associated wiring in the PIB1001 are rated for SELV levels i.e. 60 Vdc and 30 Vac rms. These levels must not be exceeded.

Connectors must be correctly terminated. Inadequate termination can degrade equipment performance and may lead to equipment damage.

PIB1000 Connections and Gland termination

1. Use screened i.e. shielded cable with correct specification and determine required length (in particular the RS232 cable). See fig 2 for cable specification and connections.

2. Unscrew gland cover nut and remove washers. 3. Insert cable through gland cover nut and rubber insert over the cable. 4. Insert cable through washer with largest hole (8.4mm, O.D15mm). 5. Remove 4 screws from top of Profibox. 6. Touch Profibox casing to discharge any static electricity. 7. Feed cable through cable connector to determine length of cores to expose. 8. Remove sheath. 9. Push back braid/foil and remove excess - leaving about 1 cm (2.54 in) of braid. 10. Insert washer with smaller hole (7.6mm, OD15mm) over cores.

Fig.1

Washer with larger hole

Braid Washer with smaller hole Sheath Cores




11. Clamp braid between washers and cut off any excess braid and foil. 12. Insert cores through hole and check required length of cores.

(The cores leading to the connector should be as short as possible.) 13. Screw on the gland cover nut and tighten. 14. Remove excess plastic and drawstring/drawwire 15. Strip cores to expose about 5mm (0.2 in) of wire. 16. Connect correct core to appropriate screw terminal..

If the Profibox is connected to the last gauge on the production line, then do not connect the 'OUT' gland. The terminating switch should in this case be in the ON position.

17. Cut off any superfluous cores, which will not be connected.

Fig. 2

18. When all connections have been correctly done, ensure all gland cover nuts are

tightly fastened to ensure IP65 protection. 19. Fit on lid and fix tightly with the 4 screws to provide protection to IP65.

24 Vdc Power Cable 16/0.2 2 core screened O.D. = 5 - 7 mm (0.23 - 0.27in)

Profibus DP Cable

O.D. = 6 - 8 mm

RS232 cable 7/0.2, 6 core screened O.D. = 5 - 7 mm (0.23 - 0.27in)

Terminating switch

OUT IN




PIB1001 Connections and Gland termination

Apart from connecting the analog/digital input (see below), the connections and

gland termination of PIB1001 glands does not, in principle, differ from the 360

Termination of the PIB1000 (see PIB1000 - Electrical Installation).

Profibus DP Cable O.D. = 6-8mm [0.24-0.31in]

Note: either side can

be used as IN or OUT

Terminating switch

24 vdc Power Cable 16/0.2 2 core screened O.D. = 5 - 7 mm [0.23-0.27in]

See below for Earthing

details. Analog/Digital Cable. 7/0.2

12 core screened.




Earthing (PIB1000 / 1001)

This equipment must be connected to a suitable earth. Use a 2.5 mm2 (0.1

inch2) cable. The cable should be as short as possible and less than 3 m (10

feet) in length. This should then be attached to a good earth or grounding box.

An example of a connected Profibox Earth stud is shown below.




PIB1001 Wiring Diagrams

The following diagrams are not normally essential for installation (with the

exception of the Preheater wiring diagram) but serve as wiring information in

case the cables are modified on site at a later stage.

PIB1001 to C580 Preheater Controller

PIB1001 C580 PIN # CONTACT1 5 CONTACT1 6

CONTACT2 7 CONTACT2 8 24V . NC DIGITAL1+ 11 DIGITAL1 - 10

9 RETURN . NC 14 DIGITAL2 - . NC DIGITAL2+ . NC ANALOG O/P 1 1 ANALOG RTN 2

ANALOG I/P - 16 ANALOG I/P + 15




PIB1001 to Sparktester Gaugehead

PIB1001 Sparktester Gaugehead CONTACT1 . NC CONTACT1 . NC Pin

CONTACT2 J CONTACT2 24V DIGITAL1 + R DIGITAL1 - RETURN D

N DIGITAL2 - DIGITAL2 + H ANALOG O/P 1 A ANALOG RTN B ANALOG I/P - F ANALOG I/P + E

Terminate screen

in cable gland. 14-19F connector CA 5100-0343

RED

GREEN

YELLOW

BLACK

BROWN

ORANGE

VIOLET

WHITE

BLUE


GSD Software Installation


Gauge Connectors (PIB1000 / PIB1001)

PIB1000 (RS232 cable)

CE compliant version

Older version

LD CON3 SKT2

CS SK1 SK1

LN CON3 SK1

LaserSpeed and SI900RC See relevant manual

PIB1001 (Analog-digital cable)

MCS (preheater) For these gauges please refer to documentation which came with the gauges.

S-series sparktester (Intelligent Gaugehead)

HFS series

GSD Software Installation

Copy file specified on disk (provided by Beta LaserMike) to directory specified in

Profibus System Documentation.


Configuration


Configuration

Two levels of configuration are supported: via RS232 or via Profibus DP.

RS232 Configuration

RS232 configuration is available through the RS232 port at 9600,7,n,2, no hand

shaking. Only TxD, RxD and GND are required. This facility is only available

after powering up the Profibox and before a DP master first establishes a

connection to the Profibox. It is recommended that the Profibus network be

disconnected from the Profibox prior to restarting the Profibox to ensure that the

DP master cannot establish a connection.

The RS232 configuration provides facilities for setting:

Profibus DP „Slave Address‟

Profibus DP „No Address Change‟

Analogue IO calibration (if fitted)

The RS232 configuration protocol is always initiated by the terminal emulator or

setup utility. The Profibox will only transmit characters in response to requests:

Request Profibox Response Description

?X1/1<CR> *X1/1=<n><CRLF> Query DP slave address

=X1/1=<N><CR> *X1/1=<N><CRLF> Set DP slave address to N (1..126)

?X1/2<CR> *X1/2=<n><CRLF> Query DP no address change

=X1/2=<N><CR> *X1/2=<N><CRLF> Set DP no address change (0..1). 0=allow set slave address telegram 1=disable set slave address telegram

?X1/3<CR> *X1/3=<n><CRLF> Query AOUT1 zero volt calibration point (response only if fitted)

?X1/4<CR> *X1/4=<n><CRLF> Query AOUT1 +10 volt calibration point (response only if fitted)

?X1/5<CR> *X1/5=<n><CRLF> Query AOUT2 zero volt calibration point (response only if fitted)

?X1/6<CR> *X1/6=<n><CRLF> Query AOUT2 +10 volt calibration point (response only if fitted)

?X1/7<CR> *X1/7=<n><CRLF> Query AIN1 zero volt calibration point (response only if fitted)

?X1/8<CR> *X1/8=<n><CRLF> Query AIN1 +10 volt calibration point (response only if fitted)

The analogue calibration points are updated using a secure procedure that is

only available to Beta LaserMike engineers. It is not possible for users to

change the analogue calibration information.

