Murdoch University Engineering Thesis Appendix XII...Make sure GSD file SI028131.gsd is installed in TIA Portal, then locate the DP/PA coupler station in TIA Portal Hardware Catalog

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.



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)



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.



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)



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)



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]



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]



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]



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



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


Main Process Value Display the scaled actual value of the measurement. [81]


2nd Cyclic Value Display the distance between the sensor membrane and the measuring surface. [81]


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]



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).


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


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]



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]



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]



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



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


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]


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]


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]



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).


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


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]



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]



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.



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.



This is the end of Appendix XII.

Documents

Murdoch University Engineering Thesis Appendix XII...Make sure GSD file SI028131.gsd is installed in TIA Portal, then locate the DP/PA coupler station in TIA Portal Hardware Catalog