The DP slave settings are stored to EEPROM immediately after being received

and validated by the Profibox. However, it is necessary to restart the Profibox

before the new settings will take effect.


Configuration


Configuration via DP Master

The Profibox must be dynamically configured by the DP master using the

parameterisation and configuration telegrams. It is possible for the master to

change the configuration information between DP sessions without needing to

restart the Profibox.

The DP parameterisation telegram contains the information for determining:

The baud rate to use for communication with an RS232 gauge

The FG gauge version

Selection between RS232 or Analogue for Sparktester profile type

The Centigrade / Fahrenheit jumper settings for the Pre-

heater/Rotatemp

A flag to indicate if DP profile parameters are to be stored to

EEPROM (if this is disabled the DP master must update all DP

parameters after the start of every DP session).

The kV generated by an analogue Sparktester for a +10V set-point *

LD emulation selection to allow the LD profile to be used for normal

LD gauges, IntelliPak gauges, LI indicators, WI indicators, or

AS3000/AS5000 gauges.

The provided „SGDP332.GSD‟ file contains the necessary information to allow

the selection and entry of the above information using the point-and-click

facilities available in the Siemens “COM PROFIBUS” database creation utility.

The DP configuration telegram is used to select the profile / gauge type to be

used by the Profibox. Only a single profile / gauge type is allowed, and the

configuration information must be understood by the Profibox. Again, the

„SGDP332.GSD‟ contains the necessary information to allow the selection of

profile type using the point-and-click facilities available in the Siemens “COM

PROFIBUS” database creation utility.

If the Profibox does not have analogue facilities it will reject a configuration

request for the Preheater/Rotatemp profile, or the Sparktester profile if „DS:

Analogue Sparktester‟ was selected in the parameterisation.

* The EHT set point voltage for all HFS sparktesters is scaled 25kV = +10V.

Therefore the Profibus parameterisation should be set to "25kV for 10V", a preset

of 6000V will then give an output to the HFS of 2.4V which will set the EHT to

6kV.


Common Status Codes


Common Status Codes

Although each gauge type has a set of unique status codes, there are some

additional status codes that may be generated by the Profibox that are common

to all gauge types:

COMMON STATUS CODES

Mnemonic Code Description

GST_RS232_PROTO 32 The gauge is not responding to a specific cell poll request. Either an old or incompatible gauge has been connected by mistake.

GST_RS232_PARAM 33 The Profibox only performs simple parameter verification, and has accepted a parameter value that the gauge will not accept via RS232. The master control computer‟s „recipe‟ should be checked to make sure all presets, tolerances, etc are within the limits acceptable by the associated gauge.

GST_DATA_INVALID 34 Not all gauge data within the „inputs‟ is valid yet. Either the master hasn‟t set the units (and/or Centerscan measurement type), or the Profibox hasn‟t collected all the required input data from the gauge.

GST_WRONG_GAUGE_TYPE 35 The RS232 data stream produced by the gauge is not understood or is known to be from an incompatible gauge. See if the wrong gauge is connected or whether the baud rate is correct.

GST_NOT_CONNECTED 36 The gauge is disconnected or turned off. Ensure the gauge is connected to the correct port and the baud rate properly configured. It is also possible to get this error if an incompatible gauge type has been connected by mistake.


General Profibus Communication


General Profibus Communication

The Profibox supports freeze and sync requests. It is unlikely that using freeze

and sync will be of any real value to a DP master, but the facilities are provided

nevertheless.

The Profibox supports „Set Slave Address‟ telegrams. The „Slave Address‟ and

„No Address Change‟ information may also be configured via RS232 as

discussed in an earlier section.

After a communications timeout all connected machines (for example the

Centerscan, Capstan Preheater, Preheater and Sparktester) are stopped.

No additional diagnostic data is provided by the DP Profibox. All gauge status

information is provided within the normal input data.

General RS232 Communication with Gauges

Communication is always 7 data bits, no parity, 2 stop bits.

Prior to the first parameterisation/configuration, the Profibox responds to any

valid configuration/calibration requests received at 9600,7,n,2. After the first

parameterisation/configuration the Profibox changes to gauge control mode.

The Profibox remains in gauge control mode even if the DP connection is

closed or lost.

The baud rate to use when communicating with a gauge is specified as part of

the DP parameterisation process. The gauge must be correctly configured to

match the selected baud rate.

Only TxD, RxD and GND are required for connection to the gauge. An RTS

output is provided by the Profibox, but the use of this signal is not required as

the Profibox can process data faster than a gauge can supply it, even at 19200

baud. The Profibox does not monitor the CTS input, instead it only sends data

requests to an RS232 gauge at a carefully controlled rate.


Data Format and Units


Data Format and Units

All data is received and transmitted in network byte order. Multi-byte values are

ordered with the most significant byte lowest in memory, and the least

significant byte higher in memory.

Wherever possible values are represented using unsigned words, but some

values are represented using 32-bit IEEE floating point numbers. Unfortunately

this means that some parameter lists are a mix of word and floating point

representations.

Wherever possible values and parameters are specified in standard units:

Measurement Type Metric Imperial

Voltage volts volts

Current amps amps

Percent percent percent

Rotational speed revs/minute revs/minute

Frequency Hz Hz

Tension Newtons Newtons

Diameter metres inches

Eccentricity (linear) metres inches

Capacitance pF/metre pF/foot

Linear speed metres/minute feet/minute

Temperature degrees Centigrade degrees Fahrenheit


Input Data


Input Data

The input data is provided by the Profibox and passed to the DP master on

every data-exchange.

The length and meaning of the input data depends on the Profibox

configuration. The PKW header is always present, and is followed by the gauge

data for the configured profile.

Output Data

The output data is provided by the DP master and passed to the Profibox on

every data-exchange.

The length and meaning of the output data depends on the Profibox

configuration. The PKW header is always present, and is followed by the output

control word for the configured profile.

As with all data, the output control word is in network byte order. Some bits in

the output control word are common/reserved for all profile types. The following

table shows the common output control bits:

Mnemonic Bit Number

Description Applicable Profile Types

0 Reserved

OCF_START 1 Machine on/off CS, CPH, Analogue ST, Analogue PH,

OCF_ZERO 2 Zero fault counts impulse LN, ST

OCF_THREADING 3 Line threading - suppress gauge status

All except CPH

The output control word contains additional bits that apply to individual profile

types. Please refer to the profile descriptions for the meaning of these bits.

The OCF_START bit functions as described in the following table:

OCF_START Description

0 Analogue PH / RT / ST off. Manual on/off of RS232 machine possible.

Analogue RT / ST on. Analogue PH on pulse generated. Single „on‟ request sent to RS232 machine.

1 Analogue RT / ST on. Manual on/off of RS232 machine possible.

Analogue PH / RT / ST off. Several „off‟ requests sent to RS232 machine.


Output Data


Each machine has safety interlocks such that a machine cannot be turned on by

the Profibox if the lid is open etc. However, it is possible that a machine can be

started by the Profibox, as a result of a request from the DP master, if the

gauge interlocks are correct, and it is therefore very important to ensure

operators are clear of machines before issuing „on‟ requests from the DP

master.

The RS232 Spark Test Indicator does not provide facilities for remote starting or

stopping, but the corresponding DP profile defines the start bit because the

profile is shared by the Analogue Spark Tester.

If it is required to disable remote starting of an analogue machine, then the

wiring of the analogue machine must be arranged such that the machine is

started by means other than a Profibox relay.

The OCF_ZERO bit in the output control word uses impulses from the DP

master to reset fault counts for a DP profile:

OCF_ZERO Description

Analogue gauge: fault count reset. RS232 gauge: counter reset request sent

other No change, fault counting continues.

The OCF_THREADING bit in the output control word is used to suppress non-

fatal gauge errors whilst the line is being threaded. This facility is provided only

as a means of assisting the DP master in alarm handling. There is no

requirement to use the facility.


Gauge Parameters


Gauge Parameters

The Profibox attempts to recover DP parameters from EEPROM each time it is

configured at the start of a DP session, but only if EEPROM storage was

enabled as part of the DP parameterisation.

Each parameter may only be recovered if a CCITT 32-bit CRC and the profile

type used at the time the parameter was stored are correct.

If the units parameter could not be recovered from EEPROM, then it will be

internally marked as „not valid‟. In this case the gauge status will remain as

SGDP_GST_DATA_INVALID because the Profibox does not know the type of

units to use for DP communication. The SGDP_GSF_PARAMS_OK flag will

also be reset.

Parameters that are sensitive to units selection cannot be recovered from

EEPROM if the units parameter was not recovered, or if the recovered units do

not match the units in use at the time the sensitive parameter was stored.

When writing to parameters, the DP master must update a gauge‟s UNITS

parameter first. If this is not done the Profibox will ignore write requests to

parameters that are sensitive to units, and the SGDP_GSF_PARAMS_OK flag

will remain reset. It is recommended that the DP master updates all write-

enabled parameters in ascending numerical order.

For simple control systems it is recommended that whenever the

SGDP_GSF_PARAMS_OK bit is clear then the DP master writes to all write-

enabled parameters in numeric order.

The gauge status is only set to a number lower than

SGDP_GST_DATA_INVALID when the units [and Centerscan measurement-

type] have been recovered or written by the master and the relevant input data

has been obtained from the RS232 gauge. Whenever the master writes the

units [or measurement type] the SGDP_GST_DATA_INVALID status will prevail

until new data has been obtained from the RS232 gauge using the new units.

The SGDP_GSF_PARAMS_OK status bit is zero until all parameters have been

recovered from EEPROM or the master has (re)written all parameters that are

write-enabled.

If a parameter has not been recovered from EEPROM or written by the master,

then the corresponding gauge value is regularly polled and stored to the

parameter, and can be read by the master if required. This also allows valid

data and units sensitive parameters to be read by the master after the master

has selected or changed the measurement units [and/or measurement type]. In

these circumstances the SGDP_GSF_PARAMS_OK bit will remain reset as not

all parameters have been written by the master.

When the master writes a parameter, and if the write is valid, the Profibox also

updates the corresponding gauge parameter. The Profibox continually monitors

the gauge's value, and if it differs from the value request by the master, then the


Gauge Parameters


Profibox re-writes the value to the gauge. Therefore, once the master has

written a parameter, the corresponding gauge parameter is kept at that value by

the Profibox using closed loop control.

It should also be noted that when a serial port gauge head type changes (e.g.

LD1040 to LD1080) then all parameters that may be affected by the gauge

head change are invalidated and the SGDP_GSF_PARAMS_OK flag will be

cleared.

Parameters are stored to EEPROM only after they have been written by the DP

master (and not subsequently altered for 30 seconds), and if EEPROM storage

is enabled as part of DP parameterisation

Parameters are updated/monitored using the parameter control headers in the

output/input data respectively. The header, in either direction, is referred to as

PKW. The first word within PKW is referred to as PKE and contains information

regarding request/response type and parameter number. The second and third

words contain the read/write parameter data or a response error code and are

referred to as PWE1 and PWE2 respectively.

PKW DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PKE BASE+0

AK SPN PRM

PWE1 BASE+1

Parameter value MSW

PWE2 BASE+2

Parameter value LSW

AK Task/reply identifier, detailed in tables below SPN Spontaneous bit, reserved for future use. PRM Parameter number within profile position

Requests are issued by the DP master using the following AK request codes in

the PKW header within the „outputs‟ telegram:

AK task codes

(Master Slave) Description

0 No task. The DP master is making no request and the PKW interface is idle. The Profibox make no use of PRM and therefore this value may be zero.

1 Request to read a parameter value.

2 Request to write a word parameter.

3 Request to write a float parameter.

The DP master recognises the response to a request when PRM in the PKW

header within the input data matches that requested. The Profibox will respond

with the same PRM value, even if the PRM value was not valid.


Gauge Parameters


Responses to requests are acknowledged by the Profibox using the following

AK response codes in the PKW header within the input data:

AK response codes

(Slave Master) Description

0 No reply. Issued in response to „no task‟.

1 Cannot complete task. An error code is provided in PWE2. PWE1 is zero. See subsequent table for a description of response error codes.

2 Response to a read or write request for a word parameter. The word parameter value (after the write operation) is contained in PWE2, and PWE1 is zero.

3 Response to a read or write request for a float parameter. The float parameter value (after the write operation) is contained in PWE1 and PWE2.

For an AK response code of 1, „task cannot be completed‟, the following error

codes are returned in PWE2:

AK error codes

Description

0 No error. Issued in response to „no task‟.

1 AK request code is invalid.

2 Reserved.

3 PRM does not specify a valid parameter number for the configured profile.

4 Cannot write parameter: it is read-only.

5 Cannot write parameter: the value provided by the master is outside of limits imposed by the Profibox.

6 Cannot write parameter: the data type (AK request code) is not compatible with the parameter.

7 Cannot write parameter: the parameter is sensitive to units selection and the master has not written to the units parameter.

8 Cannot read parameter, the Profibox has not yet received any valid value for the parameter from the DP master or the gauge.


Gauge Parameters


CS Centerscan Gauges

OUTPUT CONTROL WORD

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 CA r r r r r r r r r r r TH r ST r

r Bit is reserved, and should be set to zero by DP master. TH If set the Profibox will convert gauge status codes 1 through 6 to code 0,

thereby suppressing non-fatal errors during threading. ST The Profibox sends a single start command to the Centerscan for a 0 to 1

transition of this bit, and several stop commands for a 1 to 0 transition. The state of this bit is ignored if a calibration is in progress, but will be recognised after calibration has completed or timed-out. The Centerscan may be started and stopped manually at any time.

CA The Profibox begins the Centerscan calibration process upon a 0 to 1 transition of this bit. Other states or transitions of this bit are ignored. The ST and CA bits are ignored during the calibration process. The Profibox imposes a 10-second time limit on the calibration cycle, and ends calibration mode if the gauge has not completed within this time. Please refer to Centerscan documentation for further details about calibrating a Centerscan gauge.

INPUT DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 0 0 0 0 CS CP 0 PO STATUS

Base+4 Eccentricity MSW (bits 31...16 of float)

Base+5 LSW (bits 15...0 of float)

Base+6 Maximum wall position (MSB) and minimum wall position (LSB), 1 … 24 each

PO Bit set if all parameters are OK and have been written by the master, bit reset if at least one parameter must be re-written

CP Calibration is in progress. The Profibox has recognised the CA transition, and the calibration procedure is in progress. This bit is cleared when the calibration succeeds or if the procedure times-out after 10 seconds.

CS Cleared when the calibration procedure begins, and set only if the calibration procedure succeeded. This bit is only cleared if the calibration procedure is restarted or the Profibox is reset.

STATUS Status code, 0..255. Either a common Profibox status code or one of the following: 0 Gauge OK 1 Product out of tolerance 2 No cable 3 Motor starting 4 Motor stopping 5 Motor stopped 6 Lid open 7 Fatal fault


Gauge Parameters


PARAMETERS

Parameter Type Description

1 word DP/RS232 units: 0=metric, 1=imperial

2 word Measurement type: 0=linear, 1=eccentricity %, 2=concentricity %

3 word Rotation direction. 0=clockwise, 1=counter clockwise

4 float Preset eccentricity (tolerance), linear or percent

5 float Preset core diameter

6 float Preset outer diameter

7 word Torsion setting: 1 … 24

8 word Number of rotations to average: 20 … 100

9 word Preset RPM: 600 … 1200 (CS1010), 100 … 300 (CS1015)

10* float Calibration factor: 0.5 … 2.0

11* float Cable type gain: 0.5 … 2.0

12 float Calibration result / base frequency, for information, read-only

* Transmitted value = Measured value x [parameter 10] x [parameter 11]

Please refer to the Centerscan manual for more information regarding the use of these gauges.


Gauge Parameters


LD / MLD / AS3000 / AS5000 Diameter Gauges

For Helix mode see next page.

The 'LD' profile may be used when the PIB1000 is connected to an AccuScan LD,

IntelliPak gauges, LI indicators, WI indicators, or AS3000/AS5000 gauges. The DP

parameterisation data contains an 'LD emulation' field that is used to adjust the

PIB1000's RS232 protocol and behaviour when communicating with the gauge. To

ensure correct operation the correct 'LD emulation' setting must be selected.

OUTPUT CONTROL WORD

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 r r r r r r r r r r r r TH r r r


thereby suppressing non-fatal errors during threading.

INPUT DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 0 0 0 0 0 0 XY PO STATUS

Base+4 X diameter MSW (bits 31...16 of float)


Base+6 Y diameter MSW (bits 31...16 of float), valid for dual plane gauges only

Base+7 LSW (bits 15...0 of float), valid for dual plane gauges only

XY Bit set if gauge is dual plane, bit reset if gauge is single plane. PO Bit set if all parameters are OK and have been written by the master,

bit reset if at least one parameter must be re-written STATUS Status code, 0..255. Either a common Profibox status code or one of

the following gauge status codes: 0 Gauge OK 1 No cable detected 2 Gate obscured 3 Lens dirty 4 Too many cables detected 5 Unspecific gauge error

When using the PIB1000 with an AS3000 or AS5000 the gauge status codes between 5 and 9 have a different meaning (refer to ASx000 manual): 5 Gauge too hot inside casing 6 Wrong motor speed 7 Measured width of gauge gate incorrect 8 Wrong gauge type (internal gauge configuration error) 9 Unspecific gauge error


Gauge Parameters


PARAMETERS



2 word X gate position: -99 … +99, read only

3 word Y gate position: -99 … +99, read only (valid for dual plane gauges only)

4 word Number of samples for gauge to average: 1 … 1000 - LD, IntelliPak, LI indicator, WI indicator 1 … 6000 - ASx000 LD emulation mode

5 float Preset (target) diameter: range according to gauge, affects gauge relay output only

6 float Diameter tolerance: range according to gauge, affects gauge relay output only. Not used for ASx000 LD emulation mode.

7 - Reserved (helix table size). Read/write requests will be rejected.

8 word

Controller mode. 6=reset, 7=freeze, 8=running. The validity of this parameter does not affect the state of the PO bit. Not used for IntelliPak, LI indicator, WI indicator, or ASx000 LD emulation modes.

9 float

Preset I-Term for controller. 0.0% through 100.0%. The validity of this parameter does not affect the state of the PO bit. Not used for IntelliPak, LI indicator, WI indicator, or ASx000 LD emulation modes.

10 word

Controller output: 0=normal, 1=inverted. The validity of this parameter does not affect the state of the PO bit. Not used for IntelliPak, LI indicator, WI indicator, or ASx000 LD emulation modes.

11 float Moisture filter setting 0.00 through 999.99. The validity of this parameter does not affect the state of the PO bit. Used only for IntelliPak LD emulation mode.

12 word

Percentage of valid scans, 0...100, read only. As with all read-only parameters the validity of this parameter does not affect the state of the PO bit. Used only for IntelliPak LD emulation mode.

13 - Reserved (STAC logic). Read/write requests will be rejected.



16 word X optics condition 0..99%, read only. Only available for WI900 and ASx000 LD emulation modes.

17 word Y optics condition 0..99%, read only. Only available for WI900 and ASx000 LD emulation modes.

Please refer to the relevant manual for more information regarding the use of these gauges.


Gauge Parameters


LD Diameter Gauges in HELIX Mode

OUTPUT CONTROL WORD

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 r r r r r r r r r r r r TH r r r


thereby suppressing non-fatal errors during threading.

INPUT DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 0 0 0 0 0 0 XY PO STATUS

Base+4 Y cycle count X cycle count

Base+5 Max X diameter MSW (bits 31...16 of float)


Base+7 Min X diameter MSW (bits 31...16 of float)


Base+9 Mean X diameter MSW (bits 31...16 of float)


Base+11 Max Y diameter MSW (bits 31...16 of float), valid for dual plane gauges only


Base+13 Min Y diameter MSW (bits 31...16 of float), valid for dual plane gauges only


Base+15 Mean Y diameter MSW (bits 31...16 of float), valid for dual plane gauges only


XY Bit set if gauge is dual plane, bit reset if gauge is single plane. PO Bit set if all parameters are OK and have been written by the master,

bit reset if at least one parameter must be re-written STATUS Status code, 0..255. Either a common Profibox status code or one of

the following: 0 Gauge OK 1 No cable detected 2 Gate obscured 3 Lens dirty 4 Too many cables detected 5 Unspecific gauge error

A maximum diameter is the maximum diameter within the helix table for the corresponding plane (see the description of the helix table size parameter on the following page). A minimum diameter is the minimum diameter within the helix table for the corresponding plane. The mean diameters are the average of the mean diameters within the helix table

The X/Y cycle counters are 8 bit numbers that represent the number of RS232 continuous data messages received from the gauge for each plane. The counters operate independently, and wrap back to 0 after 255. On a single plane gauge only the X cycle count will increment (every 100ms), whilst on a dual plane gauge each increments alternately (every 200ms each). There is no guarantee that the X and Y cycle counts will remain in step - a counter will not advance if a continuous packet is lost because of RS232 transmission errors.


Gauge Parameters


A DP master may be programmed to only extract max, min, and mean data for a particular plane when it detects a change in the corresponding cycle counter. This allows the 100ms (200ms) timing for each set of measurements to be preserved, regardless of RS232 or Profibus DP propagation delays. Normally this would be done using a helix table size of 1.

PARAMETERS



2 word X gate position: -99 … +99, read only

3 word Y gate position: -99 … +99, read only (valid for dual plane gauges only)

4 word Number of samples for gauge to average: 1 … 1000. Note that this has no effect on helix measurements, but may affect locally displayed diameters or analogue outputs

5 float Preset (target) diameter: range according to gauge, affects gauge relay output only

6 float Diameter tolerance: range according to gauge, affects gauge relay output only

7 word Helix table size: 1 ... 200. See description below.

8 word

Controller mode. 6=reset, 7=freeze, 8=running. This parameter is only used by the Profibox when the DP parameterisation data (as per the GSD file) indicates that the Profibox is being used with an LD device. The validity of this parameter does not affect the state of the PO bit.

9 float

Preset I-Term for controller. 0.0% through 100.0%. This parameter is only used by the Profibox when the DP parameterisation data (as per the GSD file) indicates that the Profibox is being used with an LD device. The validity of this parameter does not affect the state of the PO bit.

10 word

Controller output: 0=normal, 1=inverted. This parameter is only used by the Profibox when the DP parameterisation data (as per the GSD file) indicates that the Profibox is being used with an LD device. The validity of this parameter does not affect the state of the PO bit.

11 float

Moisture filter setting 0.00 through 999.99. This parameter is only used by the Profibox when the DP parameterisation data (as per the GSD file) indicates that the Profibox is being used with an IntelliPak device. The validity of this parameter does not affect the state of the PO bit.

12 word

Percentage of valid scans, 0...100, read only. This read-only parameter is only updated by the Profibox when the DP parameterisation data indicates that the Profibox is being used with an IntelliPak device. As with all read-only parameters the validity of this parameter does not affect the state of the PO bit.




16 word Reserved (X optics condition). Read/write requests will be rejected.

17 word Reserved (Y optics condition). Read/write requests will be rejected.

The DP Profibox can calculate the max, min and mean values over a period of time using internal tables of historical information. This can relieve the DP master of the burden of maintaining such tables, and could be particularly useful for slow DP masters that could miss a set of max, min and mean information.


Gauge Parameters


The helix tables within the DP Profibox hold the historic values for the helix

information parsed from the gauge‟s RS232 continuous data for each plane.

Each entry in a table corresponds to a time span of 100ms for single plane

gauges or 200ms for dual plane gauges. The DP Profibox always stores historic

values up to the maximum helix table size. Each time new data is entered into a

table the max, min, mean and cycle count values for the corresponding plane

are calculated and returned in the input data area. The number of most recent

historic values used in the computation is referred to as the helix table size, and

can be set by the DP master using parameter 7.

At startup, or if an RS232 communications timeout occurs, the count of entries

within the internal helix tables are reset. When gauge communications begins,

only the most recent valid entries within the helix tables are used in the

calculations, and therefore the window sizes used for the calculations may not

be as large as the „helix table size‟ parameter. The correct window sizes will be

used once the gauge/Profibox combination has been running smoothly for a

short period (e.g. 20 seconds for a dual-plane gauge and a window size of 100).

A DP master would normally set the helix table size to 1 if it maintains its own

historical helix information tables.

Note that an RS232 communications timeout does not affect the X/Y cycle

counts. These counts are always 0 after a Profibox restart and are incremented

after a corresponding continuous data message is received from the gauge.

They are unaffected by any other activity.

Please refer to the AccuScan LD manual for more information regarding the use

of these gauges.


Gauge Parameters


LN Fault Gauges

Gauge (DP profile) type 6. Note that this profile can have two different sizes of „input data words‟: „Input size‟ = 6 input words - LN without fault information „Input size‟ = 13 input words - LN with fault information

The Profibox implements a 64-fault deep internal FIFO for fault information received from the LN gauge. This FIFO can be controlled using either the short or long profile size, but use of the FIFO is only meaningful with the longer profile size.

When the shorter profile (without fault information) is specified, the Profibox will turn off the gauge‟s continuous data (fault event reports). The shorter profile size should be used with an LN-D style gauge since the Profibox does not support the LN-D continuous data format; received fault information from an LN-D would cause an RS232 protocol error status. The shorter profile can also be used with an LN-DL if the additional fault information is not required.

When the longer profile (with fault information) is specified, the Profibox turns on continuous data from the gauge using serial port mode 2 („event mode‟). The received fault information is entered into the Profibox‟s fault FIFO without any filtering, even if the event is a duplicate of an earlier event. Only the LN-DL fault event format is supported.

OUTPUT CONTROL WORD

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 r r r r r r r r r r r RB TH ZF r r

r Bit is reserved, and should be set to zero by DP master. TH If set the Profibox will convert gauge status code 1 to code 0, thereby

suppressing errors during threading. ZF On a 0 to 1 transition of this bit the Profibox zeroes/clears:

the lump and neck fault counts the distance counter the internal fault FIFO. The 0 to 1 transition takes precedence over the „RB‟ bit, and will reset the internal fault FIFO before the state of the RB bit is checked. Therefore, if the RB bit changes simultaneously with a 0 to 1 transition of the ZF bit then the Profibox will return „FIFO empty‟ for the fault type. It is recommended that the master leave the bit set for several data cycles to ensure the transition is recognised at the Profibox. Fault counting is unaffected when this bit is a steady 1, undergoing a 1 to 0 transition, or a steady 0.

RB Request Buffer. Toggled by the master to solicit fault information from the fault FIFO. See also the definition of the AB bit below, and the subsequent RB/AB description below.


Gauge Parameters


INPUT DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 0 0 0 0 0 AB 0 PO STATUS

Base+4 Number of lump faults, unsigned word

Base+5 Number of neck faults, unsigned word

----------------------

------------------------------------------------------------------------------------------------------------------------

Base+6 0 0 0 0 0 0 0 0 0 0 0 0 0

Fault Type 0 = FIFO empty 1 = X lump 2 = X neck 3 = Y lump 4 = Y neck 5,6,7 = resvd

Base+7 Fault number, unsigned word

Base+8 Fault position MSW (bits 31..16 of float) (m or ft)

Base+9 Fault position LSW (bits 15..0 of float)

Base+10 Fault height MSW (bits 31..16 of float) (m or inches)

Base+11 Fault height LSW (bits 15..0 of float)

Base+12 Fault length MSW (bits 31..16 of float) (m or inches)

Base+13 Fault length LSW (bits 15..0 of float)

AB Acknowledge Buffer. When the Profibox detects a change in the RB bit it places the next fault information from its internal FIFO (if any) into the input data words, and then sets this bit to the same state as the master‟s RB bit. When the RB and AB bits are equal the master should check the fault information in the input data and then toggle the RB bit. If „fault type‟ is zero it indicates that the Profibox‟s fault FIFO was empty. The RB/AB bits work with either the shorter or longer profile size, but the fault information is only returned when using the longer profile size.


STATUS Status code, 0..255. Either a common Profibox status code or one of the following: 0 Gauge OK 1 Unspecific gauge error

The Profibox reacts to changes in the RB bit by putting the oldest fault information from its internal fault FIFO into the „input data‟. If the FIFO is empty then the fault information fields in the „input data‟ are cleared. The Profibox then sets the AB bit to the same state as the RB bit.

When the master‟s RB and AB bits are equal it should check the fault information and then toggle the RB bit. When the RB and AB bits are different then the master should ignore the fault information make no change to the state of the RB bit.

There is no guarantee that the number of faults returned through the RB/AB mechanism will match the sum of the lump and neck fault counts:

a. The fault counts are solicited from the LN gauge on a regular basis, whilst fault information arrives asynchronously. Transient RS232 errors do not cause the loss of fault counts, whereas they can cause the total loss of one or more fault information reports.

b. The gauge‟s internal fault FIFO may become full causing the loss of one or more fault information reports. This happens only if the rate of fault detection exceeds the rate at which the faults can be reported over the RS232 link for a sustained period.


Gauge Parameters


c. The Profibox‟s internal fault FIFO may become full causing the loss of one or more fault information reports. This happens only if the rate of received fault information exceeds the rate at which the master solicits them for a sustained period.

The Profibox‟s fault information FIFO is cleared when the master re-configures

(or first connects) to the Profibox, there is a 0 to 1 transition of the „ZF‟ bit, or

when the master changes the DP/RS232 units parameter.

The fault counts and distance are cleared on a 0 to 1 transition of the „ZF‟ bit, or

by cycling the LN gauge‟s power.

The fault information will not be collected if the master hasn‟t set the „units‟

parameter (parameter number 1).

PARAMETERS



2 float X Lump threshold

3 float X Neck threshold

4 float Y Lump threshold

5 float Y Neck threshold

Please refer to the LN manual for more information regarding the use of these

gauges.


Gauge Parameters


LS LaserSpeed Gauges

OUTPUT CONTROL WORD

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 r r r r r r r r r r r FR r ZL r r

r Bit is reserved, and should be set to zero by DP master. ZL A 0 to 1 transition of this bit will cause the Profibox to send a 'reset length'

command to the LaserSpeed. FR Final length mode request. Set this bit to 1 to use the LaserSpeed in 'Final

Length' mode. This bit will be ignored, and the Profibox will continue to use polled mode, if the connected gauge does not support the LaserSpeed 'TF' RS232 command. Clear the FR bit at any time to return the Profibox to using 'polled' mode. See also the FA acknowledgement bit. Any changes made to profile parameters when FR=1 and FA=1 will not be communicated to the LaserSpeed until FR=0. Wen FA=1 it is not possible for the Profibox to detect that a LaserSpeed has been disconnected or has been power-cycled.

INPUT DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 0 0 0 0 0 FA 0 PO STATUS

Base+4 Length MSW (bits 31...16 of a long)

Base+5 LSW (bits 15...0 of a long)

Base+6 Velocity MSW (bits 31…16 of a long)

Base+7 LSW (bits 15…0 of a long)

Base+8 Gauge Status Flags Quality Factor

Base+9 Data Cycle Counter, unsigned word

PO Bit set if all parameters are OK and have been written by the master, bit reset if at least one parameter has not been written to by the master.

FA Final length mode acknowledgement. Set to 1 if the Profibox has accepted the FR bit and placed the LaserSpeed into 'TF' mode. This bit will be 0 if the FR bit is 0, if no LaserSpeed is connected, or if a connected LaserSpeed does not support 'TF' mode. Note that any changes made to profile parameters made when FR=1 and FA=1 will not be communicated to the LaserSpeed until FR=0. Wen FA=1 it is not possible for the Profibox to detect that a LaserSpeed has been disconnected or has been power-cycled.

STATUS Status code, 0..255. For the LaserSpeed this will only be 0 (Gauge OK), or one of the common Profibox status codes.

Length The LaserSpeed's length value, -999999999 through +999999999. Note that there are three implied decimal places within this value, regardless of the selected units of measurement.

Velocity The LaserSpeed's velocity value, -999999999 through +999999999. Note that there are three implied decimal places within this value, regardless of the selected units of measurement. This value will be zero when the Profibox updates the input data with 'final length' data (FR=1, FA=1, and at least one 'TF' response has been received from the LaserSpeed).


Gauge Parameters


Gauge Status Flags is a bit field, as defined by the LaserSpeed manual. The number and meaning of the bits varies slightly between differing LaserSpeed versions. This value will have its most significant bit clear when the input data is updated using 'polled' gauge data, whereas the value will have its most significant bit set and all other bits clear when the input data is updated with 'final length' gauge data. Thus Gauge Status Flags will typically be between 0 and 63 for polled mode, and will always be 128 for final length mode. Since the profile data is always consistent, it is therefore possible to determine if the 'length' field is a polled reading or a final length reading.

Data Cycle Counter starts at zero, and counts up by 1 for every received polled

mode or final length mode response received from the gauge. Note that because the Profibox uses 'polled' mode for a short while, regardless of the FR bit, to establish the connected LaserSpeed type, then there will always be some polled readings and a non-zero Data Cycle Counter within the input data prior to any FR request being acknowledged and the first final reading being received by the Profibox. New final length readings can be detected by noting a change in the Data Cycle Counter and ensuring that the most significant bit of the Gauge Status Flags is set.

PARAMETERS


1 word LaserSpeed units of measurement: 0…N

2 word Calibration Trim: 5000. 20000

3 long Index pulse (OPR) setting: 1…999999999

4 word Material present threshold: 0…255 or 0…4095 (if relevant)

Note that although it is possible to read/write the Profibus parameters at any time, the parameter values are only communicated between the Profibox and the LaserSpeed when the Profibox is being used in 'polled' mode. Therefore if any parameter values are written when FR=1 and FA=1, the Profibox will only communicate the changes to the LaserSpeed when (and if) FR is reset to 0.

Later LaserSpeed gauges support a greater range of 'units' than earlier versions. Consult the appropriate LaserSpeed manual for detailed information.

The Material Present Threshold parameter varies significantly between LaserSpeed versions. It is important that this parameter is updated with a value relevant to the connected LaserSpeed. This parameter is ignored for versions of the LaserSpeed that do not support 'final length' mode. Again, consult the appropriate LaserSpeed manual for detailed information.


Gauge Parameters


SI900 Sparktesters

An additional bit in the DP parameterisation is used to select between SI (RS232)

and DS (Analog) machine types.

For DS Sparktesters the analogue connections are: RLY1: „Count Enable‟. Closed to enable counting. Opened to reset count. RLY2 „EHT Enable‟. Closed to enable EHT. DIG1: Input for „Operation Status‟. Current flow indicates OK. DIG2: Input for „Spark Fault‟. Current flow indicated Spark Fault. AOUT: 0 to 10V representing requested kV (0V if OCF_START is 0). AIN: 0 to 10V representing Sparktester‟s actual measured kV.

OUTPUT CONTROL WORD

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+4 r r r r r r r r r r r r TH ZF ST r

r Bit is reserved, and should be set to zero by DP master. TH If set the Profibox will convert gauge status code 1 to code 0, thereby

suppressing errors during threading. ZF The Profibox zeroes the spark count for a 0 to 1 transition of this bit. It is

recommended that the master leave the bit set for several data cycles to ensure the transition is recognised at the Profibox. Fault counting is unaffected when this bit is a steady 1, undergoing a 1 to 0 transition, or a steady 0.

ST This bit is ignored for the RS232 based SI Spark Tester as this indicator provides no facilities for remote EHT enable. For the analogue DS Sparktester, the Profibox activates the EHT enable relay when this bit is set, and deactivates the relay when the bit is clear. To disable remote enabling of the DS Sparktester it is necessary to alter the electrical connections between the machine and the Profibox.

INPUT DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 0 0 0 0 0 0 0 PO STATUS

Base+4 Measured voltage MSW (bits 31...16 of float)


Base+6 Number of spark faults, unsigned word


STATUS Status code, 0..255. Either a common Profibox status code or one of the following: 0 Gauge OK 1 Unspecific gauge error

PARAMETERS



2 float Preset voltage

Please refer to the relevant Sparktester manual for more information regarding the use of these machines.


Gauge Parameters


Preheater MCS

RLY1: „Start Preheater‟. Normally open. Pulsed closed to start machine. RLY2: „Stop Preheater‟. Normally open. Held closed when OCF_START is 1. DIG1: Input for „Preheater Operation Status‟. Current flow indicates „OK‟. DIG2: Input for „Rotatemp within 10 degrees‟. Current flow indicates „OK‟. AOUT: 0 to 10V output signal representing requested temperature (the

Profibox sets this to 0V if OCF_START is 0).

OUTPUT CONTROL WORD

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 r r r r r r r r r r r r TH r ST r

r Bit is reserved, and should be set to zero by DP master. TH If set the Profibox will convert gauge status codes 1 or 2 to code 0,

thereby suppressing errors during threading. ST If clear the Profibox‟s preset temperature output signal will be 0V and the

„Stop Preheater‟ relay output will be open. If set, the Profibox‟s output control signal will reflect the temperature requested through parameter number 2, and the „Stop Preheater‟ relay output will be closed. A 0 to 1 transition also causes the „Start Preheater‟ relay output to be closed for 500ms.

INPUT DATA WORDS

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Base+3 0 0 0 0 0 0 0 PO STATUS

Base+4 Measured temperature, unsigned word


STATUS Status code, 0..255. Either a common Profibox status code or one of the following: 0 Gauge OK 2 Preheater non-operational

PARAMETERS


1 word DP units: 0=metric, 1=imperial. See note below.

2 word Preset wire / oven temperature

Note: the Profibox parameterisation must correctly specify if the Preheater/Rotatemp gauges have been configured for metric or imperial

operation (0 to 10V representing either 0 to 1000 C or 0 to 1000 F). The Profibox provides all necessary conversions to match the Preheater/Rotatemp units to the selected DP units.

Please refer to the relevant Beta LaserMike manuals for more information regarding the use of these gauges.


Maintenance


Maintenance

The Profibox does not require cleaning or any regular maintenance by the

customer. There are no internal fuses. In the event the PIB1000 stops

functioning due to a hardware fault, please send the whole unit back to your

local BLM Service centre. However, in the case of a PIB1001 having a

hardware fault, new parts can be ordered (see table below).

Spares for PIB1001

Description Part number Quantity per

unit

2 PIB1001 PCBs with adaptor plate (assembled). SA1556-0066 1 assembly

Cable assembly (Analog interconnection lead for PIB1001 to Sparktesters)

CA5100-0343.M600 1

12 core screened cable – 1 metre. (Interconnection lead for PIB1001 to Preheaters)

405141217 1

Replacing the PIB1001 PCBs

1. Isolate Profibox from mains supply.

2. Remove 4 screws securing Profibox lid.

3. Use antistatic wrist band or touch Profibox casing to discharge any static

electricity.

4. Using small screwdriver loosen screws on PCB connectors and remove all

cable cores.

5. Remove 4 screws securing PCB adaptor plate to bottom of Profibox housing

and lift out both PCBs together with adaptor plate. (do not remove any screws

on PCB itself)

6. Fit new PCB assembly.

7. Ensure Profibox lid screws are tightly fastened to ensure IP rating.


Troubleshooting / LED Signals


Troubleshooting / LED Signals

Symptoms Possible cause Solution *

Unit not functioning

Power supply failure Check power supply at connector pins.

Faulty cable Check and replace cable if necessary

LED2 continuously flashing

Faulty PCB.

Contact Beta LaserMike Service.

The EPROMs have not been programmed correctly.

Contract Beta LaserMike Service to order new EPROMs.

LED3 (PIB1000) off LED9 (PIB1001) off

No power is going into Profibox Test cable and 24V supply

Incorrect power supply Check 24V power supply.

* Recycling the power may also solve some problems.

PIB1000 LED locations:

PIB1001 LED locations:

Watchdog LED (LED2)

Flashes once upon Power up.

If this LED flashes

continuously

off/on, there is a fault with the processor.

Power ON LED (LED3)

After Power up, should be continuously on.

Hole for viewing LED2

Flashes once on startup and

should turn off.

If flashing indicates problem

with PCB or

EPROMs.

Hole for viewing LED9

Should be permanently on

(+5V). If off,

indicates problem

with power.


Servicing and Returning your Equipment


Servicing and Returning your Equipment

Your instrument was carefully inspected electrically and mechanically prior to shipment. It should be free of surface mars and scratches, and it should be in perfect working order upon receipt. If any indication of damage is found, file a claim with the carrier immediately, prior to using the instrument. If no damage is apparent, proceed by using this manual to install and setup this instrument.

Save the shipping carton and packing material for future storing or shipment of the instrument. If, at some future time, the instrument must be returned to the factory for service, include a full description of the instrument failure and the mode of operation the instrument was in at the time of failure. Also include a contact person to discuss the instrument failure.

Field warranty service is available, if the customer pays travel expenses by advance purchase order. All service operations should be performed by skilled electronics technicians, who have been trained by Beta LaserMike.For more information see under heading Proprietary Information at the beginning of this manual.

WHEN RETURNING EQUIPMENT FOR SERVICE, IT IS IMPORTANT TO FIRST OBTAIN A RETURN MATERIAL AUTHORIZATION (RMA) NUMBER. The RMA number is needed for proper handling of returned equipment.

To get an RMA,

Go to www.betalasermike.com

Select “Service”

Select “Equipment Return / RMA” from the drop-down menu and follow the instructions.

Ship the instrument in the original carton, or, if the original carton is unavailable, ship in a carton providing sufficient protection. Send the instrument to the Asia, Europe, or USA office (addresses listed in the supplied Contacts/CE Manual), whichever is closest to you or to the office indicated by your sales engineer. Place the RMA number on the outside of the carton, and include a purchase order number and any other information specific to your instrument.

http://www.betalasermike.com/


Disposal / Recycling


Disposal / Recycling

Please check the following before disposing of your equipment:

Is the equipment worth repairing? If in doubt, contact Beta LaserMike

Service.

Does the equipment contain any hazardous materials? If you are aware of

any hazardous materials in your equipment, ensure qualified personnel

take responsibility for its disposal. Some examples of hazardous

substances are lead, mercury, cadmium, chromium VI, flame retardants,

fluorescent tubes, monitors containing cathode ray tubes and products

containing capacitors.

Can you re-use or recycle any constituent parts?. For example, if the

housing/chassis is made of metal, it can be recycled by your local

authority. Ensure qualified personnel take responsibility for dismantling

the equipment.

If the equipment does need to be disposed of, please dispose of it in a way

that doesn’t harm the environment.


Specification


Specification

General

Net weight PIB1000 = 0.781 kg (1.72 lb), PIB1001 = 2.5 kg (5.5 lb)

Noise <70 dBa

Expected life

Up to 10 years (Time frame does not exclude possible replacements of serviceable parts and is based on routine maintenance/calibration of equipment).

Environmental Conditions

Altitude Unlimited

Ambient operating temp. 5-40 C (41- 104 F)

Ambient storage temp. -40 C - +50 C (-40 F - +122 F)

Max relative humidity 80% for temp. up to 31 C or 88 F (decreasing linearly to 50% relative humidity at 40 C or 104 F)

Installation category

Installation Category 2

Pollution degree Pollution Degree 1 (Equipment has been designed for operation with a level of pollution of its

internal micro-environment, which corresponds with the definition of Pollution Degree 1 in BSEN 61010-1:1993)

IP rating

IP65 (as defined in BSEN 60529)

Voltage fluctuations +10 % of nominal voltage

Digital inputs

Voltage range 5-24vdc

Frequency range 50Hz nominal

Power <3W

Sampling rate 100Hz

Input impedance 2.2

Analog inputs

Voltage range 0-10V

Frequency 50Hz

Impedance >50Hz

Resolution 12 bit

Analog outputs

Voltage range ± 10V

Frequency 5Hz (1000Hz for fast analog output)

Impedance <10

Min load resistance 5 k

Output range Adjustable to +10V max.

Resolution 14 bit (12 bit for fast analog output)

Relay contacts

Max supply level 60 Vdc and 30 Vac rms


Index


Index

AS3000 ........................................................ 35 AS5000 ........................................................ 35 Cable .............................................................4 Cable Specifications ...................................... 17 Centerscan Gauges

Connecting to PIB1000 ............................. 11 Parameters............................................... 33

Common status codes ................................. 25 Configuration ............................................... 23 Configuration via DP Master......................... 24 Data Format and Units ................................. 27 Dimensions

PIB1000 .....................................................8 Disposal ....................................................... 50 Earthing.................................................... 4, 19 EMC Directive .................................................4 Environmental Conditions .............................. 51 European Commission Requirements ............4 Expected Life ............................................... 51 Gauge Parameters ....................................... 30 Gland Termination

PIB1000 ................................................... 16 PIB1001 ................................................... 18

Industrial environment .....................................4 Input Data .................................................... 28 Intended Use .................................................6 Interference ....................................................4 Introduction ....................................................6

LaserSpeed gauges ..................................... 43 LD Gauge

Connecting to Height Stand ...................... 10 Parameters............................................... 35

LEDs ........................................................... 48 LN Fault Gauges

Connecting to Height Stand ...................... 10 Maintenance ................................................ 47 Output Data ................................................. 28 Positioning the PIB1000 next to the LD or LN

................................................................ 10 Preheater Gauge

Parameters............................................... 46 Recycling ..................................................... 50 Returning your Equipment ............................ 49 RS232 Communication ................................ 26 RS232 Configuration .................................... 23 Safety ............................................................6 Securing PIB1000 next to the Centerscan .... 11 SELV levels ....................................................6 Service ...........................................................4 Servicing ...................................................... 49 SI/DS Sparktesters

Parameters............................................... 45 Specification ................................................ 51 Troubleshooting ........................................... 48 WI900 .......................................................... 36

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